Professional Documents
Culture Documents
Troubleshooting 3500C Marine Prop Engines
Troubleshooting 3500C Marine Prop Engines
October 2009
Troubleshooting
3500C Marine Propulsion Engines
TTA1-Up (Engine)
TTB1-Up (Engine)
M8C1-Up (Engine)
TTC1-Up (Engine)
M8D1-Up (Engine)
TTD1-Up (Engine)
TTE1-Up (Engine)
TTF1-Up (Engine)
TTG1-Up (Engine)
TTH1-Up (Engine)
TTJ1-Up (Engine)
E3W1-Up (Engine)
E3X1-Up (Engine)
E3Z1-Up (Engine)
SAFETY.CAT.COM
i03684547
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.
KENR5404-03 3
Table of Contents
Welding Precaution
Introduction SMCS Code: 1000
g01143634
Illustration 1
Service welding guide (typical diagram)
KENR5404-03 5
Troubleshooting Section
3. Connect the welding ground cable as close Two short jumper wires are needed to check the
as possible to the area that will be welded. continuity of some wiring harness circuits by shorting
Components which may be damaged by welding two adjacent terminals together in a connector. A
include bearings, hydraulic components, and long extension wire may also be needed to check the
electrical/electronic components. continuity of some wiring harness circuits.
The tools that are listed in Table 1 are required in Caterpillar Electronic Technician
order to enable a service technician to perform the
test procedures that are found in this manual. (ET)
Table 1 Cat ET can display the following information:
Required Service Tools
• Parameters
Part Description
Number • Event codes
N/A 4 mm Allen Wrench
• Diagnostic codes
6V-2197 Transducer
7X-1171 Transducer Adapter • Engine configuration
7X-1695 Cable As Cat ET can be used by the technician to perform the
146-4080 Digital Multimeter Gp (RS232) following functions:
7X-1710 Multimeter Probes • Diagnostic tests
7X-6370 Adapter Cable As (3-PIN BREAKOUT)
• Calibrations
208-0059 Adapter Cable As (70-PIN BREAKOUT)
257-8718 Adapter Cable As (120-PIN BREAKOUT) • Flash programming
167-9225 Harness (SERVICE TOOL ADAPTER) • Configuration of the Electronic Control Module
1U-5804 Crimp Tool (12−AWG TO 18−AWG) (ECM)
Table 3
Software Requirements for Cat ET
Part Description
Number
Connecting Cat ET
g01255306
Illustration 2
Connecting with the Communication Adapter II
Connecting the Communication Adapter II
Table 4 lists the standard hardware that is required in (1) Personal Computer (PC)
(2) 237-7547 Adapter Cable As
order to connect Cat ET. (3) 196-0055 Adapter Cable As
(4) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)
Table 4 (5) 275-5121 Communication Adapter As
Standard Hardware for the Use of Cat ET (6) 207-6845 Adapter Cable As
Part Number Description Note: Items (3), (5), and (6) are part of the 275-5120
Communication Adapter Gp.
N/A Personal Computer (PC)
6. Establish communication between Cat ET and the 2. Ensure that the computer has been correctly
ECM. configured for the 261-4867 Card (PCMCIA).
Verify that the PC card is installed in the
7. If Cat ET and the communication adapter computer's PCI expansion slot.
do not communicate with the ECM, refer to
Troubleshooting, “Electronic Service Tool Does 3. Connect cable (9) between communication radio
Not Communicate”. (8) and the service tool connector.
Communicating with the Wireless Communication 4. Restore the electrical power to the ECM. If Cat ET
Adapter and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Table 5 lists the optional hardware that is needed Service Tool Does Not Communicate”.
in order to connect Cat ET by using a wireless
connection.
Table 5
Optional Hardware for the Use of Cat ET
Part Number Description
Wireless Communication
261-3363(1)
Adapter Gp
(1) Refer to Tool Operating Manual, “Using the 261-3363
Wireless Communication Adapter Gp” for information that is
related to the installation and the configuration.
g01297379
Illustration 3
(1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
(8) 239-9955 Communication Radio Gp
(9) 259-3183 Data Link Cable As
Note: Items (7), (8), and (9) are part of the 261-3363
Wireless Communication Adapter Gp.
Fuel Injection
The engine ECM controls the timing and the duration
of the fuel that is injected. The engine ECM varies the
signals to the fuel injectors. Fuel is injected only while
an injector solenoid is energized by a 105 volt signal
from the engine ECM. The timing of the injection
signal determines the engine timing. The length of
the injection signal determines engine speed.
g01316909
Illustration 4
Typical example
10 KENR5404-03
Troubleshooting Section
g01019029
Illustration 5
Left side view
(1) Unfiltered fuel pressure sensor (5) Secondary ECM connector J2 (8) Secondary engine speed/timing sensor
(2) Filtered fuel pressure sensor (6) Left exhaust temperature sensor (9) Primary engine speed/timing sensor
(3) Aftercooler temperature sensor (7) Left turbocharger compressor inlet (10) Secondary ECM connector J1
(4) Coolant temperature sensor pressure sensor (11) Secondary ECM
KENR5404-03 11
Troubleshooting Section
g01019032
Illustration 6
Right side view
(12) Right turbocharger compressor inlet (13) Right exhaust temperature sensor
pressure sensor (14) Crankcase pressure sensor
12 KENR5404-03
Troubleshooting Section
g01019034
Illustration 7
Front and rear view
(4) Coolant temperature sensor (7) Left turbocharger compressor inlet (18) Atmospheric pressure sensor
(15) Filtered engine oil pressure sensor pressure sensor (19) Primary ECM connector J1
(16) Unfiltered engine oil pressure sensor (6) Left exhaust temperature sensor (20) Primary ECM
(3) Aftercooler temperature sensor (13) Right exhaust temperature sensor (21) Primary ECM connector J2
(17) Turbocharger compressor outlet (12) Right turbocharger compressor inlet
pressure sensor pressure sensor
i03158926
Control Panel
g01316970
Illustration 8
Control panel
(1) Marine Power Display (11) “Reset 1” relay (21) Overspeed indicator
(2) “ECM Ready” lamp (12) “Stop 1” relay (22) Emergency stop lamp
(3) Pyrometer (13) “Reset 2” relay (23) “STE” relay
(4) Override switch (crank) (14) “Stop 2” relay (24) “Run 1” relay
(5) Prelube override switch (15) Horn relay (25) “STPE” relay
(6) Marine override switch (16) Engine control switch (ECS) (26) “Run 2” relay
(7) Torque limit switch (17) Speed Control (27) “ECSIR” relay
(8) Local/remote switch (throttle) (18) Emergency stop switch (28) “SN” relay
(9) Diodes D1 to D10 (19) “ECM Active” lamp
(10) “RSR” relay (20) Alarm (horn)
g01621243
Illustration 9
Power distribution panel
(29) Circuit breaker for the primary ECM (20 (34) “PPR2” relay (44) “SD Notify” relay
Amp) (35) “Relay 4A” (45) Starting motor magnetic switch 2
(30) Circuit breaker for the secondary ECM (36) “Relay 4” (46) Starting motor magnetic switch 1
(20 Amp) (37) “Relay 3A” (47) “PPR1” switch
(31) Circuit breaker for the prelube and air (38) “Relay 3” (48) Air shutoff switch (ASOS)
shutoff circuits (40 Amp) (39) “Relay 2A”
(32) “Marine Power Display (MPD)” circuit (40) “Relay 2”
breaker (20 Amp) (41) “Relay 1”
(33) Starter and alternator circuit breaker (42) Air shutoff timer
(70 Amp) (43) General alarm relay
The engine's Electronic Control Module (ECM) has Codes can have two different states:
the ability to monitor the circuitry between the ECM
and the engine's components. The ECM also has the • Active
ability to monitor the engine's operating conditions. If
the ECM detects a problem, a code is generated. • Logged
There are two categories of codes: Active Codes
• Diagnostic code An active code indicates that a problem is present.
Service the active code first. For the appropriate
• Event code troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
Diagnostic Code – A diagnostic code indicates an
electrical problem such as a short or an open in the • Troubleshooting, “Diagnostic Trouble Codes ”
engine's wiring or in an electrical component.
KENR5404-03 15
Troubleshooting Section
Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired
and/or the problem may no longer exist. If the
system is powered, it is possible to generate an
active diagnostic code whenever a component is
disconnected. If the component is reconnected, the
code is no longer active but the code may become
logged.
i03496620
Programmable Parameters
SMCS Code: 1900
i02627789
Electrical Connectors
SMCS Code: 7553-WW
g01219014
Illustration 10
Connectors for the ECM
70 pin connectors
KENR5404-03 17
Troubleshooting Section
g01158896
Illustration 12
9 pin connector
g01323928
Illustration 11
85 pin connector
18 KENR5404-03
Troubleshooting Section
Harness Connectors
g01317390
Illustration 13
KENR5404-03 19
Troubleshooting Section
Configuration Parameters
i02627804
Configuration Parameters
SMCS Code: 1900
Some system configuration parameters are If a programmable parameter has not been
configurable by the customer in order to suit the programmed, the ECM will generate a 268-2
customer's particular application. The configuration diagnostic code. The unprogrammed parameters
file contains all of the adjustable settings for the will be set to default. Certain aspects of the engine's
monitoring system. The engine is shipped from the performance and engine monitoring may be affected.
factory with default values for these parameters. Program the missing parameter.
In most cases, the parameters do not need to be
changed. The system configuration parameters must If an injector code has not been programmed, the
be reprogrammed if an ECM is replaced and/or the ECM will generate a 1495-2 diagnostic code. The
engine rating is reprogrammed. System configuration injector code is a number that is found on each of
parameters do not need to be reprogrammed if the unit injectors. The ECM uses this number to
the flash file is replaced. Proper values for these compensate for manufacturing variations between
parameters are available on Caterpillar Electronic individual injectors. If you replace any of the unit
Technician (ET). Certain configuration parameters injectors, you must reprogram the code for the new
are also stamped on the engine information plate. injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes.
If the default settings for the parameters have been
modified, there will be no record at the factory of the Note: The injector codes are not part of the
changes. These settings can be downloaded into a “Configuration” screen on the electronic service tool.
laptop computer and saved to a file. The customer “Injector Codes Calibration” can be found under
can then use the file in order to ease the future “Calibrations” in the “Service” menu on Cat ET.
replacement of the ECM.
“Crank Duration”
The crank duration determines when the starting
motors will be energized. The crank duration
determines when the starting motors will be
disengaged. Programming this parameter to 0 will
prevent the ECM from engaging the starting motors.
“Total Tattletale”
The parameter counts the number of changes to
system parameters.
KENR5404-03 21
Troubleshooting Section
Parameter Table
Table 7
Parameter Table
Table 8
Customer Parameters
Parameter ECM Default Range Password
“Equipment ID” Primary N/A 17 alphanumeric No
Secondary characters
“Engine Serial Number” Primary 8 alphanumeric No
Secondary characters
#AA#####
“ECM Serial Number” Primary ECM Serial Number ECM Serial Number N/A
Secondary
“Personality Module Primary N/A
Part Number” Secondary
“Personality Module Primary Month N/A
Release Date” Secondary Year
“Engine Rotation” Primary Forward Forward/Reverse N/A
Secondary
“Engine Location” Primary Center Port No
Center
Starboard
“Full Load Setting Primary Not Programmed −128 to +127 Yes
(FLS)” Secondary
“Full Torque Setting Primary 0 −128 to +127 Yes
(FTS)” Secondary
“Rated Engine Speed” Primary Programmed at the Factory N/A
Factory
“High Idle Speed (rpm)” Primary Programmed at the Factory N/A
Factory
“Low Idle Speed (rpm)” Primary 600 300 to 900 No
Secondary
“Fuel Correction Factor” Primary 0 −64 to +63.5 No
“Coolant Level Sensor” Primary Installed “Not Installed” No
Data Link
Sensor
“Torque Limit Enable Primary “Not installed” Installed No
Status” Secondary “Not Installed”
“Maximum Engine Primary Programmed at the Factory No
Torque Limit” Secondary Factory
“Minimum Engine Primary Programmed at the Factory No
Torque Limit” Secondary Factory
“Coolant Warning Primary 40% 5 to 95% No
Engine Load Enable”
Threshold
“Air Shutoff Status” Secondary Enabled Enabled No
Disabled
24 KENR5404-03
Troubleshooting Section
Table 9
(Table 9, contd)
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure
Code and Description Procedure
13-6 Cylinder #13 Injector current above normal Troubleshooting, “Injector Solenoid - Test”
14-5 Cylinder #14 Injector current below normal Troubleshooting, “Injector Solenoid - Test”
14-6 Cylinder #14 Injector current above normal Troubleshooting, “Injector Solenoid - Test”
15-5 Cylinder #15 Injector current below normal Troubleshooting, “Injector Solenoid - Test”
15-6 Cylinder #15 Injector current above normal Troubleshooting, “Injector Solenoid - Test”
16-5 Cylinder #16 Injector current below normal Troubleshooting, “Injector Solenoid - Test”
16-6 Cylinder #16 Injector current above normal Troubleshooting, “Injector Solenoid - Test”
91-8 Throttle Position Sensor abnormal frequency, pulse Troubleshooting, “Speed Control - Test”
width, or period
91-13 Throttle Position Sensor calibration required Troubleshooting, “Throttle Position Sensor - Calibrate”
94-3 Fuel Delivery Pressure Sensor voltage above normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
94-4 Fuel Delivery Pressure Sensor voltage below normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
100-3 Engine Oil Pressure Sensor voltage above normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
100-4 Engine Oil Pressure Sensor voltage below normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
101-3 Crankcase Air Pressure Sensor voltage above normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
101-4 Crankcase Air Pressure Sensor voltage below normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
105-3 Inlet Manifold Temperature Sensor voltage above Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
normal
105-4 Inlet Manifold Temperature Sensor voltage below Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
normal
110-3 Engine Coolant Temperature Sensor voltage above Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
110-4 Engine Coolant Temperature Sensor voltage below Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
168-0 Electrical System Voltage high - most severe (3) Troubleshooting, “Electrical Power Supply - Test”
168-1 Electrical System Voltage low - most severe (3) Troubleshooting, “Electrical Power Supply - Test”
168-2 Electrical System Voltage erratic, intermittent, or Troubleshooting, “Electrical Power Supply - Test”
incorrect
175-3 Engine Oil Temperature Sensor voltage above normal Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
175-4 Engine Oil Temperature Sensor voltage below normal Troubleshooting, “Sensor Signal (Analog, Passive) - Test”
190-2 Engine Speed Sensor erratic, intermittent, or incorrect Troubleshooting, “Speed/Timing - Test”
190-3 Engine Speed Sensor voltage above normal Troubleshooting, “Speed/Timing - Test”
190-7 Engine Speed Sensor not responding properly Troubleshooting, “Speed/Timing - Test”
190-8 Engine Speed Sensor abnormal frequency, pulse Troubleshooting, “Speed/Timing - Test”
width, or period
248-9 @CatDatalinkLong@ not communicating Troubleshooting, “Cat Data Link - Test”
253-2 Personality Module erratic, intermittent, or incorrect Troubleshooting, “ECM Software - Install”
254-12 Electronic Control Module Error The Electronic Control Module (ECM) has detected a fatal
internal error. Replace the ECM. Refer to Troubleshooting,
“ECM - Replace”.
261-13 Engine Timing Calibration calibration required Troubleshooting, “Timing - Calibrate”
262-3 5 Volt Sensor DC Power Supply voltage above normal Troubleshooting, “Sensor Supply - Test”
(continued)
26 KENR5404-03
Troubleshooting Section
(Table 9, contd)
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure
Code and Description Procedure
262-4 5 Volt Sensor DC Power Supply voltage below normal Troubleshooting, “Sensor Supply - Test”
263-3 Digital Sensor Power Supply (8V Or 12V) voltage Troubleshooting, “Sensor Supply - Test”
above normal
263-4 Digital Sensor Power Supply (8V Or 12V) voltage Troubleshooting, “Sensor Supply - Test”
below normal
268-2 Programmed Parameter Fault erratic, intermittent, or Troubleshooting, “Configuration Parameters”
incorrect
273-0 Turbocharger Outlet Pressure Sensor high - most Troubleshooting, “Sensor Signal (Analog, Active) - Test”
severe (3)
273-3 Turbocharger Outlet Pressure Sensor voltage above Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
273-4 Turbocharger Outlet Pressure Sensor voltage below Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
274-3 Atmospheric Pressure Sensor voltage above normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
274-4 Atmospheric Pressure Sensor voltage below normal Troubleshooting, “Sensor Signal (Analog, Active) - Test”
275-3 Right Turbocharger Inlet Pressure Sensor voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
above normal
275-4 Right Turbocharger Inlet Pressure Sensor voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
below normal
276-3 Left Turbocharger Inlet Pressure Sensor voltage above Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
276-4 Left Turbocharger Inlet Pressure Sensor voltage below Troubleshooting, “Sensor Signal (Analog, Active) - Test”
normal
277-8 Timing Calibration Sensor abnormal frequency, pulse Troubleshooting, “Timing - Calibrate”
width, or period
279-3 Aftercooler Coolant Temperature Sensor (Front) Troubleshooting, “Sensor Signal (Analog, Active) - Test”
voltage above normal
279-4 Aftercooler Coolant Temperature Sensor (Front) Troubleshooting, “Sensor Signal (Analog, Active) - Test”
voltage below normal
289-3 Fuel Pressure Sensor - Before Fuel Filter voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
above normal
289-4 Fuel Pressure Sensor - Before Fuel Filter voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
below normal
336-2 Engine Control Switch erratic, intermittent, or incorrect Troubleshooting, “Engine Control Switch - Test”
337-2 Remote Emergency Stop Switch erratic, intermittent, Troubleshooting, “Emergency Stop (Remote) - Test”
or incorrect
338-5 Engine Pre-Lube Pump Relay current below normal Troubleshooting, “Prelubrication - Test”
338-6 Engine Pre-Lube Pump Relay current above normal Troubleshooting, “Prelubrication - Test”
342-2 Secondary Engine Speed Sensor erratic, intermittent, Troubleshooting, “Speed/Timing - Test”
or incorrect
342-3 Secondary Engine Speed Sensor voltage above Troubleshooting, “Speed/Timing - Test”
normal
342-7 Secondary Engine Speed Sensor not responding Troubleshooting, “Speed/Timing - Test”
properly
342-8 Secondary Engine Speed Sensor abnormal frequency, Troubleshooting, “Speed/Timing - Test”
pulse width, or period
(continued)
KENR5404-03 27
Troubleshooting Section
(Table 9, contd)
Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure
Code and Description Procedure
444-5 Starter Motor Relay current below normal Troubleshooting, “Starting - Test”
444-6 Starter Motor Relay current above normal Troubleshooting, “Starting - Test”
446-5 Air Shutdown Relay current below normal Troubleshooting, “Air Shutoff - Test”
446-6 Air Shutoff Relay short Troubleshooting, “Air Shutoff - Test”
542-3 Engine Oil Pressure Sensor - Before Oil Filter voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
above normal
542-4 Engine Oil Pressure Sensor - Before Oil Filter voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test”
below normal
827-8 Left Exhaust Temperature Sensor abnormal frequency, Troubleshooting, “Sensor Signal (PWM) - Test”
pulse width, or period
828-8 Right Exhaust Temperature Sensor abnormal Troubleshooting, “Sensor Signal (PWM) - Test”
frequency, pulse width, or period
1249-8 Secondary Throttle Position signal abnormal Troubleshooting, “Speed Control - Test”
1249-13 Secondary Throttle Position calibration required Troubleshooting, “Throttle Position Sensor - Calibrate”
1495-2 Injector Trim Codes Not Programmed Troubleshooting, “Configuration Parameters”
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes are also used by the service technician
to identify the nature of the problem. Caterpillar
Electronic Technician (ET) is a software program
that is designed to run on a personal computer. The
software can be used by the service technician in
order to view the diagnostic code information for
an ECM. Diagnostic codes consist of the module
identifier (MID), the component identifier (CID), and
the failure mode identifier (FMI).
Illustration 14 indicates the signal range for a typical Note: Always clear logged diagnostic codes after
analog sensor. Diagnostic codes will be generated if investigating and correcting the problem which
the sensor's output signal is below 0.2 VDC or above generated the code.
4.8 VDC.
Event Codes
i03140402
Event Codes
SMCS Code: 1900
Table 10
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 are intermittent. Refer to
used to review the performance of the engine. Troubleshooting, “Inspecting Electrical Connectors”.
Clearing Event Codes If these steps do not resolve the problem, refer to
Table 10 for the procedure to troubleshoot the event
code.
A code is cleared from memory when one of the
following conditions occur:
Trip Points for the “Caterpillar
• The code does not recur for 100 hours. Monitoring System”
• A new code is logged and there are already ten The monitoring system determines the level of action
codes in memory. In this case, the oldest code is that is taken by the ECM in response to a condition
cleared.
that can damage the engine. When any of these
conditions occur, the appropriate event code will be
• The service technician manually clears the code. generated.
Always clear logged event codes after investigating
Table 11 contains the parameters that are monitored
and correcting the problem which generated the and the appropriate event code(s) that can be
code.
generated for that parameter. Table 11 also contains
the minimum and maximum ranges for the parameter
Troubleshooting and the default trip points for each parameter. The
actual settings for each parameter can be viewed
For basic troubleshooting of the engine, perform the with Caterpillar Electronic Technician (ET). The trip
following steps in order to diagnose a malfunction: points for some of the parameters may be adjustable
with Cat ET.
1. Obtain the following information about the
complaint:
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
32 KENR5404-03
Troubleshooting Section
Table 11
Monitoring System Parameters
Delay Time in Seconds Trip Point
Parameter Action Default
Min Max Default Min Max Default State
E007(2) High Aftercooler 40 °C 107°C 107°C
Warning 1 60 5 On
Temperature Derate (104 °F) (225 °F) (225 °F)
E008(3) High Aftercooler 40 °C 107°C 107°C
Shutdown 1 60 5 On
Temperature Shutdown (104 °F) (225 °F) (225 °F)
E009(2) High Altitude 250 m 4562 m 762 m
Derate(1) N/A N/A 0 On
Derate (820 ft) (14967 ft) (2500 ft)
E012(2) High Crankcase 0.5 kPa 6 kPa 6 kPa
Derate(2) 1 60 10 On
Pressure Derate (0.1 psi) (0.9 psi) (0.9 psi)
E013(3) High Crankcase 0.5 kPa 6 kPa 3.5 kPa
Shutdown 1 60 3 On
Pressure Shutdown (0.1 psi) (0.9 psi) (0.5 psi)
E015(2) High Engine
Derate 90 °C 107 °C 107 °C
Coolant Temperature 1 60 30 On
(3) (194 °F) (225 °F) (225 °F)
Derate
E016(3) High Engine
90 °C 107 °C 107 °C
Coolant Temperature Shutdown 1 60 5 On
(194 °F) (225 °F) (225 °F)
Shutdown
E017(1) High Engine
90 °C 102 °C 102 °C
Coolant Temperature Warning 1 60 5 On
(194 °F) (216 °F) (216 °F)
Warning
E021(2) High Exhaust 500 °C 800 °C 750 °C
Derate(4) 1 60 5 On
Temperature Derate (932 °F) (1472 °F) (1382 °F)
E031(2) Air Filter 1 kPa 7 kPa
Derate 1 60 5 7 kPa (1 psi) On
Restriction Derate (0.14 psi) (1 psi)
E038(1) Low Engine
63 °C 85 °C 80 °C
Coolant Temperature Warning 1 60 5 On
(145 °F) (185 °F) (176 °F)
Warning
E040(3) Low Engine Oil
Shutdown 1 15 9 N/A N/A (5) On
Pressure Shutdown
E043(1) Low System
Warning 1 30 10 20 VDC 22 VDC 20 VDC On
Voltage Warning
E095(1) Fuel Filter 70 kPa 105 kPa 105 kPa
Warning 1 60 5 On
Restriction Warning (10 psi) (15 psi) (15 psi)
E099(1) Engine Oil Filter 70 kPa 105 kPa 105 kPa
Warning 1 60 5 On
Restriction Warning (10 psi) (15 psi) (15 psi)
E100(1) Low Engine Oil (5)
Warning 1 15 4 N/A N/A On
Pressure Warning
E101(1) High Crankcase 0.5 kPa 6 kPa 2 kPa
Warning 1 60 3 On
Pressure Warning (0.1 psi) (0.9 psi) (0.3 psi)
E173(1) High Exhaust 600 °C 500 °C 800 °C
Warning 1 60 5 On
Temperature Warning (1112 °F) (932 °F) (1472 °F)
E190(1) Engine Application
Warning 1 60 5 1200 rpm 2400 rpm On
Overspeed Warning Dependent
E272(1) Inlet Air 3 kPa 7 kPa
Warning 1 60 5 7 kPa (1 psi) On
Restriction Warning (0.4 psi) (1 psi)
E279(1) High Aftercooler 40 °C 102 °C 102 °C
Warning 1 60 5 On
Temperature Warning (104 °F) (216 °F) (216 °F)
(continued)
KENR5404-03 33
Troubleshooting Section
g01027393
Illustration 16
Oil pressure map
KENR5404-03 35
Troubleshooting Section
3. Verify that the complaint is not due to normal • Engine derate or active codes
engine operation.
