CAT C11 - C13 - C15 and C18 Industrial Engines - 5824317 - 01 PDF

C13 Industrial Engine LGK00001-UP(SEBP4130 - 62) - Documentation https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...
Welcome: schlumberger05
Product: INDUSTRIAL ENGINE
Model: C13 INDUSTRIAL ENGINE LGK22679
Configuration: C13 Industrial Engine LGK00001-UP
Troubleshooting
C11, C13, C15, and C18 Industrial Engines
Media Number -M0073474-03 Publication Date -01/08/2016 Date Updated -30/08/2016
i06844639
Electronic Service Tools

SMCS - 0785
Service Tools
Most of the tools that are listed in Table 1 are required to enable a service technician to perform the test
procedures in this manual. Some of the devices may be specific to the type of Electronic Control Module
(ECM) that is being used.
Table 1
Service Tools
Part
Description
Number
349-4200 Thermometer
360-0774 Refractometer
431-7087 Tool Gp (REFRACTOMETER (DEF))
N/A 4 mm Allen Wrench
1U-5805 Wire Removal Tool (14-GA, GREEN)
6V-2197 Magnetic Transducer As (TIMING CALIBRATION)
121-9588 Wire Removal Tool (16-GA, BLUE)
147-6456 Wedge Removal Tool
151-6320 Wire Removal Tool (14-GA TO 18-GA, RED)
1U-5804 Crimp Tool (12 AWG TO 18 AWG)
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6V-2197 Transducer
7X-1171 Transducer Adapter
7X-1695 Cable As
146-4080 Digital Multimeter Gp (RS232)
7X-1710 Multimeter Probes
326-4904 Adapter Cable As (3-PIN BREAKOUT)
Adapter Cable As (40-PIN BREAKOUT)

7X-1715
Harness (40-PIN)
134-5195
(For ADEM 2 ECM (two 40-pin connectors))
Adapter Cable As (70-PIN BREAKOUT)

208-0059 (For ADEM 3 ECM (two 70-pin connectors) and for ADEM 4 ECM (one 70-pin connector
and one 120-pin connector))
The 257-8718 Adapter Cable As is not applicable with Tier IV Engines.

(For ADEM 4 ECM (one 70-pin connector and one 120-pin connector))
N/A Torque Wrench (capable of applying 1.5 N·m (13.3 lb in))
Repair Kits for Connectors
362-3555 Connector Repair Kit (AMPSEAL)
175-3700 Connector Repair Kit (Deutsch connector)
Bypass Harnesses for the ECM
Power Cable
129-2018
(Stand alone cable for ADEM 2 ECM)
Wiring Harness (ECM BYPASS)

217-0113 (The bypass harness connects to the battery. The bypass harness is used with the following
harnesses for different types of electronic control modules.)
Harness (ENGINE ECM BYPASS)

328-2292
(For ADEM 3 ECM and ADEM 4 ECM)
Harness (ENGINE ECM BYPASS)

277-4734
(For A4:E2 ECM (Two 64-pin connectors))
276-7273 Sensor Test Box (1)

(1) Instrument used to test Cylinder Position sensors.
Two short jumper wires may be needed to check the continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A long extension wire may also be needed to check the
continuity of some wiring harness circuits.
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Except for harness tests, the use of certain test equipment is not recommended for use on modern Caterpillar
electrical circuits. Such testers include the following examples: the 8T-0500 Continuity Tester and 5P-7277
Voltage Tester.
Note: A procedure has been developed to test "In Cylinder" Position Sensors. Reference Special Instruction
REHS7338, "Procedure to Test the Position Sensor of a Hydraulic Cylinder".
Optional Service Tools

Table 2 lists the optional service tools that may be needed during testing or repair.
Table 2
Optional Service Tools
Part Number Description
198-4240 Digital Pressure Indicator

or or
1U-5470 Engine Pressure Group
4C-4075 Crimp Tool (4 AWG TO 10 AWG)
4C-4911(1) Battery Load Tester
5P-7277 Voltage Tester
6V-9130(2) Temperature Adapter (MULTIMETER)
8T-5319 Connector Tool Group
349-4199 AC/DC Current Probe
348-5430 Multi-Tool Gp
8T-8726 Adapter Cable As
177-2330 Battery Analyzer (DIGITAL)
190-8900 Connector Repair Kit
225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)
391-8170 EMISSIONS ANALYZER TOOL GP (Bluetooth Module)
393-0673 EMISSIONS ANALYZER TOOL GP

(1) Refer to Special Instructions, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries" and Special
Instructions, SEHS7633, "Battery Test Procedure".
(2) Refer to Special Instructions, SEHS8382, "Use of the 6V-9130 Temperature Adapter Group".
Cat Electronic Technician (ET)
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Cat ET can be used by the technician to help perform the following procedures:
Diagnostic testing
Calibrations
Flash programming
Configuration of the ECM
Print various reports
Cat ET can display the following information:
Status parameters
Event codes
Diagnostic codes
ECM settings
Engine configuration
Always use the latest revision of Cat ET. The media is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Software, JEBD3003, "CATERPILLAR ELECTRONIC TECHNICIAN"
Once you have downloaded Cat ET onto your PC, you will need a license from your Caterpillar dealer to use
the software. Various licenses are available for different users with different requirements. Consult your
Caterpillar dealer.
Note: For more information regarding the use of Cat ET and PC requirements, refer to the documentation
that accompanies your Cat ET program software.
Connecting Cat ET
Connecting the Communication Adapter
Note: The 466-6258 is the latest version of the Communication Adapter Group. Older service tool versions
can still be used.
Table 4 lists the standard hardware that is required to connect Cat ET.
Table 4
Standard Hardware for Connecting with Cat ET
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N/A Personal Computer (PC)
466-6258 Communication Adapter Gp
317-7492 Radio Kit (NACD only)
349-1206 Radio Kit (EAME only)
Components of the 466-6258 Communication Adapter Gp
317-7485 Communication Adapter (3)
370-4617 Cable As (USB)
457-6114 Cable As (DATA LINK)
Components of the 317-7492 Radio Kit
317-7493 Wireless Communication Radio
317-7496 Computer Cable As
317-7510 Radio Cable Assembly
326-9606 Antenna (2)
Components of the 349-1206 Radio Kit
348-9250 Communication Radio Gp
317-7496 Computer Cable As
317-7510 Radio Cable Assembly
326-9606 Antenna (2)
Tool Operating Manual & Software CD ROM, NETG5057, "Communication Adapter 3"
Follow the instructions for the communication adapter. Use the following procedure to connect Cat ET and
the communication adapter to a PC.
1. Remove the electrical power from the ECM.
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Illustration 1 g02051513
(1) PC
(2) 353-5083 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
(4) 327-8981 Cable As (DATA LINK)
2. Connect cables (2) and (4) to communication adapter (3).
Note: The communication adapter will power up when the adapter is connected to a PC or to an ECM
that is powered up.
3. Connect cable (2) to the USB port of the PC.
4. Connect cable (4) to a service tool connector.
5. Restore electrical power to the ECM. Verify that the "POWER" indicator on the communication
adapter is illuminated. Make sure that the PC is powered up.
6. Establish communication between Cat ET and the ECM. If Cat ET indicates that there is more than one
ECM, select the engine ECM.
7. If Cat ET and the communication adapter do not communicate with the ECM, refer to Troubleshooting,
"Electronic Service Tool Will Not Communicate with ECM".
Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if any of the following
conditions exist:
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Cat ET displays a message that refers to a communication problem.
Cat ET displays "Error #142 The interface hardware is not responding".
Cat ET displays a message that indicates that the firmware in the communications adapter is old.
Dual Data Link Communications (If so equipped)
When the connection of the communication adapter is complete, observe the communication adapter and Cat
ET. Certain applications require that dual data link communications be established to perform various test
procedures. These tests will be listed in the "Diagnostic Tests" menu, some tests may not be available (grayed
out). If there are diagnostic tests that are unavailable in Cat ET, ensure that your service tool is
communicating in dual data link mode.
Use the following indicators to confirm that Cat ET is communicating on dual data links:
"J1939" indicator is flashing
"Cat Data Link" indicator is flashing
Cat ET is not displaying "Service tool support is limited"
Refer to Troubleshooting, "Electronic Service Tool Does Not Communicate" if the "J1939" indicator and the
"Cat Data Link" indicator are not flashing. Both indicators will be flashing during dual data link
communications with the ECM.
Communicating with the Wireless Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed to connect Cat ET by using a wireless connection.
Note: Some applications cannot use a wireless connection. Also, a dual data link cannot be used with a
wireless connection.
Table 5
Optional Hardware for the Use of Cat ET
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(1) Personal computer (PC)
(5) 261-4867 Card (PCMCIA)
(6) 239-9955 Communication Radio Gp
(7) 259-3183 Data Link Cable As
Note: Items (5), (6), and (7) are part of the 261-3363 Wireless Communication Adapter Gp.
Note: The 261-3363 Wireless Communication Adapter Gp was canceled and replaced by the 349-1206 Radio
Kit. However, the 261-3363 Wireless Communication Adapter Gp can still be used.
Use the following procedure to connect the wireless communication adapter for use with Cat ET.
2. Ensure that the computer has been correctly configured for the 261-4867 Card. Verify that the PC card
is installed in the computer PCMCIA expansion slot.
3. Connect cable (9) between communication radio (8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET and the communication radio do not communicate
with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".
Communicating with the Wireless Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed to connect Cat ET by using a wireless connection.
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Note: Some applications cannot use a wireless connection. Also, a dual data link cannot be used with a
wireless connection.
Although changes can be made to the internal settings of the W-CA3 wirelessly. Caterpillar recommends that
the radio is connected to a PC via 317-7496 Computer Cable As (USB)Cable Assembly (8) and 317-7510
Radio Cable Assembly (9).
Table 6
Optional Hardware for the Use of Cat ET
(8) 317-7496 Computer Cable As (USB)
(9) 317-7510 Radio Cable AssemblyC
(9) 317-7510 Radio Cable Assembly
(10) W-CA3
Note: Items (8), (9), and (10) are part of the 349-1206 Radio Kit.
Use the following procedure to connect the wireless communication adapter for use with Cat ET.
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2. Ensure that the computer has been correctly configured for the 802.11a or 802.11b/g enabled wireless
card. Verify that the PC wireless is installed and working correctly.
3. Connect cable (9) between communication radio (8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET and the communication radio do not communicate
with the ECM, refer to Troubleshooting, "Electronic Service Tool Will Not Communicate with ECM".
PL1000E Communication ECM (If so equipped)
The PL1000E is an ECM that provides the customer with the ability to integrate Caterpillar engines into
specific applications. The PL1000E enables communication from a J1939 data link to a device that utilizes a
MODBUS communication protocol. A PC with the latest version of Cat ET installed can be connected to the
PL1000E through the RS232 serial port of the PC. The PL1000E contains an embedded communications
adapter that will allow Cat ET to communicate with the engine over the J1939 data link.
Refer to System Operation/Troubleshooting/Test and Adjust, RENR8091, "PL1000E Communication ECM"

for additional information.
Copyright 1993 - 2017 Caterpillar Inc. Fri Feb 17 2017 11:44:36 GMT+1000 (E. Australia Standard Time)
All Rights Reserved.
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Private Network For SIS Licensees.
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Troubleshooting
i02278907
Service Information Report

SMCS - 0336
After verifying the correct repair has been performed on the engine, it is critical to provide brief, detailed
information. This information helps Caterpillar better serve you and the customer.
Recommendations
Customer's Complaint
Obtain as much information from the customer as possible. Investigate any written information that is
available and document any information that is gathered from the customer. The following information is of
particular importance:
Indicate if the diagnostic lamp was flashing.
Indicate if the warning lamp was flashing, or if the lamp was on continuously.
Indicate the symptoms of engine operation that are present.
Be as specific as possible.
Cause of Failure
Comments on the cause of failure should include the number of diagnostic codes that were logged.
Comments should also indicate if the code was an active code. Indicate the source of the problem. Also
indicate the method that was used to discover the problem. Examples of the methods that were used to
discover the problem could be one of the following methods:
A specific procedure in the manual was followed.
A visual inspection indicated that wire abrasion on the engine harness existed.
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An engine dynamometer test indicated that the power was below the specification at 1700 rpm due to
the loss of the no. 4 injector and an engine dynamometer test indicated that the power was below the
specification at all engine speeds above 1700 rpm due to the loss of the no. 4 injector.
Repair Procedure
Comments on the repair procedure should include the following types of information:
The wiring harness was repaired.
The Full Load Setting (FLS) was changed per the factory's instructions.
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Troubleshooting
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System Overview
SMCS - 1000; 1900
System Operation
This engine is electronically controlled. Each cylinder has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector solenoid in order to control the operation of the fuel injection
system.
Electronic Controls
The electronic system consists of the following components: the ECM, the Mechanically Actuated
Electronically Controlled Unit Injectors (MEUI), the wiring harness, the switches and the sensors. The ECM
is the computer. The flash file is the software for the computer. The flash file contains the operating maps.
The operating maps define the following characteristics of the engine:
Horsepower
Torque curves
The ECM determines the timing and the amount of fuel that is delivered to the cylinders. These decisions are
based on the actual conditions and/or on the desired conditions at any given time.
The ECM compares the desired engine speed to the actual engine speed. The actual engine speed is
determined through a signal from the engine speed/timing sensor. The desired engine speed is determined
with the following factors:
Throttle signal
Other input signals from sensors
Certain diagnostic codes
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If the desired engine speed is greater than the actual engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
Cold Mode
The ECM limits engine power during cold mode operation and the ECM modifies injection timing during
cold mode operation. Cold mode operation provides the following benefits:
Increased cold weather starting capability
Reduced warm-up time
Reduced white smoke
Cold mode is activated whenever the engine temperature falls below a predetermined value. Cold mode
remains active until the engine temperature rises above a predetermined value or until a time limit is
exceeded.
Fuel Injection
The ECM controls the amount of fuel that is injected by varying the signals to the injectors. The injector will
pump fuel only if the injector solenoid is energized. The ECM sends a high voltage signal to the solenoid.
This high voltage signal energizes the solenoid. By controlling the timing and the duration of the high voltage
signal, the ECM can control injection timing and the engine RPM.
The flash file inside the ECM sets certain limits on the amount of fuel that can be injected. The "FRC Fuel
Limit" is used to control the air/fuel ratio for control of emissions. The "FRC Fuel Limit" is a limit that is
based on the turbocharger outlet pressure. A higher turbocharger outlet pressure indicates that there is more
air in the cylinder. When the ECM senses a higher turbocharger outlet pressure, the ECM increases the "FRC
Fuel Limit". When the ECM increases the "FRC Fuel Limit", the ECM allows more fuel into the cylinder.
The "FRC Fuel Limit" is programmed into the ECM at the factory. The "FRC Fuel Limit" cannot be changed.
The "Rated Fuel Limit" is a limit that is based on the power rating of the engine and on engine rpm. The
"Rated Fuel Limit" is similar to the rack stops and to the torque spring on a mechanically governed engine.
The "Rated Fuel Limit" provides the power curves and the torque curves for a specific engine family and for
a specific engine rating. The "Rated Fuel Limit" is programmed into the ECM at the factory. The "Rated Fuel
Limit" cannot be changed.
Once the ECM determines the amount of fuel that is required, the ECM must determine the timing of the fuel
injection. The ECM calculates the top center position of each cylinder from the engine speed/timing sensor's
signal. The ECM decides when fuel injection should occur relative to the top center position and the ECM
provides the signal to the injector at the desired time. The ECM adjusts timing for optimum engine
performance, for optimum fuel economy, and for optimum control of white smoke.
Programmable Parameters
Certain parameters that affect the engine operation may be changed with Caterpillar Electronic Technician
(ET). The parameters are stored in the ECM, and some parameters are protected from unauthorized changes
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by passwords. These passwords are called factory passwords.
Passwords
Several system configuration parameters and most logged events are protected by factory passwords. Factory
passwords are available only to Caterpillar dealers. Refer to Troubleshooting, "Factory Passwords" for
additional information.
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Troubleshooting
i02139021
Electronic Display Module - If Equipped

SMCS - 7490
An electronic display module may be used to display CID-FMI information from the electronic control
system. Refer to the service manual for your electronic display module for more information.
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Troubleshooting
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Configuration Parameters
SMCS - 1900
Use this procedure if the diagnostic code in Table 1 is active.
Table 1
Diagnostic Trouble Codes
CDL Code and Description Comments
The engines Electronic Control Module (ECM) detects that one or

268-2 more of the programmable parameters have not been programmed.
Programmed Parameter Fault : The ECM may use a default torque map or the ECM may limit the
Erratic, Intermittent, or Incorrect engine to low idle.
The code is active only.
Customer Specified Parameters - Customer passwords may be required to change the values of customer
specified parameters.
System Configuration Parameters - System configuration parameters affect the emissions of the engine or
the power of the engine. Factory passwords may be required to change the values of system configuration
parameters.
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Typical configuration screen
1. Connect to Cat ET.
2. Select the Service tab.
3. Select the Configuration tab to view the configuration parameters.
If an ECM is replaced, the appropriate parameters must be copied from the old ECM. Copy the parameters
with the "Copy Configuration" feature of the Cat ET. The "Copy Configuration" tab is below the
"Configuration" tab. Alternatively, the settings can be recorded on paper and then programmed into the
configuration screen that is for the new module.
NOTICE
Changing the parameters during engine operation can cause the engine
to operate erratically. Engine damage may be the result.
Only change the settings of the parameters when the engine is stopped.
Check Programmable Parameters (268-2)
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If a programmable parameter has not been programmed, the ECM will generate a 268-2 diagnostic code. The
programmable parameter that is not programmed will be listed under the code. The unprogrammed
parameters will be set to default. Certain aspects of the engines performance and engine monitoring may be
affected.
If "Injector Trim" is displayed below a 268-2 diagnostic code on Cat ET, refer to Troubleshooting, "Injector
Trim File - Install".
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Troubleshooting
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Event Codes
SMCS - 1900
Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high
coolant temperature has been detected. When the event code is generated, the event is active.
Active Event Codes

