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RENR5042 C11 C13 Troubleshooting PDF
RENR5042 C11 C13 Troubleshooting PDF
January 2006
Troubleshooting
C11, C13, C15 and C18 Industrial
Engines
JRE1-Up (Engine)
WJH1-Up (Engine)
LGK1-Up (Engine)
GLS1-Up (Engine)
i01658146
CID 0247 FMI 09 J1939 Data Link Cat Data Link Circuit - Test ................................. 101
communications .................................................. 65 Coolant Level Sensor Circuit - Test .................... 104
CID 0253 FMI 02 Personality Module mismatch .. 65 Compression Brake Solenoid Circuit - Test ........ 108
CID 0261 FMI 13 Engine Timing Calibration Diagnostic Lamp Circuit - Test ............................. 117
required ............................................................... 65 Digital Sensor Supply Circuit - Test .................... 121
CID 0262 FMI 03 5 Volt Sensor DC Power Supply ECM/Personality Module - Test .......................... 125
short to +batt ....................................................... 66 Electrical Connectors - Inspect ........................... 127
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Electrical Power Supply Circuit - Test ................. 132
short to ground .................................................... 66 Engine Pressure Sensor Open or Short Circuit -
CID 0268 FMI 02 Check Programmable Test ................................................................... 136
Parameters ......................................................... 66 Engine Speed/Timing Sensor Circuit - Test ........ 141
CID 0274 FMI 03 Atmospheric Pressure open/short Engine Temperature Sensor Open or Short Circuit -
to +batt ................................................................ 67 Test ................................................................... 147
CID 0274 FMI 04 Atmospheric Pressure short to Ether Injection System - Test .............................. 154
ground ................................................................. 67 Injector Solenoid Circuit - Test ............................ 160
CID 0342 FMI 08 Secondary Engine Speed signal Maintenance Due Lamp Circuit - Test ................. 168
abnormal ............................................................. 67 PTO Switch Circuit - Test .................................... 171
CID 0545 FMI 05 Ether Start Relay open/short to Switch Circuits - Test .......................................... 176
+batt .................................................................... 67 Throttle Position Sensor Circuit - Test ................ 179
CID 0545 FMI 06 Ether Start Relay short to Warning Lamp Circuit - Test ................................ 184
ground ................................................................. 68
CID 0791 FMI 05 Compression Brake Low/High Calibration Procedures
Solenoid current low ........................................... 68 Engine Speed/Timing Sensor - Calibrate ............ 188
CID 0791 FMI 06 Compression Brake Low/High Throttle Position Sensor - Calibrate .................... 191
Solenoid current high .......................................... 68
CID 0792 FMI 05 Compression Brake Medium/High Index Section
Solenoid current low ........................................... 69
CID 0792 FMI 06 Compression Brake Medium/High Index ................................................................... 193
Solenoid current high .......................................... 69
CID 1835 FMI 03 Auxiliary Pressure Sensor
open/short to +batt .............................................. 69
CID 1835 FMI 04 Auxiliary Pressure Sensor short to
ground ................................................................. 69
CID 1836 FMI 03 Auxiliary Temperature Sensor
open/short to +batt .............................................. 70
CID 1836 FMI 04 Auxiliary Temperature Sensor short
to ground ............................................................. 70
CID 2417 FMI 05 Ether Injection Control Solenoid
current low .......................................................... 70
CID 2417 FMI 06 Ether Injection Control Solenoid
current high ......................................................... 70
• Information access
• System diagnostics
• System calibrations
• System configurations
• Data link communications
8T-5319 Connector Tool Group Standard Hardware for the Use of Cat ET
• Parameters
• Event codes
• Diagnostic codes
• Engine configuration
Cat ET can be used by the technician to perform the
following functions:
• Diagnostic tests
• Calibrations
• Flash programming
• ECM configuration
Table 3 lists the software that is required in order to
use Cat ET. Illustration 1
g01178796
JERD2124 Single user license for Cat ET Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
Data Subscription for All Engines and
JERD2129
Machines Use the following procedure in order to connect Cat
ET and the Communication Adapter II.
i02139021
Note: Verify that the fuel lines are installed correctly. • Diagnostic
The fuel lines must not put tension on the ECM.
Rubber grommets are used to protect the ECM from • Event
excessive vibration. The ECM should move slightly in
the rubber grommets. If the ECM cannot be moved Diagnostic Code – When a problem with the
slightly, check that the fuel lines are not pulling the electronic system is detected, the ECM generates a
ECM against one side of the grommets. diagnostic code. This indicates the specific problem
with the circuitry.
c. Connect the ECM ground strap.
Diagnostic codes can have two different states:
d. Connect the P1 and P2 connectors. Tighten
the ECM connector (allen head screw) to the • Active
proper torque. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors - • Logged
Inspect” for the correct torque value.
Active Code
4. Configure the replacement ECM:
An active diagnostic code indicates that an active
a. Flash program the flash file into the ECM. Refer problem has been detected. Active codes require
to programming parameters Troubleshooting, immediate attention. Always service active codes
“Flash Programming”. prior to servicing logged codes.
Self-Diagnostics Connectors
SMCS Code: 1901
SMCS Code: 1900-NS; 7553-WW
The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
There are two types of codes:
RENR5042-03 11
Troubleshooting Section
g01215053
Illustration 3
12 RENR5042-03
Troubleshooting Section
g01099946
Illustration 4
Locations of the sensors on C11 and C13 engines
(1) Engine coolant temperature sensor (4) Fuel pressure sensor (7) Fuel temperature sensor
(2) Atmospheric pressure sensor (5) Engine oil pressure sensor (8) Intake manifold air temperature sensor
(3) Secondary engine speed/timing sensor (6) Boost pressure sensor (9) Primary engine speed/timing sensor
RENR5042-03 13
Troubleshooting Section
g01099949
Illustration 5
Locations of the sensors on C15 and C18 engines
(1) Engine coolant temperature sensor (4) Fuel pressure sensor (7) Engine oil pressure sensor
(2) Secondary engine speed/timing sensor (5) Fuel temperature sensor (8) Atmospheric pressure sensor
(3) Boost pressure sensor (6) Intake manifold air temperature sensor (9) Primary engine speed/timing sensor
i02469003 Table 6
Table 7
Metric Equivalents for AWG Numbers
AWG Diameter AWG Diameter
Number (mm) Number (mm)
20 0.8 14 1.6
g01143634
18 1.0 12 2.0 Illustration 6
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.
2. When the “Factory Password” screen appears, Since factory passwords contain alphabetic
record the information that is listed on the “Factory characters, the Caterpillar Electronic Technician (ET)
Passwords Worksheet”. Refer to programming must be used to perform these functions. In order to
parameters Troubleshooting, “Factory Passwords obtain factory passwords, proceed as if you already
Worksheet” for additional information. have the password. If factory passwords are needed,
Cat ET will request the factory passwords and Cat ET
3. Obtain the factory passwords. The information will display the information that is required to obtain
that is recorded on the “Factory Passwords the passwords. For the worksheet that is used for
Worksheet” must be provided. When you obtain acquiring factory passwords, refer to programming
the factory passwords, a permanent record of your parameters Troubleshooting, “Factory Passwords
access is generated at Caterpillar. Worksheet”.
Information From the Vehicle Odometer 3. Program the flash file into the ECM.
Engine’s Miles (km)
a. Select the engine ECM under the “Detected
Information From the “Factory Password Entry ECMs”.
Screen” on the Caterpillar Electronic Technician (ET)
Electronic Service Tool b. Press the “Browse” button in order to select the
Serial Number name of the flash file that will be programmed
into the ECM.
Engine Serial Number
ECM Serial Number c. When the correct flash file is selected, press
the “Open” button.
Total Tattletale
Reason Code d. Verify that the “File Values” match the
application. If the “File Values” do not match
From Interlock(1) the application, obtain the correct flash file.
To Interlock(1)
e. When the correct flash file is selected, press
Factory Passwords the “Begin Flash” button.
Factory Password (No. 1)
f. Cat ET will indicate when flash programming
Factory Password (No. 2) has been successfully completed.
(1) This parameter is required when the engine is being rerated.
This parameter is displayed only when the engine is being 4. Start the engine and check for proper operation.
rerated. Repair any active diagnostic or event codes.