• Cold mode
4. Perform a visual inspection of the engine. Inspect
the following items: • Flash file
• Determine if the logged diagnostic codes 3. Check the fuel tank for debris or foreign objects
correlate to probable causes. which may block the fuel supply.
36 KENR5404-03
Troubleshooting Section
Cold Mode
NOTICE
Do not crank the engine continuously for more than The Electronic Control Module (ECM) limits engine
30 seconds. Allow the starting motor to cool for two power during cold mode operation. The ECM may
minutes before cranking the engine again. modify the injection timing and the ECM may cut out
certain engine cylinders. This will increase startability
and this will reduce warm up time. Cold mode is
4. Prime the fuel system if any of the following activated whenever the engine coolant temperature
procedures have been performed: falls below a predetermined value. Cold mode
remains active until the engine has warmed or a time
• Replacement of the fuel filters limit is exceeded.
Some engine monitoring parameters that are capable Air Inlet and Exhaust System
of triggering an engine derate do not produce an
event code. Connect Caterpillar Electronic Technician 1. Observe the check engine lamp. Check for an
(ET) in order to check for a derate of the engine. air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the
Certain diagnostic codes and/or event codes may Operation and Maintenance Manual.
cause poor performance. Use Cat ET to check for
active codes and for logged codes. Troubleshoot any 2. Check the air inlet and exhaust system for
codes that are present before continuing with this restrictions and/or leaks. Refer to Systems
procedure. Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.
Note: Although a sensor's signal may be in the
operational range of the sensor, the signal may
not represent the actual reading. Use Cat ET to
check that the pressures and the temperatures are
fluctuating. Also check that the values are reasonable
for the conditions that are present.
KENR5404-03 37
Troubleshooting Section
Verify that there are no diagnostic codes for the Check the condition of the alternator drive pulley.
starting motor relays. If there are diagnostic codes Look for deep grooves that have been worn into the
for the starting motor relays, perform the appropriate pulley by the belt. If there is excessive wear, replace
troubleshooting procedure. the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
Low Air Pressure Note: Make sure that the alignment is correct.
Ensure that the air pressure is adequate for the
starting system. If necessary, charge the system. Wear of the Alternator Bearings
Check the alternator bearings for signs of wear.
Air Starting Motor Repair the alternator or replace the alternator, as
needed.
Refer to the Systems Operation/Testing and Adjusting
manual for information on the air starting motor.
Operation of the Alternator or Regulator
i03372684 Verify that the alternator or the regulator is operating
correctly. Refer to Special Instruction, REHS0354,
Alternator Problem “Charging System Troubleshooting” for the proper
(Charging Problem and/or testing procedures. Repair the alternator or replace
the alternator, as needed.
Noisy Operation)
Inspection of the Charging Circuit
SMCS Code: 1405-035
Inspect the battery cables, wiring, and connections in
Probable Causes the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts.
Alternator
i02726474
• Condition of the alternator drive belts
Coolant Contains Fuel
• Condition of the alternator drive pulley
SMCS Code: 1250-035; 1395-035
• Condition of the alternator bearings
• Operation of the regulator
Probable Causes
• Injector sleeve or injector sleeve seal
Charging Circuit
• Inspection of the charging circuit
38 KENR5404-03
Troubleshooting Section
2. Remove the fuel injectors from the cylinder head. Probable Causes
Refer to the Disassembly and Assembly manual • Engine oil cooler core
for details.
• Cylinder head gasket
• Cylinder head
Personal injury can result from hot coolant, steam
and alkali. • Cylinder liner
i03140025
Table 12
Event Code
Code and Description Conditions which Generate this Code System Response
E007(2) High Aftercooler Temperature The aftercooler temperature is above The engine will be derated.
Derate the trip point temperature. The code is logged.
E008(3) High Aftercooler Temperature The aftercooler temperature is above The engine will shut down. The code
Shutdown the trip point temperature. is logged.
E015(2) High Engine Coolant The engine coolant temperature is The engine will be derated.
Temperature Derate above the trip point temperature. The code is logged.
E016(3) High Engine Coolant The engine coolant temperature is The engine will shut down. The code
Temperature Shutdown above the trip point temperature. is logged.
E017(1) High Engine Coolant The engine coolant temperature is The code is logged.
Temperature Warning above the trip point temperature.
E279(1) High Aftercooler Temperature The aftercooler temperature is above The code is logged.
Warning the trip point temperature.
• Faulty jacket water coolant pump • Properties that are recommended by the engine's
Operation and Maintenance Manual
• Aftercooler If the coolant does not have these properties, drain
the system and flush the system. Refill the cooling
• Load on the system system according to the engine's Operation and
Maintenance Manual.
40 KENR5404-03
Troubleshooting Section
2. Check the radiator for internal blockage. Check Use this procedure in order to troubleshoot a
the temperature difference between the inlet and low coolant temperature or use this procedure
the outlet of the radiator. if the following event code is active. Refer to
Troubleshooting, “Event Codes” for information about
event codes and the default trip points for these
Coolant Leak codes. You must access the monitoring system on
Caterpillar Electronic Technician (ET) in order to view
Check the cooling system for leaks. the current trip points for these codes.
1. Inspect the coolant for presence of bubbles.
Damaged Hoses
Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
kinked or crushed during operation. These areas of
the hose restrict the coolant flow. Hoses can crack
after a period of time. The inside of a hose can
deteriorate and the loose particles of the hose can
restrict the coolant flow.
Table 13
Event Code
Code and Description Conditions which Generate this Code System Response
E038(1) Low Engine Coolant The coolant temperature is below the The code is logged.
Temperature Warning trip point temperature.
Probable Causes
• Faulty water temperature regulator
• Very light loads
Recommended Actions
Water Temperature Regulator
A regulator that is stuck open can cause overcooling.
Overcooling also occurs when the water temperature
regulator is stuck between the following positions:
open position and closed position. Coolant leaks
that are around the water temperature regulator can
cause overcooling. An example would be a leak in
the vent line.
i03140041
Table 14
Event Code
Code and Description Conditions which Generate this Code System Response
E012(2) High Crankcase Pressure Engine crankcase pressure is above the The code is logged. The engine will be
Derate trip point pressure for the delay time. derated.
E013(3) High Crankcase Pressure The code is logged. The engine will
Shutdown shut down.
E101(1) High Crankcase Pressure The code is logged.
Warning
42 KENR5404-03
Troubleshooting Section
Damaged pistons or rings can cause too much Check for the correct installation of the connector(s)
pressure in the crankcase. This condition will cause for the Electronic Control Module (ECM) J1/P1 and/or
the engine to run rough. There will be more than the J2/P2. Check for correct installation of the applicable
normal amount of fumes (blowby) rising from the fuel injector connectors. Repair the connector and/or
crankcase breather. The breather can then become replace the connector. Refer toTroubleshooting,
restricted in a very short time, causing oil leakage “Electrical Connectors - Inspect”.
at gaskets and seals that would not normally have
leakage. Blowby can also be caused by worn valve Injector
guides or by a failed turbocharger seal.
Use Caterpillar Electronic Technician (ET) to
Crankcase Breather determine if any diagnostic codes for the injector
solenoids are present. Perform the “Injector Solenoid
A plugged crankcase breather will cause excessive Test”. Observe that the injector solenoids are being
crankcase pressure. Leakage of the crankshaft seal energized on Cat ET. Perform the “Cylinder Cutout
can occur. Sealing of the piston rings can be lost. Test”. Locate the misfiring cylinder. Refer to the
This will enable crankcase blowby to further increase diagnostic functional test Troubleshooting, “Injector
the crankcase pressure. Solenoid - Test”.
i03648660 i02610526
Verify that the data link does not have an open or Note: If Cat ET will not communicate with the
short circuit. Refer to the circuit tests Troubleshooting, ECM, the problem is most likely with the electrical
“Cat Data Link - Test” or refer to the circuit tests power supply to the ECM. Refer to Troubleshooting,
Troubleshooting, “CAN Data Link - Test”. “Electrical Power Supply - Test”.
Recommended Actions Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when
Batteries and/or Battery Cables the unit injector is removed.
1. Inspect the main power switch, battery posts, Internal Engine Problem
and battery cables for loose connections and
for corrosion. If the battery cables are corroded, Disassemble the engine. Refer to the Disassembly
remove the battery cables and clean the battery and Assembly manual. Inspect the internal
cables. Tighten any loose connections. components for the following conditions:
2. Contaminants in the fuel such as hydrogen sulfide Inspect the crankshaft and the related components.
and sulfur can lead to the formation of acids in the Inspect the connecting rod bearings and the bearing
crankcase. Obtain a fuel analysis. surfaces on the crankshaft. Make sure that the
bearings are in the correct position. Look for worn
thrust plates and wear on the crankshaft. Check the
i03385119 counterweight bolts. Replace any damaged parts.
• Valve train components The probable root causes are listed in order below:
Governor
Adjust the parameters for the governor in order to
maintain stability.
i03140049
Engine Overspeeds
SMCS Code: 1915-035
Table 15
Event Code
Code and Description Conditions which Generate this Code System Response
E190(1) Engine Overspeed Warning The engine rpm has exceeded the trip The air shutoff will be activated. The
point for engine overspeed for the delay engine will shut down.
time. Power must be cycled to the engine's
Electronic Control Module (ECM) in
order to reset the code.
The code is logged.
2. Check the fuel lines for the following problems: Recommended Actions
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the Diagnostic Codes
lines and/or replace the lines.
Check for active diagnostic codes on Caterpillar
3. Check the fuel tank for debris or foreign objects Electronic Technician (ET). Troubleshoot any active
which may block the fuel supply. codes before continuing with this procedure.
6. Check the filtered fuel pressure while the • Service on the low pressure fuel supply circuit
engine is being cranked. Refer to Systems
Operation/Testing and Adjusting. • Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
If the fuel pressure is low, replace the fuel filters.
helpful in diagnosing air in the fuel. Refer to Systems
Clean the primary filter/water separator of debris.
Operation/Testing and Adjusting.
Refer to the Operation and Maintenance Manual.
5. Check the fuel tank for foreign objects which may
If the fuel pressure is still low, check the operation
block the fuel supply.
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
6. Check the fuel filters.
Refer to Systems Operation/Testing and Adjusting.
7. Check the diesel fuel for contamination. Refer to
i02958578 Systems Operation/Testing and Adjusting.
Engine Stalls at Low RPM 8. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
SMCS Code: 1000-035; 1900-035 Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Probable Causes operation.
• Throttle signal 2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position.
• Air inlet and exhaust system
3. Check the fuel lines for the following problems:
• Fuel supply restrictions, collapsed lines, pinched lines, and
loose connections. If problems are found with the
• Cylinder performance fuel lines, repair the lines and/or replace the lines.
• Service on the low pressure fuel supply circuit 8. If the repair does not eliminate the problem,
reinstall the electronic unit injectors that were
• Replacement of unit injectors removed and continue with this test procedure.
• Atmospheric pressure sensor 2. Verify that there are no active diagnostic codes for
the intake manifold pressure sensor.
• Intake manifold pressure sensor
3. Monitor the status of “Intake Manifold Pressure”
• “Fuel Position” and/or “FRC Fuel Limit” and “Atmospheric Pressure” on Caterpillar
Electronic Technician (ET). When the engine is
• Flash file not running, “Intake Manifold Pressure” should be
0 kPa (0 psi).
• Fuel quality
Note: A problem with the “FRC Fuel Limit” will only
• Valve adjustment cause black smoke during acceleration. A problem
with the “FRC Fuel Limit” will not cause black smoke
Recommended Actions during steady state operation.
1. Check the air inlet system for restrictions and for Verify that the correct flash file is installed in the
leaks. ECM. Refer to Troubleshooting, “ECM Software -
Install” for information.
a. Check for an air filter restriction.
Fuel Quality
b. Perform a visual inspection of the air inlet
piping for restrictions and for leaks. Cold weather adversely affects the characteristics of
the fuel. Refer to Operation and Maintenance Manual
2. Ensure that the turbocharger is in good repair. for information on improving the characteristics of the
fuel during cold weather operation.
3. Check the exhaust system for restrictions.
Valve Adjustment
4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any Check for the correct valve adjustment. Refer
damaged components. to Systems Operation/Testing and Adjusting for
information on adjustment of the valves.
Engine Speed/Timing Sensors
1. Check the calibration of the engine speed/timing
sensors. Refer to Troubleshooting, “Timing -
Calibrate”.
Low Compression Check for an internal coolant leak into the cylinder
and/or the exhaust.
• Component wear
Engine Speed/Timing Sensor
1. Check the calibration of the engine speed/timing
sensor(s). Refer to Troubleshooting, “Timing -
Calibrate”.
KENR5404-03 55
Troubleshooting Section
Fuel Supply
Check the fuel quality. Low cetane fuel can create
white smoke. If necessary, replace the fuel with a
higher cetane fuel.
Component Wear
1. Check the valve lash and reset the valve lash, if
necessary. Refer to Systems Operation/Testing
and Adjusting.
• Faulty piston
• Faulty piston rings
• Worn cylinder bores
• Worn valves
• Faulty cylinder head gasket
• Damaged cylinder head
3. Perform all necessary repairs. Ensure that the
repairs have eliminated the problem.
56 KENR5404-03
Troubleshooting Section
Table 16
Event Code
Code and Description Conditions which Generate this Code System Response
E173(1) High Exhaust Temperature The exhaust temperature is above the The code is logged.
Warning trip point temperature.
E021(2) High Exhaust Temperature The engine is derated. The code is
Derate logged.
Check for air inlet restrictions and/or leaks. A one • Calibration procedure of the engine speed/timing
degree increase in the inlet manifold temperature will
increase the exhaust temperature by approximately Fuel Injection System
three degrees. Check for leaks between the exhaust
manifold and the turbocharger. Check for exhaust • Unstable injection system
restrictions. Refer to the Systems Operation/Testing
and Adjusting manual for more information on Air Inlet and Exhaust System
inspecting the air inlet and exhaust system.
• Restriction in the air inlet and exhaust
Fuel Injectors
Accessory Equipment
Faulty injectors that deliver too much fuel will
increase exhaust temperatures. Connect Cat ET in • Check for damaged accessory equipment
order to determine if any diagnostic codes for the
injector solenoids are present. Perform the “Injector
Solenoid Test”. Observe that the injector solenoids Recommended Actions
are being energized on Cat ET. Perform the “Cylinder
Cutout Test”. Locate the misfiring cylinder. Refer to Look for Excessive Idle or High Load
Troubleshooting, “Injector Solenoid - Test”.
Use Caterpillar Electronic Technician (ET) to check
the “Current Totals” for excessive idle time and/or for
Aftercooler (if applicable)
a high load factor which would be indicative of poor
operating habits.
Normal intake manifold pressure with high exhaust
temperature can be caused by blockage of the fins of
the aftercooler core. Unstable Fuel Supply
If the application has an aftercooler, check the Visually check the fuel level. Do not rely on the fuel
aftercooler for correct operation. Check for blockage gauge only. If necessary, add fuel. If the engine has
in the cores of the aftercooler. been run out of fuel, it will be necessary to purge the
air from the fuel system. Refer to the Operation and
Maintenance Manual.
KENR5404-03 57
Troubleshooting Section
Ensure that the fuel supply valve (if equipped) is in 2. Check the air inlet and exhaust system for
the full OPEN position. restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting.
Check fuel lines for the following problems:
restrictions, collapse, and pinched line. Repair the Check for Damaged Accessory
lines and/or replace the lines.
Equipment
1. Check the fuel tank for foreign objects which
may block the fuel supply. Check for air leaks in Check all accessory equipment for problems that
may create excessive load on the engine. Repair
the suction line of the fuel pump. Purge the fuel
any damaged components or replace any damaged
system after you perform the following procedures:
components.
• Replacing the fuel filters
i03140114
• Working on the low pressure fuel supply circuit
Fuel Filter Is Restricted
• Replacing fuel injectors
SMCS Code: 1261-035
2. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Use this procedure if the following event code is
Maintenance Manual for information on improving active. Refer to Troubleshooting, “Event Codes” for
the characteristics of the fuel during cold weather information about event codes and the default trip
operation. points for this code. You must access the monitoring
system on Caterpillar Electronic Technician (ET) in
3. Check the fuel pressure during engine operation. order to view the current trip point for this code.
Check the fuel pressure after the fuel filter. Refer
to the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items:
fuel pump, pump coupling, and fuel pressure
regulating valve.
Table 17
Event Code
Code and Description Conditions which Generate this Code System Response
E095(1) Fuel Filter Restriction Warning The difference between the filtered fuel The code is logged.
pressure and the unfiltered fuel pressure
is greater than the trip point pressure.
Probable Causes
• Fuel filter element
Recommended Actions
Fuel Filter Element
Replace the fuel filter element.
i03140151
Table 18
Event Code
Code and Description Conditions which Generate this Code System Response
E009(2) High Altitude Derate The Electronic Control Module (ECM) The engine is derated. The code is
detects atmospheric pressure that is logged.
less than normal.
i03140181
Table 19
Event Code
Code and Description Conditions which Generate this Code System Response
E272(1) Inlet Air Restriction Warning The inlet air restriction is above the trip The code is logged.
point pressure for the delay time.
E031(2) Air Filter Restriction Derate The engine is derated. The code is
logged.
• Oil leaks on the outside of the engine Oil Leaks in the Combustion Area of the
Cylinder
• Oil leaks in the combustion area of the cylinders
Engine oil that is leaking into the combustion area of
Oil Viscosity the cylinders can be the cause of blue smoke. There
are several possible ways for engine oil to leak into
• Incorrect oil viscosity the combustion area of the cylinders:
Engine Oil Cooler Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
• Leaks in the core of oil cooler block.
• Leaking seals on the fuel line adapter for the Leaking Fuel Transfer Pump Seal
cylinder head
Ensure that the weep hole is not plugged. If
• Excessive leakage from the unit injector tip or necessary, repair the fuel transfer pump or replace
breakage of the unit injector tip the fuel transfer pump.
• Leaking seal on the fuel transfer pump Oil Filter Differential Pressure
Note: For additional information, refer to , REHS3007, Problem
“Determining the Cause of Fuel Dilution of Engine
Oil”. SMCS Code: 1308-035-PX
Table 20
Event Code
Description Default Conditions which Generate System Response
this Code
E099(1) Engine Oil Filter Restriction The difference between the filtered oil The code is logged.
Warning pressure and the unfiltered oil pressure
is greater than the trip point pressure.
• Malfunctioning of the oil filter bypass valve Use this procedure in order to troubleshoot low
engine oil pressure. Use this procedure if one
of the following event codes is active. Refer to
Recommended Repairs Troubleshooting, “Event Codes” for information about
event codes and the default trip points for these
Check the Oil Filters codes. You must access the monitoring system on
Caterpillar Electronic Technician (ET) in order to view
Check the oil filter differential pressure. If the oil filter the current trip points for these codes.
differential pressure is too high, change the oil filter
elements.
Table 21
Event Code
Code and Description Conditions which Activate the Code System Response
E100(1) Low Engine Oil Pressure The engine oil pressure is less than the The code is logged.
Warning trip point and the delay time has expired.
E039(2) Low Engine Oil Pressure The engine will be derated. The code
Derate is logged.
E040(3) Low Engine Oil Pressure Fuel injection is disabled. The code is
Shutdown logged. The engine is shut down.
• Faulty oil pressure sensors • An engine oil line or a passage for engine oil is
disconnected or broken.
• Improper circulation of the engine oil
• The engine oil cooler is clogged. Thoroughly clean
• Worn components the engine oil cooler.
If a reading is significantly different from zero, refer Obtain an analysis of the engine oil. Check the
to Troubleshooting, “Sensor Signal (Analog, Active) - analysis for the level of wear metals in the engine oil.
Test”.
64 KENR5404-03
Troubleshooting Section
Note: Use this procedure only if the engine does not ECM Power Supply
shut down completely.
1. Inspect the circuit between the ECM and
Probable Causes the batteries. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to
• Diagnostic codes Troubleshooting, “Electrical Power Supply - Test”
for more information.
• Event codes
2. Inspect the circuit between the ECM and
• Air inlet and exhaust restrictions the keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
• Throttle signal and the components in the circuit. Refer to
Troubleshooting, “Electrical Power Supply - Test”
• Power supply for the Electronic Control Module for more information.
(ECM)
Diagnostic Codes and Event Codes 3. Check the fuel lines for the following problems:
restrictions, collapsed lines, pinched lines, and
Certain diagnostic codes and/or event codes may loose connections. If problems are found with the
cause poor performance. Connect Caterpillar fuel lines, repair the lines and/or replace the lines.
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that 4. Prime the fuel system if any of the following
are present before continuing with this procedure. procedures have been performed:
Check the air inlet and exhaust system for restrictions 5. Check the fuel tank for foreign objects which may
and/or leaks. Refer to Systems Operation/Testing block the fuel supply.
and Adjusting.
6. Check the fuel filters.
8. Cold weather adversely affects the characteristics Multiple Diagnostic Codes for the Injector
of the fuel. Refer to the Operation and Solenoids
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather If two diagnostic codes for the injector solenoids are
operation. active for a 12 cylinder engine at the same time,
then the primary ECM will terminate the primary
i02628640
ECM heartbeat signal to the secondary ECM. If
four diagnostic codes for the injector solenoids
Secondary ECM Assumes are active for a 16 cylinder engine at the same
time, then the primary ECM will terminate the
Control primary ECM heartbeat signal to the secondary
ECM. The secondary ECM will assume control of
SMCS Code: 1901-035 governing if the primary ECM heartbeat signal to
the secondary ECM is interrupted. Check for active
Use this procedure in order to troubleshoot the diagnostic codes or for logged diagnostic codes
reason that the secondary Electronic Control Module for the injector solenoids. If diagnostic codes are
(ECM) has assumed control of the engine. present or if diagnostic codes were logged, refer to
Troubleshooting, “Injector Solenoid - Test”.