An active event code represents a problem with engine operation. Correct the problem as soon as possible.
Active event codes are listed in ascending numerical order. The code with the lowest number is listed first.
Illustration 1 is an example of the operating range of a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.
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Example of the typical operating range of a temperature sensor
(1) This area represents the normal operating range of the parameter. The normal output voltage of the sensor is between 0.2 VDC
and 4.2 VDC.
(2) In this area, the temperature above 107 °C (225 °F) is higher than normal. The output voltage of the sensor will generate an event
code. The sensor does not have an electronic problem.
(3) In these areas, the output voltage of the sensor is too high or too low. The voltage is outside of the normal range. The electronic
problem will generate a diagnostic code. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code" for additional
information on diagnostic codes.
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Events are represented in two formats. In the first format, the "E" means that the code is an event code. The
"XXX" represents a numeric identifier for the event code. This is followed by a description of the code. If a
warning, a derate, or a shutdown is applicable, the numeric identifiers are different. Refer to the following
example:
E004 Engine Overspeed Shutdown
In the second format, the "E" means that the code is an event code. The "XXX-X" represents a numeric
identifier for the event code. The fourth "X" identifies the event as a warning, a derate, or a shutdown. This is
followed by a description of the code. Refer to the following example:
E360 (1) Low Oil Pressure Warning
E360 (2) Low Oil Pressure Derate
E360 (3) Low Oil Pressure Shutdown
The definition for a warning, a derate, and a shutdown are defined below:
Warning - This condition represents a serious problem with engine operation. However, this condition does
not require a derate or a shutdown.
Derate - For this condition, the ECM reduces the engine's power in order to help prevent possible engine
damage.
Shutdown - For this condition, the ECM shuts down the engine in order to help prevent possible engine
damage.
Logged Event Codes

When the ECM generates an event code the ECM logs the code in permanent memory. The ECM has an
internal diagnostic clock. The ECM will record the following information when an event code is generated:
The hour of the first occurrence of the code
The hour of the last occurrence of the code
The number of occurrences of the code
Logged events are listed in chronological order. The most recent event code is listed first.
This information can be helpful for troubleshooting intermittent problems. Logged codes can also be used to
review the performance of the engine.
Clearing Event Codes

A code is cleared from memory when one of the following conditions occur:
The code does not recur for 100 hours.
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A new code is logged and there are already ten codes in memory. In this case, the oldest code is
cleared.
The service technician manually clears the code.
Always clear logged event codes after investigating and correcting the problem which generated the code.
Troubleshooting
For basic troubleshooting of the engine, perform the following steps in order to diagnose a malfunction:
1. Obtain the following information about the complaint:
The event and the time of the event
Determine the conditions for the event. The conditions will include the engine rpm and the load.
Determine if there are any systems that were installed by the dealer or by the customer that could
cause the event.
Determine whether any additional events occurred.
2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to
error of the operator.
3. Narrow the probable cause. Consider the operator information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following items:
Fuel supply
Oil level
Oil supply
Wiring
Connectors
Be sure to check the connectors. This is very important for problems that are intermittent. Refer to
Troubleshooting, "Electrical Connectors - Inspect".
If these steps do not resolve the problem, identify the procedures in this manual that best describe the event.
Check each probable cause according to the tests that are recommended.
Trip Points for the Monitoring System

The monitoring system determines the level of action that is taken by the Electronic Control Module (ECM)
in response to a condition that can damage the engine. When any of these conditions occur, the appropriate
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event code will trip.
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Troubleshooting
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Symptom Troubleshooting
SMCS - 7569
Some engine symptoms can be unrelated to the electronic control system. Gather information about the
complaint that describes the symptoms. Verify that the complaint is not due to normal engine operation.
Table 1
CDL Codes and Description Comments
E443 (1)
The code is logged.
High Auxiliary Pressure - least severe (1)
E443 (2)
The code is logged.
High Auxiliary Pressure - moderate severity (2)
E443 (3)
The code is logged.
High Auxiliary Pressure - most severe (3)
E445 (1)
The code is logged.
High Auxiliary Temperature - least severe (1)
E445 (2)
The code is logged.
High Auxiliary Temperature - moderate severity (2)
E445 (3)
The code is logged.
High Auxiliary Temperature - most severe (3)
Probable Causes
Codes
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Operator error
System failure
Electrical connectors and/or wiring
Recommended Actions
Table 2
Troubleshooting Test Steps Value Results
Result: There are not any codes.
Proceed to Test Step 2.
Result: There are codes logged

1. Check for Codes
or active.
A. Use Cat® Electronic Technician (ET) to check Codes
Repair: Troubleshoot any code
for any logged or active diagnostic codes.
before continuing with this
procedure.
If the problem is not resolved,

proceed to Test Step 2.
Result: Gathered all relative

information from the customer
2. Gather Operator Information from the that pertains the operation and
Operator
Operator symptoms of the machine.
information
Result: The symptoms are related

3. Verify that the Complaint is Not Due to to normal engine operations.
Normal Engine Operation
Return the machine to service.
A. Use information gathered from the customer to Engine
decide if symptoms are related to normal engine operation Result: The symptoms are not
operations under different conditions. Refer to the related to normal engine
Systems Operation for more information. operations.
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Result: The system components

4. Perform a Visual Inspection of the Engine. are OK.
A. Inspect the following items: Proceed to Test Step 5.
- Fuel level Result: The system components

- Fuel supply System are NOT OK.
- Engine oil level components
- Engine oil supply Repair: Make any repairs as
- Coolant level necessary.
- Intake air system
- Air exhaust system If the problem is not resolved,
5. Check the Electrical Wiring and Connectors:

Result: There were electrical
A. Inspect the wiring and connectors for the connectors and/or wiring that are
following issues: NOT OK.
Electrical
connectors and
- Damage Repair: Repair or replace the
wiring
- Abrasion electrical connectors and/or
- Corrosion wiring as necessary.
- Incorrect attachment
If the problem is not resolved, contact your Technical Communicator (TC). For further assistance, the TC can
confer with the Dealer Solution Network (DSN).
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Troubleshooting
i06857262
Coolant Level Is Low

SMCS - 1395-035
Use this procedure to troubleshoot low coolant level or use this procedure if one of the codes in Table 1 is
active.
Table 1
E2143 (1) The engine has been running for 60 seconds. The engine coolant level
Low Engine Coolant Level - has fallen below the coolant level sensor for the specified delay time.
least severe (1) The code is logged.
moderate severity (2) Engine power is derated. The code is logged.
most severe (3) Engine power is derated. The code is logged.
Probable Causes
Low coolant level
Coolant leakage
Air in cooling system
Incorrect anti-freeze mixture
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Coolant level sensor
Recommended Actions
Table 2
Troubleshooting Test Steps Values Results
Result: The engine coolant level is

OK.

1. Check for Low Coolant Level.
Coolant Result : The engine coolant level is
Level NOT OK.
A. Inspect the coolant level.
Repair : Fill the coolant tank to the
proper level if necessary.
Result : The cooling system is OK.
Result: The cooling system is NOT

OK.
2. Check the Cooling System for Leaks. Cooling Repair: Refer to Systems
system Operation/Testing and Adjusting,
"Cooling System - Test" for the correct
procedure. Repair any leaks
immediately.
If the problem is not resolved, proceed

to Test Step 3.
Result : The cooling system is OK.
3. Check for Air in the Cooling System. Cooling Proceed to Test Step 4.
system
Result : There is air in the cooling
system.
2 of 3 2/17/2017 12:09 PM
Repair : Refer to Systems

Operation/Testing and Adjusting,
"Testing the Cooling System" for the
correct procedure.

to Test Step 4.
Result : The antifreeze and water

mixture is OK.
Result : The antifreeze and water

4. Check for the Correct Mixture of Antifreeze
Antifreeze mixture is NOT OK.
and Water.
mixture
Repair : Refer to the Operation and
Maintenance Manual.

to Test Step 5.
5. Check for a Faulty Coolant Level Sensor

Result: The coolant level sensor is not
A. If an electrical problem with the coolant level Coolant operating properly.
sensor is suspected, refer to Troubleshooting, Level
"Coolant Level - Test" for information that is Sensor Repair: Replace the coolant level
related to troubleshooting an electrical problem sensor.
with the coolant level sensor.
If the procedure did not correct the issue, contact your Technical Communicator (TC). For further assistance,
the TC can confer with the Dealer Solutions Network (DSN).
schlumberger05
3 of 3 2/17/2017 12:09 PM
Troubleshooting
i06731201
Coolant Temperature Is High

SMCS - 1395-035
Use this procedure to troubleshoot high coolant temperature or if one of the codes in Table 1 is active.
Table 1
The engine coolant temperature has exceeded the trip point

E361(3)
and the delay time has expired.
Engine Coolant Temperature High - Most
Engine power is derated.
Severe (3)
The code is logged.
E361(1) The engine coolant temperature has exceeded the trip point
Engine Coolant Temperature High- Least and delay time has expired.
Severe (1) The code is logged.
E361(2) The engine coolant temperature has exceeded the trip point
High Engine Coolant Temperature High - and the delay time has expired.
Moderate Severity (2) The code is logged.
Probable Causes
Low Coolant Level and/or Coolant Leakage
Coolant Temperature Sensor
Water Temperature Regulator and/or Pressure Relief Valve
Radiator
1 of 5 2/17/2017 12:10 PM
Heat Exchanger
Engine Cooling Fan (if equipped)
Coolant Pump
Cylinder Head Gasket
Recommended Actions
Table 2

OK.

NOT OK.
Engine
1. Inspect the Engine Coolant Level
Coolant Level Repair: Check the cooling system for
leaks. Refer to Troubleshooting,
"Coolant Level is Low" for additional
information. Repair any leaks
immediately.

to Test Step 2.
Result: The temperature sensor is OK.

2. Check the Coolant Temperature Sensor
Result: The temperature sensor is
and/or the Circuit
NOT OK.
Coolant
A. Check the reading of the coolant temperature Temperature
Repair: Troubleshoot the circuit and
on Cat ET. The temperature should rise steadily Sensor
the coolant temperature sensor. Refer
as the engine is warmed. Ensure that the
to Troubleshooting, "Sensor Signal
temperature is within operating specifications.
(Analog, Passive) - Test".

to Test Step 3.
2 of 5 2/17/2017 12:10 PM
Result: The pressure relief valve

3. Check the Water Temperature Regulator and/or the water temperature regulator
and/or Pressure Relief Valve are OK.
A. Pressure-test the cooling system. Refer to Proceed to Test Step 4.

Systems Operation/Testing and Adjusting for the
correct procedure. Result: The pressure relief valve
Temperature
and/or the water temperature regulator
Regulator
B. Check that the seating surfaces of the pressure are NOT OK.
relief valve and the radiator cap are clean and
undamaged. Repair: Clean the components and/or
replace the components.
C. Check operation of the pressure relief valve
and/or the water temperature regulator. If the problem is not resolved, proceed
to Test Step 4.
4. Inspect the Radiator Result : The radiator is OK.
A. Check the radiator fins for dirt, debris, and/or Proceed to Test Step 5.
damage.
Result : The radiator fins are
B. Check for collapsed hoses and/or other damaged.
restrictions.
Repair: Remove any dirt and/or
C. Check the radiator for internal blockage. Radiator debris and straighten any bent fins.
Note: Ensure that the radiator size is sufficient. Result The radiator has internal
An undersized radiator does not have enough blockage.
area for the effective release of heat. An
undersized radiator may cause the engine to run Repair: Remove the blockage.
at a temperature that is higher than normal. The
normal temperature depends on the ambient If the problem is not resolved, proceed
temperature. to Test Step 5.
Result : The heat exchanger is OK.

5. Check the Heat Exchanger for Sufficient
Flow
Heat
Exchanger Result : The heat exchanger is NOT
A. Check for sufficient flow and temperature of
OK.
the cooling water through the heat exchanger.
Repair: Determine the location of the
3 of 5 2/17/2017 12:10 PM
obstruction. If the temperature of the

cooling water is too high, determine
the cause. Ensure that the size of the
heat exchanger is sufficient. Make the
necessary repairs.

to Test Step 6.
Result : The fan clutch is OK.

6. Faulty Engine Cooling Fan (if equipped)
Result : The fan belt is OK.
A. If the fan is belt driven, check for loose drive
belts. Proceed to Test Step 7.
Note: A loose fan drive belt will cause a Result : The fan belt is NOT OK.
reduction in the air flow across the radiator.
Engine Repair: Adjust the tension of the fan
B. Check the fan clutch, if equipped. cooling fan drive belt, if necessary. Refer to
Operation and Maintenance Manual.
Note: A fan clutch or a hydraulic driven fan that
is not turning at the correct speed can cause Result The fan clutch is NOT OK.
improper air speed across the radiator core. The
lack of proper air flow across the radiator core Repair: Refer to Troubleshooting,
can cause the coolant not to cool to the proper "Cooling Fan Control - Test" for
temperature differential. troubleshooting information.

to Test Step 7.
Result : The coolant pump is OK.
7. Inspection of the Coolant Pump Proceed to Test Step 8.
A. Inspect the impeller of the coolant pump for Result : The coolant pump is NOT
damage and/or erosion. Coolant Pump OK.
B. Make sure that the drive gear is not loose on Repair: If necessary, replace the
the drive shaft of the coolant pump. coolant pump. Refer to Disassembly
and Assembly for the correct
procedure.
4 of 5 2/17/2017 12:10 PM

to Test Step 8.
8. Inspect the Cylinder Head Gasket
A. Remove the cylinder head. Refer to the

Disassembly and Assembly manual.
B. Check the cylinder liner projection. Refer to

Result : The cylinder head was
the Systems Operation/Testing and Adjusting
Head Gasket checked for leaks and the gasket was
manual.
replaced.
C. Pressure test the head for leaks.
D. Install a new cylinder head gasket and new

water seals in the spacer plate. Refer to the
Disassembly and Assembly manual.
confer with the Dealer Solutions Network (DSN).
schlumberger05
5 of 5 2/17/2017 12:10 PM
Troubleshooting
i05451574
Engine Has Early Wear

SMCS - 1000-035; 1200-035
Probable Causes
Incorrect maintenance intervals and/or incorrect oil
Contaminated engine oil
Low oil pressure
Leaks in the air system
Inspect the fuel filters for contamination.
Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Result: The engine oil was

1. Incorrect Maintenance Intervals and/or
changed at the interval that is
Incorrect Oil
recommended by the engines
Maintenance
Operation and Maintenance
A. Use engine oil that is recommended and change intervals
Manual.
the engine oil at the interval that is recommended by
the engines Operation and Maintenance Manual.
1 of 4 2/17/2017 12:11 PM
Result: The engine oil was not

changed at the interval that is
recommended by the engines
Operation and Maintenance
Manual.
Use at least the minimum grade of

Cat oil.
Change the engine oil at the

interval that is recommended.
Repair or replace any damaged
parts.
2. Contaminated Engine Oil
A. Obtain an S-O-S oil analysis. The analysis will Result: The oil is contaminated.
contribute to a better understanding of oil
contamination. Determine the reason for any
contamination of the engine oil
B. Check the oil filter bypass valve. and make the necessary repairs.
Drain the crankcase and refill the
If the oil filter bypass valve is open, the oil will not crankcase with clean engine oil.
be filtered. Check the oil filter bypass valve for a Contamination Install new engine oil filters.
weak spring or for a broken spring. If the spring is Refer to the engines Operation
broken, replace the spring. Verify that the oil bypass and Maintenance Manual.
valve is operating correctly. Refer to the
Disassembly and Assembly manual. Result: The oil is not
contaminated.
Refer to the Caterpillar guidelines for "Reusability
and Salvage/Repair" for determining if the Proceed to Test Step 3.
replacement of parts is necessary in order to perform
a quality repair.
3. Low Oil Pressure Result: The inlet tube has a

restriction.
A. Engine oil that is contaminated with another
liquid can cause low engine oil pressure. High Clear the obstruction. Verify the
engine oil level can be an indication of Restriction repair.
contamination. Obtain an analysis of the engine oil.
Result: The inlet tube does not
B. The inlet screen of the suction tube for the engine have a restriction.
oil pump can have a restriction. This restriction will
2 of 4 2/17/2017 12:11 PM
cause cavitation and a loss of engine oil pressure.

Check the inlet screen on the suction tube and
remove any material that may be restricting engine
oil flow.
When some components of the engine show wear in

a short time, the cause can be a restriction in a
passage for engine oil. An indicator for the engine
oil pressure may indicate sufficient pressure, but a
component is worn due to a lack of lubrication. In
such a case, look at the passage for the engine oil
supply to the component. Refer to Systems
Operation/Testing and Adjusting, "Lubrication
System" for additional information.
4. Leaks in Air System Result: There are no air leaks.
A. A leak in the air intake system may allow Proceed to Test Step 5.
unfiltered air into the engine. Inspect the air intake Air leak
system for streaks which may indicate a leakage of Result: There are air leaks.
unfiltered air. Inspect all of the gaskets and the
connections. Repair any leaks.
Result: The fuel has

contamination.
5. Inspect the Fuel Filters for Contamination
Determine the cause of any
A. Remove the fuel filters. Inspect the fuel filters for
contamination and make the
contamination. Contaminants in the fuel such as Fuel filters
necessary repairs.
hydrogen sulfide and sulfur can lead to the
formation of acids in the crankcase. Obtain a fuel
Install new fuel filters. Refer to
analysis.
the Operation and Maintenance
Manual.
Complete the procedure in the order in which the steps are listed.
The procedure corrected the issue. Return the engine to service.
The procedure did not correct the issue.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the
Dealer Solutions Network (DSN).
3 of 4 2/17/2017 12:11 PM
schlumberger05
4 of 4 2/17/2017 12:11 PM
Troubleshooting
i06783071
Engine Misfires, Runs Rough or Is Unstable

SMCS - 1000-035
Note: If the symptom is intermittent and the symptom cannot be repeated, refer to Troubleshooting,
"Intermittent Low Power or Power Cutout". If the symptom is consistent and the symptom can be repeated,
continue with this procedure.
Probable Causes
Diagnostic codes
Programmable parameters
Electrical connectors
Cold mode
Fuel injectors
Fuel supply
Air inlet and exhaust system
Recommended Actions
Note: If the symptom only occurs under certain operating conditions (high idle, full load, engine operating
temperature, etc), test the engine under those conditions. Troubleshooting the symptom under other
conditions can give misleading results.
Table 1
1 of 4 2/17/2017 12:11 PM
Result: There are no active diagnostic

codes.
Result: There are active diagnostic

codes.
1. Check for Active Diagnostic Codes Codes
Repair: Troubleshoot any active
codes before continuing with this
procedure.