Exchanging injectors can help determine if a After verifying the correct repair has been performed
combustion problem is in the injector or in the on the engine, it is critical to provide brief, detailed
cylinder. If two injectors that are currently installed information. This information helps Caterpillar better
in the engine are exchanged between cylinders, serve you and the customer.
the injector trim files can also be exchanged. Press
the “Exchange” button at the bottom of the “Injector Recommendations
Trim Calibration” screen on Cat ET. Select the two
injectors that will be exchanged and press the “OK” Customer’s Complaint
button. The tattletale for the injectors that were
exchanged will increase by one. Obtain as much information from the customer
as possible. Investigate any written information
Note: The injector serial number and the injector that is available and document any information
confirmation code are located on the injector. that is gathered from the customer. The following
information is of particular importance:
1. Record the injector serial number and the injector
confirmation code for each injector.
• Indicate if the diagnostic lamp was flashing.
2. Click on “Service Software Files” in SIS Web.
• Indicate if the warning lamp was flashing, or if the
lamp was on continuously.
3. Enter the serial number for the injector in the
search field.
• Indicate the symptoms of engine operation that are
present.
4. Download the injector trim file to the PC. Repeat
this procedure for each injector, as required. Be as specific as possible.
5. Connect Cat ET to the service tool connector. Refer
to electronic troubleshooting Troubleshooting, Cause of Failure
“Electronic Service Tools”.
Comments on the cause of failure should include
6. Select the following menu options on Cat ET: 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
• Service indicate the method that was used to discover the
problem. Examples of the methods that were used to
• Calibrations discover the problem could be one of the following
methods:
• Injector Trim Calibration
7. Select the appropriate cylinder. • A specific procedure in the manual was followed.
18 RENR5042-03
Troubleshooting Section
Be as specific as possible.
Repair Procedure
Comments on the repair procedure should include
the following types of information:
Be as specific as possible.
RENR5042-03 19
Troubleshooting Section
System Configuration
Parameters
SMCS Code: 1901
Parameter Descriptions
“Equipment ID” g00763900
Illustration 7
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM) “TEL” is a customer programmable parameter that
in order to identify the machine. A maximum of defines the maximum allowable engine speed for
17 characters may be entered in the field. This maximum power. “TEL” can be programmed up to
parameter is only for reference by the customer. This the maximum rated engine speed. “TEL” is defined
parameter is not required. along the engine’s lug curve.
Program the “Engine Serial Number” to match the “Engine Accel. Rate” determines the rate of change
engine serial number that is stamped on the engine of the engine speed (acceleration or deceleration)
information plate. If the ECM is replaced, the engine during PTO operation. This rate of change is also
serial number from the engine information plate must used to achieve intermediate engine speed.
be programmed into the new ECM.
“Low Idle Speed”
Note: When you are requesting factory passwords,
always use the engine serial number that is “Low Idle Speed” is the minimum allowable operating
programmed in the ECM. speed for the engine. This parameter can be
programmed between 600 and 1400 rpm.
“Rating Number”
“PTO Mode”
The “Rating Number” corresponds to the selected
set of performance maps for the application. This “PTO Mode” allows the ECM to be programmed to
selected set of performance maps comes out of either one of the two PTO configurations that are
several unique sets of maps that are resident in the available.
flash file. The dealer and/or the OEM will need to
select the appropriate rating tier, if more than one “Ramp Up/Ramp Down” – When “PTO Mode” is
rating tier is present. The rating tiers are A through E. programmed to “Ramp Up/Ramp Down”, the ECM
allows PTO operation with traditional features.
Note: Factory passwords are required in order to
change the “Rating Number”. “Set/Resume” – When “PTO Mode” is programmed
to “Set/Resume”, the ECM allows PTO operation with
enhanced features.
20 RENR5042-03
Troubleshooting Section
g00763900 g00817759
Illustration 8 Illustration 9
“High Idle Speed” is the maximum no-load engine “Engine Torque Limit” can be used to limit torque
speed when the throttle or the PTO switch is in the output to the programmed value when the torque
maximum position. limit switch is activated.
Note: “High Idle Speed” cannot be programmed “FLS” (Full Load Setting)
lower than “TEL”.
“FLS” is a number that represents the adjustment to
“Intermediate Engine Speed” the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for
“Intermediate Engine Speed” defines the speed this parameter is stamped on the engine information
for the engine when the intermediate engine plate. Factory passwords are required in order to
speed switch is activated. This parameter can be change this parameter.
programmed to any engine speed between “Low Idle
Speed” and “TEL”. Engine speed will increase or “FTS” (Full Torque Setting)
engine speed will decrease at the rate that is defined
by the programmed value for “Engine Accel. Rate”. “FTS” is similar to “FLS”. Factory passwords are
required in order to change this parameter.
“Engine Power Trim”
“Ether Control”
This parameter cannot be changed.
Program the “Ether Control” to “Enabled” if an
ether injection system is installed on the engine.
This allows the ECM to control ether injection. If
the engine is not equipped with ether, program this
parameter to “Disabled”.
“Air Shutoff”
“Air Shutoff” allows the ECM to be programmed for
operation of an air shutoff system. If this parameter
is programmed to “Installed”, the ECM will activate
the air shutoff solenoid in the event of an engine
overspeed condition.
RENR5042-03 21
Troubleshooting Section
Note: If an engine overspeed condition occurs “Aux Temp Sensor Installation Status”
and “Air Shutoff” is programmed to “Enabled”, the
switched power to the ECM must be cycled and the Program “Aux Temp Enable” to “Installed” if an
air shutoff solenoid must be manually reset before auxiliary temperature sensor is installed. This will
the engine will restart. allow the Caterpillar Messenger Driver Information
Display to monitor the temperature of another
“Maintenance Indicator Mode” system. Program this parameter to “Not Installed” if
an auxiliary temperature sensor is not installed.
The ECM records data that is related to equipment
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is
due. The maintenance indicator lamp can be reset
by actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.
“PM1 Interval”
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator Mode”
is programmed to one of the manual options. Refer
to the engine’s Operation and Maintenance Manual
for more information.
(Table 9, contd)
System Configuration Parameters
Required
Parameter Available Range or Options Default
Password
“Installed”
“Coolant Level On” “Not Installed” None
“Not Installed”
“Installed”
“Direct Fuel Control Mode” “Not Installed” Factory
“Not Installed”
“Last Tool to change Customer
Read Only (1)
Parameters”
“Last Tool to change System
Read Only (1)
Parameters”
“Aux Temp Sensor Installation “On”
“Off” None
Status” “Off”
“Aux Press Sensor Installation “On”
“Off” None
Status” “Off”
“Total Tattletale” Read Only (1)
Monitoring System
The monitoring system determines the level of action
that is taken by the ECM in response to a condition
that can damage the engine. The monitoring of the
various sensors by the ECM can be turned “On” or
“Off”. These conditions are identified by the ECM
from the signals that are produced from the following
sensors:
RENR5042-03 25
Troubleshooting Section
Table 11
Settings for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
Derate On 1 to 54 10
“Low Coolant Level” E2143 Shutdown Off 1 to 54 10 None
Warning On 1 to 54 10
“High Fuel Pressure” E096 Warning On None 8 Maps are not programmable. (1)
Warning
On 8
“Low Engine Oil Pressure” E360 Derate None Maps are not programmable.(1)
Shutdown Off 4
85 °C (185 °F)
110 °C
Warning None 10 to
(230 °F)
110 °C (230 °F)
On
86 °C (187 °F)
“High Engine Coolant
E361 Derate 1 to 54 10 to
Temperature”
111 °C (232 °F) 111 °C
87 °C (189 °F) (232 °F)
Shutdown Off 1 to 54 10 to
111 °C (232 °F)
C11/
C13 1800-2600 2600
Warning
C15
C18 1800-2500 2500
“Engine Overspeed” E362 On None 1
C11/
C13 1800-2800 2800
Shutdown
C15
C18 1800-2700 2700
70 °C (158 °F)
Warning 1 to 54 30 to 90 °C (194 °F)
On 90 °C (194 °F)
“High Fuel Temperature” E363
Derate 1 to 54 10 71 °C (160 °F)
to 91 °C (196 °F)
Shutdown Off 1 to 54 10 91 °C (196 °F)
Warning On 1 to 54 4
0 kPa (0 psi)
1500 kPa
“High Auxiliary Pressure”(2) E443 Derate 1 to 54 3 to
Off (218 psi)
3150 kPa (457 psi)
Shutdown 1 to 54 3
105 °C
Warning On 1 to 54 4
(221 °F)
0 °C (0 °F)
“High Auxiliary 106 °C
E445 Derate 1 to 54 4 to
Temperature”(2) (223 °F)
Off 140 °C (284 °F)
107 °C
Shutdown 1 to 54 4
(224 °F)
The connection of any electrical equipment and Refer to Special Instruction, SEHS7633, “Battery
the disconnection of any electrical equipment may Test Procedure” for the proper testing procedures.