Probable Causes
Engine Overspeed Condition
• Battery voltage to the primary ECM
If an engine overspeed occurs, the secondary ECM
• Loss of primary ECM heartbeat signal will assume control of governing. The secondary
ECM will stop fuel injection to the engine. The
• Diagnostic codes for the injector solenoids secondary ECM will remain in control of governing
until keyswitch power to the primary ECM has
• Engine overspeed condition been cycled. Determine the cause for the engine
overspeed. Refer to Troubleshooting, “Engine
Recommended Actions Overspeeds”.
i02629167
Synchronization Problem
SMCS Code: 1900-035
• Engine location
• Secondary throttle
The logic and wiring for synchronization is dependent
upon the number of engines that are being
synchronized. The ECM response is dependent on
the programmed engine location. Refer to Table 22
for the engine locations that are valid for a given
number of engines.
KENR5404-03 67
Troubleshooting Section
Table 23
Engine Synchronization Input Active Throttle Synchronization
Status
1 2
Open Open Primary unavailable
Open Low Secondary unavailable
Low Open Primary unavailable
Low Low Primary unavailable
g01331942
Illustration 18
Wiring for the throttle in a twin engine installation
Table 24
Synchronization No Synchronization Synchronization Synchronization
Status Port Side Starboard Side
Port Engine Open Low Open
Synchronization
Input
1
Engine Open Open Low
Synchronization
Input
2
Active Throttle Primary Primary Secondary
Starboard Engine Open Open Low
Synchronization
Input
1
Engine Open Low Open
Synchronization
Input
2
Active Throttle Primary Secondary Primary
Table 25
Table 26
Engine Synchronization Input Active Throttle Starboard ECM
Synchronization
1 2 Status
Open Open Primary No
Synchronization
Open Low Secondary Synchronization
on the Port side
Low Open Primary Synchronization
on the Starboard
side
Low Low Primary Invalid
KENR5404-03 69
Troubleshooting Section
g01331943
Illustration 19
Wiring for the throttle in a triple engine installation (center as master throttle)
Table 27
Engine Synchronization Input No Synchronization Synchronization
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Secondary
g01331944
Illustration 20
Wiring for the throttle in a triple engine installation (Port as master throttle)
Table 28
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
g01331946
Illustration 21
Wiring for the throttle in a triple engine installation (starboard as master throttle)
72 KENR5404-03
Troubleshooting Section
Table 29
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
g01331950
Illustration 22
Wiring for the throttle in a triple engine installation (fourth throttle as master throttle)
Table 30
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Center Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
74 KENR5404-03
Troubleshooting Section
Table 31
Engine Synchronization Input Active Throttle Port
Starboard
1 2 Center
Synchronization
Status
(same for all)
Open Open Primary No
Synchronization
Open Low Secondary Synchronization
Low Open Primary Synchronization
Low Low Primary Invalid
2. Check the wiring for continuity or shorts between Remove the valve mechanism covers. Refer to
the throttle position sensor and the ECM. Disassembly and Assembly for removing the valve
mechanism cover. Check the lubrication in the valve
3. Check the wiring for continuity or shorts between compartment. Ensure that there is adequate engine
the ECM connectors. oil flow in the valve compartment. The passages for
the engine oil must be clean.
Check the synchronizing switch for proper
operation. Worn Valve Train Components
1. Disconnect the wiring from the synchronizing 1. Inspect the following components of the valve
switch. train:
• Camshaft
• Valve stems
• Rocker shafts
2. Check the components for the following conditions:
abnormal wear, excessive wear, straightness, and
cleanliness. Replace parts, if necessary.
i02643299
Probable Cause
• Valve Components
Recommended Actions
Valve components
1. A valve rotator that is cracked or a valve rotator
that is broken is an indication of an engine
overspeed. Determine the cause of the engine
overspeed. Repair the condition.
• Valve rotators
• Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the
piston. If the valve has contacted the piston, check
the exhaust system for debris.
Circuit Tests
i02634043
Table 32
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
446-5 Air Shutdown Relay current below The Electronic Control Module (ECM) The code is logged.
normal detects low current in the circuit. The
ECM can only detect this condition when
the output driver is not activated.
446-6 Air Shutoff Relay short The ECM detects excessive current flow
in the circuit. The ECM can only detect
this condition when the output driver is
activated.
The secondary ECM has the ability to stop the engine Relay “R3A” and relay “R3” are energized through
by shutting off the inlet air supply in an emergency terminal 3 of the diode assembly. Terminal 3 of the
situation. The secondary ECM activates the output diode assembly will energize relay “R3A” and relay
driver for the emergency shutdown system. The “Air “R3” for one second. The contacts of relay “R3” keep
Shutoff Switch (ASOS)” energizes the two air shutoff relay “R3A” and relay “R3” energized until power is
solenoids. The solenoids trip the air shutoff valves. cycled. The contacts of relay “R3A” keep the coils of
relay “R2” and relay “R2A” energized. When relays
There are two conditions which cause the engine “R2” and “R2A” are energized, power is removed
control to activate the output driver for the air shutoff from the primary ECM and the secondary ECM. The
relay. The first condition occurs when the operator primary ECM and the secondary ECM will power
activates the customer's emergency stop. When the down. The injection signals to the injector solenoids
customer's emergency stop button is activated, the will stop.
emergency stop inputs U and T to the primary ECM
and the secondary ECM from the customer connector The contact of relay “R3A” also supplies power to
go high. The secondary ECM will recognize this terminal 3 of the connector for a timer. When power
change. The secondary ECM will energize the output is applied to terminal 3 of the connector for the timer,
drive for the emergency shutdown system for one the timer will activate. The timer outputs 24 VDC
second through the diode assembly. from terminal 6 of the connector for the timer for
2.5 seconds. The 24 VDC from the timer is applied
The second condition occurs for an engine to the coil of the “ASOS” and to terminal 2 of the
overspeed. If an engine overspeed occurs, the ECM diode assembly. The “ASOS” energizes the two air
will activate the output driver for the emergency shutoff solenoids. The solenoids trip the air shutoff
shutdown system through the diode assembly. An valves. The 2.5 second time limit for activation of the
overspeed can be simulated by using Caterpillar “ASOS” prevents damage to the air shutoff solenoids.
Electronic Technician (ET). In order to verify that the A normally open switch at the air shutoff valves will
overspeed function is operable, the operator must close when the air shutoff solenoid activates the
access the screen for overriding parameters on Cat air shutoff valve. The switch inputs a signal to the
ET. When the override for the engine overspeed is primary ECM and to the secondary ECM. The signal
set to the ON position, the setpoint for the engine notifies the primary ECM and the secondary ECM
overspeed is at 75% of the original setpoint. When that the air shutoff valves are closed. The primary
the engine reaches the modified setpoint, the normal ECM and the secondary ECM will not send injection
strategy for an engine overspeed is initiated. signals to the injector solenoids until the switch inputs
from the air shutoff valves indicate that the valves
are open.
KENR5404-03 77
Troubleshooting Section
g01320000
Illustration 23
Typical example
KENR5404-03 79
Troubleshooting Section
g01320528
Illustration 25
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01322302
Illustration 24
Terminal locations for the following connectors P-C1/A-C90 Test Step 1. Inspect the Electrical
Connector for the power distribution panel, A-C2/J-C2 RH rigid Connectors and the Wiring
harness connector, and C-C2/J-C1 LH rigid harness connectors
(Terminal G) Drive for the air shutoff switch F708-BK A. Turn the circuit breaker for the battery to the OFF
(Terminal H) Return for the air shutoff solenoid H708-BK position.
(Terminal I) Drive for the air shutoff solenoid G708-BK
E. Check the harness and the wiring for abrasion C. Reconnect the P-C1/A-C90 connector.
and for pinch points.
D. Activate the customer's emergency stop switch.
Expected Result:
E. Monitor the voltage on the wire jumper in terminal
All connectors, pins, and sockets are completely I at connector A-C90 of the rigid harness. Refer to
coupled and/or inserted, and the harness and wiring Illustration 24 for terminal locations.
are free of corrosion, of abrasion or of pinch points.
F. Deactivate the customer's emergency stop switch.
Results:
G. Return all wiring to the original configuration.
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2. Expected Result:
• Not OK – There is a problem in the connectors The voltage measures 24 ± 3 VDC for approximately
and/or wiring. 2.5 seconds.
STOP. Results:
• Not OK – The air shutoff solenoids failed to • OK – The voltage measures 24 ± 3 VDC for
activate. Proceed to Test Step 3. approximately one second. The circuit is operating
correctly to this point. Proceed to Test Step 5.
Test Step 3. Check for the Voltage from
the “ASOS” at the Connector P-C1/A-C90 • Not OK – No voltage was measured. Proceed to
for the Power Distribution Panel Test Step 14.
A. Turn the ECS to the STOP position. Test Step 5. Test for Voltage to the Coil
of the “ASOS”
B. Remove wire G708-BK from terminal “I” of
connector A-C90. Install a wire jumper into the A. Turn the ECS to the OFF/RESET position.
connector for wire G708-BK.
KENR5404-03 81
Troubleshooting Section
F. Deactivate the customer's emergency stop switch. Repair: Verify that 24 ± 3 VDC is present on wire
K708-BK at the normally open contacts of the
G. Return all wiring to the original configuration. “ASOS”. If voltage is not present on wire K708-BK,
check the wiring and the circuit breaker for the air
Expected Result: shutoff for problems.
The voltage measures 24 ± 3 VDC for approximately Check wire 220-BK on the coil of the “ASOS” for
2.5 seconds. continuity to the −Battery. If necessary, repair the
wire or replace the wire.
Results:
If wire 220-BK is OK and voltage is present on wire
• OK – The voltage measures 24 ± 3 VDC for K708-BK, replace the “ASOS”.
approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 6. STOP.
• Not OK – No voltage was measured. Proceed to Test Step 7. Check the Voltage at the
Test Step 10. Connector for the Air Shutoff Solenoids
• Not OK – The voltage did not measure 24 ± 3 VDC A. Turn the ECS to the OFF/RESET position.
for 2.5 seconds. Proceed to Test Step 8.
B. Disconnect the connector for the air shutoff
Test Step 6. Check for Voltage from the solenoids. Disconnect the connector for the right
“ASOS” to the Air Shutoff Solenoids and left sides of the engine.
A. Turn the ECS to the OFF/RESET position. C. Connect a voltmeter between wire G708-BK on
the connector for the air shutoff solenoid and the
B. Disconnect wire G708-BK from the “ASOS”. engine ground.
C. Connect a voltmeter to the empty terminal on the D. Turn the ECS to the STOP position.
“ASOS”. Connect the other lead of the voltmeter
to engine ground. E. Activate the customer's emergency stop switch.
D. Turn the ECS to the STOP position. F. Monitor the voltage on the voltmeter.
E. Activate the customer's emergency stop switch. G. Deactivate the customer's emergency stop switch.
F. Monitor the voltage on the voltmeter. H. Reconnect the connectors for the air shutoff
solenoids.
G. Deactivate the customer's emergency stop switch.
Expected Result:
H. Reconnect wire G708-BK to the “ASOS”.
The voltage measures 24 ± 3 VDC for approximately
Expected Result: 2.5 seconds.
Repair: Check the wire H708-BK from terminal D. Turn the ECS to the STOP position.
A of the connector for the air shutoff solenoid
for continuity to the −Battery terminal. If the wire E. Activate the customer's emergency stop switch.
H708-BK to the −Battery terminal is OK, replace
the air shutoff solenoid. F. Monitor the voltage on the voltmeter.
• Not OK – The voltage did not measure 24 ± 3 VDC H. Return all wiring to the original configuration.
for approximately 2.5 seconds. System voltage
was not available at the solenoid connector. Expected Result:
Repair: Repair the wire G708-BK between the The voltage measures 24 ± 3 VDC for approximately
connector for the air shutoff solenoids and terminal 2.5 seconds.
I at connector A-C90 of the rigid harness. Refer to
Illustration 23 for a schematic of the circuit. Results:
B. Disconnect wire T120-BK from terminal 87 of Repair: Check for 24 ± 3 VDC on terminal 3 of the
relay “R3A”. connector for the timer. If voltage is not present
on terminal 3, repair the wire T120-BK between
C. Connect a voltmeter between terminal 87 of relay terminal 87 of relay “R3A” and terminal 3 of the
“R3A” and the engine ground. connector for the timer.
D. Turn the ECS to the STOP position. If voltage is present on terminal 3 of the connector
for the timer, verify that wire 220-BK on terminal 2
E. Activate the customer's emergency stop switch. of the connector for the timer has continuity to the
−Battery. If wire 220-BK does not have continuity
F. Monitor the voltage on the voltmeter. to the −Battery, repair the wire.
G. Deactivate the customer's emergency stop switch. Verify that 24 ± 3 VDC is present on terminal 1
of the connector for the timer. If 24 ± 3 VDC is
H. Reconnect wire T120-BK. not present on terminal 1 of the connector for the
timer, verify that the engine control switch is not in
Expected Result: the “OFF/RESET” position. Verify that the “MPD”
breaker is not tripped. Check the normally closed
The voltage measures 24 ± 3 VDC. contact of relay “R1” for proper operation. Check
the wire 120 between terminal 1 of the connector
Results: for the timer and relay “R1” for damage. Check
the wire A120 between relay “R1” and the “MPD”
• OK – The voltage measures 24 ± 3 VDC. Proceed breaker for damage. If necessary, repair the wires.
to Test Step 9.
If the voltage is present on terminal 1 and terminal
• Not OK – The voltage did not measure 24 ± 3 3 of the timer and wire 220-BK is OK, replace the
VDC. Proceed to Test Step 11. timer.
Test Step 10. Check the Voltage at If the voltage does not measure 24 ± 3 VDC for
Terminal 4 of the Connector for the approximately one second, repair the wire F708-BK
Diodes between the connector for the diodes and wire
F708-BK on pin G at connector A-C90 of the right
A. Turn the ECS to the OFF/RESET position. rail. Return all wiring to the original configuration.
F. Monitor the voltage on the voltmeter. C. Connect a voltmeter between wire 918-BK and
the engine ground.
G. Deactivate the customer's emergency stop switch.
D. Turn the ECS to the STOP position.
H. Return all wiring to the original configuration.
E. Activate the customer's emergency stop switch.
Expected Result:
F. Monitor the voltage on the voltmeter.
The voltage measures 24 ± 3 VDC for approximately
one second. G. Deactivate the customer's emergency stop switch.
5. Monitor the voltage on the voltmeter. If wire 220-BK is OK and voltage is present on wire
120-BK on terminal 30, replace relay “R3A”.
6. Deactivate the customer's emergency stop
switch. STOP.
If the voltage measures 24 ± 3 VDC for • Not OK – The voltage did not measure 24 ± 3
approximately one second, replace the diodes. VDC. Proceed to Test Step 13.
84 KENR5404-03
Troubleshooting Section
B. Remove wire T708 from terminal 2 of the • OK – The voltage measures 24 ± 3 VDC.
connector for the diodes.
Repair: Repair the wire 918-BK between the
C. Connect a voltmeter between wire T708 and the diodes and relay “R3A”.
engine ground.
STOP.
D. Turn the ECS to the STOP position.
• Not OK – The voltage did not measure 24 ± 3
E. Activate the customer's emergency stop switch. VDC.
H. Return all wiring to the original configuration. Test Step 14. Check the Output Driver for
the Air Shutoff System at the ECM
Expected Result:
A. Turn the ECS to the OFF/RESET position.
The voltage measures 24 ± 3 VDC.
B. Disconnect the secondary ECM connector P2.
Results:
C. Remove wire F708-BK from ECM connector
• OK – The voltage measures 24 ± 3 VDC. Proceed P2-13. Install a wire jumper into P2-13.
to Test Step 13.
D. Reconnect ECM connector P2.
• Not OK – The voltage did not measure 24 ± 3
VDC. E. Connect a voltmeter between the wire jumper in
P2-13 and engine ground.
Repair: Repair the wire T708-BK between the
diodes and the timer. F. Turn the ECS to the STOP position.
Test Step 13. Check the Voltage from H. Monitor the voltage on the voltmeter.
Terminal 3 of the Connector for the Diode
Assembly I. Deactivate the customer's emergency stop switch.
A. Turn the ECS to the OFF/RESET position. J. Return all wiring to the original configuration.
E. Activate the customer's emergency stop switch. Repair: Repair the wire F708-BK between the
ECM connector and terminal G at connector A-C90
F. Monitor the voltage on the voltmeter. of the rigid harness. Refer to Illustration 23 for a
schematic of the circuit. Check for voltage at the
G. Deactivate the customer's emergency stop switch. following connectors C-C2/J-C1 LH rigid harness
connectors and A-C2/J-C2 RH rigid harness
H. Return all wiring to the original configuration. connectors.
STOP.
KENR5404-03 85
Troubleshooting Section
STOP.
i02635725
g01321352
Illustration 26
Typical example
KENR5404-03 87
Troubleshooting Section
g01321419 g01321422
Illustration 27 Illustration 29
P1 ECM connector Customer connector
(P1-34) J1939 data link − (Terminal BT) J1939 shield
(P1-42) J1939 shield (Terminal BU) J1939 data link −
(P1-50) J1939 data link + (Terminal BV) J1939 data link +
Repair the connectors or wiring and/or replace • OK – There are no shorts. Proceed to Test Step 4.
the connectors or wiring. Ensure that all of the
seals are properly in place and ensure that the • Not OK – A short exists in the wiring harness.
connectors are completely coupled. Refer to
Troubleshooting, “Electrical Connectors - Inspect”. Repair: Make the necessary repairs.
Verify that the repair eliminates the problem. Verify that the repair eliminates the problem.
STOP. STOP.
Test Step 2. Verify the Proper Installation Test Step 4. Check for an Open Circuit
of the Data Link Circuit
A. Make sure that all connections remain
A. Disconnect any module that is connected to the disconnected.
CAN data link.
B. Fabricate a jumper wire. Use the jumper wire in
B. Disconnect J1/P1 ECM connector and measure order to short pin F to pin G on the service tool
the resistance between P1-50 (CAN data link +) connector.
and P1-34 (CAN data link -).
C. Measure the resistance between P1-50 (CAN
Expected Result: data link +) and P1-34 (CAN data link -) at the
ECM connector.
The resistance is between 57 and 63 Ohms.
D. Remove the wire short.
Results:
Expected Result:
• OK – The resistance is within the range. Proceed
to Test Step 5. The resistance measurement indicates a short circuit.
Expected Result:
Results:
STOP.
STOP.
i02635835
Table 33
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
248-9 @CatDatalinkLong@ not Communication on the Cat Data Link The ECM will log the diagnostic code.
communicating was lost for the last two seconds.
g01321352
Illustration 30
Typical example
KENR5404-03 91
Troubleshooting Section
g01156133 g01161996
Illustration 31 Illustration 32
P1 ECM connector Customer connector
(P1-8) Cat Data Link + (Terminal g) Cat Data Link +
(P1-9) Cat Data Link − (Terminal h) Cat Data Link −
g01161999
Illustration 33
Service tool connector
(Terminal D) Cat Data Link +
(Terminal E) Cat Data Link −
All connectors, pins, and sockets are completely Repair: Repair the connectors and/or the wiring.
inserted and coupled. The harness and wiring are Replace parts, if necessary. Verify that the original
free of corrosion, of abrasion, and of pinch points. problem is resolved.
Results: STOP.
• OK – The harness and the connectors appear to Test Step 3. Check for an Open Circuit
be OK. Proceed to Test Step 2.
A. Fabricate a jumper wire. Use the jumper wire in
• Not OK – The connectors and/or the wiring are order to create a short circuit between terminals
not OK. D (Cat Data Link +) and terminal E (Cat Data Link
−) on the service tool connector.
Repair: Repair the connectors and/or the wiring.
Replace parts, if necessary. Ensure that all of the B. Measure the resistance between P1-8 (Cat Data
seals are properly in place and ensure that the Link +) and P1-9 (Cat Data Link −).
connectors are completely coupled. Verify that the
original problem is resolved. C. Measure the resistance between the terminals
at the connector for each control module that
STOP. was connected to the Cat Data Link. Refer to
Illustration 30.
Test Step 2. Check for a Short Circuit
D. Remove the jumper wire from the service tool
A. Disconnect the P1 ECM connector. connector.
C. Disconnect any other control modules from the Each check of the resistance indicates a short circuit.
Cat Data Link. Refer to the electrical schematic in
order to identify other control modules on the Cat Results:
Data Link.
• OK – Each check of the resistance indicates a
D. Measure the resistance between the points that short circuit.
are listed in Table 34. Be sure to wiggle the wires
in the harnesses as you make each resistance Repair: Perform the following procedure:
measurement.
1. Connect the J1/P1 connectors. Connect Cat ET
Table 34 to the service tool connector.
Resistance Measurements for the Cat Data Link
2. Check the Cat Data Link for proper operation. If
Connector and Terminal the Data Link does not operate correctly, there
Terminal may be a problem with the ECM.
P1-8 (Cat Data Link +) All of the other terminals on
the P1 connector
Ground stud
P1-9 (Cat Data Link -) All of the other terminals on
the P1 connector
Ground stud
KENR5404-03 93
Troubleshooting Section
STOP.
STOP.
i03140238
Table 35
g01321562
Illustration 34
Typical example
96 KENR5404-03
Troubleshooting Section
g01321565
Illustration 35
P1 connections for the electrical power supply circuit
(P1-52) +Battery
(P1-53) +Battery
(P1-63) −Battery
(P1-65) −Battery
(P1-70) Keyswitch
g01321568
Illustration 36
Terminal locations for the following connectors P-C2/A-C91
Connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors.
(Terminal K) +Battery to primary ECM 150-BK
(Terminal L) +Battery to primary ECM C150-BK
(Terminal M) -Battery to primary ECM D229-BK
(Terminal N) -Battery to primary ECM 229-BK
(Terminal S) -Battery to secondary ECM A287-BK
(Terminal T) -Battery to secondary ECM B287-BK
(Terminal U) +Battery to secondary ECM A103-BK
(Terminal V) +Battery to secondary ECM 103-BK
KENR5404-03 97
Troubleshooting Section
g01320528
Illustration 38
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
g01323336 (6) C-C22 Primary ECM connector P2
Illustration 37
(7) C-C15 Primary ECM connector P1
Terminal locations for the C-C17/F-C1 LH rigid harness connectors (8) C-C28 Secondary ECM connector P2
and the connectors G-C6/F-C2 for a LH Control panel (9) C-C29 Secondary ECM connector P1
(Terminal 14) Keyswitch 113-BK (10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(Terminal 15) Remote keyswitch 040-BK (11) C-C18/TB-C1 Customer connectors
(Terminal 16) +Battery to ECS M150-BK (12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
E. Check the ECM connector (allen head screw) • Not OK – The voltage is incorrect at all of
for the proper torque. Refer to Troubleshooting, the connections to the ECM(s). The wiring or
“Electrical Connectors - Inspect” for details. components between the battery and the ECM are
preventing the voltage from reaching the ECM.
F. Check the harness and the wiring for abrasion Proceed to Test Step 3.
and for pinch points.
• Not OK - P1-70 – The voltage is not 24 ± 3 VDC
Expected Result: on the input for the keyswitch to the ECM. Proceed
to Test Step 6.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Test Step 3. Check the Battery Voltage
are free of corrosion, of abrasion or of pinch points.
A. Turn the ECS to the OFF/RESET position.
Results:
B. Turn the circuit breaker for the battery to the OFF
• OK – The connectors and wiring are OK. Proceed position.
to Test Step 2.
C. Measure no-load battery voltage at the battery
• Not OK – The connectors and/or wiring need terminals. Refer to Testing and Adjusting, “Test
repair. Tools for the Electrical System” for the proper
procedures to check the batteries.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of D. Load test the batteries. Use the 4C-4911
the seals are properly in place and ensure that the Battery Load Tester. Refer to the Operating
connectors are completely coupled. Manual, SEHS9249. Refer to Special Instruction,
SEHS7633.