Result: The programmable

parameters are correct.
Result: The programmable

2. Check the Programmable Parameters parameters are incorrect.
A. Check the following parameters on Cat ™ Programmable Repair: Determine the type of throttle
ET: Parameters that is used in the application.
Program the parameters to match the
• Throttle Position Sensor type of throttle that is used. Refer to
Troubleshooting, "Throttle Position
Sensor Circuit - Test" for more
information.

Result: The electrical connectors are

3. Check the Electrical Connectors
OK.
A. Check the connectors for the Electronic
Electrical Proceed to Test Step 4.
Control Module (ECM) and the connectors for
Connectors
the unit injectors for correct installation. Refer
Result: The electrical connectors are
to Troubleshooting, "Electrical Connectors -
worn or damaged.
Inspect".
2 of 4 2/17/2017 12:11 PM
Repair: Repair or replace the

electrical connectors.

Result: The engine is not in cold

mode.
4. Check for Cold Mode Operation Proceed to Test Step 5.
A. Use Cat™ ET to verify that the engine has Result: The engine is in cold mode.
Cold Mode
exited cold mode. Cold mode operation may
cause the engine to run rough and the engine Repair: Take the engine out of cold
power may be limited. mode.

5. Check the Fuel Injectors
A. Use Cat ET to determine if there are any

Result: The fuel injectors are OK.
active diagnostic codes for the unit injectors.
B. Perform the injector solenoid test on Cat ET
in order to determine if all of the injector
Result: The fuel injectors are NOT
solenoids are being energized by the ECM.
Fuel Injectors OK.
Refer to Troubleshooting, "Injector Solenoid
Circuit - Test" for the proper procedure.
Repair: Replace the fuel injectors.
C. Perform the cylinder cutout test on Cat ET in
order to identify any injectors that might be
misfiring. Refer to Troubleshooting, "Injector
Solenoid Circuit - Test" for the proper
procedure.
6. Check the Fuel Supply Result: The fuel supply is OK.
A. Check the fuel lines for the following Fuel Supply Proceed to Test Step 7.
problems: restrictions, collapsed lines, and
pinched lines. If problems are found with the Result: The fuel supply is NOT OK.
fuel lines, repair the lines and/or replace the
3 of 4 2/17/2017 12:11 PM
lines.
B. Check the fuel tank for foreign objects which

may block the fuel supply.
Prime the fuel system if any of the following

Repair: Repair or replace any worn
procedures have been performed:
or damaged components.
• Replacement of the fuel filters
Relieve any blockages in the fuel
supply.
• Service on the low-pressure fuel supply circuit
• Replacement of unit injectors
Note: Cold weather adversely affects the
characteristics of the fuel. Refer to the
Operation and Maintenance Manual for
information on improving the characteristics of
the fuel during cold-weather operation.
7. Check the Air Inlet and Exhaust System

Result: The air inlet and exhaust
system is OK.
A. Check for an air filter restriction. Clean
plugged air filters or replace plugged air filters.
Return the unit to service.
Refer to the Operation and Maintenance
Manual for additional information.
Result: The air inlet and exhaust
Air Inlet and
system is NOT OK.
Check the air inlet and exhaust system for Exhaust System
restrictions and/or for leaks. Refer to Systems
Repair: Repair or replace any worn
Operation/Testing and Adjusting, "Air Inlet and
or damaged components.
Exhaust System". Check the air inlet and
exhaust system for restrictions and/or for leaks.
Remove any blockages or plugged
Refer to Systems Operation/Testing and
filters.
Adjusting, "Air Inlet and Exhaust System".
schlumberger05
4 of 4 2/17/2017 12:11 PM
Troubleshooting
i06731214
Engine Overspeeds
SMCS - 1915-035
Use this procedure to troubleshoot an engine overspeed or use this procedure if one of the codes in Table 1 is
active.
Table 1
CDL Code Comments
E362 (3)
The code requires factory passwords to be cleared.
Engine Speed : High - most severe (3)
E362 (1)
The code is logged.
Engine Speed : High - least severe (1)
Probable Causes
Proceeding down steep grades (if applicable)
Proper operation of the turbocharger
Intake air
Starting aids that are not operating properly
Recommended Actions
1 of 3 2/17/2017 12:12 PM
Table 2
Result: Steep grades are not the

cause of the overspeed.
1. Check for Steep Grade Acceleration (If
Applicable) Proceed to Test Step 2.
Note: Engaging the engine brakes on a steep Result: Steep grades are the cause of
grade may be necessary. Steep Grades the overspeed.
A. The operator needs to understand the proper Repair: Control the engine speed
operation of the machine while using the engine during steep grades.
brakes.
Result: The turbocharger is OK.
2. Check for Proper Operation of the Proceed to Test Step 3.

Turbocharger
Result: The turbocharger is NOT
A. Check for proper operation of the OK.
Turbocharger
turbocharger.
Repair: Repair or replace the
B. Check for any oil that may be leaking into the turbocharger.
air inlet.
3. Inspect the Intake Air

Result: The atmosphere has
combustible gases.
A. Check for combustible gases in the
Intake air
surrounding atmosphere.
quality Repair: Do not operate the engine in
an environment with combustible
B. Check for proper operation of starting aids (if
gases.
equipped).
2 of 3 2/17/2017 12:12 PM
schlumberger05
3 of 3 2/17/2017 12:12 PM
Troubleshooting
i06783082
Engine Stalls at Low RPM

SMCS - 1000-035; 1900-035
Probable Causes
Unit injectors
Fuel supply
Air supply
Engine idle
Accessory equipment
Recommended Actions
Table 1
Result: The J1/P1 and

1. Unit Injectors
J2/P2 connectors have been
installed correctly.
A. Check for correct installation of the J1/P1 and J2/P2
connectors for the Electronic Control Module (ECM). Unit
Injectors
B. Check for correct installation of the J300/P300 connectors
Result: The J300/P300
for the unit injectors. Refer to the diagnostic functional test
connectors have been
Troubleshooting, "Electrical Connectors - Inspect".
installed correctly.
1 of 4 2/17/2017 12:13 PM
Result: The connectors

have not been installed
properly.
Repair: Repair the

connectors.
If the problem is not

resolved, proceed to Test
Step 2.
Result: The fuel lines are

OK.
2. Fuel Supply Result: The fuel lines are

NOT OK.
A. Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting. Repair: Replace or repair
the fuel lines.
B. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. Result: The fuel tank is
OK.
C. Check the fuel tank for foreign objects which may block
the fuel supply. Proceed to Test Step 3.
Fuel Supply
Note: A sight glass in the low-pressure supply line is helpful Result: The fuel tank is
in diagnosing air in the fuel. Refer to Systems NOT OK.
Operation/Testing and Adjusting.
Repair: Repair the
D. Cold weather adversely affects the characteristics of the blockage in the fuel tank.
fuel. Refer to the Operation and Maintenance Manual.
Result: The fuel pressure is
E. Check the fuel pressure after the fuel filter while the OK.
engine is being cranked. For the correct pressure values, refer
to the Systems Operation/Testing and Adjusting manual. Proceed to Test Step 3.

NOT OK.
Repair: Make the
2 of 4 2/17/2017 12:13 PM
necessary repairs.

Step 3.
Result: The are no

restrictions in the air inlet
system.
Result: There are

3. Air Supply
Air inlet
system.
A. Check for restrictions in the air inlet system. Refer to system
Systems Operation/Testing and Adjusting.
Repair: Repair the
system.

Step 4.
Result: The low engine

idle parameters are OK.
4. Engine Idle Result: The low engine

idle parameters are NOT
A. Check the parameter for the low engine idle (if Parameters OK.
applicable). Refer to Troubleshooting, "System Configuration
Parameters". Repair: Repair the low
engine idle parameters.

Step 5.
5. Engine Accessories Engine Result: An engine

accessories accessory is creating an
3 of 4 2/17/2017 12:13 PM
excessive load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair: Repair the engine
accessory.
If the problem is not resolved, contact your Cat dealer Technical Communicator (TC). For further assistance,
your TC can confer with the Dealer Solutions Network (DSN).
schlumberger05
4 of 4 2/17/2017 12:13 PM
Troubleshooting
i06782689
Exhaust Temperature Is High

SMCS - 1088-035-TA ; 7498-035
The Engine Control Module (ECM) monitors the following parameters to calculate an exhaust temperature:
Barometric pressure
Intake manifold air temperature
Engine speed
Certain operating conditions may cause the calculated exhaust temperature to increase to a level that may
damage engine components. If a high exhaust temperature occurs, the ECM derates the engine to reduce the
calculated exhaust temperature. The engine is derated only to a level that allows the calculated exhaust
temperature to return to an acceptable level.
Table 1
E194 (1) The code is logged.

High Exhaust Temperature Engine power is reduced.


Note: High intake manifold air temperature, high altitude operation, and high engine loads can cause the
exhaust temperature to increase to a level that may damage the components of the exhaust system. When this
occurs, the ECM derates the engine to reduce the exhaust temperature. This protects the components of the
1 of 3 2/17/2017 12:14 PM
exhaust system from damage.
Probable Causes
Associated codes
Boost Leak
Engine operating conditions
High altitude
Obstructed aftercooler
Table 2
Result: Boost leakage was not

found.

1. Check for Boost Leakage
Result: Boost leakage was
Boost leaks
A. Apply a light load to the engine and check for boost found.
leakage.
Repair: Repair the leaks.

Result: The code was not

2. Check the Engine Operating Conditions
logged during a heavy load.
A. Check the histogram to determine if the high exhaust
temperature was due to normal operation.
B. When possible, interview the operator. Determine if
Result: The code was logged
the engine is being operated under heavy load. Ensure Operating
during a heavy load.
that the engine is being operated at the proper engine conditions
speed.
Repair: Reduce the load on
the engine.
C. If derates are suspected, reset histogram and return the
unit to service. If the histogram repopulates without fault
codes, the derate was under normal engine operation.
2 of 3 2/17/2017 12:14 PM
3. Check the Engine Operating Altitude

Result: The engine was
A. Check the engine operating altitude. operating at high altitudes. The
high exhaust temperature was
Note: High altitudes can cause high exhaust due to high altitudes.
temperatures, consider the operational altitude when High
troubleshooting a high exhaust temperature. High operational Return the unit to service.
exhaust temperatures are associated with high altitudes
operational altitudes. Result: The engine was not
operating at high altitudes.
Note: When operating below 5500ft and the ambient
temperature is below 30° C (85° F), altitude should not Proceed to Test Step 4.
cause a high exhaust temperature derate.
4. Check for an Obstructed Aftercooler

Result: The engine aftercooler
was obstructed.
A. The intake manifold air temperature can increase if Obstructed
the flow through the aftercooler is obstructed. Check the aftercooler
Repair: Clear any
aftercooler for obstructions or debris. Ensure that the
obstructions.
flow of air or coolant through the aftercooler is adequate.
The procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further
assistance, your TC can confer with the Dealer Solutions Network (DSN).
schlumberger05
3 of 3 2/17/2017 12:14 PM
Troubleshooting
i06730913
Fuel Pressure Is High

SMCS - 1250-035
Use this procedure to troubleshoot high fuel pressure. Use this procedure if one of the codes in Table 1 is
active or logged.
Note: High fuel pressure may cause high fuel temperatures. Troubleshoot a code for high fuel pressure before
troubleshooting a code for high fuel temperature.
Table 1

High Fuel Pressure - least severe (1) The fuel pressure is above the trip point pressure.

High Fuel Pressure - moderate severity (2) The fuel pressure is above the trip point pressure.

High Fuel Pressure - most severe (3) The fuel pressure is above the trip point pressure.
Probable Causes
Codes
Fuel pressure sensor
Fuel lines
Fuel transfer pump
1 of 4 2/17/2017 12:15 PM
Fuel return pressure regulator
Recommended Actions
Table 2
Required Tooling
8T-7860 Connector
110-6349 Fitting as
8T-0855 Pressure Gauge
6V-3990 Coupler
Table 3
Engine RPM Fuel pressure from Cat ET Fuel pressure from the mechanical gauge
800
1800
Table 4
Result: A code is present.
1. Check for Codes Result: A code not in Table

1 is present.
A. Connect Cat® Electronic Technician (ET) to the service tool
Codes
connector. Repair: Troubleshoot the
code. Refer to the proper
B. Determine if a code is present. troubleshooting procedure.

Step 2.
2. Check the Fuel Pressure Sensor Result: The fuel pressure is

Fuel OK.
Note: Do not use the fuel sampling port (2) for measuring the pressure
pressure. Proceed to Test Step 3.
2 of 4 2/17/2017 12:15 PM
A. Record the fuel pressure in Cat ET. Enter the data in Table
3.
B. Remove the fuel pressure sensor.
C. Install an 8T-7860 Connector into the port of the pressure

sensor.
D. Install the 110-6349 Fitting as onto the 8T-7860 Connector.
NOT OK.
E. Install a 8T-0855 Pressure Gauge onto a 6V-3990 Coupler.
Repair: Replace the
pressure sensor.
F. Install the 6V-3990 Coupler onto the 110-6349 Fitting as.
G. After the pressure sensor is removed, a code for low fuel
pressure will become active. After the sensor is reinstalled,
Step 3.
reset all active codes and clear all logged codes by cycling the
keyswitch to Off.
H. Record the fuel pressure on the pressure gauge. Record the

data in Table 3.
The gauge value of the fuel pressure should be within 137 kPa
(20 psi) of the fuel pressure reading shown in Cat ET.
Result: The fuel lines and

the cooler are OK.

3. Inspect the Fuel Supply Lines
Result: The fuel lines and
A. Visually inspect the fuel lines between the primary filter
Fuel supply the cooler are NOT OK.
base and the inlet to the cylinder head. Also, inspect the fuel
lines
cooler, if equipped. Inspect the fuel return line from the head to
Repair: Make the
the fuel tank. Inspect the lines for restrictions, pinching, and
necessary repairs.
swelling.
Step 4.
Fuel Result: The regulator was

4. Replace the Return Fuel Pressure Regulator pressure replaced.
regulator
3 of 4 2/17/2017 12:15 PM

Step 5.
Result: The relief valve is

NOT OK.
Repair: Replace the fuel

transfer pump.
5. Inspect the Relief Valve for the Fuel Transfer Pump
Relief
valve Result: The relief valve is
Note: The spring must move freely.
OK.
Repair: Clean the relief

valve and reinstall the relief
valve.
If the problem is not resolved, contact your Technical Communicator (TC). The TC can confer with the
Dealer Solution Network (DSN) for further assistance.
schlumberger05
4 of 4 2/17/2017 12:15 PM
Troubleshooting
i06731237
Fuel Temperature Is High

SMCS - 1250-035-TA
Use this procedure to troubleshoot high fuel temperature. Use this procedure if one of the codes in Table 1 is
active.
Table 1
Diagnostic Trouble Code
The fuel temperature is above an acceptable level.

E363 (1)
If equipped, the action lamp will illuminate.
Engine Fuel Temperature High - least severe (1)
The code is logged.
E363 (2) The fuel temperature is above an acceptable level.

Engine Fuel Temperature High - moderate severity (2) If equipped, the action lamp will illuminate.
Engine Fuel Temperature High - most severe (3) There may be a decrease in power.
Table 2
Associated Codes
Suspect Parameter Number (SPN)
E1218
Probable Causes
Codes
1 of 4 2/17/2017 12:15 PM
Fuel level in the tank
Fuel temperature sensor
Fuel Cooler (if equipped)
Fuel return pressure regulator
Restriction in the fuel lines
Fuel injector
Recommended Actions
Table 3
Result: A code is not present.

1. Check for Codes
A. Check for codes in Cat® Electronic
Result: A code is present.
Technician (ET).
Codes
Repair: Troubleshoot any active codes
B. Check Cat ET for any associated codes that
before continuing with this procedure.
are listed in Table 2. Troubleshoot any active
codes before continuing with this procedure.
to Test Step 2.
Result: The fuel level is OK.
Result: The fuel level is NOT OK.

2. Check the Fuel Level in the Fuel Tank Fuel level
Repair: Fill the tank.

to Test Step 3.
3. Inspect the Fuel Supply Lines Fuel supply Result: The fuel lines and the cooler are
lines OK.
A. Visually inspect the fuel lines between the
2 of 4 2/17/2017 12:15 PM

priming pump and the inlet to the cylinder head.
Result: The fuel lines and the cooler are
Also, inspect the fuel cooler for dirt, debris, or
NOT OK.
damage, if equipped. Inspect the fuel return line
from the head to the fuel tank. Inspect the lines
Replace damaged fuel lines and/or fuel
for restrictions, pinching, and swelling. Refer to
cooler (if equipped). Remove dirt or
Systems Operation/Testing and Adjusting, "Fuel
debris from fuel cooler fins (if
System - Inspect" for additional information.
equipped). Verify that the problem has
been resolved.
B. If equipped, Inspect the fuel cooler for dirt,
debris, or damage.
to Test Step 4.
Result: An E363 code is active or

logged.
4. Replace the Fuel Temperature Sensor Fuel Proceed to Test Step 5.

temperature
A. Check for active codes or logged codes. sensor Result: An E363 code is not active or
logged.
Result: The problem has been resolved.