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip- Probable Causes
ment or disconnect any electrical equipment in an
explosive atmosphere. • Worn battery
2. Check the tension on the alternator drive belts. Can Not Reach Top Engine
Adjust the tension, if necessary. RPM
Charging Circuit SMCS Code: 1915-035
Inspect the battery cables, wiring, and connections in Note: If this problem occurs only under load, refer to
the charging circuit. Clean all connections and tighten Troubleshooting, “Low Power/Poor or No Response
all connections. Replace any faulty parts. to Throttle”.
Probable Causes
• Diagnostic codes
• Event codes
RENR5042-03 27
Troubleshooting Section
The engine may be derated due to high exhaust • Service on the low pressure fuel supply circuit
temperature. Connect Cat ET to the service tool
connector. Check for an active engine derate on the • Replacement of unit injectors
status screens.
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel.
28 RENR5042-03
Troubleshooting Section
4. Cold weather adversely affects the characteristics 2. Drain the crankcase and refill the crankcase with
of the fuel. Refer to the Operation and clean engine oil. Install new engine oil filters.
Maintenance Manual for information on improving Refer to the Operation and Maintenance Manual.
the characteristics of the fuel during cold weather
operation. Cylinder Head Gasket
5. Check the fuel pressure during engine cranking. 1. Remove the cylinder head. Refer to the
Check the fuel pressure on the outlet side of Disassembly and Assembly manual.
the fuel filter. Refer to Specifications for correct
pressure values. If the fuel pressure is low, 2. Check the cylinder liner projection. Refer to the
replace the fuel filters. If the fuel pressure is still Systems Operation/Testing and Adjusting manual.
low, check the following items: fuel transfer pump,
fuel transfer pump coupling, and fuel pressure 3. Install a new cylinder head gasket and new water
regulating valve. seals in the spacer plate. Refer to the Disassembly
and Assembly manual.
Air Inlet and Exhaust System
Cylinder Head
1. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance Check for cracks in the cylinder head. If a crack
Manual. is found, repair the cylinder head and/or replace
the cylinder head. Refer to the Disassembly and
2. Check the air inlet and exhaust system for Assembly manual.
restrictions and/or leaks. Refer to Testing and
Adjusting, “Air Inlet and Exhaust System”.
Cylinder Liner
Accessory Equipment Check for cracked cylinder liners. Replace any
cracked cylinder liners. Refer to the Disassembly and
Check all accessory equipment for problems that Assembly manual.
may create excessive load on the engine. Repair
any damaged components or replace any damaged
components.
Cylinder Block
Inspect the cylinder block for cracks. If a crack is
i02381103 found, repair the cylinder block or replace the cylinder
block.
Coolant in Engine Oil
SMCS Code: 1348-035; 1395-035 i02194394
Recommended Actions
Engine Oil Cooler Core
1. Check for leaks in the oil cooler core. If a leak is
found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
RENR5042-03 29
Troubleshooting Section
One of the following items may not be recorded 2. Connect the electronic service tool to the
correctly on the Caterpillar Electronic Technician service tool connector. If the ECM does not
(ET): communicate with the electronic service tool,
refer to troubleshooting without a diagnostic code
• Passwords Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
• Serial numbers
3. Troubleshoot the Cat Data Link for possible
• Total tattletale problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
• Reason code
4. Troubleshoot the CAN data link (if equipped)
for possible problems. Refer to the diagnostic
Recommended Actions functional test Troubleshooting, “CAN Data Link
Circuit - Test”.
1. Verify that the correct passwords were entered.
Check every character in each password. Remove
the electrical power from the engine for 30 i02429900
seconds and then retry.
Electronic Service Tool Will
2. Verify that Cat ET is on the “Factory Password” Not Communicate with ECM
screen.
SMCS Code: 0785-035; 1901-035
3. Use Cat ET to verify that the following information
has been entered correctly:
Probable Causes
• Engine serial number
• Configuration for the communications adapter
• Serial number for the electronic control module
• Electrical connectors
• Serial number for Cat ET
• Communication adapter and/or cables
• Total tattletale
• Electrical power supply to the service tool
connector
• Reason code
• Caterpillar Electronic Technician (ET) and related
i02480112 hardware
ECM Will Not Communicate • Electrical power supply to the Electronic Control
with Other Systems or Display Module (ECM)
Probable Causes
• Wiring and/or electrical connectors
• Cat Data Link
• CAN data link (if equipped)
30 RENR5042-03
Troubleshooting Section
• Electrical power to the Electronic Control Module 7. Check the fuel pressure during engine cranking.
(ECM) Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, “Fuel
• Starting aids System” for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
• Engine shutdown switches pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
• Air shutoff system fuel pressure regulating valve.
• Starting motor, solenoid, or starting circuit Diagnostic Codes and Event Codes
• Engine speed/timing Certain diagnostic codes and/or event codes may
prevent the engine from starting. Connect the
• Unit injector Caterpillar Electronic Technician (ET) and check for
active codes and/or for logged codes. Troubleshoot
• Combustion any codes that are present before continuing with
this procedure.
Recommended Actions
Electrical Power Supply to the ECM
Fuel Supply
If the ECM is not receiving battery voltage, the ECM
1. Visually check the fuel level. Do not rely on the fuel will not operate. Refer to Troubleshooting, “Electrical
gauge only. If necessary, add fuel. If the engine Power Supply Circuit - Test”.
has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to Starting Aids
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure. If cold ambient conditions exist, check operation of
starting aids. Verify that the ether system is operating
2. Check the fuel lines for the following problems: correctly. Refer to Troubleshooting, “Ether Injection
restrictions, collapsed lines, and pinched lines. If System - Test”.
problems are found with the fuel lines, repair the
lines and/or replace the lines. Engine Shutdown Switches
3. Check the fuel tank for foreign objects which may The engine shutdown switches must be in the RUN
block the fuel supply. position in order to start the engine. Use Cat ET to
verify the status of the shutdown switches. When an
4. Prime the fuel system if any of the following engine shutdown switch is used to shut down the
procedures have been performed: engine, the keyswitch must be turned to the RUN
position for at least 15 seconds before restarting the
• Replacement of the fuel filters engine.
• Service on the low pressure fuel supply circuit Air Shutoff System
• Replacement of unit injectors Check the air shutoff mechanism. If an engine
Note: A sight glass in the low pressure supply line is overspeed has occurred, the keyswitch must be
helpful in diagnosing air in the fuel. Refer to Testing cycled. There may be a manual reset for the air
and Adjusting for more information. shutoff mechanism that is on the engine. Refer to
Troubleshooting, “Air Shutoff System - Test” for
5. Check the fuel filters. information.
6. Cold weather adversely affects the characteristics Starting Motor, Solenoid, or Starting
of the fuel. Refer to the Operation and Circuit
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather Remove the starter and visually inspect the pinion of
operation. the starter and the flywheel ring gear for damage.
• Diagnostic codes Monitor the throttle signal on Cat ET. Verify that the
throttle signal is stable from the low idle position to
• Programmable parameters the high idle position.
5. Check the fuel pressure during engine cranking. 3. Install a new cylinder head gasket and new water
Check the fuel pressure after the fuel filter. Refer seals in the spacer plate. Refer to Disassembly
to Systems Operation/Testing and Adjusting, “Fuel and Assembly, “Cylinder Head - Install” for the
System” for the correct pressure values. If the fuel correct procedure.
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
i02424562
transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve. Engine Oil Temperature Is Too
Air Inlet and Exhaust System High
1. Check for an air filter restriction. Clean plugged air SMCS Code: 1348-035-TA
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual for additional Probable Causes
information.
• Oil specifications
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems • Engine oil temperature reading
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”. • Engine oil cooler bypass valve
i02173692
• High coolant temperature
2. Check the fuel lines for the following problems: Engine Vibration
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the SMCS Code: 1000-035
lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may Probable Causes
block the fuel supply.
• Vibration damper
• Engine supports
36 RENR5042-03
Troubleshooting Section
Hydraulic Cylinder Lock 4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any
Check for fluid in the cylinders (hydraulic cylinder damaged components that were found.
lock) by removing the individual unit injectors.