STOP.
Expected Result:
Test Step 2. Check the Voltage to the ECM
The no-load voltage at the batteries is at least 23.5
A. Disconnect the primary ECM connector J1/P1 and VDC and the batteries pass the load test.
the secondary ECM connector J1/P1.
Results:
B. Turn the circuit breaker for the battery to the ON
position. • OK – The no-load voltage at the batteries is at
least 23.5 VDC, and the batteries pass the load
C. Turn the ECS to the STOP position. test. Proceed to Test Step 4.
D. Measure the voltage between the following pins • Not OK – The no-load voltage at the batteries is
on the primary ECM and on the secondary ECM. less than 23.5 VDC, and/or the batteries fail the
load test.
• P1-52 and P1-63
Repair: The batteries or the alternator are causing
• P1-53 and P1-65 the problem. Recharge the batteries or replace
the batteries. Refer to Systems Operation/Testing
• P1-70 and P1-65 and Adjusting.
The voltage measures 24 ± 3 VDC. The difference Test Step 4. Check the Voltage from the
between the three voltage measurements is less Power Distribution Panel
than 0.5 VDC.
A. Disconnect the P-C2/A-C91 connector on the RH
Results: rigid rail.
• OK – The ECM is receiving the correct battery B. Measure the voltage between the following
voltage. terminals on the P-C2 connector.
Repair: Check continuity of the wiring between • Not OK – The voltage is not 24 ± 3 VDC on
connector A-C91 and the ECM connectors. Check terminal 87A of relay “R2” and/or relay “R2A”.
for opens in the wiring and for shorts in the wiring.
Refer to Illustration 34 for the connectors and Repair: Verify that voltage is not present on wire
terminals that interconnect the two connectors. T120 at the coil of relay “R2A”. If voltage is present
Repair the wiring and/or connectors. on wire T120, check all emergency stop switches
for proper operation. Check for diagnostic codes
STOP. for an engine overspeed. If voltage is not present
on wire T120, replace relay “R2A”.
• Not OK – The voltage does not measure 24 ± 3
VDC. Verify that the wiring to the −Battery does not Verify that voltage is not present on wire T120
have an open circuit. Proceed to Test Step 5. at the coil of relay “R2”. If voltage is present on
wire T120, check all emergency stop switches for
Test Step 5. Check the Voltage at Relay proper operation. Check for a diagnostic code for
“R2” and/or Relay “R2A” an engine overspeed. If voltage is not present on
wire T120, replace relay “R2”.
A. Turn the circuit breaker for the battery to the OFF
position. STOP.
B. Remove the wire 103-BK and the wire A103-BK Test Step 6. Check the Voltage at the ECS
from terminal 87A of relay “R2”.
A. Turn the ECS to the OFF/RESET position.
C. Remove the wire 150-BK and the wire C150-BK
from terminal 87A of relay “R2A”. B. Remove wire 113-BK from terminal 16 of the ECS.
D. Turn the circuit breaker for the battery to the ON C. Turn the ECS to the STOP position.
position.
D. Measure the voltage between terminal 16 and
E. Measure the voltage between the following engine ground. Measure the voltage between
terminals on relay “R2” and relay “R2A”. terminal 20 and engine ground.
• Terminal 87A and the −Battery terminal The voltage measures 24 ± 3 VDC on both terminals.
The voltage measures 24 ± 3 VDC on all terminals. • OK – The voltage is 24 ± 3 VDC on both terminals.
Results: Repair: The wire 113-BK between the ECS and
the primary ECM and/or the secondary ECM needs
• OK – The voltage is 24 ± 3 VDC. repair. Repair the connectors or wiring and/or
replace the connectors or wiring.
Repair: Repair the wiring between relay “R2”
and/or relay “R2A” and the P-C2 connector on the STOP.
RH rigid rail.
• Not OK - Terminal 16 – The correct voltage is not
STOP. present on terminal 16 of the ECS.
100 KENR5404-03
Troubleshooting Section
Repair: If 24 ± 3 VDC is present on terminal 20 of Relay “R3A” and relay “R3” are energized at the
the ECS, replace the ECS. same time as the “ASOS” through terminal 3 of the
diode assembly. Terminal 3 of the diode assembly will
STOP. energize relay “R3A” and relay “R3” for 2.5 seconds.
The relays “R3A” and “R3” will de-energize after 2.5
• Not OK - Terminal 20 – The correct voltage is not seconds. The overspeed indicator on the control
present on terminal 20 of the ECS. panel will illuminate for 2.5 seconds.
Repair: Repair wire M150-BK between terminal In order to start the engine after an emergency
20 of the ECS and the ECM. Check for voltage stop condition, the ECS must be turned to the
at the connectors for the control panel. Check for OFF/RESET position. This resets the ECM and the
voltage at diode D9. Refer to Illustration 34 for the air shutoff timer. In addition to turning the ECS to the
connectors and terminals between the ECM and OFF/RESET position, the operator must manually
terminal 20 on the ECS. open the air shutoff valves before starting the engine.
STOP.
i02637229
g01322358
Illustration 39
Typical example
102 KENR5404-03
Troubleshooting Section
g01320528
Illustration 40
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2 g01322359
Illustration 41
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2 Terminal locations for the C-C17/F-C1 LH rigid harness connectors
(9) C-C29 Secondary ECM connector P1 and the connectors G-C6/F-C2 for a LH Control panel
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel (Terminal 11) 24 VDC 120-BK
(11) C-C18/TB-C1 Customer connectors (Terminal 12) Emergency stop signal 354-BK
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
KENR5404-03 103
Troubleshooting Section
g01322364
Illustration 42
Terminal locations for the P-C2/A-C91 connectors for the power
distribution panel
(Terminal B) Emergency stop signal 354-BK
(Terminal E) 24 VDC 120-BK
g01322442
Illustration 43
Terminal locations for the C-C1/E-C1 LH rigid harness connectors
and the A-C1/E-C2 RH rigid harness connectors
(Terminal f) 24 VDC 120-BK
(Terminal m) Emergency stop signal 354-BK
C. Thoroughly inspect the ECM connectors J1/P1 • Not OK – The air shutoff solenoids failed to
and J2/P2. Inspect all of the other connectors. activate. Proceed to Test Step 3.
Check the allen head screw on each of the
ECM connectors for the proper torque. Refer to Test Step 3. Check for Voltage from the
Troubleshooting, “Electrical Connectors - Inspect” “ASOS” at the Connector P-C1 for the
for the correct torque values. Power Distribution Panel
D. Perform a 45 N (10 lb) pull test on each of the A. Turn the ECS to the OFF/RESET position.
wires in the ECM connectors that are associated
with the circuit. B. Remove wire G708-BK from terminal “I” of
connector A-C90. Install a wire jumper into the
E. Check the harness and the wiring for abrasion connector for wire G708-BK.
and for pinch points.
C. Turn the ECS to the STOP position.
Expected Result:
D. Activate the local emergency stop switch.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring E. Monitor the voltage on the wire jumper in terminal
are free of corrosion, of abrasion or of pinch points. I at connector A-C90 of the rigid harness. Refer to
Illustration 39 for a schematic of the circuit.
Results:
F. Activate the local emergency stop switch.
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2. G. Return all wiring to the original configuration.
D. Monitor the air shutoff solenoids. B. Remove wire 354-BK from terminal “B” of
connector A-C91.
E. Deactivate the local emergency stop switch.
C. Turn the ECS to the STOP position.
Expected Result:
D. Activate the local emergency stop switch.
The air shutoff solenoids activated.
E. Monitor the voltage on wire 354 at connector
Results: A-C91 of the rigid harness.
• OK – The air shutoff solenoids activated correctly. F. Deactivate the local emergency stop switch.
Repair: The problem may be intermittent. If the G. Return all wiring to the original configuration.
problem is intermittent, refer to Troubleshooting,
“Electrical Connectors - Inspect”. Expected Result:
Test Step 5. Test for Voltage at the Coil • OK – The voltage measures 24 ± 3 VDC for
of the “ASOS” approximately 2.5 seconds. The circuit is operating
correctly to this point.
A. Turn the ECS to the OFF/RESET position.
Repair: Repair the wire G708-BK between the
B. The input to the coil of the “ASOS” is wire T708-BK “ASOS” and wire G708-BK on pin I at connector
from terminal 6 of the timer. Remove wire T708-BK P-C1 of the rigid harness.
from the “ASOS”.
STOP.
C. Connect a voltmeter between wire T708-BK from
the “ASOS” and the engine ground. • Not OK – The voltage did not measure 24 ± 3 VDC
for approximately 2.5 seconds.
D. Turn the ECS to the STOP position.
Repair: Verify that 24 ± 3 VDC is present on wire
E. Activate the local emergency stop switch. K708-BK at the normally open contacts of the
“ASOS”. If voltage is not present on wire K708-BK,
F. Monitor the voltage on the voltmeter. check the wire K708-BK and the circuit breaker for
the air shutoff for problems.
G. Deactivate the local emergency stop switch.
If voltage is present on the wire K708-BK, check
H. Return all wiring to the original configuration. wire 220-BK on the coil of the “ASOS” for continuity
to the −Battery. If necessary, repair the wire or
Expected Result: replace the wire. If wire 220-BK is OK and voltage
is present on wire K708-BK, replace the “ASOS”.
The voltage measures 24 ± 3 VDC for approximately
2.5 seconds. STOP.
Test Step 6. Check for Voltage from the C. Connect a voltmeter between wire G708-BK on
“ASOS” to the Air Shutoff Solenoids the connector for the air shutoff solenoid and the
engine ground.
A. Turn the ECS to the OFF/RESET position.
D. Turn the ECS to the STOP position.
B. Disconnect wire G708-BK from the “ASOS”.
E. Activate the local emergency stop switch.
C. Connect a voltmeter to the empty terminal on
the “ASOS”. Connect the other lead from the F. Monitor the voltage on the voltmeter.
voltmeter to engine ground.
G. Deactivate the local emergency stop switch.
D. Turn the ECS to the STOP position.
H. Reconnect the connectors for the air shutoff
E. Activate the local emergency stop switch. solenoids.
The voltage measures 24 ± 3 VDC for approximately The voltage measures 24 ± 3 VDC.
2.5 seconds.
Results:
Results:
• OK – The voltage measures 24 ± 3 VDC. Proceed
• OK – The voltage measures 24 ± 3 VDC for to Test Step 9.
approximately 2.5 seconds. The circuit is operating
correctly to this point. • Not OK – The voltage did not measure 24 ± 3
VDC. Proceed to Test Step 10.
Repair: Check the wire H708-BK from terminal A
of the connector for continuity to the −Battery. If Test Step 9. Check the Voltage at Terminal
the wire H708-BK to the −Battery terminal is OK, 6 of the Connector for the Timer
replace the air shutoff solenoid. Verify that the
circuit operates correctly. A. Turn the ECS to the OFF/RESET position.
If the wire H708-BK does not have continuity to the B. Disconnect wire T708-BK from terminal 6 of the
−Battery from terminal A of the connector, check for connector for the timer.
continuity on wire H708-BK on pin H at connector
P-C1/A-C90 of the rigid harness to −Battery. If C. Connect a voltmeter between terminal 6 of the
the wire H708-BK does not have continuity to the connector for the timer and engine ground.
−Battery from pin H at connector P-C1 of the rigid
harness, verify that the breaker for the air shutoff D. Turn the ECS to the STOP position.
is not tripped.
E. Activate the local emergency stop switch.
STOP.
F. Monitor the voltage on the voltmeter.
• Not OK – The voltage did not measure 24 ± 3 VDC
for approximately 2.5 seconds. System voltage G. Deactivate the local emergency stop switch.
was not available at the solenoid connector.
H. Return all wiring to the original configuration.
Repair: There is a problem in the wiring between
the connector for the air shutoff solenoids and wire Expected Result:
G708-BK on pin I at connector P-C1/A-C90 of
the rigid harness. Repair the connectors or wiring The voltage measures 24 ± 3 VDC for approximately
and/or replace the connectors or wiring. 2.5 seconds.
STOP. Results:
Test Step 8. Check the Voltage at the • OK – The voltage measures 24 ± 3 VDC for
Contact of Relay “R4A” approximately 2.5 seconds.
A. Turn the ECS to the OFF/RESET position. Repair: Repair the wire T708-BK between the
“ASOS” and terminal 6 of the timer.
B. Disconnect wire T120-BK from terminal 87 of
relay “R4A”. STOP.
C. Connect a voltmeter between terminal 87 of relay • Not OK – The voltage did not measure 24 ± 3 VDC
“R4A” and the engine ground. for approximately 2.5 seconds.
D. Turn the ECS to the STOP position. Repair: Check for 24 ± 3 VDC on terminal 3 of the
connector for the timer.
E. Activate the local emergency stop switch.
If voltage is not present on terminal 3, repair the
F. Monitor the voltage on the voltmeter. wire T120-BK between terminal 87 of relay “R4A”
and terminal 3 of the connector for the timer.
G. Deactivate the local emergency stop switch.
If voltage is present on terminal 3 of the connector
H. Turn the ECS to the OFF/RESET position. for the timer, verify that wire 220-BK on terminal 2
of the connector for the timer has continuity to the
I. Reconnect wire T120-BK. −Battery. If wire 220-BK does not have continuity
to the −Battery, repair the wire.
KENR5404-03 107
Troubleshooting Section
Verify that 24 ± 3 VDC is present on terminal 1 of Repair: Repair the wire 354-BK between the coil
the connector for the timer. If 24 ± 3 VDC is not of the “ASOS” and the connector P-C2/A-C91 on
present on terminal 1 of the connector for the timer, the power distribution panel.
verify that the ECS is not in the “OFF/RESET”
position. Verify that the “MPD” breaker is not STOP.
tripped. Check the normally closed contact of
relay “R1” for proper operation. Check the wire Test Step 11. Check the Voltage from the
120-BK between terminal 1 of the connector for Local Emergency Stop Switch to Relay
the timer and relay “R1” for damage. Check the “R4A”
wire A120-BK between relay “R1” and the “MPD”
breaker for damage. If necessary, repair the wires. A. Turn the ECS to the OFF/RESET position.
If the voltage is present on terminal 1 and 3 of the B. Disconnect wire 354-BK from the local emergency
timer and wire 220-BK is OK, replace the timer. stop switch.
C. Turn the ECS to the STOP position. G. Deactivate the local emergency stop switch.
F. Deactivate the local emergency stop switch. The voltage measures 24 ± 3 VDC.
Check for 24 ± 3 VDC on wire 120-BK on terminal • Not OK – The voltage did not measure 24 ± 3
30 of relay “R4A”. If 24 ± 3 VDC is not present VDC. Proceed to Test Step 12.
on wire 120-BK, verify that the ECS is not in the
“OFF/RESET” position. Verify that the “MPD” Test Step 12. Check the Voltage to the
breaker is not tripped. Check the normally closed Local Emergency Stop Switch
contact of relay “R1” for proper operation. Check
the wire 120-BK between terminal 30 of the relay A. Turn the ECS to the OFF/RESET position.
“R4A” and relay “R1” for damage. Check the
wire A120-BK between relay “R1” and the “MPD” B. Connect a voltmeter between wire 120-BK on the
breaker for damage. If necessary, repair the wires. local emergency stop switch and engine ground.
If wire 220-BK is OK and voltage is present on wire C. Turn the ECS to the STOP position.
120-BK on terminal 30, replace relay “R4A”.
D. Monitor the voltage on the voltmeter.
STOP.
Expected Result:
• Not OK – The voltage did not measure 24 ± 3
VDC. The voltage measures 24 ± 3 VDC.
108 KENR5404-03
Troubleshooting Section
Results:
STOP.
STOP.
i02639558
Table 36
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
337-2 Remote Emergency Stop Switch The two inputs from the customer The code is logged.
erratic, intermittent, or incorrect shutdown switch are in the opposite
state.
When the customer's emergency stop button is Relay “R3A” and relay “R3” are energized through
activated, the emergency stop inputs U and T to terminal 3 of the diode assembly. Terminal 3 of the
the primary ECM and the secondary ECM from the diode assembly will energize relay “R3A” and relay
customer connector go high. The secondary ECM will “R3” for one second. The contacts of relay “R3” keep
recognize this change. The secondary ECM activates relay “R3A” and relay “R3” energized until the Engine
the output driver for the emergency shutdown Control Switch (ECS) is cycled to the OFF/RESET
system. The “Air Shutoff Switch (ASOS)” energizes position. The contacts of relay “R3A” keep the coils
the two air shutoff solenoids. The solenoids trip the of relay “R2” and relay “R2A” energized. When relays
air shutoff valves. “R2” and “R2A” are energized, power is removed
from the primary ECM and the secondary ECM. The
primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop.
KENR5404-03 109
Troubleshooting Section
g01322358
Illustration 44
Typical example
KENR5404-03 111
Troubleshooting Section
g01323905
Illustration 45
P1 ECM connector
(P1-23) “E-Stop 1”
(P1-28) “E-Stop 2”
g01323796
Illustration 47
Terminal locations for the TB-C1/C-C18 customer connector
(Terminal U) “E-Stop 1”
(Terminal T) “E-Stop 2”
g01324224
Illustration 46
P2 ECM connector
(P2-13) Drive for the air shutoff
112 KENR5404-03
Troubleshooting Section
g01320528
Illustration 49
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) TB-C1/C-C18 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01322302
Illustration 48
Terminal locations for the following connectors P-C1/A-C90 Test Step 1. Inspect the Electrical
Connector for the power distribution panel, A-C2/J-C2 RH rigid Connectors and the Wiring for the
harness connector, and C-C2/J-C1 LH rigid harness connectors Customer's Emergency Stop
(Terminal G) Drive for the air shutoff switch F708-BK
(Terminal H) Return for the air shutoff solenoid H708-BK Note: The 337-2 diagnostic code is generated
(Terminal I) Drive for the air shutoff solenoid G708-BK
because of a problem with the emergency stop
inputs to the ECM from the customer connector. The
two signals should be at a low potential or the two
signals should be at a high potential. When the two
signals are at a different potential from each other
the diagnostic code is generated.
D. Check for an open circuit in the wiring. Test Step 2. Test the Air Shutoff System
a. Install a wire jumper between terminal U and A. Turn the circuit breaker for the battery to the ON
terminal T at the customer connector. position.
b. Measure the resistance between P1-23 and B. Turn the ECS to the STOP position. The engine
P1-28 on the primary P1 ECM connector and should be off.
on the secondary P1 ECM connector. Wiggle
the harness while performing the resistance C. Activate the customer's emergency stop switch.
checks.
D. Monitor the air shutoff solenoids.
c. Remove the wire jumper.
E. Deactivate the customer's emergency stop switch.
E. Check for a short circuit in the wiring.
Expected Result:
a. Measure the resistance between wire F715-BK
and every wire on the following connectors. The air shutoff solenoids activated.
b. Measure the resistance between wire F719-BK • Not OK – The air shutoff solenoids failed to
and every wire on the following connectors. activate. Proceed to Test Step 3.
• C-C18 customer connector Test Step 3. Check for the Voltage from
the “ASOS” at the Connector P-C1/A-C90
• P1 primary ECM connector for the Power Distribution Panel
• P1 secondary ECM connector A. Turn the ECS to the STOP position. The engine
should be off.
• P2 primary ECM connector
B. Remove wire G708-BK from terminal “I” of
• P2 secondary ECM connector connector A-C90. Install a wire jumper into the
connector for wire G708-BK.
Expected Result:
C. Activate the customer's emergency stop switch.
The resistance checks indicate a short circuit when
the wire jumper is installed. The resistance checks D. Monitor the voltage on the wire jumper in terminal
indicate an open circuit when the wire jumper is I at connector A-C90 of the rigid harness. Refer to
removed. Illustration 44 for terminal locations.
• OK – The harness and wiring appear to be OK. F. Return all wiring to the original configuration.
Verify that the two input signals on terminal U and
terminal T from the customer connector TB-C1 are
at the same potential before proceeding. Proceed
to Test Step 2.
114 KENR5404-03
Troubleshooting Section
The voltage measures 24 ± 3 VDC for approximately D. Activate the customer's emergency stop switch.
2.5 seconds.
E. Monitor the voltage on the voltmeter.
Results:
F. Deactivate the customer's emergency stop switch.
• OK – The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. The circuit is operating G. Return all wiring to the original configuration.
correctly to this point. Proceed to Test Step 7.
Expected Result:
• Not OK – The voltage did not measure 24 ± 3
VDC for approximately 2.5 seconds. Proceed to The voltage measures 24 ± 3 VDC for approximately
Test Step 4. 2.5 seconds.
D. Monitor the voltage on the wire jumper in terminal Test Step 6. Check for Voltage from the
G at connector A-C90 of the rigid harness. Refer “ASOS” to the Air Shutoff Solenoids
to Illustration 44 for terminal locations.
A. Turn the ECS to the OFF/RESET position.
E. Deactivate the customer's emergency stop switch.
B. Disconnect wire G708-BK from the “ASOS”.
F. Return all wiring to the original configuration.
C. Connect a voltmeter to the empty terminal on the
Expected Result: “ASOS”. Connect the other lead of the voltmeter
to engine ground.
The voltage measures 24 ± 3 VDC for approximately
one second. D. Turn the ECS to the STOP position. The engine
should be off.
Results:
E. Activate the customer's emergency stop switch.
• OK – The voltage measures 24 ± 3 VDC for
approximately one second. The circuit is operating F. Monitor the voltage on the voltmeter.
correctly to this point. Proceed to Test Step 5.
G. Deactivate the customer's emergency stop switch.
• Not OK – No voltage was measured. Proceed to
Test Step 14. H. Reconnect wire G708-BK to the “ASOS”.
Repair: Repair the wire G708-BK between the Repair: Check the wire H708-BK from terminal
“ASOS” and terminal I at connector P-C1 of the A of the connector for the air shutoff solenoid
power distribution panel. for continuity to the −Battery terminal. If the wire
H708-BK to the −Battery terminal is OK, replace
STOP. the air shutoff solenoid.
If wire 220-BK is OK and voltage is present on wire Test Step 8. Check the Voltage at the
K708-BK, replace the “ASOS”. Contact of Relay “R3A”
STOP. A. Turn the ECS to the OFF/RESET position.
Test Step 7. Check the Voltage at the B. Disconnect wire T120-BK from terminal 87 of
Connector for the Air Shutoff Solenoids relay “R3A”.
A. Turn the ECS to the OFF/RESET position. C. Connect a voltmeter between terminal 87 of relay
“R3A” and the engine ground.
B. Disconnect the connector for the air shutoff
solenoids. Disconnect the connector for the right D. Turn the ECS to the STOP position.
and left sides of the engine.
E. Activate the customer's emergency stop switch.
C. Connect a voltmeter between wire G708-BK on
the connector for the air shutoff solenoid and the F. Monitor the voltage on the voltmeter.
engine ground.
G. Deactivate the customer's emergency stop switch.
D. Turn the ECS to the STOP position. The engine
should be off. H. Reconnect wire T120-BK.
H. Reconnect the connectors for the air shutoff • OK – The voltage measures 24 ± 3 VDC. Proceed
solenoids. to Test Step 9.
E. Monitor the voltage on the voltmeter. F. Monitor the voltage on the voltmeter.
F. Deactivate the customer's emergency stop switch. G. Deactivate the customer's emergency stop switch.
The voltage measures 24 ± 3 VDC for approximately The voltage measures 24 ± 3 VDC for approximately
2.5 seconds. 2.5 seconds.
Results: Results:
• OK – The voltage measures 24 ± 3 VDC for • OK – The voltage measures 24 ± 3 VDC for
approximately 2.5 seconds. Proceed to Test Step approximately 2.5 seconds.
12.