Fuel Return
5. Replace the Fuel Return Pressure
pressure
Regulator Result: The problem has not been
regulator
resolved.
Result: The Cylinder Cutout Test was

not successful.
6. Perform a "Cylinder Cutout Test" in Cat Cylinder Repair: Replace the identified injectors.
ET Cutout Test Verify that all trim files are installed into
the ECM correctly. Refer to
Troubleshooting, "Injector Trim File -
Install". Repeat the "Fuel System
Verification Test" after making the
3 of 4 2/17/2017 12:15 PM
necessary repairs. Repeat the process

until all the injectors are operating
properly.
schlumberger05
4 of 4 2/17/2017 12:15 PM
Troubleshooting
i06731411
Intake Manifold Air Temperature Is High

SMCS - 1058-035-TA
Table 1 lists the diagnostic trouble codes for high intake manifold air temperature.
Table 1
E539 (1) The code indicates that the temperature of the intake air into the
High Intake Manifold Air engine has risen above a predetermined threshold.
Temperature - least severe (1) Engine power may be derated.
E539 (2) The code indicates that the temperature of the intake air into the
High Intake Manifold Air engine has risen above a predetermined threshold.
Temperature - moderate severity (2) Engine power may be derated.
Table 2
Associated Diagnostic Trouble Codes
E1092
Probable Causes
Codes
Aftercooler leaks or restrictions
Cooling fan
1 of 3 2/17/2017 12:17 PM
Charge Air Cooler Outlet Temperature Sensor
Recommended Actions
Table 3
1. Check for Codes
A. Establish communication Result: An associated code is active.

between Cat® Electronic
Technician (ET) and the Repair: Refer to Troubleshooting, "Diagnostic Trouble
Electronic Control Module Codes" to troubleshoot the associated diagnostic code.
(ECM).
Result: An E539 diagnostic code is active.
B. Download the "Warranty Codes
Report" from the engine ECM Proceed to Test Step 2.
before troubleshooting or
clearing diagnostic trouble Result: A code is not active or logged.
codes.
C. Determine if an associated
code is active or logged. Table 2
lists associated diagnostic codes.
Result: The ATAAC is OK.
2. Check the Aftercooler for Result: The ATAAC is NOT OK.

Leaks or Restrictions
Repair: Clean the ATAAC. Refer to the machine Test
A. Inspect the exterior surface of and Adjust manual.
the ATAAC for excessive Aftercooler
buildup of dirt or debris. Also If the problem still exists, proceed to Test Step 3.
verify that the fins of the
ATAAC are not damaged. Result: The surface of the ATAAC is NOT OK.
Repair: Replace the ATAAC.
If the problem is not resolved, proceed to Test Step 3.
3. Check the Operation of the Cooling Result: The fan drive system is OK.
2 of 3 2/17/2017 12:17 PM
Cooling Fan
A. Verify that the cooling fan

that is being used to transfer heat
from the ATAAC is working
Result: The fan drive system is NOT OK.
properly.
Repair: Make the necessary adjustments to the clutch or
B. If the fan is belt driven, verify
the belt tension if the fan is mechanically driven . Refer
that the belt tension is adequate.
Fan to the machine Test and Adjust for the proper procedure.
Also, verify that the clutch is
Repair leaks or make the necessary adjustments to the
operating properly.
motor or the hydraulic pump if the fan is hydraulically
driven . Refer to Testing and Adjusting for the proper
C. If the fan is hydraulically
procedure.
driven, verify that there is no
leakage around the motor and
that the pressure for the fan is
adequate.
4. Check the Operation of the

Charge Air Cooler Outlet
Temperature Sensor
A. Remove the charge air cooler

Result: The charge air cooler outlet temperature sensor
outlet temperature sensor. Allow
is OK.
the charge air cooler outlet
temperature sensor to rest in
Repair: Reinstall the sensor. Torque the sensor to the
ambient air for 2 minutes.
proper specifications.
B. Connect to the engine ECM Sensor
Result: The charge air cooler outlet temperature sensor
by using Cat ET.
is NOT OK.
C. Monitor the value of the
Repair: Replace the charge air cooler outlet temperature
charge air cooler outlet
sensor.
temperature sensor on Cat ET.
The value should be within

± 9° C (±15° F) of the ambient
temperature.
schlumberger05
3 of 3 2/17/2017 12:17 PM
Troubleshooting
i06731179
Oil Pressure Is Low

SMCS - 1348-035-PX
Use this procedure to troubleshoot low engine oil pressure. Use this procedure for one of the codes in Table
1.
Table 1
CDL Code and

Comments
Description
Oil pressure is lower than the specified pressure for at least 4 seconds.
E360 (3) Engine power is reduced. A snapshot is triggered. The code is logged.
Low Engine Oil Pressure - Factory passwords are required.
most severe (3) After 30 seconds, the ECM will shut down the engine if the "Engine
Monitoring Mode" parameter is programmed to "Shut down".
E360 (1)
Oil pressure is below the specified pressure for at least 8 seconds. A snapshot
Low Engine Oil Pressure -
is triggered. The code is logged. Engine performance is not affected.
least severe (1)
Oil pressure is lower than the specified pressure for at least 4 seconds.
Engine power is reduced. A snapshot is triggered. The code is logged.
E360 (2)
Factory passwords are required.
Low Engine Oil Pressure -
After 30 seconds, the Engine Control Module (ECM) will shut down the
moderate severity (2)
engine if the "Engine Monitoring Mode" parameter is programmed to "Shut
down".
Probable Causes
1 of 5 2/17/2017 12:18 PM
Low engine oil level
Aeration in the oil
Low oil viscosity
Plugged Oil Filter
Faulty oil pump
Faulty engine oil pressure sensor
Faulty bypass valve
Damaged suction tube or cracked suction tube
Excessive wear of engine components
Recommended Actions
Table 2
Result: The engine oil is OK.
Result: The engine oil level is NOT OK.
1. Check the Engine Oil Level Repair: Add engine oil in order to obtain
the correct engine oil level. Refer to
A. Check the engine oil level in the crankcase. Engine oil Operation and Maintenance Manual,
Refer to the Operation and Maintenance level "Engine Oil" for the recommendations of
Manual for calibration of the dipstick gauge. engine oil.
Start the engine. Inspect the exterior of the

engine for oil leaks. Repair any oil leaks.
If the problem is not resolved, proceed to

Test Step 2.
2. Check for Aeration of the Engine Oil Result: The oil is OK.
A. Sample the engine oil for aeration. Aeration Proceed to Test Step 3.
Note: Foamy oil on the dipstick is a good Result: The oil is NOT OK.
2 of 5 2/17/2017 12:18 PM
indication of aeration.
Result: The oil viscosity is OK.

3. Check the Oil Viscosity
A. Sample the engine oil viscosity. Obtain
anS·O·S Oil Analysis to determine the Result: The oil viscosity is NOT OK.
characteristics of the oil.
Repair: Replace the engine oil.
Oil
B. Access the "Cylinder Cutout Test" in the
Viscosity
"Diagnostic Tests" under the "Diagnostics" Refer to Operation and Maintenance
menu. Manual, "Engine Oil" for the
recommendations of engine oil.
C. Perform the "Automatic Cylinder Cutout
Test" in Cat® Electronic Technician (ET). If the problem is not resolved, proceed to
Test Step 4.
Result: The oil filter was changed.

4. Replace the Engine Oil Filter
Filter If the problem is not resolved, proceed to
Test Step 5.
Result: The oil pressure is OK.
5. Check the Oil Pump Pressure Proceed to Test Step 6.
A. Manually check the engine oil pressure. Result: The oil pressure is NOT OK.
Oil pump
Refer to the Systems Operation/Testing and
pressure
Adjusting, "Engine Oil Pressure - Test" for the Repair: Replace the oil pump.
correct procedure.
Test Step 6.
6. Check the Operation of the Engine Oil Result The pressure is OK.
Pressure Sensor
A. Remove the connector and the oil pressure Sensor
sensor. Result The pressure is NOT OK.
3 of 5 2/17/2017 12:18 PM
B. Install an appropriate "T" fitting in the

pressure sensor port.
C. Install a manual gauge on one side of the

Repair: Replace the sensor.
"T" fitting. Install the oil pressure sensor on the
other side of the pipe "T" fitting.
Test Step 7.
D. Start the engine and compare the oil
pressure between the manual gauge and Cat
ET. The pressure reading must be within
± 34 kPa (± 5 psi).
Result: The oil filter base was replaced.

7. Replace the Engine Oil Filter Bypass Oil filter
base
Test Step 8.
8. Inspect the Oil Pump Suction Tube Result: The suction tube and seal are OK.
A. Remove the oil pan. Proceed to Test Step 9.
B. Inspect the suction tube. Check the joints of Result: The suction tube and seal are not
the tube for cracks or for a damaged O-ring Suction OK.
seal at the connection to the pump. tube
Repair: Replace any damaged parts.
C. Inspect the inlet screen of the suction tube
for a restriction. This restriction will cause If the problem is not resolved, proceed to
cavitation and a loss of engine oil pressure. Test Step 9.
9. Check for Worn Engine Components
A. Remove the valve covers.

Result: There are worn engine
B. Inspect the camshaft and bearings. components.
Worn
C. Remove the oil pan. Repair: Replace parts, if necessary. Check
Parts
the Reuse and Salvage Guidelines for the
D. Excessive clearance at the crankshaft or reusability of existing engine components.
camshaft bearings will cause low engine oil
pressure. Check the engine components for
excessive clearance. Also, inspect the piston
cooling jets.
4 of 5 2/17/2017 12:18 PM
schlumberger05
5 of 5 2/17/2017 12:18 PM
Troubleshooting
i04563324
Valve Rotator or Spring Lock Is Free

SMCS - 1109-035
Use this procedure in order to troubleshoot a problem with the valve rotators or spring locks.
Probable Cause
Valve Components
Recommended Actions
Table 1
1. Valve Components
A. Inspect the following components

for damage: Result: The valve components are damaged.
1. Valve rotators Replace the damaged components.

2. Spring locks
Damaged
3. Valve springs A valve rotator that is cracked or a valve
components
4. Valves rotator that is broken is an indication of an
engine overspeed. Determine the cause of the
B. Ensure that the valve has not engine overspeed. Repair the condition.
contacted the piston. If the valve has
contacted the piston, check the exhaust
system for debris.
1 of 2 2/17/2017 12:19 PM
Complete the procedure in the order in which the steps are listed.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further
schlumberger05
2 of 2 2/17/2017 12:19 PM
Troubleshooting
i06729595
Coolant Level - Test

SMCS - 1395-038; 1439-038-CLT; 7422-038-CLT
The Engine Control Module (ECM) monitors a coolant level sensor to determine the coolant level. The
coolant level sensor is installed by the vehicle manufacturer. The coolant level sensor is one of the following
types:
4-Pin Sensor
2 Wire Float
2-Pin Switch
The "Coolant Level Sensor" parameter must be programmed to match the type of sensor in order for the
monitoring system to function correctly. The following tables describe each sensor.
Table 1
Operation of the 4-Pin Sensor
This sensor has two output terminals. The voltage on the terminals indicates the coolant level.
Code
Output Terminal on
Suspect Failure
Condition Terminal Voltage on the P1
Parameter Mode Code
on the the Connector
Number Identifier Description
4-Pin Terminal
(SPN) (FMI)
Sensor
Normal Minimum
Coolant N/A D of 4.1 P1-49
Level VDC
1 of 9 2/17/2017 12:20 PM
Maximum
A P1-54
of 0.5 VDC
Maximum
Low Engine Coolant D of 0.5 P1-49
Coolant 111 17 Level : Low - VDC
Level Least Severe (1) Minimum
A P1-54
of 4.1 VDC
Low Engine Coolant This code is activated after the "low

Coolant 111 1 Level : Low - coolant level" condition has existed for a
Level Most Severe (3) few seconds.
Engine Coolant
Level : Erratic, This code is activated if both outputs are
111 2
Intermittent, or the same voltage for at least 2 seconds.
Incorrect
Table 2
Operation of the 2-Wire Float Sensor (1)
This sensor has one output terminal. The voltage on the terminal indicates the coolant level.
Code
Terminal on
Suspect Failure Mode Voltage
Condition the P1
Parameter Identifier Code Description Range (2)
Connector
Number (SPN) (FMI)
Normal 0.8 VDC

Coolant N/A to
Level 1.8 VDC
Engine Coolant 2.0 VDC

Low Coolant
111 17 Level : Low - Least to
Level
Severe (1) 3.0 VDC
Engine Coolant 3.3 VDC

Low Coolant
111 1 Level : Low - Most to P1-26
Level
Severe (3) 4.3 VDC
Engine Coolant Voltage is

111 3 Level : Voltage greater than
Above Normal 4.5 VDC.
Engine Coolant Voltage is

111 4 Level : Voltage less than 0.5
Below Normal VDC.
(1) There are two types of sensor that can be utilized when the ECM is programmed to this option. Some sensors will have 2 wires
and some sensors will have 3 wires. A sensor with 3 wires requires 5 VDC to operate. The power wire for this sensor may be
2 of 9 2/17/2017 12:20 PM
connected to terminal 2 of the P1 connector. The 2-wire float sensor does not require electrical power to operate.
(2) The voltage that is between the ranges is a hysteresis band. The hysteresis band will prevent false indications when the coolant
sloshes in the tank.
Table 3
Operation of the 2-Pin Switch
This switch creates a short circuit when coolant is present.
Condition Code Condition of the Circuit
Suspect Failure Mode

Parameter Identifier Code Description
Number (SPN) (FMI)
Normal
Short circuit between P1-49
Coolant N/A
and sensor common
Level
Engine Coolant
Low Coolant Open circuit between P1-49
111 17 Level : Low - Least
Level and sensor common
Severe (1)
This code is activated after

Engine Coolant
Low Coolant the "low coolant level"
111 1 Level : Low - Most
Level condition has existed for a
Severe (3)
few seconds.
A typical schematic for the 4-pin sensor.
The return wire may be connected to P1-3, P1-5, or P1-18.
Probable Causes
Codes
3 of 9 2/17/2017 12:20 PM
Sensor supply voltage
Coolant level sensor
Wiring harness
ECM
Recommended Actions
Table 4
Troubleshooting Test Step Value Result
Result: There is a 111-2 code. There

1. Check for Codes
is a problem with the circuit for the
4-pin sensor.
A. Establish communication between Cat®
Electronic Technician (ET) and the engine ECM.
B. Access the "Active Diagnostic" screen. Codes
Result: There is a 111-3 or 111-4
code. There is a problem with the
C. Verify that a code for the coolant level switch is
circuit for the 2-wire float sensor.
active.
2. Inspect Electrical Connectors and Wiring for

the 4-Pin Sensor
Result: All connectors, pins, and
sockets are OK.
A. Thoroughly inspect the J1/P1 ECM connector,
the connector for the extension harness for the
Proceed to Test Step 3
coolant level, and the terminals for the coolant level
sensor in the connectors.
Result: All connectors, pins, and
sockets are NOT OK.
Note: The connector for the extension harness for
the coolant level connects the coolant level sensor Electrical
Repair: Repair the connectors or
to the vehicle harness in the engine compartment of connectors
wiring and/or replace the connectors
some chassis. Refer to Troubleshooting, "Electrical
or wiring. Ensure that all the seals are
Connectors - Inspect" for details.
properly in place and ensure that the
connectors are coupled.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the following connections:
- P1-2 +5V supply
- P1-5 AP sensor/switch common
- P1-49 Coolant level normal
4 of 9 2/17/2017 12:20 PM
- P1-54 Coolant level low
C. Check the ECM connector for the proper torque.

Refer to Troubleshooting, "Electrical Connectors -
Inspect" for details.
D. Check the harness and wiring for abrasion and

for pinch points from the sensor to the ECM.
3. Disconnect the Coolant Level Sensor and

Check the Supply Voltage
Result: The measured voltage is OK.
A. Turn the keyswitch to OFF.
Proceed to Test Step 4
B. Disconnect the coolant level sensor from the
Supply
harness. Result: The measured voltage is
voltage
NOT OK.
C. Use a multimeter to measure the voltage at the
harness connector from terminal C to terminal B. Proceed to Test Step 5
D. Turn the keyswitch to ON.
4. Disconnect the Coolant Level Sensor and

Check the Coolant Level Harness
Result: The coolant level status is
A. Turn the keyswitch to OFF. OK. The coolant level status indicates
"LOW" with the jumper in place.
B. Disconnect the coolant level sensor from the
harness. Leave the jumper wire in place. If a
breakout T is installed, leave the
C. Use a jumper wire to connect terminal D to breakout T in place also.
Coolant
terminal B at the harness connector.
level sensor
Result: The coolant level status is
E. While the jumper wire is in place, access the NOT OK.
status screen that indicates the coolant level status.
F. Wait for 30 seconds. Read the status and record
the status.
5. Disconnect the Terminal for the Sensor Supply Result: The measured voltage is OK.
5 of 9 2/17/2017 12:20 PM
The problem is located in the harness

wiring.
Repair: Repair the wiring or replace

the wiring, as required.
Result: The measured voltage is

Supply from the ECM Connector NOT OK. The problem is on the
ECM side.
Repair: 1. Temporarily connect a test
B. Disconnect the J1/P1 ECM connector. ECM. Ensure that the "Coolant Level
Sensor" is programmed to match the
C. Install a jumper wire between the J1 and the P1 voltage old ECM.
ECM connector.
2. Check the test ECM by measuring
D. Turn the keyswitch to ON. the voltage at the breakout T from
terminal 2 to terminal 5 again.
E. Measure the voltage terminal 2 to terminal 5.
3. If the problem is resolved with the
test ECM, reconnect the suspect
ECM. If the problem returns with the
suspect ECM, replace the ECM.