Engine Speed/Timing
Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when 1. Check the calibration of the engine speed/timing
the unit injector is removed. sensor. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Internal Engine Problem
2. Verify that the crankshaft and the camshaft drive
Disassemble the engine. Refer to the Disassembly gears are set with the proper orientation. Refer to
and Assembly manual. Inspect the internal the Disassembly and Assembly manual.
components for the following conditions:
Atmospheric Pressure Sensor
• Seizure
1. Remove the sensor.
• Broken components
2. Remove debris, moisture, or ice from the sensor.
• Bent components
3. Install the sensor.
i02432467
4. Check the Caterpillar Electronic Technician (ET)
Excessive Black Smoke for active diagnostic codes on the sensor. If no
active diagnostic code exists, the sensor may be
SMCS Code: 1088-035 used. The correct reading for the atmospheric
pressure is between 50 kPa (7.25 psi) and
100 kPa (14.5 psi).
Probable Causes
• Air inlet or exhaust system Boost Pressure Sensor, “Fuel Position”,
and/or “FRC Fuel Limit”
• Engine speed/timing sensor
1. Monitor the status of “Fuel Position” and “Rated
• Atmospheric pressure sensor Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
• Boost pressure sensor and “Fuel Position” is less than “FRC Fuel Limit”,
the Electronic Control Module (ECM) is providing
• “Fuel Position” and/or “FRC Fuel Limit” the correct control. Otherwise, proceed to the next
Step.
• Flash file
2. Verify that there are no active diagnostic codes for
• Fuel quality the boost pressure sensor.
Check the engine compartment for oil leaks. Repair • Accessory equipment
any oil leaks that are identified.
Recommended Actions
Oil Level
Engine Operation
Check the engine oil level. Too much oil in the engine
crankcase can cause the engine to consume oil. Use the Caterpillar Electronic Technician (ET) to
Remove excessive engine oil from the crankcase. check the “Current Totals” for excessive idle time
and/or for a high load factor which would be indicative
Ensure that the dipstick is properly calibrated of poor operating habits.
and/or that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick. Note: Engine operation may also be affected by
environmental conditions such as wind and snow.
Turbocharger
Fuel Leaks
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from Check the fuel pressure during engine cranking.
the turbocharger. Check the compressor wheel and Check the fuel pressure after the fuel filter. Refer
the turbine for evidence of an oil leak. If necessary, to Systems Operation/Testing and Adjusting for the
repair the turbocharger or replace the turbocharger. correct pressure values. If the fuel pressure is low,
Refer to Systems Operation/Testing and Adjusting. replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel
transfer pump coupling, and fuel pressure regulating
valve.
RENR5042-03 39
Troubleshooting Section
Accessory Equipment 3. Adjust the engine valve lash. Refer to the engine’s
Systems Operation/Testing and Adjusting manual.
Check all accessory equipment for problems that
may create excessive load on the engine. Repair i02312564
any damaged components or replace any damaged
components. Excessive White Smoke
SMCS Code: 1088-035
i02424626
Excessive Valve Lash Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
SMCS Code: 1105-035 normally. If the white smoke persists, there may be
a problem.
Probable Causes
Probable Causes
• Lubrication
• Starting aids
• Valve lash
• Water temperature regulators
• Valve train components
40 RENR5042-03
Troubleshooting Section
• Fuel supply 3. Ensure that the fuel system has been primed.
Refer to the engine’s Operation and Maintenance
• Cooling system Manual for the correct procedure.
• Component wear 4. Check for fuel supply lines that are restricted.
Ensure that the air inlet heater is functioning properly. Cooling System
For additional information, refer to Troubleshooting,
Check for an internal coolant leak. Check for coolant
“Air Inlet Heater Circuit - Test”.
in the engine oil, coolant in the cylinders, and
coolant in the exhaust system. Refer to Systems
Ether Injection System (If Equipped)
Operation/Testing and Adjusting, “Cooling System -
Ensure that the ether injection system is programmed Test”.
to “On”.
Component Wear
Ensure that the ether injection system is functioning
properly. For additional information, refer to Check the following components for excessive wear:
Troubleshooting, “Ether Injection System - Test”.
• Valves
Water Temperature Regulators
• Pistons
Check the water temperature regulators for correct
operation. Refer to Systems Operation/Testing and • Rings
Adjusting, “Cooling System” for the proper procedure.
• Cylinder liners
Unit Injectors
i02332993
Use Cat ET to perform the cylinder cutout test. Try
to simulate the conditions for the test that were Exhaust Temperature Is Too
experienced during operation. Cut out each cylinder High
individually for approximately one minute in order
to isolate any misfiring cylinders. If the misfire SMCS Code: 1088-035-TA
can be isolated to a specific cylinder, proceed to
Troubleshooting, “Injector Solenoid Circuit - Test”.
Probable Causes
Flash File • Diagnostic codes
Verify that the correct flash file is installed in the
Engine Control Module (ECM).
• Electrical connectors
• Air inlet and exhaust system
Fuel Supply
1. Monitor the exhaust for smoke while the engine
is being cranked.
Diagnostic Codes
Fuel Dilution of Engine Oil
SMCS Code: 1348-035
Connect the Caterpillar Electronic Technician (ET)
and check for active diagnostic codes. Troubleshoot
any active diagnostic codes before continuing with Probable Causes
this procedure.
• Leaking seals on the case of the unit injector or on
Electrical Connectors the barrel of the unit injector
Check for correct installation of the J2/P2 Electronic • Leaking seals on the fuel line adapter for the
Control Module (ECM) connector and of the cylinder head
J300/P300 connector that is for the injectors. Refer
to Troubleshooting, “Electrical Connectors - Inspect” • Excessive leakage from the unit injector tip or
for more information. breakage of the unit injector tip
SMCS Code: 1350-035 Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
Probable Causes lines or components.
• Internal cylinder head Excessive Leakage from the Unit Injector
Tip or Breakage of the Unit Injector Tip
Recommended Actions
Look for signs of damage to the unit injectors. If
Internal Cylinder Head necessary, repair the unit injectors or replace the unit
injectors.
1. Remove the valve mechanism covers.
Cracked Fuel Supply Manifold
2. Remove the fuel supply and the fuel return line
from the cylinder head. Look for signs of damage to the fuel supply manifold.
3. Cap the fuel return connector and apply 700 kPa
(100 psi) maximum air pressure to the fuel supply Leaking Fuel Transfer Pump Seal
connector. Check for fuel leakage around the unit
injectors. If leakage is present, remove the unit Ensure that the weep hole is not plugged. If
injector and install a new O-ring seal. necessary, repair the fuel transfer pump or replace
the fuel transfer pump.
42 RENR5042-03
Troubleshooting Section
Recommended Actions 1. Access the status screen that displays the remote
shutdown switch status. The remote shutdown
switch status on Cat ET is called “User Shutdown”.
Diagnostic Codes or Event Codes
2. Refer to Table 12. Measure the voltage between
Certain diagnostic codes and/or event codes each terminal that is listed and the engine ground.
may cause the engine to shutdown. Connect the
Caterpillar Electronic Technician (ET) and check for Table 12
active codes and/or for logged codes. Troubleshoot
any codes that are present before continuing with Measured Voltage at
“User Shutdown” Status
J1-44 or P61-27
this procedure.
ON <0.9 VDC
Operating Conditions OFF >10 VDC
Probable Causes 2. Check the fuel tank for foreign objects which may
block the fuel supply.
• Diagnostic codes
NOTICE
• Event codes Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
• Throttle signal minutes before cranking the engine again.
4. Cold weather adversely affects the characteristics Check the operation of oil filter bypass valve. Clean
of the fuel. Refer to the Operation and the bypass valve and the housing. If necessary,
Maintenance Manual for information on improving install new parts.
the characteristics of the fuel during cold weather
operation. Engine Oil Pump
5. Check the fuel pressure after the fuel filter while Check for blockage of the inlet screen for the engine
the engine is being cranked. Refer to Systems oil pump. Check the components of the engine oil
Operation/Testing and Adjusting, “Fuel System pump for excessive wear. If necessary, repair the oil
Pressure - Test” for the correct pressure values. pump or replace the oil pump.
If the fuel pressure is low, replace the fuel filters.
If the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
Oil Cooler
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting, “Fuel Check the engine’s oil cooler for plugging or
blockage. Clean the engine oil cooler core(s) and/or
System” for additional information.
install new engine oil cooler core(s).
Check the service records of the engine for • Derate due to high exhaust temperature
information that is related to the last oil change. If
necessary, perform an oil change on the engine and • Electrical connectors
replace the engine oil filters.