Repair: Repair the wire T708 between the
• Not OK – The voltage did not measure 24 ± 3 VDC connector for the diodes and the “ASOS”.
for approximately 2.5 seconds.
STOP.
Repair: Check for 24 ± 3 VDC on terminal 3 of the
connector for the timer. If voltage is not present • Not OK – The voltage did not measure 24 ± 3 VDC
on terminal 3, repair the wire T120-BK between for approximately 2.5 seconds.
terminal 87 of relay “R3A” and terminal 3 of the
connector for the timer. Repair:
If voltage is present on terminal 3 of the connector 1. Turn the ECS to the OFF/RESET position.
for the timer, verify that wire 220-BK on terminal 2
of the connector for the timer has continuity to the 2. Disconnect wire F708-BK from terminal 1 of the
−Battery. If wire 220-BK does not have continuity connector for the diodes.
to the −Battery, repair the wire.
3. Connect a voltmeter between wire F708-BK and
Verify that 24 ± 3 VDC is present on terminal 1 the engine ground.
of the connector for the timer. If 24 ± 3 VDC is
not present on terminal 1 of the connector for the 4. Turn the ECS to the STOP position.
timer, verify that the engine control switch is not in
the “OFF/RESET” position. Verify that the “MPD” 5. Activate the customer's emergency stop switch.
breaker is not tripped. Check the normally closed
contact of relay “R1” for proper operation. Check 6. Monitor the voltage on the voltmeter.
the wire 120 between terminal 1 of the connector
for the timer and relay “R1” for damage. Check 7. Deactivate the customer's emergency stop
the wire A120 between relay “R1” and the “MPD” switch.
breaker for damage. If necessary, repair the wires.
If the voltage measures 24 ± 3 VDC for
If the voltage is present on terminal 1 and terminal approximately one second, replace the diodes.
3 of the timer and wire 220-BK is OK, replace the
timer. If the voltage does not measure 24 ± 3 VDC
for approximately one second, repair the wire
STOP. F708-BK between the connector for the diodes
and wire F708-BK on pin G at connector A-C90
Test Step 10. Check the Voltage at of the right rail.
Terminal 4 of the Connector for the
Diodes STOP.
A. Turn the ECS to the OFF/RESET position. Test Step 11. Check the Voltage at the
Coil of Relay “R3A”
B. Disconnect wire T708-BK from terminal 4 of the
connector for the diodes. A. Turn the ECS to the OFF/RESET position.
C. Connect a voltmeter between terminal 4 of the B. Disconnect wire 918-BK from terminal 86 of relay
connector for the diodes and the engine ground. “R3A”.
D. Turn the ECS to the STOP position. C. Connect a voltmeter between wire 918-BK and
the engine ground.
E. Activate the customer's emergency stop switch.
KENR5404-03 117
Troubleshooting Section
E. Activate the customer's emergency stop switch. • OK – The voltage measures 24 ± 3 VDC. Proceed
to Test Step 13.
F. Monitor the voltage on the voltmeter.
• Not OK – The voltage did not measure 24 ± 3
G. Deactivate the customer's emergency stop switch. VDC.
H. Return all wiring to the original configuration. Repair: Repair the wire T708-BK between the
diodes and the timer.
Expected Result:
STOP.
The voltage measures 24 ± 3 VDC.
Test Step 13. Check the Voltage from
Results: Terminal 3 of the Connector for the Diode
Assembly
• OK – The voltage measures 24 ± 3 VDC.
A. Turn the ECS to the OFF/RESET position.
Repair: Check wire 220-BK on the coil of the “R3A”
relay for continuity to the −Battery. If necessary, B. Connect a voltmeter between terminal 3 of the
repair the wire or replace the wire. connector for the diode assembly and the engine
ground.
Check for 24 ± 3 VDC on wire 120-BK on terminal
30 of relay “R3A”. If 24 ± 3 VDC is not present on C. Turn the ECS to the STOP position. The engine
wire 120-BK, verify that the engine control switch should be off.
is not in the “OFF/RESET” position. Verify that the
“MPD” breaker is not tripped. Check the normally D. Activate the customer's emergency stop switch.
closed contact of relay “R1” for proper operation.
Check the wire 120-BK between terminal 30 of the E. Monitor the voltage on the voltmeter.
relay “R3A” and relay “R1” for damage. Check the
wire 120-BK between relay “R1” and the “MPD” F. Deactivate the customer's emergency stop switch.
breaker for damage. If necessary, repair the wires.
Expected Result:
If wire 220-BK is OK and voltage is present on wire
120-BK on terminal 30, replace relay “R3A”. The voltage measures 24 ± 3 VDC.
STOP. Results:
• Not OK – The voltage did not measure 24 ± 3 • OK – The voltage measures 24 ± 3 VDC.
VDC. Proceed to Test Step 13.
Repair: Repair the wire 918-BK between the
Test Step 12. Check the Voltage to diodes and relay “R3A”.
Terminal 2 of the Connector for the
Diodes from the Timer STOP.
A. Turn the ECS to the OFF/RESET position. • Not OK – The voltage did not measure 24 ± 3
VDC.
B. Connect a voltmeter between the terminal 2 of the
connector for the diodes and the engine ground. Repair: Replace the diodes.
F. Deactivate the customer's emergency stop switch. B. Disconnect the secondary ECM connector P2.
Expected Result:
Results:
STOP.
STOP.
i02640069
Table 37
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
336-2 Engine Control Switch erratic, The two inputs from the engine control The code is logged.
intermittent, or incorrect switch are in the opposite state.
The ECS can operate in four modes: OFF/RESET, When the ECS is in the STOP position, the following
START, STOP, and REMOTE. relays energize: “Stop 1” relay and “Stop 2” relay. The
start/run/stop inputs P1-21 and P1-22 will be high.
The primary electronic control module (ECM)
receives three signals that allow the ECM to When the ECS is in the OFF/RESET position, none
determine the mode of operation. The input signals of the relays are energized.
on P1-21 and P1-22 tell the ECM the position of the
ECS. The input signals on P1-21 and P1-22 must
be at the same potential or a diagnostic code will be
generated. The third input signal on P1-68 tells the
ECM if the ECS is in the REMOTE position. If the
input signal on P1-68 is low, the ECM knows that the
ECS is in the REMOTE position. If the input signal on
P1-68 is not low, the ECM knows that the ECS is not
in the REMOTE position.
• C remote start 2
• D remote start 1
• E remote stop 1
• F remote stop 2
• S “ECS (remote/auto)”
• c keyswitch
When the ECS is in the REMOTE position, the
“Remote Start” relay and the “Remote Stop” relay are
energized. When the remote start inputs C and D go
low, the following relays energize: “Run 1” relay, “Run
2” relay, “Reset 1” relay, and “Reset 2” relay. The
start/run/stop inputs P1-21 and P1-22 will be pulled
low. The engine will begin the start cycle. When the
customer's remote stop inputs F and E are low, the
following relays energize: “Stop 1” relay and “Stop
2” relay. The start/run/stop inputs P1-21 and P1-22
will be high. The engine will begin the stop function.
When the ECS is in the REMOTE position, the “ECS
in Remote” relay energizes. The “ECS in Remote”
relay sends a signal to the customer connector that
allows the customer to determine the position of the
ECS.
g01324399
Illustration 50
Typical example
KENR5404-03 121
Troubleshooting Section
g01324452 g01324924
Illustration 51 Illustration 52
P1 Primary ECM connector P2 Primary ECM connector
(P1-21) “Start/Run/Stop 1” (P2-54) “Digital return”
(P1-22) “Start/Run/Stop 2” (P2-55) “Digital return”
122 KENR5404-03
Troubleshooting Section
g01320528
Illustration 53
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01324537
Illustration 54
Terminal locations for the A-C1/E-C2 RH rigid harness connectors
and the C-C1/E-C1 LH rigid harness connectors
(Terminal i) “Start/Run/Stop 1”
(Terminal j) “Start/Run/Stop 2”
(Terminal AL) “Digital return”
(Terminal AK) “Digital return”
KENR5404-03 123
Troubleshooting Section
g01324917
Illustration 55
Terminal locations for the following connectors G-C6/F-
C2/F-C1/A-C92 Connectors for a RH Control panel and
G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(Terminal 19) “Start/Run/Stop 1”
(Terminal 20) “Start/Run/Stop 2”
(Terminal 23) Digital return
(Terminal 45) Digital return
g01324914
Illustration 56
Terminal locations for the TB-C1/C-C18 customer connector
(Terminal C) “Remote start 2”
(Terminal D) “Remote start 1”
(Terminal E) “Remote stop 1”
(Terminal F) “Remote stop 2”
(Terminal S) “ECS in remote”
(Terminal c) “Keyswitch”
C. Thoroughly inspect the primary ECM connectors Test Step 3. Check the Status of the ECS
J1/P1 and J2/P2. Inspect all of the other in the START Position
connectors. Check the allen head screw on each
of the ECM connectors for the proper torque. A. Turn the ECS on the control panel to the START
Refer to Troubleshooting, “Electrical Connectors - position.
Inspect” for the correct torque values.
B. Observe the status for the ECS on Cat ET.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connectors that are associated Expected Result:
with the circuit.
The status for the ECS is “RUN”.
E. Check the harness and the wiring for abrasion
and for pinch points. Results:
C. Turn the ECS on the control panel to the STOP • ECS Not OK – The status for the ECS is not
position. “AUTO”. Proceed to Test Step 6.
D. Observe the status for the ECS on Cat ET. Test Step 5. Install a Wire Jumper at the
ECM in order to Simulate a START/STOP
Expected Result: Function
The status for the ECS is “STOP”. A. Turn the ECS to the OFF/RESET position.
• OK – The ECS is functioning correctly. Proceed C. Remove wire F716 from P1-21. Install a wire
to Test Step 3. jumper into the socket P1-21.
• Not OK – The status for the ECS is not “STOP”. D. Remove wire F717 from P1-22. Install a wire
Proceed to Test Step 5. jumper into the socket P1-22.
G. Install the wire jumper between the wire jumpers J. Observe the status for the ECS on Cat ET.
in P1-21 and P1-22 and engine ground.
K. Turn the ECS to the OFF/RESET position.
H. Turn the ECS to the STOP position. Remove the wire jumpers and replace all wires.
Reconnect the primary ECM connector P1.
I. Observe the status for the ECS on Cat ET.
Expected Result:
J. Remove the wire jumper between the wire jumpers
in P1-21 and P1-22 and engine ground. The status for the ECS displays “AUTO” while the
wire jumper is installed. The status for the ECS
K. Observe the status for the ECS on Cat ET. displays “OFF” when the wire jumper is removed.
Repair: Replace the ECM. Refer to • Not OK – The status for the ECS does not display
Troubleshooting, “ECM - Replace”. the correct state.
F. Install the wire jumper between the wire jumper in D. Measure the voltage between wire F716 and
P1-68 and engine ground. engine ground.
G. Turn the ECS to the STOP position. E. Turn the ECS that is on the control panel to the
OFF/RESET position.
H. Observe the status for the ECS on Cat ET.
F. Replace all wiring to the original configuration.
I. Remove the wire jumper between the wire jumper
in P1-68 and engine ground.
126 KENR5404-03
Troubleshooting Section
• OK – The voltage is 6.5 ± 0.5 VDC. Proceed to B. Remove wire PR775 from terminal 11 of the
Test Step 8. “Remote Start” relay.
• Not OK – The voltage is not 6.5 ± 0.5 VDC. C. Turn the ECS on the control panel to the START
position.
Repair: Repair the wire F716 between the normally
closed contacts on the “Stop 1” relay and the D. Measure the voltage between wire DM775 and
ECM. Refer to Illustration 50 for a schematic of the engine ground at the “Run 1” relay.
connections between the control panel and the
ECM. E. Measure the voltage between wire PR775 and
engine ground at the “Remote Start” relay.
STOP.
F. Turn the ECS that is on the control panel to the
Test Step 8. Check for Voltage at the OFF/RESET position.
Normally Closed Contacts of the “Stop
1” Relay G. Leave wire DM775 disconnected from terminal
21 of the “Run 1” relay. Reconnect wire PR775 to
A. Remove wire DM775 from terminal 21 of the “Stop terminal 11 of the “Remote Start” relay.
1” relay.
Expected Result:
B. Turn the ECS on the control panel to the START
position. The voltage is 6.5 ± 0.5 VDC.
D. Turn the ECS that is on the control panel to the Repair: There is a problem with the wire LR775
OFF/RESET position. between terminal 9 of the ECS and the “Remote
Start” relay. Repair the wire LR775.
E. Reconnect wire LR775 to terminal 12 of the
“Remote Start” relay. STOP.
STOP. Results:
Test Step 11. Check for Voltage on Wire • OK – The voltage is 6.5 ± 0.5 VDC. Proceed to
LR775 at Terminal 9 of the ECS Test Step 13.
A. Remove wire LR775 from terminal 9 of the ECS. • Not OK – The voltage is not 6.5 ± 0.5 VDC.
B. Turn the ECS on the control panel to the START Repair: Repair the wire F717 between the normally
position. closed contacts on the “Stop 2” relay and the
ECM. Refer to Illustration 50 for a schematic of the
C. Measure the voltage between wire LR775 and connections between the control panel and the
engine ground. ECM.
The voltage is 6.5 ± 0.5 VDC. B. Turn the ECS on the control panel to the START
position.
Results:
C. Measure the voltage between terminal 21 of the
• OK – The voltage is 6.5 ± 0.5 VDC. Wire F716 “Stop 2” relay and engine ground.
is OK. Proceed to Test Step 12 in order to check
wire F717. D. Turn the ECS that is on the control panel to the
OFF/RESET position.
• Not OK – The voltage is not 6.5 ± 0.5 VDC.
E. Replace all wiring to the original configuration.
128 KENR5404-03
Troubleshooting Section
Repair: Check the voltage across the coil of the Test Step 15. Check for Voltage at
“Stop 2” relay. If voltage is present across the coil the Normally Closed Contacts of the
of the “Stop 2” relay, ensure that the ECS is not in “Remote Start” Relay
the STOP position.
A. Remove wire LR775 from terminal 22 of the
If no voltage is measured across the coil of the “Remote Start” relay.
“Stop 2” relay, there is a problem with the normally
closed contacts between wire F717 and wire B. Turn the ECS on the control panel to the START
DM776. Replace the “Stop 2” relay and check for position.
diagnostic codes.
C. Measure the voltage between terminal 22 of the
STOP. “Remote Start” relay and engine ground.
Test Step 14. Check for Voltage on Wire D. Turn the ECS on the control panel to the
DM776 OFF/RESET position.
A. Remove wire DM776 from terminal 21 of the “Run E. Reconnect wire LR775 to terminal 22 of the
2” relay. “Remote Start” relay.
D. Measure the voltage between wire DM776 and • OK – The voltage is 6.5 ± 0.5 VDC. Wire F717 is
engine ground at the Run 2 relay. OK.
E. Measure the voltage between wire PR776 and Repair: Check wire C998 for continuity between
engine ground at the Remote Start relay. the ECS and the ECM connector P2-54.
F. Turn the ECS on the control panel to the Check the ECS for proper operation. Check
OFF/RESET position. continuity between terminal 6 and terminal 9 of the
ECS. Check continuity with the ECS in the START
G. Leave wire DM776 disconnected from terminal and STOP positions.
21 of the “Run 2” relay. Reconnect wire PR776 to
terminal 21 of the “Remote Start” relay. Refer to Illustration 50 for a schematic of the
connections between the control panel and the
Expected Result: ECM.
If voltage is not present across the coil of the System Operation Description:
“Remote Start” relay, replace the “Remote Start”
relay. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the injectors
STOP. or if any one of the diagnostic codes in Table 38 is
active or easily repeated.
Test Step 16. Check for Voltage on Wire
LR775 at Terminal 9 of the ECS
A. Remove wire LR775 from terminal 9 of the ECS.
Expected Result:
Results:
STOP.
STOP.
130 KENR5404-03
Troubleshooting Section
Table 38
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
1-5 Cylinder #1 Injector current below The engine's Electronic Control Module The code is logged.
normal (ECM) detects an open circuit. The ECM continues to fire the injector
solenoid.
1-6 Cylinder #1 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
2-5 Cylinder #2 Injector current below The ECM detects an open circuit. The code is logged.
normal The ECM continues to fire the injector
solenoid.
2-6 Cylinder #2 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
3-5 Cylinder #3 Injector current below The ECM detects an open circuit. The code is logged.
normal The ECM continues to fire the injector
solenoid.
3-6 Cylinder #3 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
4-5 Cylinder #4 Injector current below The ECM detects an open circuit. The code is logged.
normal The ECM continues to fire the injector
solenoid.
4-6 Cylinder #4 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
5-5 Cylinder #5 Injector current below The ECM detects an open circuit. The code is logged.
normal The ECM continues to fire the injector
solenoid.
5-6 Cylinder #5 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
6-5 Cylinder #6 Injector current below The ECM detects an open circuit. The code is logged.
normal The ECM continues to fire the injector
solenoid.
6-6 Cylinder #6 Injector current above The ECM detects a short circuit. The code is logged.
normal The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
(continued)
KENR5404-03 131
Troubleshooting Section
Perform this procedure under conditions that are If an open is detected in the solenoid circuit, a
identical to the conditions that exist when the problem diagnostic code is generated. The ECM continues
occurs. Typically, problems with the injector solenoid to try to fire the injector. If a short is detected, a
occur when the engine is warmed up and/or when diagnostic code is generated. The ECM will disable
the engine is under vibration (heavy loads). the solenoid circuit. The ECM will periodically try
to fire the injector. If the short circuit remains, this
These engines have Electronic Unit Injectors (EUI) sequence of events will be repeated until the problem
that are mechanically actuated and electronically is corrected.
controlled. The ECM sends a 105 volt pulse to each
injector solenoid. The pulse is sent at the proper time When an injector is replaced, program the new
and at the correct duration for a given engine load injector code into the ECM. If the ECM is replaced, all
and speed. The solenoid is mounted on top of the sixteen injector codes must be programmed into the
fuel injector body. new ECM. The injector codes are a four digit number.
Refer to Troubleshooting, “Configuration Parameters”
for information on injector codes.
g01325305
Illustration 57
Typical schematic
KENR5404-03 135
Troubleshooting Section
g01152207
Illustration 58
P2 terminals that are associated with the injector solenoids
(P2-1) Injector cylinder #1 power
(P2-2) Injector cylinder #1 return
(P2-3) Injector cylinder #2 power
(P2-4) Injector cylinder #2 return
(P2-40) Injector cylinder #3 power
(P2-41) Injector cylinder #3 return
(P2-42) Injector cylinder #4 power
(P2-43) Injector cylinder #4 return
(P2-14) Injector cylinder #5 power
(P2-15) Injector cylinder #5 return
(P2-16) Injector cylinder #6 power
(P2-17) Injector cylinder #6 return
(P2-48) Injector cylinder #7 power
(P2-49) Injector cylinder #7 return
(P2-50) Injector cylinder #8 power
(P2-51) Injector cylinder #8 return
(P2-24) Injector cylinder #9 power
(P2-25) Injector cylinder #9 return
(P2-34) Injector cylinder #10 power
(P2-35) Injector cylinder #10 return
(P2-58) Injector cylinder #11 power
(P2-59) Injector cylinder #11 return g01325367
Illustration 59
(P2-52) Injector cylinder #12 power
(P2-62) Injector cylinder #12 return Terminal locations for the C-C1/E-C1 LH rigid harness connectors
(P2-32) Injector cylinder #13 power and the A-C1/E-C2 RH rigid harness connectors
(P2-33) Injector cylinder #13 return
(P2-60) Injector cylinder #14 power
(P2-61) Injector cylinder #14 return
(P2-5) Injector cylinder #15 power
(P2-18) Injector cylinder #15 return
(P2-26) Injector cylinder #16 power
(P2-27) Injector cylinder #16 return
136 KENR5404-03
Troubleshooting Section
(Terminal BC) Injector cylinder #1 power B. Thoroughly inspect the ECM connector J2/P2.
(Terminal BM) Injector cylinder #1 return Inspect the connectors for the injectors. Refer to
(Terminal BD) Injector cylinder #3 power
the diagnostic functional test Troubleshooting,
(Terminal BN) Injector cylinder #3 return
(Terminal BE) Injector cylinder #5 power “Electrical Connectors - Inspect” for details.
(Terminal BP) Injector cylinder #5 return
(Terminal BF) Injector cylinder #7 power C. Perform a 45 N (10 lb) pull test on each of the
(Terminal BR) Injector cylinder #7 return wires in the ECM connector that are associated
(Terminal BH) Injector cylinder #9 power
(Terminal BS) Injector cylinder #9 return
with the circuit.
(Terminal BJ) Injector cylinder #11 power
(Terminal BT) Injector cylinder #11 return D. Check the allen head screw on each ECM
(Terminal BK) Injector cylinder #13 power connector for the proper torque. Refer to
(Terminal BU) Injector cylinder #13 return
Troubleshooting, “Electrical Connectors - Inspect”
(Terminal BL) Injector cylinder #15 power
(Terminal BV) Injector cylinder #15 return for the correct torque values.
Expected Result:
Results:
STOP.
• Not OK – A 1-06 to 16-06 code is logged. Proceed Test Step 4. Check the Harness between
to Test Step 5. the ECM and the Injector Connectors for
an Open Circuit
Test Step 3. Perform the “Cylinder Cutout
Test”
A. Remove power from the ECM. Do not come in contact with the fuel injector ter-
minals while the engine is running.
B. Verify that the ECM connector J2/P2 and the
injector connectors are properly connected. A. Remove power from the ECM.
C. Restore power to the ECM. B. Disconnect the connectors for the suspect
injector(s).
D. Start the engine.
C. Fabricate a jumper wire 100 mm (4 inch) long with
E. Apply a load to the engine. Deutsch pins on both ends of the wire.
F. Perform the following steps on all suspect D. Insert one end of the jumper wire into the socket
cylinders (solenoids). for the suspect injector's power wire. Insert the
other end of the jumper wire into the socket for the
G. Use the diagnostic tests on Cat ET to initiate the suspect injector's return wire. This will replace the
“Cylinder Cutout Test”. injector solenoid with a short circuit.
H. Perform the “Cylinder Cutout Test”. Disable the E. Restore power to the ECM.
suspect cylinder(s) during the test.
Note: This test will help the service technician verify
Expected Result: that the ECM can fire the solenoids. Do not try to
manually crank the engine during this test. The ECM
The results indicated that the remaining injectors will terminate the “Injector Solenoid Test”.
used more fuel when the “Cylinder Cutout Test”
disabled the suspect injector(s). F. Perform the “Injector Solenoid Test” at least two
times.
Results:
G. Repeat this test for each suspect injector. Stop
• OK – There was a noticeable change in fuel usage. the “Injector Solenoid Test” before handling the
jumper wire.
Repair: The injectors are firing in all cylinders.
Reset the system and check for diagnostic codes. Expected Result:
STOP. Cat ET displays “Short” for the cylinder with the
jumper wire.
• Not OK – There was no noticeable change in fuel
usage. Results:
Repair: Verify that the engine valve lash for that
injector is set correctly. Rerun the “Cylinder Cutout
• OK – Cat ET displays “Short” for the cylinder with
the jumper wire. The harness between the ECM
Test”. If the problem is still present, replace the and the injector connector does not have an open
injector. If the new injector has a trim code that is circuit. Proceed to Test Step 9.
different from the old injector, change the trim code
in the ECM.
• Not OK – Cat ET displays “Open” for a right side
cylinder with a jumper wire. There is a problem
STOP. in the wiring between the ECM and the injector
connector. Proceed to Test Step 7.