Result: The 111-2 diagnostic code is

6. Check the Wire Harness for the Coolant Level
not active.
Low
B. Use two jumper wires to connect terminal A
active. The harness and the ECM are
(coolant level low) and terminal D to terminal B at
working correctly.
the harness connector.
Code
Repair: Remove the jumpers.
C. Turn the keyswitch to ON.
Replace the sensor and ensure that
111-2 diagnostic code disappears
D. While the jumper wires are in place, access the
with the new sensor.
"Active Diagnostic Code" screen in Cat ET.
E. Verify that 111-2 diagnostic code is active.
6 of 9 2/17/2017 12:20 PM
7. Check the ECM
B. Fabricate two jumper wires 100 mm (4 inch)

long. Crimp a Deutsch pin to both ends of each
wire.

active. The ECM is functioning
D. Observe the "Coolant Level Sensor" status in
properly.
Cat ET. Install the jumper into the breakout T to
connect terminal 49 to terminal 5.
Repair: Repair the harness or replace
the harness, as required.
E. Monitor the "Coolant Level Sensor" status while
the jumper is being inserted and removed. Wait for
30 seconds between the insertion of the jumper and
not active. There may be a problem
the removal of the jumper. A diagnostic code for
with the ECM.
"Low Coolant Level" should be active.
Repair: 1.Temporarily connect a test
F. Record the result. Leave the jumper installed in ECM
ECM. Ensure that the "Coolant Level
the breakout T. Install a jumper wire from 54
coolant level low to 18 input sensor common 1 of
old ECM.
the breakout T.
G. While both jumper wires are in place, access the
"Active Diagnostic Code" screen. Verify that a
111-2 diagnostic code is active. Wait for 30 seconds
for the activation of the diagnostic code.
H. The coolant level sensor status behaves in the
following manner:
- The Coolant Level Sensor Status indicates "OK"
before the jumper wire is installed between
terminal 49 and terminal 5. 111-2 diagnostic code
may be active.
- The coolant level sensor status changes to "LOW"
after the jumper wire is installed between terminal
49 and terminal 5. Also, a diagnostic code for low
coolant level becomes active.
8. Inspect Electrical Connectors and Wiring for Result: The wiring appears to be OK.
the 2-Wire Float Sensor Electrical
connectors Proceed to Test Step 9.
7 of 9 2/17/2017 12:20 PM
A. Thoroughly inspect the J1/P1 ECM connector,

the connector for the coolant level sensor, and the
terminals for the coolant level sensor in the
connectors. Refer to Troubleshooting, "Electrical Result: The wiring appears to be
Connectors - Inspect". NOT OK.
B. Perform a 45 N (10 lb) pull test on each of the Repair: Repair the connectors or
wires in the ECM connector that are associated wiring and/or replace the connectors
with the following connections: or wiring. Ensure that all the seals are
- P1-26 coolant level input properly in place and ensure that the
- P1-5 AP sensor/switch common connectors are coupled.
C. Check the ECM connector for the proper torque. If the problem is not resolved,
D. Check the harness and wiring for abrasion and
for pinch points from the sensor to the ECM.
9. Disconnect the Coolant Level Sensor and Result: The sensor supply voltage is
Check the Supply Voltage NOT OK.
A. Turn the keyswitch to OFF. Proceed to Test Step 10.
B. Disconnect the coolant level sensor from the Result: The sensor supply voltage is
Supply
harness. OK.
Voltage
C. Use a multimeter to measure the voltage at the Repair: Replace the sensor.
harness connector.
D. Turn the keyswitch to ON. proceed to Test Step 10.
10. Disconnect the Terminal for the Sensor Result: The supply voltage is OK.
Supply From the ECM Connector The problem is located in the harness
wiring.
Repair: Repair the wiring or replace
B. Disconnect the J1/P1 ECM connector. the wiring, as required.
Supply
C. Install a breakout T between the J1 and P1 ECM Voltage Result: The supply voltage is NOT
connector. OK. The problem is on the ECM
side.
Repair: 1. Temporarily connect a test
E. Measure the voltage at the breakout T from ECM. Ensure that the "Coolant Level
8 of 9 2/17/2017 12:20 PM

old ECM.
2. Check the test ECM by measuring

the voltage at the breakout T from
terminal 26 to terminal 5. terminal 26 to terminal 5 again.

If the problem is not resolved, contact your Technical Communicator (TC). The TC can confer with the
Dealer Solution Network (DSN) to resolve any issues.
schlumberger05
9 of 9 2/17/2017 12:20 PM
Troubleshooting
i06730612
Data Link - Test

SMCS - 1900-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with the CAN data link or
the Cat Data Link. Also use this procedure if a diagnostic code in Table 1 is active or easily repeated.
Table 1
Diagnostic Codes Table
The Electronic Control Module (ECM) has lost

246-9
communications over the CAN data link.
Proprietary CAN Data Link : Abnormal
The code is logged.
Update Rate
The check engine lamp is illuminated.
The ECM has lost all communications over the global CAN
247-9
data link.
SAE J1939 Data Link : Abnormal
The code is logged.
Update Rate
The ECM has lost all communications with the transmission

296-9
over the Cat Data Link.
Transmission Control : Abnormal
The code is logged.
Update Rate
The ECM has lost all communications with the all wheel drive
297-9
over the Cat Data Link.
All Wheel Drive Control : Abnormal
The code is logged.
Update Rate
1 of 5 2/17/2017 12:20 PM
The ECM has lost all communications with the Cat Monitoring
562-9
System over the Cat Data Link.
Caterpillar Monitoring System :
The code is logged.
Abnormal Update Rate
The ECM has lost all communications with the implement

596-9
control over the Cat Data Link.
Implement Control : Abnormal Update
The code is logged.
Rate
The Electronic Control Module (ECM) has lost

639-9
communications over the J1939 data link.
J1939 Network #1 : Abnormal Update
The code is logged.
Rate
1603-9
The code is logged.
Machine Control Module : Abnormal
Update Rate
The ECM has lost communications with the Machine Security

1639-2
System Module (MSSM) over the Cat Data Link.
Machine Security System Module :
The code is logged.
Erratic, Intermittent, or Incorrect
The ECM has lost all communications with the Cat Monitoring
1639-9
System over the Cat Data Link.
Machine Security System Module :
The code is logged.
The ECM has lost all communications with the DPF #1 Soot
3397-9
Loading Sensor over the Cat Data Link.
DPF #1 Soot Loading Sensor :
The code is logged.
The ECM has lost all communications with the ARD

3472-9
combustion air controller over the Cat Data Link.
ARD Air Pressure Control System :
The code is logged.
Note: If a 1639-2 diagnostic code is active, verify that the following information is correct before proceeding
with this procedure:
The part number of the flash software for the Machine ECM
The part number of the flash software for the Machine Security System ECM
The part number of the Machine ECM
The part number of the Machine Security System ECM
2 of 5 2/17/2017 12:20 PM
Schematic for the Cat Data Link and the CAN data link
Probable Causes
Short circuit
Open circuit
Termination resistors
Recommended Actions
Table 2
1. Check for a Short Circuit Result: Each check of the resistance indicates
an open circuit.
Short Proceed to Test Step 2
B. Thoroughly inspect the connectors that circuit
are associated with the data link circuits. Result: At least one check of the resistance
Refer to Troubleshooting, "Electrical does not indicate an open circuit. There is a
3 of 5 2/17/2017 12:20 PM
Connectors - Inspect".
C. Disconnect the P1 and the P2 ECM

connector.
D. Disconnect Cat ET from the service tool

connector.
E. Measure the resistance between the

points that are listed below. Be sure to
wiggle the wires in the harnesses as you short circuit in the harness or in a connector.
make each resistance measurement.
Repair: Repair the connectors and/or the
- P1-8 to all P1 connector terminals and wiring. Replace parts, if necessary. Verify that
negative ground the original problem is resolved.
- P1-9 to all P1 connector terminals and
negative ground
negative ground
negative ground
negative ground
negative ground
2. Check for an Open Circuit

Result: Each check of the resistance indicates
A. Fabricate a jumper wire that is long a short circuit.
enough to create a test circuit across two
terminals. Create a short circuit between Remove the jumper wire from the service tool
terminals D and E on the service tool connector. Proceed to Test Step 3.
connector.
Result: At least one of the resistance
B. Measure the resistance between P1-8 and measurements indicates an open circuit.
P1-9. Open
circuit
Repair: Remove the jumper wire from the
C. Fabricate a jumper wire that is long ECM connector. Determine the cause of the
enough to create a test circuit across two open circuit. Repair the problem, when
terminals. Create a short circuit between possible. Replace parts, if necessary.
terminals G and F on the service tool
connector. If the problem is not resolved, proceed to Test
Step 3.
D. Measure the resistance between P1-50
and P1-34).
4 of 5 2/17/2017 12:20 PM
E. Fabricate a jumper wire that is long

enough to create a test circuit across two
terminals. Use the jumper wire to create a
short circuit between terminals 23 and 24 on
the Clean Emissions Module (CEM)
connector.
F. Measure the resistance between P2-12

and P2-11.
Result: The termination resistors are OK.

There is an intermittent problem in a
connector or in the harness.
Repair: Repair the problem.
3. Check the Termination Resistors for Result: The resistance is approximately 120Ω.
the CAN Data Link There is a problem with a termination resistor.
Note: Perform this test only if you are Repair: At least one measurement is less than
troubleshooting a problem with the CAN 5Ω. The wiring for a data link has a short
data link. circuit. Determine the cause of the missing
Resistance
termination resistor. Repair the problem, when
A. At the service tool connector, measure possible. Replace parts, if necessary. Verify
the resistance between the terminals for the that the problem is resolved.
CAN data link. The resistance should be
between 45Ω to 75Ω. Result: The resistance is greater than 140Ω.
There is a problem with both termination
resistors.
Repair: Determine the cause of the problem.

Repair the problem, when possible. Replace
parts, if necessary.
schlumberger05
5 of 5 2/17/2017 12:20 PM
Troubleshooting
i06729829
Electrical Power Supply - Test

SMCS - 1401-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with the power to the
engine Electronic Control Module (ECM). Also use this procedure if any one of the diagnostic codes in Table
1.
Table 1
111–2 The engine is running. The battery voltage falls below 6 VDC and the
Engine Coolant Level Sensor : voltage returns above 9 VDC for three voltage readings in the last 7
Erratic, Intermittent, or Incorrect seconds.
1834-2 The ECM detects an erratic signal from the keyswitch because the
Ignition Key Switch loss of signal keyswitch was cycled at least three times in the last second
168-0
Electrical System Voltage : The ECM detects voltage that is above the acceptable value.
Voltage Above Normal
168-1
Electrical System Voltage : The ECM detects voltage that is below the acceptable value.
Voltage Below Normal
168-2 The engine is running. The battery voltage falls below 6 VDC and the
Electrical System Voltage : voltage returns above 9 VDC for three voltage readings in the last 7
Erratic, Intermittent, or Incorrect seconds.
1 of 4 2/17/2017 12:21 PM
Probable Causes
Codes
Wiring
Charging circuit
Battery charge
Recommended Actions
Table 2
1. Check for Codes Result: A 168-2 or a 1834-2 diagnostic

code is active.
A. Establish communication between the Cat®
Codes
Electronic Technician (ET) and the ECM. Proceed to Test Step 2.
Result: A 168-0 diagnostic code is active.
2 of 4 2/17/2017 12:21 PM
B. Start the engine. Run the engine until the

engine is at normal operating temperature.
C. Download the "Warranty Report" from the

engine ECM before performing any
troubleshooting or clearing diagnostic trouble Proceed to Test Step 3.
codes. Check for the codes listed below:
· 168-2 Result: A 168-1 diagnostic code is active.
· 168-0 Proceed to Test Step 4.
· 168-1
· 1834-2
Result: The harness and connectors are

OK. There is a problem with the charging
system.
Repair: Refer to Special Instruction,

2. Inspect the Electrical Connectors and the REHS0354, "Charging System
Wiring For the Charging Circuit Troubleshooting".
A. Turn the keyswitch to OFF. Result: The connectors and/or wiring are
not OK.
Connectors
B. Check the harness connections at the battery
and Wiring
and at the alternator. Repair: Repair the wiring and/or the
connectors. Replace parts, if necessary.
C. Check the harness between the battery and Ensure that all the seals are properly in
the alternator. place and ensure that the connectors are
coupled. Verify that the repair eliminates
the problem.

Test Step 3.
Result: The charging system is OK.

3. Check the Charging Circuit
A. Check the charging circuit. Refer to Special Charging
Instruction, REHS0354, "Charging System Circuit Result: The charging system is not OK.
Troubleshooting".
Repair: Refer to Special Instruction,
3 of 4 2/17/2017 12:21 PM
REHS0354, "Charging System

Troubleshooting".

Test Step 4.
Result: The batteries are OK.
Repair: 1. Verify that the "System

Operating Voltage Configuration" is
correctly configured in the engine ECM
4. Check the Battery Charge
configuration parameters.
A. Measure the no-load battery voltage at the
2. Check the connectors between the
battery posts.
batteries and the ECM for moisture and/or
corrosion.
B. Load-test the batteries. Use the 4C-4911 Battery
Battery Load Tester. Refer to Special Charge
3. Check the wiring between the batteries
Instruction, SEHS9249, "Use of 4C-4911
and the ECM.
Battery Load Tester for 6, 8 V and 12 V Lead
Acid Batteries" and Special Instruction,
4. Repair the wiring and/or the connectors.
SEHS7633, "Battery Test Procedure".
Result: The battery voltage is NOT OK.
Repair: Recharge or replace the faulty

batteries.
schlumberger05
4 of 4 2/17/2017 12:21 PM
Troubleshooting
i06723405
Injector Solenoid - Test

SMCS - 1290-038-JV
This procedure covers the diagnostic trouble codes in Table 1:
Table 1
1-5
Cylinder #1 Injector : Current Below
Normal
1-6
Cylinder #1 Injector : Current Above
Normal
2-5
Normal These codes relate to the electrical circuit that includes
2-6 injector terminals 1 and 3.
Normal
3-5
Normal
3-6
Normal
1 of 9 2/17/2017 12:22 PM
4-5
Normal
4-6
Normal
5-5
Normal
5-6
Normal
6-5
Normal
6-6
Normal
2602-6
Cylinder #1 Injector Actuator #2 : Current
Above Normal
2602-5
Below Normal
2604-6
Above Normal
2604-5
These codes relate to the electrical circuit that includes
injector terminals 2 and 4.
Below Normal
2606-6
Above Normal
2606-5
Below Normal
2608-6
Above Normal
2 of 9 2/17/2017 12:22 PM
2608-5
Below Normal
2610-6
Above Normal
2610-5
Below Normal
2612-6
Above Normal
2612-5
Below Normal
3 of 9 2/17/2017 12:22 PM
Schematic for the injector solenoids
Probable Causes
Codes
Wiring
Open circuit
4 of 9 2/17/2017 12:22 PM
Short Circuit
ECM
Recommended Actions
Table 2
Result: A code is logged or active.

1. Check for Codes
Electronic Technician (ET) and the ECM . Refer
Result: A code is not logged or active. There
to Troubleshooting, "Electronic Service Tools", Codes
is not an electronic problem with the
if necessary.
injectors at this time.
B. Determine if a code is active or logged.
2. Inspect the Wiring Harness Between the

ECM and the Valve Cover Base Result: The connectors and the wiring
appear to be OK.
A. Turn the keyswitch to OFF. The harness between the ECM and the
connector does not have an open circuit.
B. Thoroughly inspect the connectors. Refer to
Troubleshooting, "Electrical Connectors - Proceed to Test Step 3.
Inspect" for details.
Result: There is a problem with the
C. Perform a 45 N (10 lb) pull test on each of connectors and/or wiring.
the wires in the ECM connector. Perform a pull
Wiring
test on each of the wires that are associated with Repair: Repair the connectors or wiring
injector solenoids. and/or replace the connectors or wiring.
Ensure that all of the seals are properly in
D. Check the allen head screw on the ECM place and ensure that the connectors are
connector for the proper torque. Refer to coupled. Perform an injector solenoid test in
Troubleshooting, "Electrical Connectors - order to verify that the problem has been
Inspect" for the correct torque values. resolved.
E. Check the harness and wiring for abrasions If the problem is not resolved, proceed to
and for pinch points from the valve cover base to Test Step 3.
the ECM.
5 of 9 2/17/2017 12:22 PM
3. Check the Harness between the ECM and

the Valve Cover Base for an Open Circuit
A. Turn the keyswitch to OFF. A strong

electrical shock hazard is present if the
keyswitch is not turned off.
B. Remove electrical power from the engine

ECM.
C. Disconnect the connectors of the injector

harness at the valve cover base. Result: The harness is OK.
D. Fabricate a jumper wire long enough to create Proceed to Test Step 4.

a short circuit on the different terminal locations
at the connector of the injector harness. Crimp Result: The harness is NOT OK
connector pins on both ends of the jumper wire.
Repair: Repair the harness or replace the
Open
E. Insert one end of the jumper wire into the harness between the ECM and the valve
circuit
connector socket for the suspect injectors supply cover base. Perform an injector solenoid test
wire. Insert the other end of the jumper wire into in order to verify that the problem is
the connector socket for the suspect injectors resolved.
return wire. The jumper wire will bypass the
injector solenoid. If the problem is not resolved, proceed to
Test Step 4.
F. Restore electrical power to the engine ECM.
G. Turn the keyswitch to ON.
H. Perform the "Injector Solenoid Test" in Cat

ET.
I. Repeat this test for each suspect circuit. Stop

the "Injector Solenoid Test" before handling the
jumper wire. Restore the wiring to the original
configuration.
4. Check the Harness between the ECM and Result: The harness is OK.
the Valve Cover Base for a Short Circuit
A. Turn the keyswitch to OFF. A strong Short
electrical shock hazard is present if the circuit Result: The harness is NOT OK.
Repair: The problem is in the wiring to the
6 of 9 2/17/2017 12:22 PM

ECM.
C. Disconnect the connectors of the injector ECM or the ECM is not operating properly.
harness at the valve cover base. Repair the wiring or replace the wiring to the
ECM. Perform an injector solenoid test in
D. Restore electrical power to the engine ECM. order to verify that the problem is resolved.
E. Turn the keyswitch to ON. If the problem is not resolved, proceed to