RENR5042-03 45
Troubleshooting Section
Check the following parameters on Cat ET: If the value of the “PTO Enable Switch” parameter
matches the position of the switch, continue with
• Throttle position sensor troubleshooting.
i02477338
Check for signs of damage and/or wear to the valves,
cylinder head gasket, etc. Inspect the condition of
Noise Coming from Cylinder the camshafts.
Unit Injectors
Recommended Actions
3. Perform the cylinder cutout test on Cat ET in order • Replacement of unit injectors
to identify any injectors that might be misfiring.
Note: A sight glass in the low pressure supply line is
Refer to Troubleshooting, “Injector Solenoid
helpful in diagnosing air in the fuel. Refer to Testing
Circuit - Test” for the proper procedure.
and Adjusting for more information.
Fuel Position, Rated Fuel Limit, and FRC 4. Cold weather adversely affects the characteristics
Fuel Position of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
1. Monitor the status of “Fuel Position” and “Rated the characteristics of the fuel during cold weather
Fuel Limit” while the engine is operating under full operation.
load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”, 5. Check the fuel pressure after the fuel filter while
the electronics are operating correctly. Otherwise, the engine is being cranked. Refer to Testing and
proceed to the next Step. Adjusting for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If
2. Verify that there are no active diagnostic codes for the fuel pressure is still low, check the following
the boost pressure sensor. items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting for
more information.
RENR5042-03 49
Troubleshooting Section
i01405939
Probable Causes
• Cracked valve rotator
• Broken spring locks
• Broken valve spring(s)
• Broken valve
Recommended Actions
1. Determine the cause of an engine overspeed that
would crack the valve rotator. Repair the condition.
• Valve rotators
• Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the
piston. If the valve has contacted the piston, check
the exhaust system for debris.
i02432846
Diagnostic Codes
SMCS Code: 1900
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to
the service technician. The Caterpillar Electronic
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that
has Cat ET software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).
Table 13
i02430358 Troubleshooting:
CID 0001 FMI 05 Cylinder #1 Perform the following diagnostic procedure: “Injector
Injector open circuit Solenoid Circuit - Test”
System Response:
• The engine may experience low power.
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
RENR5042-03 55
Troubleshooting Section
• The engine may misfire. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• The engine may experience low power. code has been logged.
Perform the following diagnostic procedure: “Injector • The engine may misfire.
Solenoid Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02430362
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
• The engine may misfire. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• The engine may experience low power. code has been logged.
Perform the following diagnostic procedure: “Injector • The engine may misfire.
Solenoid Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02430363
i02430366 Troubleshooting:
CID 0003 FMI 06 Cylinder #3 Perform the following diagnostic procedure: “Injector
Injector short Solenoid Circuit - Test”
The ECM will log the diagnostic code. The ECM will CID 0006 FMI 05 Cylinder #6
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• The engine may misfire.
The Electronic Control Module (ECM) is attempting
• The engine may experience low power. to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
The ECM will log the diagnostic code. The ECM will CID 0006 FMI 06 Cylinder #6
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• The engine may misfire.
The Electronic Control Module (ECM) is attempting to
• The engine may experience low power. operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
Perform the following diagnostic procedure: “Injector The Electronic Control Module (ECM) will log the
Solenoid Circuit - Test” diagnostic code. The diagnostic code may be viewed
on a display module or on Caterpillar Electronic
Results: Technician (ET). The ECM flags all digital sensors
as invalid data and all digital sensors are set to the
• OK – STOP. respective default values.
• The engine may experience low power. Conditions Which Generate This Code:
CID 0041 FMI 04 8 Volt DC • The engine speed is limited to low idle.
Supply short to ground Troubleshooting:
i02426246 i02424763
Conditions Which Generate This Code: Conditions Which Generate This Code:
The duty cycle of the signal from the throttle that is The Electronic Control Module (ECM) reads signal
connected to the primary throttle input is incorrect. voltage that is below normal.
The Electronic Control Module (ECM) will log the The ECM will log the diagnostic code. The ECM flags
diagnostic code. The ECM flags the throttle position fuel pressure as invalid data and a default value is
as invalid data and a default value of zero percent used.
is used.
Possible Performance Effect:
Possible Performance Effect:
• There are no performance effects.
• The engine speed is limited to low idle.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure: “Throttle Pressure Sensor Open or Short Circuit - Test”
Position Sensor - Calibrate”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02416374
Results: • OK – STOP.
• OK – STOP.
60 RENR5042-03
Troubleshooting Section
Conditions Which Generate This Code: The Electronic Control Module (ECM) will log the
diagnostic code. The ECM will flag the boost pressure
This code indicates that the 5 volt supply is missing as invalid data and a default value is used.
from the sensor connector.
Possible Performance Effect:
During normal engine operation, the oil pressure
fluctuates slightly. When the 5 volt supply is missing • The engine may experience low power.
from the oil pressure sensor, the signal from the
oil pressure sensor goes to a midrange value. The Troubleshooting:
signal does not fluctuate. If the signal from the oil
pressure sensor remains abnormally steady for more Perform the following diagnostic procedure: “Engine
than 30 seconds, the Engine Control Module (ECM) Pressure Sensor Open or Short Circuit - Test”
activates this code.
Results:
System Response:
• OK – STOP.
A snapshot is triggered. The ECM uses a default
value for the oil pressure.
RENR5042-03 61
Troubleshooting Section
The signal voltage from the boost pressure sensor is Expected Result:
below normal.
The problem is resolved.
System Response:
Results:
The Electronic Control Module (ECM) will log the
diagnostic code. The ECM will flag the boost pressure • OK – The problem is resolved. STOP.
as invalid data and a default value is used.
• Not OK – The problem is not resolved.
Possible Performance Effect:
Repair: Replace the sensor.
• The engine may experience low power.
STOP.
Troubleshooting:
i02427678 Troubleshooting:
CID 0110 FMI 04 Engine Perform the following diagnostic procedure: “Coolant
Coolant Temperature short to Level Sensor Circuit - Test”
ground Results:
• The engine may experience reduced speed (rpm) • For 24 Volt systems, the ECM reads battery
and/or low power. voltage that is above 32 VDC.
i02480853
• There are no performance effects.
• The contacts for the starting motor solenoid may System Response:
be chatter during cranking. This can damage the
contacts. The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags engine coolant
Troubleshooting: temperature as invalid data and a default value of
40 °C (104 °F) is used.
Perform the following diagnostic procedure:
“Electrical Power Supply Circuit - Test” Possible Performance Effect:
Results: None
• OK – STOP. Troubleshooting:
Results:
i02416427
i02416432 Troubleshooting:
CID 0174 FMI 04 Fuel Perform the following diagnostic procedure: “Engine
Temperature short to ground Speed/Timing Sensor Circuit - Test”
System Response:
i02441856 B. Verify that the part number for the flash file agrees
with the latest update that is available on Service
CID 0247 FMI 09 J1939 Data Technician Workbench (STW), or on SIS Web.
Link communications
Expected Result:
SMCS Code: 1901-038
The correct flash file is installed in the ECM.
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) has detected a
loss of communications with the J1939 data link. • OK – The correct flash file is installed in the ECM.
System Response: Repair: The engine will not start until the 253-02
diagnostic code is cleared. Clearing this code
The ECM will log the diagnostic code. requires factory passwords.
i02428636
i02348802
CID 0253 FMI 02 Personality
CID 0261 FMI 13 Engine Timing
Module mismatch
Calibration required
SMCS Code: 1902-038
SMCS Code: 1912-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The flash file that is used for replacement is for
a different engine family or for a different engine The timing has not been calibrated since the
application. Electronic Control Module (ECM) was installed or the
calibration is incorrect.
System Response:
System Response:
Caterpillar Electronic Technician (ET) will not be able
to clear the code. The ECM will log the diagnostic code.
• The fuel injection system is disabled and the Possible Performance Effect:
engine will not start.
• Engine misfires
Troubleshooting:
• Low power
Check the Part Number of the Flash File
• Reduced engine speed
A. Restore the electrical power to the Electronic
Control Module (ECM). • White exhaust smoke
• Increased exhaust emissions
66 RENR5042-03
Troubleshooting Section
Perform the following diagnostic procedure: “Engine The code is logged. The check engine lamp will
Speed/Timing Sensor - Calibrate” illuminate while this diagnostic code is active. The
ECM sets all of the pressure sensors to the default
Results: value.
i02416460
• The engine power is derated.
i02281091 i02286859
Conditions Which Generate This Code: Conditions Which Generate This Code:
The signal voltage from the atmospheric pressure The Electronic Control Module (ECM) detects the
sensor is above 4.8 VDC for at least eight seconds. following conditions:
Possible Performance Effect: The ECM will log the diagnostic code. The ECM flags
the secondary engine speed signal as invalid data
Low power and a default value of zero rpm is used.