138 KENR5404-03
Troubleshooting Section
• Not OK – Cat ET displays “Open” for a left side Test Step 6. Check the Harness between
cylinder with a jumper wire. There is a problem the ECM and the Rigid Harness for a
in the wiring between the ECM and the injector Short Circuit
connector. Proceed to Test Step 8.
All of the suspect cylinders indicate “Open” on Cat ET. • OK – All cylinders indicate “Open” on Cat ET.
The injector wires between the ECM and the rigid
Results: harness do not have a short circuit.
• OK – All cylinders indicate “Open” on Cat ET. Repair: The short circuit is in the harness between
The harness between the ECM and the injector the rigid harness and the connector for the suspect
connector does not have a short circuit. Proceed injector. Repair the harness or the connector.
to Test Step 9.
STOP.
• Not OK – Cat ET displays “Short” for a right side
cylinder. Note the cylinders that indicate “Short”. • Not OK – One or more cylinders indicate “Short”
Proceed to Test Step 6. on Cat ET. Note the cylinders that indicate “Short”.
Proceed to Test Step 8.
• Not OK – Cat ET displays “Short” for a left side
cylinder. Note the cylinders that indicate “Short”.
Proceed to Test Step 8.
KENR5404-03 139
Troubleshooting Section
Test Step 7. Check the Harness between • Not OK – Cat ET displays “Open” for the cylinder
ECM and the Rigid Harness for an Open with the jumper wire. There is a problem in the
Circuit harness between the ECM and the rigid harness.
Proceed to Test Step 8.
Do not come in contact with the fuel injector ter- B. Check the operation of the ECM by creating an
minals while the engine is running. open at the ECM.
D. Install the wire jumper between the suspect c. Reconnect the ECM connector.
injector's power wire and the suspect injector's
return wire. This will replace the injector solenoid d. Restore power to the ECM.
with a short circuit. Refer to Illustration 59 for the
terminal locations for the rigid harness. Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to
E. Restore power to the ECM. manually crank the engine during this test. The ECM
will terminate the “Injector Solenoid Test”.
Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to e. Perform the “Injector Solenoid Test”.
manually crank the engine during this test. The ECM
will terminate the “Injector Solenoid Test”. f. All of the suspect cylinders indicate “Open” on
Cat ET.
F. Perform the “Injector Solenoid Test” at least two
times. g. Remove power from the ECM.
G. Repeat this test for each suspect injector. Stop C. Check the operation of the ECM by creating a
the “Injector Solenoid Test” before handling the short at the ECM.
jumper wire.
a. Create a short between the wire jumper for the
Expected Result: suspect power wire and engine ground.
Cat ET displays “Short” for the cylinder with the b. Restore power to the ECM.
jumper wire.
Note: This test will help the service technician verify
Results: that the ECM can fire the solenoids. Do not try to
manually crank the engine during this test. The ECM
• OK – Cat ET displays “Short” for the cylinder with will terminate the “Injector Solenoid Test”.
the jumper wire. The harness between the rigid
harness and the ECM does not have an open c. Perform the “Injector Solenoid Test”.
circuit.
d. Cat ET displays “Short” for the cylinder with the
Repair: The open circuit is in the harness between jumper wire.
the rigid harness and the connector for the suspect
injector. Repair the harness or the connector. e. Remove power from the ECM.
STOP.
Prelubrication - Test
SMCS Code: 1319-038
• Not OK – The ECM did not detect the open or the
short. System Operation Description:
Repair: Replace the ECM. Refer to Use this procedure to troubleshoot the electrical
Troubleshooting, “ECM - Replace”. Verify system if a problem is suspected with a prelubrication
that the problem is resolved. system or if one of the diagnostic codes in Table 39
is active or easily repeated.
STOP.
Expected Result:
Results:
Table 39
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
338-5 Engine Pre-Lube Pump Relay The engine's Electronic Control Module The code is logged.
current below normal (ECM) detects an open circuit at the
prelube relay.
The ECM detects a short to battery
voltage at the prelube relay.
338-6 Engine Pre-Lube Pump Relay The engine's ECM detects a short
current above normal circuit at the prelube relay.
The ECM has the ability to automatically prelube When the ECM is in the START position, the ECM
the engine before cranking. This prelubrication may will activate the output driver for the “PPR1” relay.
increase the life of certain engine parts. The ECM will When the “PPR1” relay energizes, the normally
prelube the engine, when the Engine Control Switch open contacts of the “PPR1” relay close. This allows
(ECS) is placed in the START position. The ECM will current to flow to the prelube motor. The prelube
prelube the engine, when the ECS is placed in the motor activates the prelube pump. The prelube pump
AUTO position and the remote start/run/stop switch builds pressure in the engine's lubrication system.
is closed. The length of time for the prelube cycle When the “prelube pressure switch” closes as a
can be programmed by the customer. The prelube result of the increased pressure, the ECM input for
cycle will end when the “prelube pressure switch” the “prelube pressure switch” is taken low. The ECM
closes or when the customer programmed time ends. then knows that the pressure in the prelube system is
The engine speed must equal zero rpm before the adequate. The ECM will begin the starting sequence.
prelube will begin.
g01325464
Illustration 61
Typical schematic
KENR5404-03 143
Troubleshooting Section
g01325606 g01325604
Illustration 62 Illustration 63
P1 Primary ECM connector P2 Primary ECM connector
(P1-5) “Digital return” (P2-12) “Prelube drive”
(P1-66) “Prelube override switch” (P2-66) “Digital return”
144 KENR5404-03
Troubleshooting Section
g01325611 g01325633
Illustration 64 Illustration 65
Terminal locations for the P-C1/A-C90 Connector for the power Terminal locations for the P-C2/A-C91 Connector for the power
distribution panel distribution panel
(Terminal c) “Prelube drive +” (Terminal d) Contacts for the prelube motor
(Terminal O) Drive for the prelube motor (Terminal e) Contacts for the prelube motor
(Terminal R) Return for the prelube motor
KENR5404-03 145
Troubleshooting Section
g01325642
Illustration 66
Terminal locations for the following connectors G-C6/F-
C2/F-C1/A-C92 Connectors for a RH Control panel and
G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(Terminal 2) Prelube override switch
(Terminal 34) Digital return
g01325774
Illustration 67
Terminal locations for the A-C1/E-C2/E-C1/C-C1 rigid harness
(Terminal V) Prelube override switch
(Terminal AY) Digital return
146 KENR5404-03
Troubleshooting Section
g01320528
Illustration 69
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01325637 B. Turn the breaker for the ECM to the OFF position.
Illustration 68
Terminal locations for the TB-C1/C-C18 customer connector C. Thoroughly inspect the ECM connectors J1/P1
(Terminal i) Prelube override and J2/P2. Inspect all of the other connectors in
(Terminal y) Contacts for the prelube motor the circuit. Refer to Troubleshooting, “Electrical
(Terminal z) Contacts for the prelube motor
Connectors - Inspect” for the proper procedure for
inspecting system wiring.
F. Check the harness and the wiring for abrasion • Not OK – A 6 diagnostic code is active at this time.
and for pinch points. Proceed to Test Step 3.
Test Step 2. Check for Active Diagnostic Note: Wait at least 30 seconds in order for the
Codes diagnostic code to become active.
A. Connect Cat ET to the service tool connector. E. Select diagnostic tests from Cat ET.
B. Turn the breaker for the ECM to the ON position. F. Select the “Override Parameters” screen on Cat
ET.
C. Turn the ECS to the STOP position.
G. Activate the prelube override.
D. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active H. Monitor the active diagnostic code screen on
diagnostic code. Cat ET. Check the prelube system for an active
diagnostic code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. Note: Wait at least 30 seconds in order for the
diagnostic code to become active.
E. Select diagnostic tests from Cat ET.
I. Turn the ECS to the OFF/RESET position.
F. Select the “Override Parameters” screen on Cat
ET. J. Return all wiring to the original configuration.
H. Monitor the active diagnostic code screen on A 6 diagnostic code was active for the prelube relay.
Cat ET. Check the prelube system for an active After creating an open at the connector P-C1/A-C90
diagnostic code. for the power distribution panel, a 5 diagnostic code
is now active for the prelube relay.
Note: Wait at least 30 seconds in order for the
diagnostic code to become active. Results:
Test Step 4. Create a Short at the Test Step 5. Test the Operation of the
Connector P-C1/A-C90 for the Power ECM
Distribution Panel
A. Fabricate a jumper wire that is long enough to
A. Turn the ECS to the OFF/RESET position. create a test circuit at the ECM connector. Crimp
a connector socket to one end of the jumper wire.
B. Disconnect wire F705-BK from terminal c of the
connector P-C1/A-C90 for the power distribution B. Disconnect the J2/P2 ECM connector.
panel.
C. Remove the wire for the prelube relay from
C. Install a jumper wire between wire F705-BK and terminal P2-12 of ECM connector P2.
engine ground.
D. Install the jumper wire into the terminal location for
D. Turn the ECS to the STOP position. the prelube relay at the ECM connector.
E. Monitor the active diagnostic code screen on E. Connect the ECM connector.
Cat ET. Check the prelube system for an active
diagnostic code. F. Check the operation of the ECM by creating an
open at the ECM connector:
Note: Wait at least 30 seconds in order for the
diagnostic code to become active. a. Hold the loose end of the jumper wire away
from any components in order to create an
F. Select diagnostic tests from Cat ET. open circuit condition.
G. Select the “Override Parameters” screen on Cat b. Turn the ECS to the STOP position.
ET.
c. Monitor the active diagnostic code screen on
H. Activate the prelube override. Cat ET. Check the prelube system for an active
diagnostic code.
I. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active Note: Wait at least 30 seconds in order for the
diagnostic code. diagnostic code to become active.
Note: Wait at least 30 seconds in order for the d. Select diagnostic tests from Cat ET.
diagnostic code to become active.
e. Select the “Override Parameters” screen on
J. Disable the prelube override. Cat ET.
K. Turn the ECS to the OFF/RESET position. f. Activate the prelube override.
L. Return all wiring to the original configuration. g. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active
Expected Result: diagnostic code.
A 6 diagnostic code is active when the jumper wire Note: Wait at least 30 seconds in order for the
is installed. A 5 diagnostic code is active when the diagnostic code to become active.
jumper wire is removed.
h. Disable the prelube override.
Results:
G. Check the operation of the ECM by creating a
• OK – A 6 diagnostic code is active when the short circuit at the ECM connector:
jumper wire is installed. A 5 diagnostic code is
active when the jumper wire is removed. The a. Short the jumper wire in the socket for the
engine harness and the ECM are OK. The open prelube relay to engine ground.
circuit is in the power distribution panel. Proceed
to Test Step 7. b. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active
• Not OK – The 5 diagnostic code remains active diagnostic code.
with the jumper in place. The open circuit is
between the connector P-C1/A-C90 for the power Note: Wait at least 30 seconds in order for the
distribution panel and the ECM. Proceed to Test diagnostic code to become active.
Step 5.
c. Select diagnostic tests from Cat ET.
KENR5404-03 149
Troubleshooting Section
d. Select the “Override Parameters” screen on Note: Wait at least 30 seconds in order for the
Cat ET. diagnostic code to become active.
e. Activate the prelube override. E. Select diagnostic tests from Cat ET.
f. Monitor the active diagnostic code screen on F. Select the “Override Parameters” screen on Cat
Cat ET. Check the prelube system for an active ET.
diagnostic code.
G. Activate the prelube override.
Note: Wait at least 30 seconds in order for the
diagnostic code to become active. H. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active
g. Disable the prelube override. diagnostic code.
H. Turn the ECS to the OFF/RESET position. Note: Wait at least 30 seconds in order for the
diagnostic code to become active.
I. Return all wiring to the original configuration.
I. Disable the prelube override.
Expected Result:
J. Turn the ECS to the OFF/RESET position.
A 5 diagnostic code is active when the wire for the
prelube relay is open at the ECM connector. A 6 K. Leave wire F705-BK disconnected from the
diagnostic code is active if the wire for the prelube “PPR2” relay.
relay is shorted at the ECM connector.
Expected Result:
Results:
A 6 diagnostic code was active for the prelube relay.
• OK – The ECM is operating properly. The problem After creating an open at the “PPR2” relay, the 6
is in the wiring between the ECM and the connector diagnostic code is no longer active.
P-C1/A-C90 for the power distribution panel.
Results:
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. • OK – A 6 diagnostic code is no longer active.
STOP. Repair: The short circuit is in the coil of the “PPR2”
relay. Replace the relay. Return all wiring to the
• Not OK – One of the following conditions exists: original configuration.
The 5 diagnostic code is not active when the
wire for the prelube relay is disconnected. The 6 STOP.
diagnostic code is not active when the wire jumper
is connected to engine ground. • Not OK – A 6 diagnostic code remains active. The
short circuit is in the wiring between the connector
Repair: Replace the ECM. Refer to P-C1/A-C90 for the power distribution panel and
Troubleshooting, “ECM - Replace”. Verify the “PPR1” relay or the short circuit is in the
that the problem is resolved. “PPR1” relay.
Test Step 6. Create an Open at the “PPR2” 1. Remove wire F705-BK from terminal 4 of the
Relay in the Power Distribution Panel “PPR1” relay. Activate the prelube override.
A. Turn the ECS to the OFF/RESET position. If the 6 diagnostic code changes to a 5
diagnostic code, the short is in the “PPR1” relay.
B. Disconnect wire F705-BK from terminal 86 of the Replace the “PPR1” relay.
“PPR2” relay in the power distribution panel.
If the 6 diagnostic code does not change, the
C. Turn the ECS to the STOP position. short is in the wiring between the relays and
terminal c on the connector P-C1/A-C90 for the
D. Monitor the active diagnostic code screen on power distribution panel. Repair the wire.
Cat ET. Check the prelube system for an active
diagnostic code. STOP.
150 KENR5404-03
Troubleshooting Section
Test Step 7. Create a Short at the “PPR1” Verify that wire D229-BK has continuity to the
Relay and at the “PPR2” Relay in the “Primary ECM” breaker from the “PPR1” relay
Power Distribution Panel and from the “PPR2”. If wire D229-BK is OK, the
open is in either the “PPR1” relay or in the “PPR2”.
A. Turn the ECS to the OFF/RESET position. Check the coils of the relays for an open circuit.
F. Monitor the active diagnostic code screen on Test Step 8. Check the Voltage at the
Cat ET. Check the prelube system for an active Prelube Motor
diagnostic code.
A. Turn the ECS to the OFF/RESET position.
Note: Wait at least 30 seconds in order for the
diagnostic code to become active. B. Disconnect connector A-C60 for the prelube
motor.
G. Select diagnostic tests from Cat ET.
C. Connect a voltmeter between terminal 4 and
H. Select the “Override Parameters” screen on Cat engine ground.
ET.
D. Turn the ECS to the STOP position.
I. Activate the prelube override.
E. Select diagnostic tests from Cat ET.
J. Monitor the active diagnostic code screen on
Cat ET. Check the prelube system for an active F. Select the “Override Parameters” screen on Cat
diagnostic code. ET.
Note: Wait at least 30 seconds in order for the G. Activate the prelube override.
diagnostic code to become active.
H. Measure the voltage between terminal 4 and
K. Turn the ECS to the OFF/RESET position. engine ground.
L. Return all wiring to the original configuration. I. Disable the prelube override.
A 5 diagnostic code was active for the prelube relay. K. Return all wiring to the original configuration.
After creating a short at the “PPR1” relay and at the
“PPR2” relay, the 5 diagnostic code changed to a 6 Expected Result:
diagnostic code.
The voltage is 24 ± 3 VDC.
Results:
Results:
• OK – A 6 diagnostic code is active for the prelube
relay. The wiring between the relays and the ECM • OK – The voltage is 24 ± 3 VDC. Proceed to Test
is OK. Step 9.
Repair: The open circuit is in one of the following • Not OK – The voltage is not 24 ± 3 VDC.
components.
Repair: Perform the following steps.
• “PPR1” relay
• “PPR2” relay
• Wire D229-BK
KENR5404-03 151
Troubleshooting Section
STOP.
Expected Result:
Results:
STOP.
STOP.
152 KENR5404-03
Troubleshooting Section
Table 40
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
94-3 Fuel Delivery Pressure Sensor The Electronic Control Module (ECM) The code is logged.
voltage above normal detects signal voltage that is above The value of the parameter is set to
normal for one second. 500 kPa (75 psi).
The ECM has been powered for at least
three seconds.
94-4 Fuel Delivery Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second.
The ECM has been powered for three
seconds.
100-3 Engine Oil Pressure Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal above normal for one second. The value of the parameter is set to
The ECM has been powered for at least 500 kPa (75 psi).
three seconds.
100-4 Engine Oil Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second.
The ECM has been powered for three
seconds.
101-3 Crankcase Air Pressure Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal above normal for one second. The value of the parameter is set to
The ECM has been powered for at least zero.
three seconds.
101-4 Crankcase Air Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second.
The ECM has been powered for at least
three seconds.
110-3 Engine Coolant Temperature The ECM detects signal voltage that is The code is logged.
Sensor voltage above normal above normal for eight seconds. The value of the parameter is set to
The ECM has been powered for at least −40 °C (−40 °F).
two seconds.
110-4 Engine Coolant Temperature The ECM detects signal voltage that is
Sensor voltage below normal below normal for eight seconds.
The ECM has been powered for two
seconds.
273-0 Turbocharger Outlet Pressure The ECM reads turbocharger outlet The code is logged.
Sensor high - most severe (3) pressure above 200 kPa (29 psi). The The value of the parameter is set to
engine speed is within 50 rpm of low idle zero.
for 5 seconds.
273-3 Turbocharger Outlet Pressure The ECM detects signal voltage that is
Sensor voltage above normal above normal for one second.
The ECM has been powered for at least
three seconds.
273-4 Turbocharger Outlet Pressure The ECM detects signal voltage that is
Sensor voltage below normal below normal for one second.
The ECM has been powered for three
seconds.
274-3 Atmospheric Pressure Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal above normal for one second. The value of the parameter is set to
The ECM has been powered for at least 45 kPa (6.5 psi).
three seconds.
274-4 Atmospheric Pressure Sensor The ECM detects signal voltage that is
voltage below normal below normal for one second.
The ECM has been powered for three
seconds.
(continued)
KENR5404-03 153
Troubleshooting Section
g01327574
Illustration 70
Typical schematic
156 KENR5404-03
Troubleshooting Section
g01326575 g01217213
Illustration 71 Illustration 72
P1 ECM connector P2 ECM connector
(P1-2) “5 V sensor supply (LH)” (P2-36) Turbocharger outlet pressure sensor
(P1-3) “Sensor return (LH)” (P2-37) Atmospheric sensor
(P1-6) Aftercooler temperature sensor (P2-38) Left turbocharger inlet pressure sensor
(P1-7) Coolant temperature sensor (P2-39) Right turbocharger inlet pressure sensor
(P1-16) Filtered engine oil pressure sensor (P2-46) Crankcase pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) “5 V sensor supply (RH)”
(P1-24) Filtered fuel pressure
(P1-25) Unfiltered fuel pressure
(P1-35) “Sensor return (RH)”
KENR5404-03 157
Troubleshooting Section
g01094844
Illustration 74
Sensor connector
(Pin A) Sensor supply
(Pin B) Sensor return
(Pin C) Signal
g01326578 g01320528
Illustration 73 Illustration 75
Terminal locations for the A-C1/E-C2 RH rigid harness connectors Connector locations
and the C-C1/E-C1 LH rigid harness connectors
(1) A-C1/E-C2 RH rigid harness connectors
(Terminal A) “Sensor return (RH)” (2) A-C2/J-C2 RH rigid harness connectors
(Terminal B) “5 V sensor supply (RH)” (3) P-C1/A-C90 Connectors for the power distribution panel
(Terminal K) Right turbocharger inlet pressure sensor (4) P-C2/A-C91 Connectors for the power distribution panel
(Terminal d) Crankcase pressure sensor (5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
158 KENR5404-03
Troubleshooting Section
Results:
STOP.
D. Determine if a diagnostic code has occurred • OK – The supply voltage is 5.0 ± 0.5 VDC. An
several times. active 3 diagnostic code is present. Proceed to
Test Step 3.
Note: A diagnostic code that is logged several
times is an indication of an intermittent problem. • OK – The supply voltage is 5.0 ± 0.5 VDC. An
Most intermittent problems are the result of a bad active 4 diagnostic code is present. Proceed to
connection between a socket and a pin in a connector Test Step 5.
or a bad connection between a wire and a terminal.
The problem may be caused by moisture, corrosion, • Not OK – The supply voltage is not 5.0 ± 0.5 VDC.
or wear.
Repair: There is an open in the wiring or
E. Determine if the problem is active and related to connectors between the suspect sensor and the
one of the following diagnostic codes: ECM. Inspect the wiring and connectors. Refer to
Illustration 70 for a schematic of the circuit.
• 3 STOP.
• 4
Expected Result:
Test Step 3. Check for Battery Voltage on Repair: Temporarily connect a new sensor to the
the Signal Wire harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
A. Measure the voltage on the harness side of the codes for the sensor. If there are no active
sensor connector between pin B and pin C for the diagnostic codes for the sensor, permanently
suspect sensor(s). install the new sensor. Clear any logged diagnostic
codes.
Expected Result:
STOP.
The signal voltage is less than Battery voltage.
• Not OK – A 3 diagnostic code is still active for the
Results: suspect sensor(s). The problem may be in the
harness or with the ECM. Proceed to Test Step 6.
• OK – The signal voltage is less than Battery
voltage. Proceed to Test Step 4. Test Step 5. Create an Open at the
Suspect Sensor Connector
• Not OK – The signal voltage is equal to Battery
voltage. A. Remove electrical power from the ECM.
Repair: There is a short in the harness to the B. Disconnect the sensor connector of the suspect
+Battery. Repair the wiring. sensor(s) with the active 4 diagnostic code.
Test Step 4. Create a Short at the Sensor D. Monitor the diagnostic codes on Cat ET. Check for
Connector an active 3 diagnostic code for the suspect sensor.
A. Remove electrical power from the ECM. Note: Wait at least 30 seconds in order for the
diagnostic code to become active.
B. Disconnect the suspect sensor.
E. Remove electrical power from the ECM.
C. Use a wire jumper in order to create a short
between terminal C (signal) and terminal B Expected Result:
(sensor return) at the sensor connector.
A 3 diagnostic code is now active for the suspect
D. Restore electrical power to the ECM. sensor(s).
C. Remove the signal wire for the suspect sensor If the code is only active for one sensor, the
from the ECM connector. problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. Refer
D. Install the jumper wire into the terminal location for to Illustration 70 for a schematic of the circuit.
the suspect sensor at the ECM connector.
STOP.
E. Connect the ECM connector.
• Not OK – One of the following conditions exists:
F. Check the operation of the ECM by creating The 3 diagnostic code is not active when the sensor
an open at the ECM: signal wire is disconnected. The 4 diagnostic code
is not active when the wire jumper is shorted to
a. Hold the loose end of the jumper wire away ground.
from any components in order to create an
open circuit condition. Repair: Replace the ECM. Refer to
Troubleshooting, “ECM - Replace”. Verify
b. Turn the ECS to the STOP position. that the problem is resolved.
a. Short the jumper wire for the suspect sensor to System Operation Description:
engine ground in order to create a short circuit
condition. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the sensors
b. Turn the ECS to the STOP position. or if any one of the diagnostic codes in Table 41 is
active or easily repeated.
c. Monitor the active diagnostic code screen on
Cat ET. Check for a 4 diagnostic code for the
suspect sensor.
Expected Result:
Table 41
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
105-3 Inlet Manifold Temperature The engine's Electronic Control Module The code is logged.
Sensor voltage above normal (ECM) detects signal voltage that is The value of the parameter is set to
more than 4.8 VDC for one second. zero.
The ECM has been powered for at least
three seconds.