Test Step 8.
F. Perform the Injector Solenoid Test at least two

times.
5. Inspect the Wiring Harness Between the

Valve Cover Base and the Injectors
Result: The connectors and the wiring are
A. Turn the keyswitch to OFF. A strong OK.
electrical shock hazard is present if the
keyswitch is not turned off. Proceed to Test Step 6.
B. Remove electrical power from the engine Result: The connectors and/or wiring are
ECM. NOT OK.
C. Thoroughly inspect the connectors. Refer to Wiring Repair: Repair the connectors or wiring
Troubleshooting, "Electrical Connectors - and/or replace the connectors or wiring.
Inspect" for details. Ensure that all of the seals are properly in
place and ensure that the connectors are
D. Perform a 45 N (10 lb) pull test on each of coupled. Perform an injector solenoid test in
the wires that are associated with injector order to verify that the problem is resolved.
solenoids.
E. Check the harness and wiring for abrasions Test Step 6.
and for pinch points from the valve cover base to
the injectors.
6. Check the Injector Harness under the Result: Cat ET displays "Open" for the
Valve Cover for a Short Circuit solenoid that is not connected.
A. Turn the keyswitch to OFF. A strong Short Proceed to Test Step 7.

electrical shock hazard is present if the circuit
keyswitch is not turned off. Result: Cat ET displays "Short" for the
solenoid that is not connected. There is a
7 of 9 2/17/2017 12:22 PM

ECM.
C. Remove the valve cover in order to gain

access to the suspect injector.
problem with the injector harness under the
D. Disconnect the harness connector from the
valve cover.
suspect injector.
Repair: Repair the wiring and/or the
E. Inspect the seal around each wire. Verify that
connector, when possible. Replace parts, if
the seal is sealing correctly.
necessary. Perform an injector solenoid test
in order to verify that the problem is
F. Pull on each wire in order to verify that the
resolved.
wire and the terminal are correctly installed.
G. Restore power to the ECM.
Test Step 7.
H. Turn the keyswitch ON.
I. Activate the "Injector Solenoid Test". Allow

the Injector Solenoid Test to continue until each
solenoid is activated at least two times.
7. Check the Injector Harness under the

Valve Cover for an Open Circuit
Result: Cat ET displays "Short" for the
A. Turn the keyswitch to OFF. A strong connector that has the jumper wire. The
electrical shock hazard is present if the wiring is OK.
ECM. Result: Cat ET displays "Open" for the
connector that has the jumper wire. The
C. Determine the appropriate terminals for the Open wiring has an open.
solenoid with the code. Refer to Table 1 for the circuit
proper terminal connections. Connect a jumper Repair: Repair the harness or replace the
wire between the terminal for the supply and the harness under the valve cover. Perform an
terminal for the return. The jumper wire will injector solenoid test in order to verify that
replace the injector solenoid with a short circuit. the problem is resolved.
D. Turn the keyswitch ON. If the problem is not resolved, proceed to

Test Step 8.
E. Activate the "Injector Solenoid Test". Allow
8 of 9 2/17/2017 12:22 PM
8. Check the ECM for Proper Operation
A. Turn the keyswitch OFF. A strong electrical

shock hazard is present if the keyswitch is not Result: Cat ET displays "Short" for the
turned off. solenoid with the jumper wire. Cat ET will
display "Open" when the P2 connector is not
B. Disconnect the P2 connector. connected to the ECM. The problem is in the
When the P2 connector is disconnected, injector.
numerous diagnostic codes will be generated
when the keyswitch is turned ON. The codes are Repair: Replace the injector. Perform an
normal. Ignore the codes. Reset all active codes injector solenoid test in order to verify that
and clear all logged codes after you complete the problem is resolved.
this Test Step.
Result: Cat ET does not display "Short" for
C. Turn the keyswitch ON. the solenoid with the jumper wire. Cat ET
does not display "Open" when P2 is not
D. Activate the "Injector Solenoid Test". Allow ECM connected to the ECM.
solenoid is activated at least two times. Repair: Perform the following procedure:
1. Temporarily connect a test ECM. Refer to
E. Turn the keyswitch OFF. A strong electrical Troubleshooting, "Test ECM Mode".
shock hazard is present if the keyswitch is not 2. Activate the "Injector Solenoid Test".
turned off. Allow the Injector Solenoid Test to continue
until each solenoid is activated at least two
F. Use a jumper wire in order to create a short times.
circuit on J2 between the terminals for the
solenoids supply and the solenoids return. If the test ECM fixes the problem, connect
the suspect ECM. If the problem returns with
G. Turn the keyswitch ON. the suspect ECM, replace the ECM. Verify
that the problem is resolved.
H. Activate the Injector Solenoid Test. Allow
schlumberger05
9 of 9 2/17/2017 12:22 PM
Troubleshooting
i06730691
Retarder - Test
SMCS - 1129-038
Use this procedure for the following diagnostic trouble codes:
Table 1
Diagnostic Codes
791-5
The code is logged when there is an electrical or wiring problem with the brake assemble positioned
Compression Brake Low/High Solenoid #1 : Current
over cylinder 3 and cylinder 4.
Below Normal
791-6
The code is logged when there is an electrical or wiring problem with the brake assemble positioned
Compression Brake Low/High Solenoid #1 : Current
over cylinder 3 and cylinder 4.
Above Normal
792-5
The code is logged when there is an electrical or wiring problem with the brake assembles positioned
Compression Brake Medium/High Solenoid #1 :
over cylinders 1 and 2 or cylinders 5 and 6.
Current Below Normal
792-6
The code is logged when there is an electrical or wiring problem with the brake assembles positioned
Compression Brake Medium/High Solenoid #1 :
over cylinders 1 and 2 or cylinders 5 and 6.
Current Above Normal
Schematic for the compression brake circuit
Probable Causes
Codes
Short circuit
Open circuit
Recommended Actions
1 of 4 2/17/2017 12:23 PM
Table 2
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Turn the keyswitch to ON.
C. Access the diagnostic overrides under the "Diagnostics" menu.
D. Start the "Compression Brake Low/High Override". Result: A 791-5, or 792-5 diagnostic code is active.
E. Once Cat ET displays the status of the compression brake solenoid, stop the Proceed to Test Step 2.
"Compression Brake Low/High Override".
Codes
Result: A 791-6, or 792-6 diagnostic code is active.
F. Monitor the "Active Diagnostic Code" screen on Cat ET. Record any active
diagnostic codes. Proceed to Test Step 4.
G. Start the "Compression Brake Med/High Override".
H. Once Cat ET displays the status of the compression brake solenoid, stop the
"Compression Brake Med/High Override".
I. Monitor the "Active Diagnostic Code" screen on Cat ET. Record any active
diagnostic codes.
2. Create a Short Between the Wires of the Suspect Compression Brake Solenoid
at the Valve Cover Connector
Note: To troubleshoot a 791-5 diagnostic code, use the "Compression Brake Low/High
Override" in Cat ET. To troubleshoot a 792-5 diagnostic code, use the "Compression
Brake Med/High Override" in Cat ET.
B. Disconnect the harness at the valve cover connector.

Result: A 791-6, or 792-6 diagnostic code is active. The
C. Fabricate a jumper wire to create a short between the supply wire for the suspect
harness wiring is OK.
compression brake solenoid and engine ground.
Short circuit
Result: A 791-5, or 792-5 diagnostic code is active.
E. Access the diagnostic overrides under the "Diagnostics" menu.
Repair: Repair the harness or replace the harness.
F. Start the override for the compression brake.
G. Once Cat ET displays the status of the compression brake solenoid, stop the
override.
H. Monitor the "Active Diagnostic Code" screen in Cat ET. Record any active
diagnostic codes.
I. Turn the keyswitch to OFF. Remove the jumper wire.
Note: A -5 open circuit diagnostic code will be active for the other compression brake
solenoid. Ignore the diagnostic codes for the other compression brake solenoid. Ignore
any diagnostic codes for the injector solenoids.
3. Create a Short Circuit at the Compression Brake Solenoid Result: A 791-6 or a 792-6 diagnostic code is active.
The harness wiring between the connector for the
Note: Two solenoids are activated to create a medium braking action. The open could compression brake solenoid and the ECM is OK.
be in either solenoid or in the harness. To isolate the problem for a medium braking Short
action, run this test step for each of the solenoids. The short must be created separately circuit Repair: Replace the suspect compression brake
at each solenoid. solenoid. Verify that the problem is resolved.
2 of 4 2/17/2017 12:23 PM
Override" on Cat ET. To troubleshoot a 792-5 diagnostic code, use the "Compression
Brake Med/High Override" on Cat ET.
B. Remove the valve cover.
C. Reconnect the valve cover connector.
D. Disconnect the connector on the suspect compression brake solenoid.
E. Inspect the terminals on the connector for the compression brake solenoid for
damage.
Result: A 791-5 or a 792-5 diagnostic code is active.
F. Fabricate a jumper wire to short the two wires for the suspect solenoid on the
solenoid connector. Crimp a pin to each end of the jumper wire.
Repair: Repair the harness or replace the harness
between the connector for the compression brake
G. Make sure that the solenoid connector securely holds the jumper wire.
solenoid and the valve cover connector.
Note: Worn terminals and/or damaged terminals on the solenoid connector could cause
an intermittent "Open".
H. Turn the keyswitch to ON.
I. Access the diagnostic override under the "Diagnostics" menu.
J. Start the override for the compression brake.
K. Once Cat ET displays the status of the compression brake solenoid, stop the
override.
L. Monitor the "Active Diagnostic Code" screen on Cat ET. Record any active
diagnostic codes.
M. Turn the keyswitch to OFF. Remove the jumper wire.
4. Create an Open Between the Wires of the Suspect Compression Brake Solenoid
at the Valve Cover Connector
The harness wiring between the valve cover connector
and the ECM is OK.
B. Disconnect the harness at the valve cover connector.
Open circuit
D. Access the diagnostic override under the "Diagnostics" menu. detected
E. Start the override for the compression brake.
between the P2 connector and the valve cover connector.
F. Once Cat ET displays the status of the compression brake solenoid, stop the override.
G. Monitor the Active Diagnostic Code screen on Cat ET. Record any active diagnostic
codes.
H. Turn the keyswitch to OFF. Remove the wire short.
I. Reconnect the valve cover connector.
5. Create an Open Circuit at the Compression Brake Solenoid Result: A 791-5 or a 792-5 diagnostic code is active.
The harness wiring between the connector for the
Note: Two solenoids are activated to create a medium braking action. The short could Open circuit compression brake solenoid and the ECM is OK.
be in either solenoid or in the harness. To isolate the problem for a medium braking detected
action, run this test step for each of the solenoids. The open must be created separately Repair: Replace the suspect compression brake
at each solenoid. solenoid. Verify that the repair eliminates the problem.
3 of 4 2/17/2017 12:23 PM
B. Remove the valve cover.
C. Reconnect the valve cover connector.

D. Disconnect the connector on the suspect compression brake solenoid.
There is a short circuit between the valve cover
connector and the connector for the compression brake
E. Inspect the terminals on the connector for the compression brake solenoid for
solenoid.
damage.
F. Turn the keyswitch to ON.
between the connector for the compression brake
solenoid and the valve cover connector. Verify that the
G. Access the diagnostic override under the "Diagnostics" menu.
problem is resolved.
H. Start the override for the compression brake.
I. Once Cat ET displays the status of the compression brake solenoid, stop the override.
J. Monitor the Active Diagnostic Code screen on Cat ET. Check and record any active
diagnostic codes.
K. Turn the keyswitch to OFF.
If the problem is not resolved, contact your Technical Communicator (TC). For further assistance, the TC can confer with the Dealer Solutions Network (DSN).
schlumberger05
4 of 4 2/17/2017 12:23 PM
Troubleshooting
i06909808
Sensor Signal (Analog, Active) - Test

SMCS - 1439-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with the sensors. Use this
procedure if any of the diagnostic codes in Table 1 are active or easily repeated.
Table 1
The ECM detects signal voltage that is not in the acceptable

94–3
range.
Fuel Delivery Pressure Sensor :
The code is logged.
The value of the parameter is set to a gauge pressure.

94–4
range.
Fuel Delivery Pressure Sensor :
The code is logged.

100-3
range.
Engine Oil Pressure Sensor : Voltage
The code is logged.
Above Normal

100-4
range.
Engine Oil Pressure Sensor : Voltage
The code is logged.
Below Normal
1 of 6 2/17/2017 12:23 PM

101-3
range.
Crankcase Air Pressure Sensor :
The code is logged.

101-4
range.
Crankcase Air Pressure Sensor :
The code is logged.

274-3
range.
Atmospheric Pressure Sensor : Voltage
The code is logged.
Above Normal

274-4
range.
Atmospheric Pressure Sensor : Voltage
The code is logged.
Below Normal

460-3
range.
Fuel Pressure Sensor - After Fuel Filter
The code is logged.
: Voltage Above Normal

460-4
range.
Fuel Pressure Sensor - After Fuel Filter
The code is logged.
: Voltage Below Normal

1785-3
range.
Intake Manifold Pressure Sensor :
The code is logged.

1785-4
range.
Intake Manifold Pressure Sensor :
The code is logged.

1835-3
range.
Auxiliary Pressure Sensor : Voltage
The code is logged.
Above Normal

1835-4
range.
Auxiliary Pressure Sensor : Voltage
The code is logged.
Below Normal
2 of 6 2/17/2017 12:23 PM
1924-3 The ECM detects signal voltage that is not in the acceptable
Engine Intake Valve Actuation System range. The code is logged. The value of the parameter is set to a
Oil Pressure : Voltage Above Normal gauge pressure.
1924-4 The ECM detects signal voltage that is not in the acceptable
Engine Intake Valve Actuation System range. The code is logged. The value of the parameter is set to a
Oil Pressure : Voltage Below Normal gauge pressure.
Probable Causes
Codes
Short circuit
Open circuit
Supply voltage
Wiring
3 of 6 2/17/2017 12:23 PM
DPF components
Recommended Actions
Table 2
1. Check for Codes

Result: A -3 diagnostic code is active.
Electronic Technician (ET) and the ECM . Refer to
Troubleshooting, "Electronic Service Tools", if
necessary. Codes
Result: A -4 diagnostic code is active.
C. Look for "-3", or "-4" active or logged codes.
Result: A -4 diagnostic code does not

2. Create a Short at the Sensor Connector
become active for the suspect sensor.
A. Use a test lamp to create a short between
terminal 3 (signal) and terminal 2 (sensor return) at
the sensor connector.
Result: A -4 diagnostic code became
active after creating the short at the
B. Turn the keyswitch to ON. Short
sensor connector. The wiring is OK.
circuit
C. Monitor the diagnostic codes on Cat ET. Check
for an active -4 diagnostic code for the suspect
sensor.
D. Turn the keyswitch to OFF.
Test Step 3.
3. Create an Open at the Suspect Sensor Result: A -3 diagnostic code did not
Connector become active after disconnecting the
sensor.
A. Turn the keyswitch to OFF. Open
circuit Proceed to Test Step 4.
B. Disconnect the sensor connector of the suspect
sensor with the active -4 diagnostic code. Result: A -3 diagnostic code became
4 of 6 2/17/2017 12:23 PM
active after disconnecting the sensor. The

wiring is OK.
D. Monitor the diagnostic codes on Cat ET. Check
for an active -3 diagnostic code for the suspect
sensor.
Test Step 4.
E. Turn the keyswitch to OFF.
Result: The supply voltage is OK.
Repair: Connect the sensor.
4. Check the 5 VDC Supply Voltage at the Sensor Proceed to Test Step 5
Connector
Result: The supply voltage is NOT OK.
A. Turn the keyswitch to ON. 5.0 ± 0.2 There is a short in the harness to the
VDC battery.
B. Measure the voltage between pin 1 and pin 2 at
the suspect sensor. Repair: Repair the wiring or replace the
harness

Test Step 5.
5. Perform the Wiggle Test Result: The wiring failed the Wiggle
Test.
Carefully following this procedure is the best way
to identify the root cause of an intermittent problem. Repair: There is a problem with the
wiring. Repair the wiring or replace the
A. Turn the keyswitch to ON. wiring.
B. Use Cat ET to run the "Wiggle Test". Result: The wiring passed the Wiggle
Test. The problem may be intermittent.
C. Slowly wiggle the wiring and the connectors Wiring
between the P2 connector and the sensor. Pay Repair: Inspect the wiring. Refer to
particular attention to the wiring near each Troubleshooting, "Electrical Connectors
connector. Be sure to wiggle all the wiring. - Inspect".
As you wiggle the wiring look for these problems. If the wiring looks OK, perform the
1. Loose connectors or damaged connectors following procedure.
2. Moisture on the connectors or the wiring 1. Turn the keyswitch to the OFF
3. Damaged that is caused by excessive heat position.
5 of 6 2/17/2017 12:23 PM
2. Disconnect the connectors. Carefully

inspect the terminals for proper
installation. Make sure that each terminal
4. Damage that is caused by chafing
is clean and dry.
5. Improper routing of wiring
3. Insert a pin into each socket. Verify
6. Damaged insulation
that each socket grips the pin firmly.
Repair any problems.
4. Connect all connectors.
schlumberger05
6 of 6 2/17/2017 12:23 PM
Troubleshooting
i06723611
Sensor Signal (Analog, Passive) - Test