System Response:
CID 0545 FMI 05 Ether Start
Relay open/short to +batt
The Electronic Control Module (ECM) will log
the diagnostic code. The ECM flags atmospheric SMCS Code: 4493-038
pressure as invalid data and a default value is used.
Conditions Which Generate This Code:
Possible Performance Effect:
The Electronic Control Module (ECM) is attempting to
• The engine may experience low power. energize the ether relay. The ECM detects an open
circuit in the circuit for the ether relay.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” The ECM will log the diagnostic code.
Perform the following diagnostic procedure: “Ether The ECM will log the diagnostic code.
Injection System - Test”
Possible Performance Effect:
Results:
The engine retarder may not activate.
• OK – STOP.
Troubleshooting:
i02179467
Perform the following diagnostic procedure:
CID 0545 FMI 06 Ether Start “Compression Brake Solenoid Circuit - Test”
CID 0791 FMI 05 Compression The engine retarder may not activate.
i02432881 Troubleshooting:
CID 0792 FMI 05 Compression Perform the following diagnostic procedure:
Brake Medium/High Solenoid “Compression Brake Solenoid Circuit - Test”
The engine retarder may not activate. The ECM logs the diagnostic code. The value of the
auxiliary pressure is set to a default value.
Troubleshooting:
Possible Performance Effect:
Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test” • There are no performance effects.
Results: Troubleshooting:
The Electronic Control Module (ECM) detects a short Conditions Which Generate This Code:
to ground condition for the medium/high solenoid
during an attempt to activate the compression brake. The Electronic Control Module (ECM) detects a
signal voltage from the auxiliary pressure sensor that
System Response: is below normal.
Possible Performance Effect: The ECM logs the diagnostic code. The value of the
auxiliary pressure is set to a default value.
The engine retarder may not activate.
70 RENR5042-03
Troubleshooting Section
• There are no performance effects. The ECM logs the diagnostic code. The value of the
auxiliary temperature is set to a default value.
Troubleshooting:
Possible Performance Effect:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” • There are no performance effects.
Results: Troubleshooting:
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects
signal voltage from the auxiliary temperature sensor excessive current flow in the circuit.
that is below normal.
RENR5042-03 71
Troubleshooting Section
System Response:
Results:
• OK – STOP.
72 RENR5042-03
Troubleshooting Section
Troubleshooting with an
Event Code
i02290980
Event Codes
SMCS Code: 1901
g01138880
Illustration 11
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.
In the second format, the “E” means that the code is Always clear logged event codes after investigating
an event code. The “XXX-X” represents a numeric and correcting the problem which generated the
identifier for the event code. The fourth “X” identifies code.
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the Troubleshooting
following example:
For basic troubleshooting of the engine, perform the
• E360-1 Low Oil Pressure Warning following steps in order to diagnose a malfunction:
• E360-2 Low Oil Pressure Derate 1. Obtain the following information about the
complaint:
• E360-3 Low Oil Pressure Shutdown
The definition for a warning, a derate, and a shutdown • The event and the time of the event
are defined below:
• Determine the conditions for the event. The
conditions will include the engine rpm and the
Warning – This condition represents a serious load.
problem with engine operation. However, this
condition does not require a derate or a shutdown.
• Determine if there are any systems that were
installed by the dealer or by the customer that
Derate – For this condition, the ECM reduces the
could cause the event.
engine’s power in order to help prevent possible
engine damage.
• Determine whether any additional events
occurred.
Shutdown – For this condition, the ECM shuts down
the engine in order to help prevent possible engine 2. Verify that the complaint is not due to normal
damage.
engine operation. Verify that the complaint is not
due to error of the operator.
Logged Event Codes
3. Narrow the probable cause. Consider the operator
When the ECM generates an event code the ECM information, the conditions of operation, and the
logs the code in permanent memory. The ECM has history of the engine.
an internal diagnostic clock. The ECM will record
the following information when an event code is 4. Perform a visual inspection. Inspect the following
generated: items:
Table 14
Warning
On 8
Low Engine Oil Pressure E360 Derate None Maps are not programmable. (1)
Shutdown Off 4
85 °C (185 °F)
110 °C
Warning None 10 to
(230 °F)
110 °C (230 °F)
On
86 °C (187 °F)
High Engine Coolant
E361 Derate 1 to 54 10 to
Temperature
111 °C (232 °F) 111 °C
87 °C (189 °F) (232 °F)
Shutdown Off 1 to 54 10 to
111 °C (232 °F)
C11/
C13 1800-2600 2600
Warning
C15
C18 1800-2500 2500
Engine Overspeed E362 On None 1
C11/
C13 1800-2800 2800
Shutdown
C15
C18 1800-2700 2700
(continued)
RENR5042-03 75
Troubleshooting Section
System Response: B. After allowing the engine to cool, check the coolant
level. Refer to the Operation and Maintenance
The Electronic Control Module (ECM) will log the Manual.
event.
Expected Result:
Possible Performance Effect:
The coolant level is low.
• Engine power is reduced.
Results:
Troubleshooting:
• OK – The coolant level is low.
• The coolant level is most likely low.
Repair: Check the cooling system for leaks. Repair
• Air may be trapped in the cooling system. any problems that are found. Refill the cooling
system to the proper level.
• There may be a problem with the coolant level
sensor. STOP.
76 RENR5042-03
Troubleshooting Section
• Not OK – The coolant level is not low. Check the Coolant Level
Repair: There may be air in the cooling system.
For information on checking the cooling system,
refer to the engine’s Systems Operation/Testing Pressurized System: Hot coolant can cause seri-
and Adjusting manual. ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
Ensure that any repairs eliminate the problem. components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
STOP. sure.
• Not OK – The coolant level is not low.
A. Stop the engine.
Repair: There may be a problem with the coolant
level sensor. Refer to the diagnostic functional test B. After allowing the engine to cool, check the coolant
Troubleshooting, “Coolant Level Sensor Circuit - level. Refer to the Operation and Maintenance
Test”. Manual for the proper procedure.
Results:
i02435668
Conditions Which Generate This Code: Ensure that any repairs eliminate the problem.
Possible Performance Effect: Ensure that any repairs eliminate the problem.
Troubleshooting: i02473288
• The coolant level is most likely low. E096 High Fuel Pressure
• Air may be trapped in the cooling system. SMCS Code: 1250-038-HQ
• There may be a problem with the coolant level Conditions Which Generate This Code:
sensor.
The Electronic Control Module (ECM) detects a
Check the Coolant Level problem with the engine’s fuel pressure. Information
on default settings and ranges for this event code
can be found in Troubleshooting, “Event Codes”.
The coolant level is low. B. Check the return line from the check valve to the
fuel tank for damage or collapse.
Results:
Results:
• OK – The coolant level is low.
• OK – A problem was found in either the check
Repair: Check the cooling system for leaks. Repair valve or in the return line to the fuel tank.
any problems that are found. Refill the cooling
system to the proper level. Repair: Replace all suspect parts.
STOP. STOP.
78 RENR5042-03
Troubleshooting Section
i02274316 C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This
E360 Low Engine Oil Pressure restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
SMCS Code: 1348-038-LP the oil pickup tube and remove any material that
may be restricting engine oil flow. Low engine oil
Conditions Which Generate This Code: pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
The Electronic Control Module (ECM) detects a oil pickup tube for cracks or a damaged O-ring
problem with the engine’s oil pressure. Information seal.
on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”. D. If the engine oil bypass valves are held in the
open position, a reduction in the oil pressure can
System Response: be the result. This may be due to debris in the
engine oil. If the engine oil bypass valves are
The event code will be logged. stuck in the open position, remove each engine
oil bypass valve and clean each bypass valve in
Possible Performance Effect: order to correct this problem. You must also clean
each bypass valve bore.
E360-1 (Warning)
E. Engine oil that is contaminated with fuel or coolant
None will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of
E360-2 (Derate) contamination.
The engine power will be derated. F. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the engine
E360-3 (Shutdown) components for excessive bearing clearance.
The engine will shut down. G. An oil line that is open, broken, or disconnected
will cause low engine oil pressure.
Troubleshooting:
Expected Result:
There may be a problem with the engine’s lubrication
system. An inspection of the engine’s lubrication system
indicated a problem.