105-4 Inlet Manifold Temperature The ECM detects signal voltage that is
Sensor voltage below normal less than 0.2 VDC for one second.
The ECM has been powered for at least
three seconds.
175-3 Engine Oil Temperature Sensor The ECM detects signal voltage that is The code is logged.
voltage above normal more than 4.8 VDC for one second. The value of the parameter is set to
The ECM has been powered for at least zero.
three seconds.
175-4 Engine Oil Temperature Sensor The ECM detects signal voltage that is
voltage below normal less than 0.2 VDC for one second.
The ECM has been powered for at least
three seconds.
System Operation
g01355698
Illustration 77
Typical schematic
162 KENR5404-03
Troubleshooting Section
g01242612
Illustration 78
P1 ECM connector
(P1-3) Sensor return (left rail)
(P1-14) “Inlet manifold temperature sensor”
(P1-26) Engine oil temperature sensor
(P1-35) Sensor return (right rail)
g01341888
Illustration 79
Terminal locations for the A-C1/E-C2/E-C1/C-C1 rigid harness
(Terminal B) Sensor return
(Terminal H) Engine oil temperature
KENR5404-03 163
Troubleshooting Section
Results:
STOP.
Expected Result:
Results:
STOP.
STOP.
i02646178
Table 42
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
827-8 Left Exhaust Temperature Sensor The Electronic Control Module (ECM) The value of the parameter is set to
abnormal frequency, pulse width, or detects a sensor frequency that is zero.
period greater than 1000 Hz or less than 150 The code is logged.
Hz.
The ECM detects a duty cycle that is
greater than 90 percent or a duty cycle
that is less than 10 percent.
828-8 Right Exhaust Temperature The ECM detects a sensor frequency
Sensor abnormal frequency, pulse that is greater than 1000 Hz or less than
width, or period 150 Hz.
The ECM detects a duty cycle that is
greater than 90 percent or a duty cycle
that is less than 10 percent.
System Operation
• Terminal A 8 V supply
• Terminal B sensor return
• Terminal C sensor signal
The ECM performs an automatic calibration of these
sensors whenever the ECM is powered and the
engine has been off for at least five seconds.
g01327527
Illustration 82
Typical schematic
g01213937 g01327661
Illustration 83 Illustration 84
P1 ECM connector P2 ECM connector
(P1-4) “8 V digital sensor supply (LH)” (P2-56) “8 V digital sensor supply (RH)”
(P1-5) “Digital sensor return (LH)” (P2-66) “Digital sensor return (RH)”
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
168 KENR5404-03
Troubleshooting Section
g01320528
Illustration 86
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01327759
Illustration 85
Terminal locations for the A-C1/E-C2 RH rigid harness connectors
and the C-C1/E-C1 LH rigid harness connectors
(Terminal C) “8 V digital sensor supply (RH)”
(Terminal D) “Digital sensor return (RH)”
(Terminal R) “Right exhaust temperature”
KENR5404-03 169
Troubleshooting Section
Expected Result:
Results:
C. Turn the ECS to the STOP position. • Not OK – The duty cycle is not correct.
D. Measure the frequency and the duty cycle Repair: There is a problem in the wiring between
between the sensor's signal wire and pin B of the the ECM and the connector for the sensor. Repair
suspect digital sensor at the sensor connector. the connectors and/or wiring between the ECM
and the connector for the sensor.
E. Turn the ECS to the OFF/RESET position.
STOP.
F. Replace the sensor's signal wire and reconnect
the sensor.
i02646020
STOP.
Expected Result:
Results:
STOP.
KENR5404-03 171
Troubleshooting Section
Table 43
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
262-3 5 Volt Sensor DC Power Supply The analog sensor supply voltage is The code is logged.
voltage above normal above normal for two seconds. All sensors are set to default values.
262-4 5 Volt Sensor DC Power Supply The analog sensor supply voltage is
voltage below normal below normal for two seconds.
263-3 Digital Sensor Power Supply (8V The digital sensor supply voltage is
Or 12V) voltage above normal above normal for two seconds.
263-4 Digital Sensor Power Supply (8V The digital sensor supply voltage is
Or 12V) voltage below normal below normal for two seconds.
g01327574
Illustration 89
Typical schematic 5 V supply
KENR5404-03 173
Troubleshooting Section
g01327527
Illustration 90
Typical schematic 8 V supply
g01327649 g01327661
Illustration 91 Illustration 92
P1 ECM connector P2 ECM connector
(P1-2) “5 V analog sensor supply (LH)” (P2-56) “8 V digital sensor supply (RH)”
(P1-3) “Analog sensor return (LH)” (P2-66) “Digital sensor return (RH)”
(P1-4) “8 V digital sensor supply (LH)”
(P1-5) “Digital sensor return (LH)”
(P1-18) “5 V analog sensor supply (RH)”
(P1-35) “Analog sensor return (RH)”
174 KENR5404-03
Troubleshooting Section
g01320528
Illustration 94
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01327616
Illustration 93
Terminal locations for the A-C1/E-C2 RH rigid harness connectors
and the C-C1/E-C1 LH rigid harness connectors
(Terminal A) “Analog sensor return (RH)”
(Terminal B) “5 V analog sensor supply (RH)”
(Terminal C) “8 V digital sensor supply (RH)”
(Terminal D) “Digital sensor return (RH)”
KENR5404-03 175
Troubleshooting Section
Expected Result:
Results:
STOP.
Illustration 96
g01094844
• 262-3
Sensor connector
(Pin A) Sensor supply
• 262-4
(Pin B) Sensor return
(Pin C) Signal • 263-3
Test Step 1. Inspect the Electrical • 263-4
Connectors and the Wiring
Note: Wait at least 30 seconds in order for the
A. Remove electrical power from the ECM. diagnostic codes to become active.
• Not OK – Either the 262-3 or 262-4 diagnostic • Not OK – The 262-3 or 262-4 diagnostic code
code is active at this time. Proceed to Test Step 3. remains active after all of the sensors are
disconnected. Leave the sensors disconnected.
• Not OK – Either the 263-3 or 263-4 diagnostic The sensors are not the cause of the diagnostic
code is active at this time. Proceed to Test Step 5. code. Proceed to Test Step 4.
Test Step 3. Disconnect the 5 Volt Test Step 4. Check the 5 Volt Supply
Sensors while you Monitor the Active Voltages at the ECM
Diagnostic Codes
A. Remove electrical power from the ECM.
A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 5 Volt sensor at the B. Remove the supply wire from P1-2. Install a wire
sensor connector. Check for an active 262-3 code jumper into the socket P1-2.
or an active 262-4 code.
C. Remove the supply wire from P1-18.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. D. Restore electrical power to the ECM.
a. Disconnect the following sensors one at a time: E. Measure the voltage between the wire jumper in
terminal P1-2 and engine ground.
• Aftercooler temperature sensor
F. Remove electrical power from the ECM.
• Atmospheric pressure sensor
G. Remove the wire jumper and replace all wires.
• Coolant temperature sensor
Expected Result:
• Crankcase pressure sensor
Each voltage measurement is 5.0 ± 0.2 VDC.
• Filtered engine oil pressure sensor
Results:
• Filtered fuel pressure sensor
• OK – The voltage measurement is 5.0 ± 0.2 VDC.
• Turbocharger outlet pressure sensor The ECM is operating correctly.
• Left turbocharger inlet pressure sensor Repair: The supply wire is shorted to another wire
in the harness or the supply wire is shorted to
• Right turbocharger inlet pressure sensor engine ground. Repair the supply wire.
• Unfiltered fuel pressure sensor • Not OK – The voltage measurement is not 5.0 ±
0.2 VDC.
B. Remove electrical power from the ECM.
Repair: Replace the ECM. Refer to
Expected Result: Troubleshooting, “ECM - Replace”.
• Exhaust temperature sensor (RH) Repair: The supply wire is shorted to another wire
in the harness or the supply wire is shorted to
B. Remove electrical power from the ECM. engine ground. Repair the supply wire.
The diagnostic code deactivates when a particular • Not OK – The voltage measurement is not 8.0 ±
sensor is disconnected. 0.4 VDC.
Expected Result:
Results:
Table 44
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
91-8 Throttle Position Sensor abnormal The Electronic Control Module (ECM) The code is logged. The ECM flags the
frequency, pulse width, or period detects an incorrect frequency on the throttle position as invalid data and a
throttle signal or an incorrect duty cycle default value of zero percent is used.
1249-8 Secondary Throttle Position on the throttle signal. The frequency is The engine speed is limited to low idle.
signal abnormal below 150 Hz or the frequency in above
1000 Hz. The duty cycle is less than 5
percent or the duty cycle is greater than
95 percent.
g01328300
Illustration 97
Typical example
KENR5404-03 179
Troubleshooting Section
g00725481
Illustration 98
Throttle Position Versus PWM Input
g01328305
Illustration 99
Terminal locations for the following connectors P-C2/A-C91
Connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors.
(Terminal L) +Battery to local speed control
180 KENR5404-03
Troubleshooting Section
g01328307
Illustration 100
Terminal locations for the C-C17/F-C1 LH rigid harness connectors
and the connectors G-C6/F-C2 for a LH Control panel
(Terminal 16) +Battery to local speed control
g01328312
Illustration 101
Terminal locations for the TB-C1/C-C18 customer connector
(Terminal BM) Local speed control
(Terminal BN) Customer's speed control
KENR5404-03 181
Troubleshooting Section
Expected Result:
Results:
STOP.
g01320528
B. Turn the ECS to the STOP position.
Illustration 102
Connector locations C. Observe the position of the throttle on Cat ET.
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors D. Adjust the speed control to the lowest setting.
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
E. Start at the lowest position. Slowly adjust the
(6) C-C22 Primary ECM connector P2 speed control to the highest setting. Monitor the
(7) C-C15 Primary ECM connector P1 position of the throttle on Cat ET.
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1 Expected Result:
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors The throttle position on Cat ET is 0 percent at the
(13) C-C1/E-C1 LH rigid harness connectors lowest setting and 0 to 100 percent as the speed
control is adjusted to the highest setting.
Test Step 1. Inspect the Electrical
Connectors and the Wiring Results:
A. Turn the Engine Control Switch (ECS) to the • OK – The speed control is operating correctly.
OFF/RESET position.
Repair: There may be an intermittent problem. If
B. Thoroughly inspect the ECM connectors J1/P1 the problem is intermittent, refer to Troubleshooting,
and J2/P2. Inspect the wiring and the connectors “Electrical Connectors - Inspect” for details on
that are associated with the circuit. Refer to inspecting wiring and connectors.
Troubleshooting, “Electrical Connectors - Inspect”
for details. STOP.
C. Perform a 45 N (10 lb) pull test on each of the • Not OK – The throttle position on Cat ET does not
wires in the ECM connectors that are associated change correctly. If you are troubleshooting either
with the circuit. the primary speed control or the secondary speed
control from the customer, proceed to Test Step 3.
D. Check the ECM connector (allen head screw) If you are troubleshooting the local speed control
for the proper torque. Refer to Troubleshooting, on the instrument panel, proceed to Test Step 5.
“Electrical Connectors - Inspect” for details.
182 KENR5404-03
Troubleshooting Section
Test Step 3. Check the Signal Frequency E. Set the multimeter to “VDC”. Press the “Hz” button
and the Duty Cycle at the Customer twice so that the % symbol is displayed.
Connector
F. Place the red probe of the multimeter on wire that
A. Turn the ECS to the OFF/RESET position. was removed from the ECM connector. Place
the black probe of the multimeter on the −Battery
B. Remove the wire for the throttle signal from the terminal.
customer's connector. Refer to Illustration 97 for
the schematic of the circuit. G. Turn the ECS to the STOP position.
C. Turn the ECS to the STOP position. H. Measure the percent duty cycle of the throttle
signal. Move the speed control from the lowest
D. Measure the frequency and the duty cycle of the setting to the highest setting.
throttle signal. Adjust the speed control from the
lowest position to the highest position. I. Turn the ECS to the OFF/RESET position.
E. Turn the ECS to the OFF/RESET position. J. Replace all connectors and wires.
Test Step 4. Check the Duty Cycle at the Repair: Repair the wire between the ECM
ECM Connector connector and the customer connector.
• OK – The voltage is 24 ± 3 VDC. The local speed • P-C2/A-C91 Terminal L Connectors for the
control is receiving the correct voltage. Proceed power distribution panel
to Test Step 7.
• G-C6/F-C2/F-C1/A-C92 Terminal 16 Connectors
• Not OK – The voltage is not 24 ± 3 VDC. Verify for a RH Control panel
that the wire CA998 has continuity to a digital
reference. The local speed control is not receiving Refer to Illustration 102 in order to locate the
the correct voltage. Proceed to Test Step 6. various connectors on the rigid harness.
B. Remove wire C150 from terminal L of connector Repair: Verify that the breaker for the primary ECM
P-C2 of the rigid harness. is not tripped. Check for 24 ± 3 VDC on terminal
87A at the normally closed contact of relay “R2A”.
C. Connect the red probe of the digital multimeter to Relay R2A is located in the power distribution
wire C150. Connect the black probe of the digital panel. Verify that the normally closed contact of
multimeter to the −Battery. Refer to Illustration relay “R2A” is operating correctly.
102 in order to locate the various connectors on
the rigid harness. If voltage is present on terminal 87A at the normally
closed contact of relay “R2A”, repair the wire C150
D. Turn the ECS to the STOP position. between the contacts of relay “R2A” and terminal L
of connector P-C2 of the rigid harness.
E. Monitor the voltage on the digital multimeter.
If 24 ± 3 VDC is present on wire C150 at diode D9,
F. Turn the ECS to the OFF/RESET position. verify that voltage is present on wire M150 at diode
D9. If 24 ± 3 VDC is not present on wire M150 at
Expected Result: diode D9, replace the diode D9.
Repair: Check for 24 ± 3 VDC on wire C150 at Test Step 7. Check the Signal Frequency
diode D9 in the control panel. If voltage is not and the Duty Cycle Of the Local Speed
present on wire C150 at diode D9, repair the Control
wire C150 between diode D9 and terminal L of
connector P-C2 of the rigid harness. The following A. Turn the ECS to the OFF/RESET position.
connectors are between connector P-C2 and
connector G-C6 of the marine power display panel. B. Remove the wire 389 from the S terminal at the
The terminal locations for wire C150 are listed with local speed control.
the connectors.
C. Turn the ECS to the STOP position.
Left hand control panel
D. Measure the frequency and the duty cycle
• P-C2/A-C91 Terminal L Connectors for the between terminal S of the local speed control and
power distribution panel engine ground. Adjust the local speed control from
the lowest setting to the highest setting.
• A-C2/J-C2 Terminal L RH rigid harness
connectors E. Turn the ECS to the OFF/RESET position.
• J-J1/C-C2 Terminal L LH rigid harness F. Reconnect the wire 389 to the S terminal at the
connectors local speed control.
Results: STOP.
• OK – The local speed control is supplying the • Not OK – The duty cycle reading is not correct.
correct signal. Proceed to Test Step 8. The throttle position signal is not reaching the
ECM.
• Not OK – The duty cycle or the frequency is not
correct on the multimeter. Repair: The signal is lost between the S terminal
of the local speed control and the ECM. Repair the
Repair: Temporarily install another speed control. wire 389 between the local speed control and the
Verify that the problem is no longer present. ECM.
Reinstall the old speed control. If the problem
returns, replace the local speed control. STOP.
STOP.
i02648157
Expected Result:
Results:
Table 45
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
190-2 Engine Speed Sensor erratic, The engine speed signal cannot be The secondary engine speed/timing
intermittent, or incorrect detected. The timing gear pattern signal will be used if the primary engine
returns within one second before being speed/timing signal is lost. The code is
lost and the battery voltage is greater logged.
than 9 VDC for the last two seconds.
The code will be active and logged if
the Electronic Control Module (ECM)
detects an incorrect signal for one
second. The battery voltage is greater
than 9 VDC for the last two seconds.
190-3 Engine Speed Sensor voltage A wire on the engine speed/timing The secondary engine speed/timing
above normal sensor is disconnected and/or broken. signal will be used if the primary engine
There is a short circuit to the +Battery speed/timing signal is lost. The code is
terminal. logged.
190-7 Engine Speed Sensor not The primary engine speed/timing sensor The code is active.
responding properly is connected to the harness for the
secondary engine speed/timing sensor.
190-8 Engine Speed Sensor abnormal The engine speed is greater than zero The secondary engine speed/timing
frequency, pulse width, or period rpm and the pattern from the timing ring signal will be used if the primary engine
is incorrect for five seconds. speed/timing signal is lost.
The code is logged if the pattern from
the timing ring returns for five seconds.
342-2 Secondary Engine Speed Sensor The engine speed signal cannot be The primary engine speed/timing signal
erratic, intermittent, or incorrect detected. The timing gear pattern will be used if the secondary engine
returns within one second before being speed/timing signal is lost. The code is
lost and the battery voltage is greater logged.
than 9 VDC for the last two seconds.
The code will be active and logged if the
ECM detects an incorrect signal for one
second. The battery voltage is greater
than 9 VDC for the last two seconds.
342-3 Secondary Engine Speed Sensor A wire on the engine speed/timing The primary engine speed/timing signal
voltage above normal sensor is disconnected and/or broken. will be used if the secondary engine
There is a short circuit to the +Battery speed/timing signal is lost. The code is
terminal. logged.
342-7 Secondary Engine Speed Sensor The secondary engine speed/timing The code is active.
not responding properly sensor is connected to the harness for
the primary engine speed/timing sensor.
342-8 Secondary Engine Speed Sensor The engine speed is greater than zero The primary engine speed/timing signal
abnormal frequency, pulse width, or rpm and the pattern from the timing ring will be used if the secondary engine
period is incorrect for five seconds. speed/timing signal is lost.
The code is logged if the pattern from
the timing ring returns for five seconds.
g01328994
Illustration 103
Typical schematic
KENR5404-03 187
Troubleshooting Section
Expected Result:
Results:
g01328997
Illustration 104
P1 ECM connector • OK – The harness and connectors appear to be
(P1-13) Secondary engine speed/timing signal OK. Proceed to Test Step 2.
(P1-33) Primary engine speed/timing signal
(P1-40)
(P1-41)
Engine timing calibration -
Engine timing calibration +
• Not OK – There is a problem with the connectors
and/or wiring.
(P1-43) +12.5 V supply
(P1-51) Digital return
Repair: Repair the connectors or wiring and/or
Note: The timing calibration sensor is only on the replace the connectors or wiring. Ensure that all of
J1/P1 connector for the primary ECM. the seals are properly in place and ensure that the
connectors are completely coupled.
STOP.
Expected Result:
Results:
g01234146
Illustration 105 • OK – A diagnostic code for the engine speed/timing
Location of ECM connectors sensor is not active or logged repeatedly.
188 KENR5404-03
Troubleshooting Section
• Not OK – The supply voltage is not 12.5 ± 1 VDC. d. Measure the voltage between the sensor's
Proceed to Test Step 6. signal wire and the digital return on P1-51.
Crank the engine and measure the voltage
Test Step 4. Check the Signal Voltage at between the sensor signal wire and P1-51.
the Sensor Perform this step on the primary ECM and on
the secondary ECM.
A. Remove electrical power from the ECM.
C. Check the signal voltage for the secondary
B. Remove the wire from terminal C of the sensor engine speed/timing sensor.
connector.
a. Remove the signal wire F732 from the primary
C. Restore electrical power to the ECM. ECM connector P1-13 and from the secondary
ECM connector P1-13.
D. Measure the voltage between the sensor's signal
wire and terminal B of the sensor connector. Crank b. Reconnect ECM connector J1/P1.
the engine and measure the voltage between the
sensor signal wire and terminal B. c. Restore electrical power to the ECM.
E. Remove electrical power from the ECM. d. Measure the voltage between the sensor's
signal wire and the digital return on P1-51.
F. Reconnect the signal wire. Crank the engine and measure the voltage
between the sensor signal wire and P1-51.
Expected Result: Perform this step on the primary ECM and on
the secondary ECM.
The voltage measures less than 3 VDC or more than
9 VDC when the ECM is powered and the engine D. Remove electrical power from the ECM.
is not cranking. While the engine is cranking, the
voltage is between 2 VDC and 7 VDC. E. Replace all wires. Reconnect ECM connector
J1/P1.
Note: The voltage output is determined by the
presence or the absence of a tooth on the timing gear.
KENR5404-03 189
Troubleshooting Section
The voltage measures less than 3 VDC or more than d. Measure the supply voltage between wire
9 VDC when the ECM is powered and the engine G791 in ECM connector P1-51 and the wire
is not cranking. While the engine is cranking, the jumper in P1-43.
voltage is between 2 VDC and 7 VDC.
E. Remove electrical power from the ECM.
Note: The voltage signal is generated by the
presence or the absence of a tooth on the timing F. Remove the wire jumper and replace all wires.
gear. Reconnect ECM connector J1/P1.
• OK – The correct voltage appears at ECM The supply voltage is 12.5 ± 1 VDC.
connector P1 but the ECM is not reading the signal.
Results:
Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, “ECM - Replace”. • OK – The supply voltage is 12.5 ± 1 VDC. There is
an open circuit or a short circuit between the ECM
STOP. and the connector for the engine speed/timing
sensor.
• Not OK – There is a problem in the engine
speed/timing circuit. Repair: Repair the connectors and/or wiring or
replace the connectors and/or wiring.
Repair: The problem is between the ECM and the
engine speed/timing sensor. Repair the connectors STOP.
and/or wiring or replace the connectors and/or
wiring. • Not OK – The supply voltage is not 12.5 ± 1 VDC.
The supply voltage is incorrect.
STOP.
Repair: Replace the ECM. Refer to
Test Step 6. Check the Supply Voltage Troubleshooting, “ECM - Replace”.
for the Engine Speed/Timing Sensor at
the ECM STOP.
Table 46
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
444-5 Starter Motor Relay current below The Electronic Control Module (ECM) The code is logged.
normal detects an open circuit and/or a short to
the +Battery in the start relay. The ECM
can only detect this condition when the
start relay is not energized.
444-6 Starter Motor Relay current above The ECM detects a short circuit to
normal ground in the start relay. The ECM can
only detect this condition when the start
relay is energized.
The ECM has the ability to crank the engine when the
Engine Control Switch (ECS) is placed in the START
position. After the ECS is placed in the START
position, the ECM will begin the prelube cycle. The
ECM will send an engine start signal to terminal BH
of the customer connector after the prelube cycle
is complete. The customer's engine start signal will
return on terminal BJ of the customer connector. The
signal is then sent to terminal f of the A-C90/P-C1
connector on the power distribution panel.