SMCS - 1439-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with the sensor. Also use
this procedure if any one of the diagnostic codes in Table 1.
Table 1
110-3
The code is logged if the engine has been running for more than
Engine Coolant Temperature Sensor :
7 minutes and an open circuit has been detected.
110-4
The code is logged. The ECM detects voltage that is not in the
Engine Coolant Temperature Sensor :
acceptable range.
172–3
The code is logged.
Intake Manifold Air Temperature Sensor
The ECM detects voltage that is not in the acceptable range.
: Voltage Above Normal
172-4
The code is logged.
Intake Manifold Air Temperature Sensor
: Voltage Below Normal
174-3 The code is logged. The ECM will flag the fuel temperature as
Fuel Temperature Sensor : Voltage invalid data and the fuel temperature is set to a default value of
Above Normal 40 °C (104 °F).
174-4 The code is logged. The ECM will flag the fuel temperature as
Fuel Temperature Sensor : Voltage invalid data and the fuel temperature is set to a default value of
1 of 5 2/17/2017 12:24 PM
Below Normal 40 °C (104 °F).
3683-3
The code is logged.
Auxiliary Temperature #2 : Voltage
Above Normal
3683-4
The code is logged.
Auxiliary Temperature #2 : Voltage
Below Normal
1836-3
The code is logged. The ECM will flag the temperature as
Auxiliary Temperature Sensor : Voltage
invalid data and the temperature is set to a default value.
Above Normal
1836-4
The code is logged. The ECM will flag the temperature as
Auxiliary Temperature Sensor : Voltage
invalid data and the temperature is set to a default value.
Below Normal
3372-3
Engine Charge Air Cooler #1 Outlet The code is logged.
Temperature Sensor : Voltage Above The ECM detects voltage that is not in the acceptable range.
Normal
3372-4
Engine Charge Air Cooler #1 Outlet The code is logged.
Temperature Sensor : Voltage Below The ECM detects voltage that is not in the acceptable range.
Normal
2 of 5 2/17/2017 12:24 PM
Schematic for the passive analog sensors
Probable Causes
Codes
Short circuit
Open circuit
Wiring
EGR temperature sensor
Recommended Actions
Table 2
1. Check for Codes Result: A -3 diagnostic code is

active.
A. Connect to Cat® Electronic Technician (ET).
Result: A -4 diagnostic code is
C. Access the "Active Diagnostic Code" screen on Cat active.
Codes
ET.
Note: Wait at least 30 seconds in order for the diagnostic
codes to become active. Result: For a diagnostic code that
is logged but not currently active,
D. Look for -3 and/or -4 codes: proceed to Test Step 4.
2. Create a Short at the Sensor Connector Result: The -3 diagnostic code

remains active for the suspect
A. Turn the keyswitch to OFF. sensor. There is an open in the
harness.
B. Disconnect the suspect sensor. Short
Circuit Repair: Repair the wiring or
C. Install the jumper wire between terminal 1 (sensor replace the harness.
signal) and terminal 2 (sensor return) at the sensor
connector. Result: A -4 diagnostic code
3 of 5 2/17/2017 12:24 PM
D. Turn the keyswitch to ON. became active after creating the

short at the sensor connector. The
E. Monitor the diagnostic codes on Cat ET. Check for an wiring is OK.
active -4 diagnostic code for the suspect sensor.
Note: Wait at least 30 seconds in order for the diagnostic
codes to become active. If the problem is not resolved,
F. Turn the keyswitch to OFF.
3. Create an Open at the Suspect Sensor Connector
A. Turn the keyswitch to OFF. Result: The -4 diagnostic code

remains active for the suspect
B. Disconnect the sensor connector of the suspect sensor sensor. There is an open in the
with the active -4 diagnostic code. harness.
C. Turn the keyswitch to ON. Repair: Repair the wiring or

replace the harness.
D. Monitor the diagnostic codes on Cat ET. Check for an
Open
active -3 diagnostic code for the suspect sensor. Result: A -3 diagnostic code
Circuit
became active after disconnecting
Note: Wait at least 30 seconds in order for the diagnostic the sensor. The wiring is OK.
codes to become active.
Note: For a 110-3 code, start the engine and let the engine
idle for 7 minutes. The engine must be running for at least If the problem is not resolved,
7 minutes in order for the diagnostic to run. proceed to Test Step 4.
E. Turn the keyswitch to OFF.
4. Perform the Wiggle Test Result: The wiring failed the

Wiggle Test.
A. Turn the keyswitch to ON.
Repair: Repair the wiring or
B. Use Cat ET to run the "Wiggle Test". replace the wiring.
Wiggle
C. Slowly wiggle the wiring and the connectors between Test Result: The wiring passed the
the P2 connector and the sensor. Slowly wiggle the wiring Wiggle Test.
and the connectors between the P1 connector and the
sensor. Pay particular attention to the wiring near each Repair: The problem may be
connector. Be sure to wiggle all the wiring. intermittent. Inspect the wiring.
4 of 5 2/17/2017 12:24 PM
Refer to Troubleshooting,
"Electrical Connectors - Inspect".
Repair: If the wiring looks OK,

perform the following procedure.
D. As you wiggle the wiring look for these problems. 1. Turn the keyswitch to OFF.
- Loose connectors or damaged connectors 2. Disconnect the connectors.

- Moisture on the connectors or the wiring Carefully inspect the terminals for
- Damage that is caused by excessive heat proper installation. Make sure that
- Damage that is caused by chafing each terminal is clean and dry.
- Improper routing of wiring
- Damaged insulation 3. Insert a pin into each socket.
Verify that each socket grips the
pin firmly. Repair any problems.
4. Connect all connectors.
schlumberger05
5 of 5 2/17/2017 12:24 PM
Troubleshooting
i06723492
Sensor Supply - Test

SMCS - 1439-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with a sensor supply. Use
this procedure if any one of the diagnostic codes in Table 1 is active or easily repeated.
Note: Some of the following codes may not be applicable for certain applications.
Table 1
41-3
The code is logged.
8 VDC Supply : Voltage Above Normal
41-4
The code is logged.
8 VDC Supply : Voltage Below Normal
100–10 The ECM detects supply voltage that is not in the

Engine Oil Pressure Sensor : Abnormal Rate of acceptable range.
Change The code is logged.
262-3
The code is logged.
5 V Sensor DC Power Supply : Voltage Above
All sensors are set to default values.
Normal
262-4
The code is logged.
5 V Sensor DC Power Supply : Voltage Below
All sensors are set to default values.
Normal
269-3 The code is logged.

5 V Sensor DC Power Supply #2 : Voltage Engine power may be derated.
1 of 4 2/17/2017 12:25 PM
Above Normal
269-4
The code is logged.
5 V Sensor DC Power Supply #2 : Voltage
Engine power may be derated.
Below Normal
The ECM detects supply voltage that is not in the

1785-10
acceptable range.
Intake Manifold Pressure Sensor : Abnormal
The code is logged. The value of the parameter is set to
Rate of Change
a gauge pressure.
The signal wires are not shown.
Probable Causes
Codes
Sensors
Recommended Actions
Table 2
1. Check for Codes Result: A -3 or -4 code is present.

Codes
2 of 4 2/17/2017 12:25 PM
A. Connect Cat® Electronic Technician

(ET) to the service tool connector. Refer to
Troubleshooting, "Electronic Service
Tools".
Result: A -10 code is present.
C. Determine if a diagnostic trouble code
is present.
2. Check for a Failed Sensor
A. Connect to Cat ET. Result: The suspect sensor supply active code
changes to logged when a sensor is unplugged.
Repair: Replace the failed sensor.
C. Disconnect a sensor on the suspect
sensor supply circuit. Result: The suspect sensor supply active code
remains active after all sensors on the sensor
D. Monitor Cat ET while the sensor is Sensor supply circuit have been checked.
disconnected to see if the active code
changes to logged. Repair: A failed wiring harness has been
detected. Repair or replace the wiring harness.
E. Connect the suspect sensor to the
wiring harness If the problem is not resolved, proceed to Test
Step 3.
F. Repeat steps C through E for each
sensor on the suspect sensor supply.
3. Check the Sensor Supply Voltage Result: A -4 code is activated on the suspect
sensor supply.
Repair: Remove the sensor. Check the sensor
B. Unplug the suspect sensor from the passage for a blockage or obstruction. Also,
wiring harness. check for moisture frozen in the lines. If
Sensor blockage is not found, replace the sensor.
C. Place a jumper wire between pin 1 and supply
pin 2 on the suspect sensor wiring harness voltage Result: A -4 code is not activated on the suspect
connector. sensor supply.
D. Connect to Cat ET. Repair: The problem is in the wiring from the
ECM to the sensor connector. Repair the wiring
E. Turn the keyswitch to ON. or replace the wiring.
3 of 4 2/17/2017 12:25 PM
F. Monitor the diagnostic codes using Cat

ET.
schlumberger05
4 of 4 2/17/2017 12:25 PM
Troubleshooting
i06723599
Speed Control - Test

SMCS - 7332-038-VF
Use this procedure to troubleshoot the electrical system if a problem is suspected with the circuit that is for
the throttle position sensor. Also use this procedure if one of the diagnostic codes in Table 1 is active or easily
repeated.
Table 1
The Electronic Control Module (ECM) has detected an invalid

combination of positions for the multi-position switches.
774-2
The code is logged. If equipped, the warning light will come on.
Accelerator Pedal Position 2 :
Engine RPM defaults to a predetermined safe speed. The throttle
switch is ignored by the ECM until the fault is cleared and the
keyswitch is cycled.
The ECM detects signal voltage that is not in the acceptable range.
774-3
The code is logged. The ECM flags the throttle position as invalid
data and a default value is used. The engine speed is limited to
high idle.
774-4
high idle.
774-8 The ECM detects an incorrect frequency on the throttle signal or

Accelerator Pedal Position 2 : an incorrect duty cycle on the throttle signal.
Abnormal Frequency, Pulse Width, The code is logged. The ECM flags the throttle position as invalid
1 of 4 2/17/2017 12:26 PM

or Period
high idle.
The ECM has detected an invalid combination of positions for the

multi-position switches.
91-2
The code is logged. If equipped, the warning light will come on.
Engine RPM defaults to a predetermined safe speed. The throttle
switch is ignored by the ECM until the fault is cleared and the
keyswitch is cycled.
91-3
high idle.
91-4
high idle.
The ECM detects an incorrect frequency on the throttle signal or

91-8
an incorrect duty cycle on the throttle signal.
Abnormal Frequency, Pulse Width,
or Period
high idle.
Schematic for throttle position sensor
Probable Causes
Sensor
Recommended Actions
2 of 4 2/17/2017 12:26 PM
Table 2
1. Check the Signal Frequency and the

Duty Cycle at the Sensor
B. Remove the wire from terminal location C

(throttle position) on the harness side of the Result: The ECM detects an incorrect
connector for the throttle position sensor. frequency on the throttle signal or an
incorrect duty cycle on the throttle signal.
C. Install a 326-4904 Adapter Cable As The frequency is below 150 Hz or the
(3-PIN BREAKOUT) at the connector for the frequency is above 1000 Hz. The duty cycle
throttle position sensor. is less than 5 percent or the duty cycle is
greater than 95 percent.
D. Connect the connector for the throttle
Frequency
position sensor. Proceed to Test Step 2.
Duty
E. Turn the keyswitch to the ON position. Result: The frequency and the duty cycle are
Cycle
OK.
F. Measure the frequency and the duty cycle
between terminal B (digital return) and Repair: Repair the harness or replace the
terminal C (throttle position) at the 326-4904 harness.
Adapter Cable As (3-PIN BREAKOUT).
Operate the throttle pedal while making the If the problem is not resolved, proceed to
measurements. Test Step 2.
G.Turn the keyswitch to OFF .
H.Remove the breakout harness. Restore the

wiring for the harness connector to the
original configuration.
2. Check the Supply Voltage to the Sensor Result: The supply voltage is above 7.5
VDC at the sensor connector.
Repair: The wiring is OK. Replace the
B. Disconnect the harness connector for the sensor. Verify that the problem is resolved.
Supply
throttle position sensor.
voltage
Result: The supply voltage is not above 7.5
C. Measure the voltage across terminal A (8 VDC at the sensor connector. The supply
V supply) and terminal B (digital return) on voltage is not reaching the speed control.
the harness side of the connector. The voltage
3 of 4 2/17/2017 12:26 PM
Repair: Repair the harness wiring or replace

should measure 7.5 VDC. the harness. Verify that the problem is
resolved.
schlumberger05
4 of 4 2/17/2017 12:26 PM
Troubleshooting
i06729949
Speed/Timing - Test
SMCS - 1912-038
Use this procedure to troubleshoot the electrical system if a problem is suspected with the primary engine
speed/timing sensor. Also use this procedure if a problem is suspected with the secondary engine
speed/timing sensor. Use this procedure to troubleshoot the electrical system if a diagnostic code in Table 1 is
active or easily repeated.
Table 1
CDL Code and

Comments
Description
The code is logged. The Electronic Control Module (ECM) can default to the
190-8
secondary engine speed/timing sensor. The default will occur if a valid signal is
Engine Speed Sensor :
not received from the primary engine speed/timing sensor. The engine will
Abnormal Frequency,
shutdown only if the signals from the primary engine speed/timing sensor and
Pulse Width, or Period
the secondary engine speed/timing sensor are abnormal.
342-8 The code is logged. If a valid signal is not received from the secondary engine
Secondary Engine Speed speed/timing sensor, the ECM will default to the primary engine speed/timing
Sensor : Abnormal sensor. The engine will shutdown only if the signals from the primary engine
Frequency, Pulse Width, speed/timing sensor and the secondary engine speed/timing sensor are
or Period abnormal.
1 of 5 2/17/2017 12:27 PM
Probable Causes
Codes
Speed/Timing circuit
Battery voltage
Cranking speed
Sensor
Resistance
Recommended Actions
Table 2
1. Check for Codes Result: There is an active

diagnostic code or there is a timing
A. While the engine is running, monitor Cat® pattern that is "Not Detected".
Electronic Technician (ET) for codes. Also monitor
the "Engine Starting" screen for an engine Proceed to Test Step 5.
speed/timing that is "Not Detected".
Codes Result: There is not an active
B. Wait at least 30 seconds for activation of the diagnostic code and there is not a
diagnostic codes. Look for these codes on Cat ET: timing pattern that is "Not
190-8 Detected".
342-8
Repair: Download the "Warranty
2 of 5 2/17/2017 12:27 PM
Report" from the engine ECM.

Troubleshoot any diagnostic codes
that may be present.

2. Check the Engine Speed/Timing Circuit
A. Establish communication between Cat ET and

the ECM .
Result: The engine started.
Speed/Timing
C. Monitor the "Engine Starting" screen in Cat ET.
circuit Result: The engine did not start.
D. Start the engine and run the engine. The problem
may occur when the engine is at any operating
temperature. However, the problem is more likely
to occur when the engine is at the normal operating
temperature.
Result: The battery voltage is OK.

3. Check the Battery Voltage
Result: The battery voltage is
A. Monitor the "Engine Starting" screen in Cat ET.
NOT OK.
Battery
B. Monitor the battery voltage. Crank the engine for
voltage Repair: Refer to Troubleshooting,
5 seconds.
"Engine Cranks but Does Not
Start".
C. Monitor the battery voltage while cranking.
4. Check the Engine Speed and the Engine Result: A sensor is NOT OK. The
Speed/Timing Status timing pattern shows "Not
Cranking Detected".
A. Monitor the "Engine Starting" screen in Cat ET. speed
B. Crank the engine for 5 seconds. Verify that the
3 of 5 2/17/2017 12:27 PM
Result: The sensors are OK. The

timing pattern shows "Detected".
sensors show an acceptable cranking speed. Repair: Refer to Troubleshooting,
"Engine Cranks but Does Not
C. While the engine is cranking, check the status of Start".
the engine speed/timing sensors.
5. Inspect the Sensor Assembly
B. Visually inspect the sensor and the sensor

assembly without removing the sensor assembly
Result: The sensor and the sensor
from the engine. Flanges must be flush against the
assembly mounting are OK.
surface of the front timing gear housing to ensure
proper operation.
C. Inspect the sensor bracket . Verify that the
Result: The sensor and/or the
bracket securely holds the flanges of the sensors
sensor assembly are NOT OK.
flush against the engine.
Sensors
Repair: Repair the sensor and/or
D. Verify that the bracket is not bent. If the bracket
the sensor assembly or replace the
is bent or if an obstruction is preventing the sensor
sensor and/or the sensor assembly.
assembly from being installed correctly, the engine
will not start.
E. Disconnect the harness from the speed/timing
sensors. Check the harness for debris and for
corrosion.
F. Perform a 45 N (10 lb) pull test on the harness

wiring.
6. Use a Multimeter to Check the Harness Result: The voltage is OK.

Wiring
A. Turn the keyswitch to ON.
Voltage Result: The voltage is NOT OK.
B. Perform the following procedure for each sensor. There is a problem in the harness
The voltage is 2.4 ± 0.2 VDC. wiring.
4 of 5 2/17/2017 12:27 PM
Repair: Repair the appropriate

1. Measure the voltage between terminal 1 and a
harness wiring or replace the
good engine ground.
appropriate harness.
2. Measure the voltage between terminal 2 and a
good engine ground.
Result: The resistance is OK.