Check the Engine’s Lubrication System
Results:
A. Check the engine oil level. If the oil level is below
the oil pump’s supply tube, the oil pump will not • OK – There is a problem in the engine’s lubrication
have the ability to supply enough lubrication to system.
the engine components. If the engine oil level is
low, add engine oil in order to obtain the correct Repair: Repair the problem. Ensure that the repair
engine oil level. eliminates the problem.
B. Check the following problems that may occur to STOP.
the engine oil pump:
c. If the engine is equipped with a scavenge The Electronic Control Module (ECM) detects a
pump, the scavenge pump may not be problem with the engine’s cooling system. Information
supplying oil to the main engine oil pump. on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”.
RENR5042-03 79
Troubleshooting Section
• There are no performance effects. G. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
E361-2 (Derate) common causes of air in the cooling system are
the incorrect filling of the cooling system and
• The engine power will be derated. combustion gas leakage into the cooling system.
Combustion gas can get into the system through
E361-3 (Shutdown) inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket.
• The operator is alerted to shut down the engine as
soon as possible in order to avoid engine damage. H. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen.
Troubleshooting: Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
There may be a problem with the engine’s cooling kinked or crushed during operation. These areas
system. of the hose can restrict the coolant flow. Hoses
become soft and/or get cracks after a period of
Check the Engine’s Cooling System time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
A. Verify that the cooling system is filled to the proper flow.
level. If the coolant level is too low, air will get into
the cooling system. Air in the cooling system will I. If the cooling system for this application is
cause a reduction in coolant flow. equipped with an expansion tank, check the shunt
line for the expansion tank. The shunt line must be
B. Check the radiator or the heat exchanger for a submerged in the expansion tank. A restriction of
restriction to coolant flow. the shunt line from the expansion tank to the inlet
of the jacket water pump will cause a reduction in
a. Check for debris or damage between the fins water pump efficiency. A reduction in water pump
of the radiator core. Debris between the fins of efficiency will result in low coolant flow.
the radiator core restricts air flow through the
radiator core. J. If the cooling system for this application
is equipped with an aftercooler, check the
b. Check internally for debris, dirt, or deposits on aftercooler. A restriction of air flow through the air
the radiator core. Debris, dirt, or deposits will to air aftercooler can cause overheating. Check
restrict the flow of coolant through the radiator. for debris or deposits which would prevent the free
flow of air through the aftercooler.
C. Check the mixture of antifreeze and water.
Make sure that the coolant mixture meets K. Check for a restriction in the air inlet system. A
recommendations. restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
D. Check the water temperature regulator. A water cylinder temperatures cause higher than normal
temperature regulator that does not open, or a temperatures in the cooling system.
water temperature regulator that only opens part
of the way can cause overheating. L. Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the
E. Check the water pump. A water pump with a engine can cause high cylinder temperatures.
damaged impeller does not pump enough coolant.
Remove the water pump and check for damage M. Consider high ambient temperatures. When
to the impeller. ambient temperatures are too high for the rating
of the cooling system, there is not enough of a
temperature difference between the ambient air
and coolant temperatures.
80 RENR5042-03
Troubleshooting Section
None
Check the Fuel System
Expected Result:
None
A thorough inspection of the fuel system revealed
E362-3 (Shutdown)
a problem.
The engine will be shut down.
Results:
• High ambient air temperature Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the
• High inlet air restriction and/or high altitude engine can cause high cylinder temperatures.
• Faulty inlet air temperature sensor and/or circuit A problem has been found in the inlet air system
and/or the related engine systems.
Perform the following Inspections
Results:
A. Check for High Ambient Air Temperature
• OK – A thorough inspection revealed a problem.
a. Determine if the ambient air temperature is
within the design specifications for the inlet Repair: Repair the problem.
air system. When ambient temperatures
are too high for the rating of the inlet air STOP.
system, there is not enough of a temperature
difference between the ambient air and inlet • Not OK – A thorough inspection did not reveal a
air temperatures. problem.
b. Determine the cause of the high inlet air Repair: Connect Caterpillar Electronic Technician
temperature. Correct the situation, when (ET) to the service tool connector. Check Cat ET
possible. for active/logged diagnostic codes related for the
inlet air system. If an active/logged code is found,
B. Check for High Inlet Air Restriction and/or refer to the appropriate troubleshooting procedure.
High Altitude Operation
STOP.
When inlet air pressure is low, the turbocharger
works harder in order to achieve the desired
inlet manifold pressure. This increases inlet air
temperature.
Diagnostic Functional
Tests
i02432893
g01215526
Illustration 12
Schematic for the 5 volt supply
g01121143
Illustration 13
Left side view
(1) Boost pressure sensor
(2) Atmospheric pressure sensor
(3) J2/P2 connectors
(4) J1/P1 connectors
(5) Engine oil pressure sensor
86 RENR5042-03
Troubleshooting Section
g01121144
Illustration 14
The location of the fuel pressure sensor depends on the engine’s
configuration.
(6) Fuel pressure sensor
g01123205
Illustration 15
P2 terminals that are associated with the 5 volt supply for the
pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
RENR5042-03 87
Troubleshooting Section
g01123208
Illustration 17
J61/P61 terminals that are associated with the 5 volt supply for the
pressure sensors
(14) +5 VDC
(15) Return
g01123207
Illustration 16
P1 terminals that are associated with the 5 volt supply for the
pressure sensors
(P1-2) +5 VDC
(P1-3) Return
g01123211
Illustration 18
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
E. Check the allen head screw on the customer • Active 04 code – An 04 diagnostic code is active.
connector for the proper torque. Refer to Proceed to Test Step 4.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. • Active 10 code – A 10 diagnostic code is active.
Proceed to Test Step 3.
F. Check the harness and the wiring for abrasion
and for pinch points from each sensor back to the • No active codes – None of the above codes are
ECM. active.
C. Observe the “Active Diagnostic” screen on Cat ET. C. Turn the keyswitch to the ON position.
Wait at least 15 seconds so that any codes may
become active. Look for these codes: Note: Be sure to wiggle the harness during the
following measurements in order to reveal an
• 262-03 intermittent condition.
Repair: Connect all of the sensor connectors. • Not OK – The 262-04 diagnostic code remains
Clear all diagnostic codes. Check for active after all of the sensors are disconnected. Leave
diagnostic codes. If the problem is intermittent, the sensors disconnected. Proceed to Test Step 5.
refer to Troubleshooting, “Electrical Connectors
- Inspect”. Test Step 5. Check the +5 V Supply Wire
for a Short to Engine Ground or a Short
STOP. Circuit
• Yes – The voltage measurement is 5.0 ± 0.2 A. Turn the keyswitch to the OFF position.
VDC. The 5 volt supply is present at the harness
connector for the suspect sensor. However, there B. Disconnect the J2/P2 ECM connector. Disconnect
is an active 10 diagnostic code. the J1/P1 ECM connector.
Repair: Replace the suspect sensor. C. Verify that all of the pressure sensors are
disconnected.
Verify that the problem is resolved.
Note: Wiggle the harness during the following
STOP. measurements in order to reveal an intermittent
condition.
• Not OK – At least one voltage measurement is not
5.0 ± 0.2 VDC. There is a problem with the wiring D. Measure the resistance between terminal P2-72
or with the ECM. Proceed to Test Step 5. (+5 V Supply) and all of the other terminals on the
P2 connector.
Test Step 4. Disconnect the +5 V Pressure
Sensors and Check for Active Diagnostic E. Measure the resistance between terminal P2-72
Codes and the engine ground.
A. Disconnect the following sensors one at a time: F. Measure the resistance between terminal P2-80
(+5 V Supply) and all of the other terminals on the
• Boost pressure sensor J200/P200 P2 connector.
• Atmospheric pressure sensor J203/P203 G. Measure the resistance between terminal P2-80
and the engine ground.
• Fuel pressure sensor J209/P209
H. Measure the resistance between terminal P1-2
• Engine oil pressure sensor J201/P201 (+5 V Supply) and all of the remaining terminals
on the P1 connector.
• Auxiliary pressure sensor J220/P220 (if
equipped) a. Measure the resistance between terminal P1-2
and the engine ground.
B. Wait for 15 seconds after you disconnect each
sensor. Look for the active 262-04 code in order Expected Result:
to deactivate.
Each resistance measurement indicates an open
Expected Result: circuit.
• OK – The 262-04 diagnostic code deactivates • Not OK – At least one of the resistance
when a particular sensor is disconnected. measurements does not indicate an open circuit. A
+5 V supply wire has a problem. There may be a
Repair: Connect the suspect sensor. If the code problem with a connector.
returns, replace the sensor.