The crank cycle will continue for the cycle crank time
that has been programmed or the crank cycle will
continue until the engine speed reaches the crank
terminate speed.
g01328451
Illustration 106
Typical example
192 KENR5404-03
Troubleshooting Section
g01242365
Illustration 107
P2 ECM connector
(P2-6) Starter drive (+)
(P2-7) Return (-)
g01328549
Illustration 108
Customer connector
(Terminal BH) Start signal from ECM
(Terminal BJ) Start signal from customer
KENR5404-03 193
Troubleshooting Section
g01328550 g01328551
Illustration 109 Illustration 110
Terminal locations for the P-C1/A-C90 connector for the power Terminal locations for the following connectors P-C2/A-C91
distribution panel connector for the power distribution panel, A-C2/J-C2 RH rigid
harness connectors, and C-C2/J-C1 LH rigid harness connectors
(Terminal d) Override to starting motor switches
(Terminal f) Customer's start signal to starting motor switches (Terminal L) +Battery to the control panel
(Terminal O) Power to starting motor #1
(Terminal R) Power to starting motor #2
194 KENR5404-03
Troubleshooting Section
g01328552
Illustration 111
Terminal locations for the A-C92/F-C1 RH rigid harness connectors
and the connectors G-C6/F-C2 for a RH control panel
(Terminal 13) Override to starting motor switches
(Terminal 16) +Battery to crank override switch
g01328594
Illustration 112
Terminal locations for the A-C2/J-C2 RH rigid harness connectors
and the C-C2/J-C1 LH rigid harness connectors
(Terminal d) Override to right hand air start solenoid
(Terminal e) Return for the right hand air start solenoid
KENR5404-03 195
Troubleshooting Section
g01320528
Illustration 114
Connector locations
(1) A-C1/E-C2 RH rigid harness connectors
(2) A-C2/J-C2 RH rigid harness connectors
(3) P-C1/A-C90 Connectors for the power distribution panel
(4) P-C2/A-C91 Connectors for the power distribution panel
(5) G-C6/F-C2/F-C1/A-C92 Connectors for a RH Control panel
(6) C-C22 Primary ECM connector P2
(7) C-C15 Primary ECM connector P1
(8) C-C28 Secondary ECM connector P2
(9) C-C29 Secondary ECM connector P1
(10) G-C6/F-C2/F-C1/C-C17 Connectors for a LH Control panel
(11) C-C18/TB-C1 Customer connectors
(12) C-C2/J-C1 LH rigid harness connectors
(13) C-C1/E-C1 LH rigid harness connectors
g01328876
Illustration 113
Terminal locations for the A-C1/E-C2 RH rigid harness connectors
and the E-C1/C-C1 LH rigid harness connectors
(Terminal E) Start signal from customer
196 KENR5404-03
Troubleshooting Section
STOP.
B. Turn the circuit breaker for the battery to the OFF Results:
position.
• OK – The “startup mode” parameter on the status
C. Thoroughly inspect the ECM connectors J1/P1 screen on Cat ET displays “CRANK”. The engine
and J2/P2. Inspect all of the other connectors. cranks.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. Repair: The problem may be intermittent. If the
problem is intermittent, refer to Troubleshooting,
D. Perform a 45 N (10 lb) pull test on each of the “Electrical Connectors - Inspect”.
wires in the ECM connector that are associated
with the circuit. STOP.
E. Check the allen head screw on each ECM • Not OK - Engine Doesn't Crank – The “startup
connector for the proper torque. Refer to mode” parameter on the status screen on Cat
Troubleshooting, “Electrical Connectors - Inspect” ET displays “CRANK”. The engine will not crank.
for the correct torque values. Proceed to Test Step 3.
F. Check the harness and the wiring for abrasion • Not OK - Status Screen – The “startup mode”
and for pinch points. parameter on the status screen on Cat ET does
not display “CRANK”.
Expected Result:
Repair: Refer to Troubleshooting, “Engine Control
All connectors, pins, and sockets are completely Switch - Test”.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion, and of pinch points. STOP.
B. Turn the ECS to the START position. Verify that the engine prelube is operating correctly.
Refer to Troubleshooting, “Prelubrication - Test”.
C. Monitor the voltage on the voltmeter.
If the above systems are operating correctly,
D. Turn the ECS to the OFF/RESET position. the problem may be in the ECM. Refer to
Troubleshooting, “ECM - Relace”.
E. Reconnect all wires.
STOP.
Expected Result:
Test Step 5. Check the Start Signal to the
The voltage is 24 ± 3 VDC. Power Distribution Panel
Results: A. Remove wire F701 from terminal f of connector
“A-C90” on the right hand rail. Connect one end of
• OK – The voltage is 24 ± 3 VDC. Proceed to Test a voltmeter to the −Battery terminal. Connect the
Step 5. other end of the voltmeter to wire F701.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed B. Turn the ECS to the START position.
to Test Step 4.
C. Monitor the voltage on the voltmeter.
Test Step 4. Check the Start Signal at the
ECM D. Turn the ECS to the OFF/RESET position.
B. Remove wire G701 from the ECM connector P2-6. Expected Result:
Install a wire jumper into P2-6.
The voltage is 24 ± 3 VDC.
C. Reconnect the ECM connector J2/P2.
Results:
D. Connect one end of a voltmeter to the −Battery
terminal. Connect the other end of the voltmeter • OK – The voltage is 24 ± 3 VDC. If electric starting
to the wire jumper in P2-6. motors are installed on the engine, proceed to Test
Step 6.
E. Turn the ECS to the START position.
• OK – The voltage is 24 ± 3 VDC. If air start
F. Monitor the voltage on the voltmeter. solenoids are installed on the engine, proceed to
Test Step 10.
G. Turn the ECS to the OFF/RESET position.
• Not OK – The voltage is not 24 ± 3 VDC.
H. Remove the wire jumper and replace all wires.
Repair: Repair the wire F701 between terminal
Expected Result: f of connector “A-C90” on the right hand rail and
terminal BJ on the customer connector. Check
The voltage is 24 ± 3 VDC. the voltage at the A-C1/E-C2 RH rigid harness
connectors and at the C-C1/E-C1 LH rigid harness
Results: connectors. Refer to Illustration 106 for a schematic
of the circuit.
• OK – The voltage is 24 ± 3 VDC.
STOP.
Repair: Check wire G701 for continuity between
ECM connector P2-6 and terminal BH of the Test Step 6. Check the Voltage from
customer connector. If necessary, repair the wire. “SMMS1” and “SMMS2” to the Starting
If wire G701 is OK, repair the wiring or devices on Motors
the customer's side of the customer connector.
A. Remove wire 304 from terminal O of connector
STOP. “A-C91” on the right hand rail. Install a wire jumper
into terminal O of connector “A-C91”. Connect
• Not OK – The voltage is not 24 ± 3 VDC. one end of a voltmeter to the −Battery terminal.
Connect the other end of the voltmeter to the wire
Repair: Check the electrical power to the ECM. jumper in terminal O of connector “A-C91”.
Refer to Troubleshooting, “Electrical Power Supply
- Test”. B. Turn the ECS to the START position.
198 KENR5404-03
Troubleshooting Section
D. Turn the ECS to the OFF/RESET position. • OK – The voltage is 24 ± 3 VDC. The problem
appears to be in the starting motor.
E. Remove wire 314 from terminal R of connector
“A-C91” on the right hand rail. Install a wire jumper Repair: Install a new starting motor. Verify that the
into terminal R of connector “A-C91”. Connect problem is no longer present.
one end of a voltmeter to the −Battery terminal.
Connect the other end of the voltmeter to the wire STOP.
jumper in terminal R of connector “A-C91”.
• Not OK – The voltage is not 24 ± 3 VDC.
F. Turn the ECS to the START position.
Repair: The problem is in the wire 314 between the
G. Monitor the voltage on the voltmeter. starting motor and terminal R of connector “P-C2”
or in the wire 304 between the starting motor and
H. Turn the ECS to the OFF/RESET position. terminal O of connector “P-C2”. Check the voltage
at the A-C1/J-C2 RH rigid harness connectors and
I. Reconnect all wires. at the C-C2/J-C1 LH rigid harness connectors.
Refer to Illustration 106 for a schematic of the
Expected Result: circuit.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed B. Remove wire G701 from terminal 3 of “SMMS1”
to Test Step 8. and from terminal 3 of “SMMS2”.
Test Step 7. Check the Voltage at the C. Connect a voltmeter between wire G701 and
Starting Motor engine ground.
A. Turn the ECS to the OFF/RESET position. D. Turn the ECS to the START position.
B. Remove wire 314 from terminal S of the starting E. Monitor the voltage on the voltmeter.
motor. Connect one end of a voltmeter to the
−Battery terminal. Connect the other end of the F. Turn the ECS to the STOP position.
voltmeter to wire 314.
G. Reconnect all wires.
C. Turn the ECS to the START position.
Expected Result:
D. Monitor the voltage on the voltmeter.
The voltage is 24 ± 3 VDC.
E. Turn the ECS to the STOP position.
Results:
F. Remove wire 304 from terminal S of the starting
motor. Connect one end of a voltmeter to the • OK – The voltage is 24 ± 3 VDC. Proceed to Test
−Battery terminal. Connect the other end of the Step 9.
voltmeter to wire 304.
• Not OK – The voltage is not 24 ± 3 VDC.
G. Turn the ECS to the START position.
Repair: Repair the wire G701 between the “SMMS”
H. Monitor the voltage on the voltmeter. switches and the diodes in the power distribution
panel. Repair the wire F701 between the diodes
I. Turn the ECS to the STOP position. in the power distribution panel and terminal f of
connector “P-C1” on the power distribution panel.
Expected Result: Refer to Illustration 106 for a schematic of the
circuit.
The voltage is 24 ± 3 VDC.
STOP.
KENR5404-03 199
Troubleshooting Section
Test Step 9. Check the Voltage from the If 24 ± 3 VDC is present on terminal 1 of “SMMS1”
Starting Motor Magnetic Switch(s) or on terminal 1 of “SMMS2” and wire G229 and
wire A287 are OK, replace either “SMMS1” or
A. Remove wire 314 from terminal 2 of the “SMMS2” “SMMS2”.
switch. Connect one end of a voltmeter to the
−Battery terminal. Connect the other end of the STOP.
voltmeter to terminal 2 of “SMMS2”.
Test Step 10. Check the Start Signal from
B. Turn the ECS to the START position. the Power Distribution Panel
C. Monitor the voltage on the voltmeter. A. Remove wire G701 from terminal d of connector
“A-C90” on the right hand rail. Install a wire jumper
D. Turn the ECS to the STOP position. into terminal d of connector “A-C90”. Connect
one end of a voltmeter to the −Battery terminal.
E. Remove wire 304 from terminal 2 of the “SMMS1” Connect the other end of the voltmeter to the wire
switch. Connect one end of a voltmeter to the jumper in terminal d of connector “A-C90”.
−Battery terminal. Connect the other end of the
voltmeter to terminal 2 of “SMMS1”. B. Turn the ECS to the START position.
F. Turn the ECS to the START position. C. Monitor the voltage on the voltmeter.
G. Monitor the voltage on the voltmeter. D. Turn the ECS to the OFF/RESET position.
Expected Result:
Results:
STOP.
STOP.
KENR5404-03 201
Troubleshooting Section
Service i02826488
• Passwords
Note: Factory passwords are provided only to
Caterpillar dealers. • Serial numbers
Factory passwords are required to perform each of • Total tattletale
the following functions:
• Reason code
• Program a new Electronic Control Module (ECM).
When an ECM is replaced, the system configuration Recommended Actions
parameters must be programmed into the new
ECM. A new ECM will allow these parameters to 1. Verify that the correct passwords were entered.
be programmed once without factory passwords. Check every character in each password. Remove
After the initial programming, some parameters are the electrical power from the engine for 30
protected by factory passwords. seconds and then retry.
The following conditions can cause a communication • Not OK – An incorrect communication adapter or
problem: cable was being used.
• Configuration for the communications adapter Attempt to establish communication. Continue with
this procedure if the communication adapter does
• Electrical power supply to the service tool not communicate on the data link.
connector
Test Step 3. Verify that Cat ET is
• Cat Data Link Configured Correctly
This procedure determines the root cause of failure Cat ET must be configured correctly in order to
to communicate on the data link. communicate. Perform the following procedure:
Test Step 1. Verify that the Newest A. Click on the “Utilities” menu.
Version of Cat ET is Being Used
B. Click on the “Preferences” menu.
Check the version of Cat ET. Cat ET must be the
newest version. C. Select the “Communications” tab.
Repair: Download the newest version of Cat ET. Continue with this procedure.
Attempt to establish communication. Continue with E. Check for any hardware that is utilizing the
this procedure if the communication adapter does same port as the communications adapter. If any
not communicate. devices are configured to use the same port, exit
or close the software programs for that device.
Test Step 2. Verify that the Correct
Communication Adapter and Cables are Note: The most commonly used port is “COM 1”.
Being Used
F. Click “OK”.
Refer to Troubleshooting, “Electronic Service Tools”
in order to determine the correct communication Note: Cat ET must reconnect in order for any
adapter and cables. changes to be used. Electronically disconnect Cat
ET if changes were made to any of the settings
Expected Result: for communications. Electronically connect Cat ET.
Attempt to establish communication. Observe the
The correct communication adapter and cables are indicator on the communications adapter.
used.
KENR5404-03 203
Troubleshooting Section
Expected Result: Repair: Verify that the cable between the service
tool connector and the communication adapter is
Cat ET communicates. OK. Replace the cable, if necessary.
Battery voltage is not present at the service tool • OK – The harness for the data link is OK.
connector.
Repair: Refer to Troubleshooting, “Cat Data Link -
Results: Test” or refer to Troubleshooting, “CAN Data Link -
Test”.
• OK – Battery voltage is not present at the service
tool connector. STOP.
Table 47
Diagnostic Codes Table
Code Conditions which Generate System Response Procedure
this Code
253-2 Personality Module The flash file is for a different The engine will not start. Program the correct flash file.
: Erratic, Intermittent, or engine family or for a different Clearing this diagnostic code
Incorrect engine application. requires factory passwords.
The personality module code
must be reset to zero.
Flash Programming – This is a method of 4. Start the engine and check for proper operation.
programming or updating the flash file in an engine's Repair any active diagnostic or event codes.
Electronic Control Module (ECM).
“WinFlash” Error Messages
Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine's ECM. If you receive any error messages during flash
programming, click on the “Cancel” button in order
If you do not have the flash file, use the “Flash File to stop the process. Access the information about
Search” tool on the Service Technician Workbench the “ECM Summary” under the “Information” menu.
(STW) to obtain the flash file for your engine. Make sure that you are flashing the correct file for
Alternatively, use the “Service Software Files” feature your engine.
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct i02629894
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference. ECM - Replace
SMCS Code: 1901-510
Programming a Flash File
NOTICE
1. Establish communication between Cat ET and the Care must be taken to ensure that fluids are contained
engine's ECM. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
2. Select “WinFlash” from the “Utilities” menu on Cat collect the fluid with suitable containers before open-
ET. ing any compartment or disassembling any compo-
nent containing fluids.
Note: If “WinFlash” will not communicate with the
ECM, refer to troubleshooting without a diagnostic Refer to Special Publication, NENG2500, “Caterpillar
code Troubleshooting, “Electronic Service Tool Does Dealer Service Tool Catalog” for tools and supplies
Not Communicate”. suitable to collect and contain fluids on Caterpillar
products.
3. Program the flash file into the ECM.
Dispose of all fluids according to local regulations and
a. Select the engine ECM under the “Detected mandates.
ECMs”.
d. Verify that the “File Values” match the The Electronic Control Module (ECM) contains no
application. If the “File Values” do not match moving parts. Replacement of the ECM can be
the application, obtain the correct flash file. costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this
e. When the correct flash file is selected, press manual in order to ensure that replacing the ECM will
the “Begin Flash” button. correct the problem and that the ECM is the cause
of the problem.
f. Cat ET will indicate when flash programming
has been successfully completed.
KENR5404-03 205
Troubleshooting Section
Note: Ensure that the ECM is receiving power and d. Remove the mounting bolts from the ECM.
that the ECM is properly wired to the negative battery
circuit before you attempt to replace the ECM. Refer e. Disconnect the ECM ground strap from the
to Troubleshooting, “Electrical Power Supply - Test”. engine.
1. Print the parameters from the “Configuration” c. Ensure that the ECM mounting hardware
screen on Caterpillar Electronic Technician is installed correctly. The rubber grommets
(ET). If a printer is unavailable, record all of the are used to protect the ECM from excessive
parameters. Record any logged diagnostic codes vibration. The ECM must be able to drift in the
and logged event codes for your records. Record rubber grommets. If the installation is equipped
the injector trim codes from the “Calibrations” with fuel lines, the fuel lines must not put
screen under the “Service” menu on Cat ET. tension on the ECM. If the ECM cannot be
moved slightly in the grommets, check that the
Note: The injector trim code is a number that is found fuel lines are not pulling the ECM against one
on each of the unit injectors. The ECM uses this side of the grommets.
number to compensate for manufacturing variations
between individual injectors. If you replace any of d. Connect the ECM ground strap.
the unit injectors, you must reprogram the injector
trim code for the new injector. Also, if you replace e. Connect the J1/P1 and J2/P2 ECM connectors.
the ECM, you must reprogram all of the injector trim Tighten the allen head screw on each of the
codes. ECM connectors to the proper torque. Refer
to Troubleshooting, “Electrical Connectors -
2. Use the “Copy Configuration/ECM Replacement” Inspect” for the correct torque value.
feature that is found under the “Service” menu on
Cat ET. Select “Load from ECM” in order to copy 5. Install the ECM software. Refer to Troubleshooting,
the configuration from the suspect ECM. “ECM Software - Install”.
Note: If the “Copy Configuration” process fails and 6. If the replacement ECM was used previously for a
the parameters were not obtained in Step 1, the different application, obtain factory passwords in
parameters must be obtained elsewhere. Some order to reset the interlock codes.
parameters are stamped on the engine information
plate, but most parameters must be obtained from 7. Configure the ECM.
the factory.
a. If the “Load from ECM” process from Step
3. Remove the ECM from the engine. 2 was successful, return to the “Copy
Configuration/ECM Replacement” screen on
a. Remove the electrical power from the ECM. Cat ET and select “Program ECM”.
b. Disconnect the J1/P1 and J2/P2 ECM After using the “Program ECM” feature, be sure
connectors. to cycle the power to the ECM. Wait at least
30 seconds after turning the keyswitch to the
NOTICE OFF position.
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately. Note: Some control modules have a power off delay.
The 30 seconds will be sufficient to cover this delay.
Note: If the “Copy Configuration” process fails and • If a wire is cut, always install a new terminal for
the parameters were not obtained in Step 1, the the repair.
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
The connection of any electrical equipment and
d. If necessary, program the engine monitoring the disconnection of any electrical equipment may
system. cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
8. Program the injector trim codes. ment or disconnect any electrical equipment in an
explosive atmosphere.
9. Check for an active diagnostic code for timing
calibration. 1. Determine If The Problem Is Intermittent.
If the diagnostic code is active, calibrate the If the problem is intermittent, attempt to test
injection timing. Refer to calibration procedures the circuit before you disconnect any electrical
Troubleshooting, “Timing - Calibrate”. connectors. This helps identify the root cause of
intermittent problems.
10. Check for diagnostic codes and for event codes.
The “Wiggle Test” on the Caterpillar Electronic
Technician (ET) may be able to test the circuit.
i02614068
Refer to the documentation that accompanies Cat
Electrical Connectors - Inspect ET.
SMCS Code: 7553-040-WW Perform the wiggle test on the circuit, when
possible. Otherwise, continue with this procedure.
Most electrical problems are caused by poor
connections. The following procedure will assist in 2. Check the Connectors for Moisture and For
detecting problems with connectors and with wiring. Corrosion.
If a problem is found correct the condition and verify
that the problem is resolved.
g01131276 g01131165
Illustration 118 Illustration 120
Diagram for the installation of a connector plug (typical example) Seal for ECM connector (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug c. Disconnect the suspect connector and inspect
(3) Incorrectly inserted plug the connector seal. Ensure that the seals are
in good condition. If necessary, replace the
b. Ensure that the sealing plugs are in place. If connector.
any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into d. Thoroughly inspect the connectors for evidence
the connector. Refer to Illustration 118. of moisture entry.
Illustration 119
g01131019 • Missing seals
Seal for a three-pin connector (typical example)
• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
connector, thoroughly check the connector's
harness for damage. Also check other
connectors that share the harness for moisture.
3. Check the Wires for Damage to the Insulation. b. Perform the 45 N (10 lb) pull test on each
wire. Each terminal and each connector should
a. Carefully inspect each wire for signs of easily withstand 45 N (10 lb) of tension and
abrasion, of nicks, and of cuts. each wire should remain in the connector
body. This test checks whether the wire was
Inspect the wires for the following conditions: properly crimped in the terminal and whether
the terminal was properly inserted into the
• Exposed insulation connector.
• Rubbing of a wire against the engine 6. Check Individual Pin Retention into the Socket.
a. Ensure that the locking wedge for the connector a. Connect the ECM connectors.
is installed properly. Terminals cannot be
retained inside the connector if the locking
wedge is not installed properly.
KENR5404-03 209
Troubleshooting Section
g01132827 g01133047
Illustration 123 Illustration 126
Allen head screw for the 120 pin ECM connector (typical example) Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
b. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). f. 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).
i02629921
i02630330
Table 48
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
91-13 Throttle Position Sensor The duty cycle for the throttle position The Electronic Control Module (ECM)
calibration required sensor signal is less than 5 percent or sets the desired engine speed to
more than 95 percent. programmed low idle while this
1249-13 Secondary Throttle Position diagnostic code is active. Caterpillar
calibration required Electronic Technician (ET) will indicate
a throttle position of 0 percent while this
diagnostic code is active.
i02969123
g01319129
Illustration 127
Timing - Calibrate
Typical example
SMCS Code: 1000-524; 1900-524; 1912-524
1. Check the Throttle Linkage for Damage.
Use this procedure if the diagnostic code in Table
a. Turn off the power to the engine's ECM. 49 is active.
b. Inspect the throttle linkage for components with
the following conditions:
• Loose
• Bent
• Broken
• Missing
• Worn
Repair any damaged components.
212 KENR5404-03
Troubleshooting Section
Table 49
Diagnostic Codes Table
Code Conditions which Generate this Code System Response
261-13 Engine Timing Calibration : The engine speed/timing sensor has not This will not keep the engine from
Calibration Required been calibrated. running. The fuel injection timing may
be out of adjustment.
The engine speed/timing sensors provide engine g. Connect the 7X-1695 cable from the engine
information to the Electronic Control Module (ECM). timing calibration probe to the connector P26.
The sensor generates a pulse signal. A loss of the
signals from the secondary engine speed/timing h. Start the engine. Allow the engine to exit cold
sensor and the primary engine speed/timing sensor mode operation.
causes the ECM to stop sending power to the fuel
injectors. 2. Calibrate the Fuel Injection Timing.
The ECM provides the engine speed/timing sensor a. Select “Calibrations” from the “Service” menu
with 12.5 ± 1.0 VDC. A unique tooth on the timing onCaterpillar Electronic Technician (ET). Select
reference gear generates a unique duty cycle. The the “Timing Calibration” from the “Calibrations”
signal provides the ECM with information on the menu.
engine position.
Note: Engine speed will be set to 800 rpm by the
If the primary engine speed/timing sensor fails, the ECM during the calibration.
ECM will use the secondary engine speed/timing
sensor until electrical power is removed from the b. Follow the instructions on the Cat ET screen.
ECM. To prevent any unnecessary down time,
replace the primary engine speed/timing sensor at Note: If the Cat ET screen reads “COULD NOT
the earliest possible convenience. CALIBRATE”, the timing has not been set. Verify that
the engine speed was stable during the testing (±
1. Install the Timing Calibration Probe. 50 rpm). If the engine speed was unstable or the
engine speed could not be controlled within ± 50 rpm
a. Turn the Engine Control Switch (ECS) to the because of mechanical factors or electrical factors,
OFF position. refer to the diagnostic procedure Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”.
b. Remove the timing calibration plug from the
flywheel housing. If all of the problems have been corrected
but the timing can not be calibrated, check
c. Examine the flywheel through the timing the cable of the 189-5746 Speed Sensor.
calibration hole. Ensure that the probe is not Check the 189-5746 Speed Sensor in order
inserted into the timing pin hole. If necessary, to verify that the probe is not bent. Verify that
rotate the engine crankshaft. the probe is installed correctly before restarting
this procedure.
d. Install the 6V-3093 Transducer Adapter
into the hole for the timing calibration at the
flywheel.
NOTICE
Do not install the timing calibration probe over the tim-
ing pin hole at the flywheel or damage will result.
Index
A E