7. Measure the Resistance of the Sensor
Repair: If the engine was running
before removing the sensor,
reinstall the sensor.
B. Disconnect the engine harness from the sensor.
Use Cat ET to check for any active
C. Remove the sensor. Check the sensor tip for any
diagnostic codes. Troubleshoot any
damage.
active diagnostic codes.
D. For the primary engine speed/timing sensor,
If the engine was not running
measure the resistance between terminal 2 to
before removing the sensor, refer
terminal 1. Resistance values should be 75Ω to
Resistance to Troubleshooting, "Engine
230Ω.
Cranks but Does Not Start".
E. For the secondary engine speed/timing sensor,
Result: The resistance is NOT
measure the resistance between terminal 2 to
OK. There is damage to the sensor
terminal 1. Resistance values should be 600Ω to
tip.
1800Ω.
Repair: Inspect the housing for a
F. Turn the keyswitch to ON.
cause of the sensor damage. Make
any necessary repairs.
G. Check for -13 codes. Wait at least 30 seconds in
order for the diagnostic codes to become active.
Replace the sensor assembly.
schlumberger05
5 of 5 2/17/2017 12:27 PM
Troubleshooting
i03502923
Customer Passwords
SMCS - 0785; 1900
Customer passwords may be used to protect customer parameters from being changed. Caterpillar Electronic
Technician (ET) can be used to change certain parameters. There are some parameters that cannot be changed
and there are some applications that do not allow any changes to the programmable monitoring system. The
passwords are programmed into the Electronic Control Module (ECM) with the Cat ET. One password may
be programmed or both passwords may be programmed. If customer passwords are not programmed,
customer parameters may be changed by anyone.
To obtain customer passwords, contact the owner of the engine. If the owner has forgotten the customer
passwords, customer passwords may be read by using Cat ET. Factory passwords are required in order to
read customer passwords.
Use the following procedure in order to read customer passwords with Cat ET:
1. Select the "Information" menu. Then select "Passwords".
2. When the "Factory Password" screen appears, record the information that is listed on the "Factory
Passwords Worksheet". Refer to programming parameters Troubleshooting, "Factory Passwords
Worksheet" for additional information.
3. Obtain the factory passwords. The information that is recorded on the "Factory Passwords Worksheet"
must be provided. When you obtain the factory passwords, a permanent record of your access is
generated at Caterpillar.
4. From the "Factory Password" screen, enter the factory passwords.
5. When the "Read Customer Passwords" screen appears, record the customer passwords. The customer
passwords may then be used to change parameters that are customer programmable.
1 of 2 2/17/2017 12:28 PM
Private Network For SIS Licensees. schlumberger05
2 of 2 2/17/2017 12:28 PM
Troubleshooting
i02433393
Factory Passwords
SMCS - 0785; 1900
NOTICE
Operating the engine with a flash file not designed for that engine will
damage the engine. Be sure the flash file is correct for your engine.
Note: Factory passwords are provided only to Caterpillar dealers.
Factory passwords are required to perform each of the following functions:
Program a new Electronic Control Module (ECM). When an ECM is replaced, the system
configuration parameters must be programmed into the new ECM. A new ECM will allow these
parameters to be programmed once without factory passwords. After the initial programming, some
parameters are protected by factory passwords.
Clear event codes. Most event codes require the use of factory passwords to clear the code once the
code has been logged. Clear these codes only when you are certain that the problem has been corrected.
Unlock parameters. Factory passwords are required in order to unlock certain system configuration
parameters. Refer to Troubleshooting, "System Configuration Parameters".
Since factory passwords contain alphabetic characters, the Caterpillar Electronic Technician (ET) must be
used to perform these functions. In order to obtain factory passwords, proceed as if you already have the
password. If factory passwords are needed, Cat ET will request the factory passwords and Cat ET will
display the information that is required to obtain the passwords. For the worksheet that is used for acquiring
factory passwords, refer to programming parameters Troubleshooting, "Factory Passwords Worksheet".
1 of 2 2/17/2017 12:29 PM
schlumberger05
2 of 2 2/17/2017 12:29 PM
Troubleshooting
i06910188
ECM Will Not Accept Factory Passwords

SMCS - 0785; 1901
Probable Causes
One of the following items may not be recorded correctly on the Cat® Electronic Technician (ET):
Passwords
Serial numbers
Total tattletale
Reason code
Recommended Actions
Table 1
Troubleshooting Test Steps Values Steps
1. Check the Factory Passwords Result: The factory passwords were not accepted in
Cat ET.
A. Verify that the correct
passwords were entered. Factory Repair: Check every character in each password and
Passwords remove the electrical power from the engine for 30
B. Verify that Cat® Electronic seconds and then retry.
Technician (ET) is displaying the
"Enter Factory Passwords" dialog Use Cat ET to verify that the following information
box. has been entered correctly: Engine Serial Number,
1 of 2 2/17/2017 12:29 PM
Serial Number for the Electrical Control Module,

Serial Number for Cat ET, Total Tattletale, and Reason
Code.
For additional information, refer to Troubleshooting, "Factory Passwords".
If the procedure did not correct the issues, contact your Cat dealer Technical Communicator (TC). For further
schlumberger05
2 of 2 2/17/2017 12:29 PM
Troubleshooting
i06796105
ECM Software - Install

SMCS - 1901-591; 7620-012
Use this procedure to troubleshoot the electrical system if the diagnostic code in Table 1 is active.
Table 1
The flash file is for a different engine family or for a different engine
253-2
application.
Personality Module : Erratic,
The engine will not start. Clearing this diagnostic code requires factory
Intermittent, or Incorrect
passwords. The personality module code must be reset to zero.
Flash programming is a method of programming or updating the flash file in the engine Electronic Control
Module (ECM). Cat® Electronic Technician (ET) is used to flash program a file into the memory of the
engine ECM.
Note: Customer versions of Cat ET do not have the capability for flash programming. Consult your local Cat
Dealer for assistance.
If you do not have the flash file, use the "Flash File Search" tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine. Alternatively, use the "Service Software Files" feature on SIS
Web to obtain the flash file for your engine. You must have the engine serial number in order to search for the
flash file. After locating the correct flash file, download the flash file to your PC. Write down the name of the
flash file for future reference.
Table 2
1 of 3 2/17/2017 12:30 PM
1. Programming a Flash File
A. Establish communication between Cat ET and the engine

ECM.
B. Select "WinFlash" from the "Utilities" menu on Cat ET.

If "WinFlash" will not communicate with the ECM, refer to Result: The flash
Troubleshooting, "Electronic Service Tool Does Not programming was
Communicate". successfully.
C. Program the flash file into the ECM. Return the unit to
service.
D. Select the engine ECM under the "Detected ECMs".
Result: The flash
E. Press the "Browse" button in order to select the name of the programming was
Programmed
flash file that will be programmed into the ECM. not successfully.
successfully
F. When the correct flash file is selected, press the "Open" button. Repair: Repair any
active diagnostic or
G. Verify that the "File Values" match the application. If the "File event codes.
Values" do not match the application, obtain the correct flash file.
H. When the correct flash file is selected, press the "Begin Flash" resolved, proceed to
button. Test Step 2.
I. Cat ET will indicate when flash programming has been

successfully completed.
J. Start the engine and check for proper operation. Repair any
active diagnostic or event codes.
2. "WinFlash" Error Messages
A. If you receive any error messages during flash programming,

Result: There are no
click on the "Cancel" button in order to stop the process. Access
error messages.
the information about the "ECM Summary" under the
Error
"Information" menu. Make sure that you are flashing the correct
messages Return the unit to
file for your engine.
service.
B. Record all error messages. The recorded error messages will
be necessary if further assistance is needed.
Contact your Cat dealer Technical Communicator (TC) if further assistance is needed, your TC can confer
2 of 3 2/17/2017 12:30 PM
with the Dealer Solutions Network (DSN).
schlumberger05
3 of 3 2/17/2017 12:30 PM
Troubleshooting
i06730105
Timing - Calibrate
SMCS - 1000-524; 1900-524; 1912-524
Use this procedure if the diagnostic code in Table 1 is active.
Table 1
CDL Code and

Comments
Description
261-11
The wiring to the sensors might have the wrong polarity. The timing of the
Engine Timing Offset
front gear train may be incorrect.
fault
261-13
A timing calibration is required for a new engine, replacing an Electronic
Engine Timing
Control Module (ECM) that fails to communicate or following work on the
Calibration : Calibration
front gear train, the camshaft, or the crankshaft.
Required
Table 2 lists the special tools that are required to perform this procedure.
Table 2
Required Special Tools
7X-1171 Transducer Adapter
6V-2197 Transducer
7X-1695 Cable as
1 of 8 2/17/2017 12:30 PM
170-3519 Harness (1)

(1) This item is not required if the engine harness has a connector for timing calibration.
(A) Timing mark
(B) Idler gear
Table 3
Note: Test Step 1 applies to C15 and C18 engines only.

Result: After
1. Check the Gear Train Timing starting the
engine, the code is
Note: The camshaft gear will be off a half tooth if the engine is timed still present.
when Cylinder # 6 is at Top Dead Center (TDC). The engine MUST be
timed when Cylinder #1 is at TDC. This could be possible anytime you do Proceed to Test
Gear
not time the engine at the crank to idle gear mesh. Step 2.
timing
Note: Remove the rocker arms before rotating the engine to prevent Result: After
piston/valve damage from occurring. starting the
engine, the code
A. If the engine is at TDC for cylinder 6, remove cam idler gear (B) and did not return.
rotate the crankshaft 360 degrees and repin the flywheel.
2 of 8 2/17/2017 12:30 PM
B. Install idler gear (B).
C. Check timing mark (A).
D. Rotate the engine by hand 360° to ensure that the engine rotates freely.
If the engine does not rotate freely, the engine is not timed correctly.
Remove the front housing and check all timing marks. Refer to Testing and
Adjusting, "Gear Group (Front) - Time" for the correct procedure.
E. Connect to Cat® Electronic Technician (ET) and clear the DTC.
F. Start the engine.
Table 4
Crankshaft Rotation
Engine Model Number of Degrees Direction of Rotation
C7 100 Normal Rotation
C-9 85 Normal Rotation
C9.3 85 Normal Rotation
C-10 60 Opposite Normal Rotation
C15 60 Opposite Normal Rotation
C18 30 Opposite Normal Rotation
Table 5
Location of the Timing Calibration Port
Engine Model Crankshaft Counterweight Engine Location
C7 3 Left Side
3 of 8 2/17/2017 12:30 PM
C-9 3 Left Side
C9 3 Left Side
C9.3 3 Left Side
C-10 8 Right Side
C11 8 Left Side
C-12 8 Right Side
C13 8 Left Side
C-15 2 Left Side
C15 2 Left Side
C-16 2 Left Side
C18 2 Left Side
Table 6
2. Install the Transducer Adapter
A. Remove the electrical power from the ECM.
B. Use the appropriate engine turning tool to put either the No. 1
piston or the No. 6 piston at the top center. Refer to the Systems
Operation/Testing and Adjusting. Result: The
transducer adapter
C. Refer to Table 4. After the top center position has been located, was installed.
Transducer
rotate the crankshaft for the number of degrees that is applicable to
adapter
your engine model. Be sure to rotate the crankshaft in the direction of Proceed to Test
rotation that is specified in the Table. Step 3.
D. Refer to Table 5. Locate the engines timing calibration port.
E. Remove any components from the timing calibration port.
F. Thread the transducer adapter into the port
3. Install the Transducer Result: The

Transducer transducer was
Note: If the crankshaft is not in the correct position when the installed.
4 of 8 2/17/2017 12:30 PM
transducer is installed, the transducer will be damaged when the

engine is started.
A. Apply clean engine oil to a 2D-6392 O-Ring Seal. Install the

O-ring seal on the end of the 6V-2197 Transducer.
Proceed to Test
B. Push the transducer through the transducer adapter until the
Step 4.
transducer contacts the crankshaft counterweight.
C. Withdraw the transducer 1.0 mm (0.04 inch) and hand tighten the
nut on the adapter sleeve to secure the transducer. Move the O-ring
seal against the adapter.
Table 7
Terminal Locations for Connection of the 170-3519 Harness
ECM Type ADEM 3 ADEM 4
Connector P2 P1 P2 P1
Timing Calibration +
(White) 22 24 26 24
(Terminal 1) Location
Timing Calibration -
(Yellow) 23 25 36 25
(Terminal 2) Location
Table 8
4. Connect the 7X-1695 Cable as
A. If the engine harness is equipped with a

connector for timing calibration, connect the
7X-1695 Cable as to the connector for timing
calibration and to the transducer. Result: The wiring is installed
correctly.
B. If the engine harness is not equipped with a Wiring
connector for timing calibration, or the connector is Proceed to Test Step 5.
not easily accessible, a connector can be installed.
The connector can be installed on either ECM
connector.
C. Refer to Table 7 to determine the proper terminal
5 of 8 2/17/2017 12:30 PM
locations for the connector that is easily accessible.
D. Remove the sealing plugs from the appropriate

terminals. Do not discard the sealing plugs. The
sealing plugs may be reinstalled when the timing
calibration is complete.
E. Install the WH(White)wire of the 170-3519

Harness into the appropriate location.
F. Install the YL(Yellow)wire of the 170-3519

Harness into the appropriate location. Disregard the
pin-outs on the label of the harness.
G. Ensure that each wire is installed into the correct

location. The timing calibration will not be
successful if the wires are installed incorrectly.
5. Check for Codes

Result: There are active codes other
A. Connect Cat® Electronic Technician (ET) to the
than a 261-13 diagnostic code.
service tool connector.
Repair: Troubleshoot the active
B. Start the engine and run the engine until the
diagnostic other than the 261-13
engine is at the normal operating temperature.
diagnostic code.
Codes
C. Check for active diagnostic codes. Wait at least
Result: There are no active codes
30 seconds in order for the codes to become active.
other than a 261-13 diagnostic code.
Note: The engine must not have any active
diagnostic codes during the timing calibration
except for a 261-13 diagnostic code.
6. Calibrate the Timing Result: The timing calibration was

successful.
A. After the engine has warmed up, access the
"Timing Calibration" screen on the Cat ET. Access Return the unit to service.
the following display screens in order: Timing
calibration Result: The timing calibration was
- Service not successful.
- Calibrations Repair: The following conditions

can cause the timing calibration to
6 of 8 2/17/2017 12:30 PM
- Timing Calibration
B. Set the engine speed to 1100 ± 50 rpm.
Note: The engine speed must be steady within this

rpm range in order for the calibration to be
successful.
C. To calibrate the timing, select "Continue" on Cat

ET. Wait until Cat ET indicates that the timing is fail:
calibrated.
1. The crankshaft and camshaft gears
D. Perform the following procedure if Cat ET have been reassembled incorrectly.
indicates that the timing is calibrated:
2. The timing calibration probe is not
1. Set the engine speed to low idle. installed correctly.
2. Disconnect the 7X-1695 Cable as before you exit 3. The engine speed is not correct
the "Timing Calibration" screen. Otherwise, and the engine speed is unstable. If
diagnostic codes may be activated. the engine speed is unstable, refer to
Troubleshooting, "Engine Misfires,
3. Exit the "Timing Calibration" screen on Cat ET. Runs Rough, or Is Unstable".
4. Remove the electrical power from the ECM. 4. There is a problem with the
transducer or with the cables. Obtain
5. Remove the transducer and remove the transducer a new transducer and/or a new cable
adapter. and repeat the timing calibration.
6. Reinstall the original components into the timing 5. There is an active 190-8 code or an
calibration port. active 342–8 code. Troubleshoot the
active codes before calibration.
7. If a 170-3519 Harness was installed, the harness
may be removed or permanently installed for future Correct any of the above conditions
use. If removed, install the sealing plugs into the and repeat the calibration procedure.
unused cavities of the ECM connector to prevent
moisture and debris from entering the connector.
8. If permanently installing the harness, fasten the

harness to the existing engine wiring harness with
cable ties. Also, install a 3E-3364 Receptacle and
two 8T-8737 Seal Plugs on the P400timing
calibration probe connector to prevent moisture and
debris from entering the connector.
7 of 8 2/17/2017 12:30 PM
schlumberger05
8 of 8 2/17/2017 12:30 PM

CAT C11 - C13 - C15 and C18 Industrial Engines - 5824317 - 01 PDF

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C13 Industrial Engine LGK00001-UP(SEBP4130 - 62) - Documentation https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?return...

Electronic Service Tools

431-7087 Tool Gp (REFRACTOMETER (DEF))

N/A 4 mm Allen Wrench

1U-5805 Wire Removal Tool (14-GA, GREEN)

6V-2197 Magnetic Transducer As (TIMING CALIBRATION)

121-9588 Wire Removal Tool (16-GA, BLUE)

147-6456 Wedge Removal Tool

151-6320 Wire Removal Tool (14-GA TO 18-GA, RED)

1U-5804 Crimp Tool (12 AWG TO 18 AWG)

7X-1171 Transducer Adapter

146-4080 Digital Multimeter Gp (RS232)

7X-1710 Multimeter Probes

326-4904 Adapter Cable As (3-PIN BREAKOUT)

Adapter Cable As (40-PIN BREAKOUT)

Adapter Cable As (70-PIN BREAKOUT)

The 257-8718 Adapter Cable As is not applicable with Tier IV Engines.

N/A Torque Wrench (capable of applying 1.5 N·m (13.3 lb in))

Repair Kits for Connectors

362-3555 Connector Repair Kit (AMPSEAL)

175-3700 Connector Repair Kit (Deutsch connector)

Bypass Harnesses for the ECM

Wiring Harness (ECM BYPASS)

Harness (ENGINE ECM BYPASS)

Harness (ENGINE ECM BYPASS)

276-7273 Sensor Test Box (1)

Optional Service Tools

Part Number Description

198-4240 Digital Pressure Indicator

4C-4075 Crimp Tool (4 AWG TO 10 AWG)

4C-4911(1) Battery Load Tester

5P-7277 Voltage Tester

6V-9130(2) Temperature Adapter (MULTIMETER)

8T-5319 Connector Tool Group

349-4199 AC/DC Current Probe

8T-8726 Adapter Cable As

163-5443 Adapter Cable As (3-PIN BREAKOUT)

177-2330 Battery Analyzer (DIGITAL)

190-8900 Connector Repair Kit

225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)

391-8170 EMISSIONS ANALYZER TOOL GP (Bluetooth Module)

393-0673 EMISSIONS ANALYZER TOOL GP

Cat Electronic Technician (ET)

Configuration of the ECM

Print various reports

Cat ET can display the following information:

Connecting the Communication Adapter

Part Number Description

N/A Personal Computer (PC)

466-6258 Communication Adapter Gp

317-7492 Radio Kit (NACD only)

349-1206 Radio Kit (EAME only)

Components of the 466-6258 Communication Adapter Gp

317-7485 Communication Adapter (3)

370-4617 Cable As (USB)

457-6114 Cable As (DATA LINK)

Components of the 317-7492 Radio Kit

317-7493 Wireless Communication Radio

317-7496 Computer Cable As

317-7510 Radio Cable Assembly

326-9606 Antenna (2)

Components of the 349-1206 Radio Kit

348-9250 Communication Radio Gp