Repair: Repair the wire and/or the connector,
Connect all of the connectors. Verify that the when possible. Replace parts, if necessary. Verify
problem is resolved. that the problem is resolved.
STOP. STOP.
90 RENR5042-03
Troubleshooting Section
Test Step 6. Check the +5 V Supply and I. Restore both wires to the original configuration.
the Sensor Common for an Open Circuit
Expected Result:
A. Install a wire jumper between terminals P2-72 (+5
V Supply) and P2-3 (Sensor Common). Both voltage measurements are 5.0 ± 0.2 VDC.
g01165526
Illustration 19
Schematic for the air shutoff system
g01167488 g01210157
Illustration 20 Illustration 22
ECM connectors (typical example) Air shutoff mechanism
(1) J1/P1 ECM connectors (3) Terminals for the air shutoff solenoid
g01146383
Illustration 21
Customer connector (typical example)
(2) J61 customer connector
RENR5042-03 93
Troubleshooting Section
Expected Result:
Results:
g01212805
Illustration 24
Terminal locations at the P61 customer connector that are g01165714
associated with the air shutoff system Illustration 25
C. Connect a test lamp between the output of the D. Start the engine.
solenoid for the air shutoff relay and engine
ground. E. Activate the overspeed verify switch.
D. Start the engine. F. Monitor the test lamp while you increase the
engine speed past 75 percent of the programmed
E. Activate the overspeed verify switch. overspeed setpoint.
F. Monitor the test lamp while you increase the G. Stop the engine.
engine speed past 75 percent of the programmed
overspeed setpoint. Expected Result:
G. Stop the engine. The test lamp illuminated when the engine speed
increased past 75 percent of the programmed
H. Remove the test lamp from the circuit. Restore the overspeed setpoint.
wiring to the original configuration.
Results:
Expected Result:
• OK – The test lamp illuminated.
The test lamp illuminated when the engine speed
increased past 75 percent of the programmed Repair: The voltage is present at the air shutoff
overspeed setpoint. solenoid. Check for continuity of the ground circuit
for the air shutoff solenoid before proceeding. If
Results: the ground circuit is OK, replace the air shutoff
solenoid. Verify that the problem is resolved.
• OK – The test lamp illuminated. The air shutoff
relay is operating correctly. Proceed to Test Step 3. STOP.
• Not OK – The test lamp did not illuminate. No • Not OK – The test lamp did not illuminate.
voltage is present at the output of the relay.
Proceed to Test Step 4. Repair: System voltage was not present at the air
shutoff solenoid. There is a problem in the wiring
Test Step 3. Test for Voltage at the Air between the output of the air shutoff relay and the
Shutoff Solenoid input of the air shutoff solenoid . There may be a
problem in a connector. Repair the wiring and/or
A. Ensure that the keyswitch is in the OFF position. the connector. Replace parts, if necessary. Verify
that the problem is resolved.
STOP.
The test lamp illuminated when the engine speed The test lamp illuminated when the engine speed
increased past 75 percent of the programmed increased past 75 percent of the programmed
overspeed setpoint. overspeed setpoint.
Results: Results:
• OK – The test lamp illuminated. Control input • OK – The test lamp illuminated.
voltage is reaching the relay. Proceed to Test Step
6. Repair: The ECM is operating correctly. Perform
the following procedure:
• Not OK – The test lamp did not illuminate. The
voltage from the ECM was not present at the coil 1. Verify the continuity of the ground circuit for the
of the air shutoff relay. Restore the wiring to the overspeed verify switch.
original configuration. Proceed to Test Step 5.
2. Isolate the overspeed verify switch from the
Test Step 5. Check the Output Voltage for circuit. Close the switch and measure the
the Air Shutoff Relay at the ECM continuity across the switch. Open the switch
and measure the continuity across the switch.
A. Ensure that the keyswitch is in the OFF position.
3. Verify the continuity of the circuit between
B. Disconnect the P1 ECM connector. the overspeed verify switch and the P1 ECM
connector.
C. Fabricate a jumper wire that is long enough to
reach from the P1-54 ECM connector to engine 4. Restore the wiring to the original configuration.
ground. Crimp a connector socket to one end of
the jumper wire. If the overspeed verify switch is OK and the
circuit has continuity from the P1 and the
D. Remove the wire from terminal location P1-54 engine ground stud, there is a problem in the
(overspeed verify switch) at the ECM connector. wiring between the P1 ECM connector and the
Insert the jumper wire into this terminal location. air shutoff relay.
E. Fabricate two other jumper wires that can be Repair the circuit connectors or wiring and/or
used as test leads at the ECM connector. Crimp a replace the circuit connectors or wiring. Verify that
connector socket to one end of each jumper wire. the problem is resolved.
B. Remove the diode from the air shutoff relay. Test Step 8. Check the Voltage from the
Keyswitch to the Voltage Input of the Air
C. Select the “Diode Check” function on a digital Shutoff Relay
voltmeter.
A. Ensure that the keyswitch is in the OFF position.
D. Refer to Illustration 27. Place the red lead of the
digital voltmeter on the diode at location (A). Place
the black lead of the digital voltmeter on the diode
at location (B).
Expected Result:
Results:
• Not OK – The voltage drop across the diode is B. Remove the wire at the voltage input of the air
greater than one volt. shutoff relay.
Repair: The diode is damaged. Replace the diode. C. Connect the test lamp between the wire for the
Verify that the problem is resolved. voltage input and the terminal for the voltage input
at the air shutoff relay.
STOP.
D. Turn the keyswitch to the ON position.
Test Step 7. Test the Diode for Current
Flow E. Check the test lamp.
A. Reverse the position of the leads for the digital F. Turn the keyswitch to the OFF position.
voltmeter.
Expected Result:
B. Measure the voltage drop across the diode.
The test lamp illuminates.
Expected Result:
Results:
For a diode that is operating properly, the digital
voltmeter will indicate an OL across the diode. • OK – The test lamp illuminated.
Results: Repair: The relay contacts are not passing the
secondary voltage to the circuit for the air shutoff
• OK – The digital voltmeter indicates an OL across solenoid. Replace the air shutoff relay. Verify that
the diode for this measurement. The diode is OK. the problem is resolved.
Proceed to Test Step 8.
STOP.
• Not OK – The digital voltmeter does not indicate
an OL across the diode. • Not OK – The test lamp did not illuminate. Input
voltage is not reaching the relay. Proceed to Test
Repair: The diode is damaged. Replace the diode. Step 9.
Verify that the problem is resolved.
Test Step 9. Check the Harness between
STOP. the Keyswitch and the Air Shutoff Relay
A. Turn the keyswitch to the OFF position.
RENR5042-03 97
Troubleshooting Section
Refer to Illustration 19 for details. The CAN data link is used to communicate
information between the Electronic Control Module
E. Measure the voltage between terminal R (ECM) and other modules. Use this procedure to
(keyswitch) of the keyswitch and engine ground. troubleshoot any suspect problems with the CAN
data link.
F. Turn the keyswitch to the OFF position.
This procedure covers the 247-09 J1939 Data Link
Expected Result: communications.
Voltage is present on terminal B (+Battery) and This procedure identifies the following problems:
terminal R (keyswitch) at the keyswitch.
• Faulty connectors
Results:
• Missing termination resistors
• OK – Voltage is present on terminal B and terminal
R at the keyswitch. • Short circuits
STOP.
STOP.
STOP.
98 RENR5042-03
Troubleshooting Section
g01119843
Illustration 29
Schematic for the CAN data link
g01149983
Illustration 31
Engine view (typical example)
(2) J61 customer connector
(3) J63 service tool connector
g01167488
Illustration 30
Engine view (typical example) B. Thoroughly inspect connectors (1), (2), and (3).
(1) J1/P1 ECM conntctors
Thoroughly inspect the connectors for each
module that is connected to the CAN data link.
Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
RENR5042-03 99
Troubleshooting Section
g01123351
Illustration 33
J61/P61 terminals that are associated with the CAN data link
(16) CAN shield
(17) CAN data link +
(18) CAN data link −
Expected Result:
Results:
Repair: Repair the connectors and/or the wiring. Repair: Verify that two terminating resistors exist
Replace parts, if necessary. Ensure that all of the on the data link. One resistor must be located on
seals are properly in place and ensure that the each end of the data link. If the optional harness is
connectors are completely coupled. Verify that the ordered with the engine, the engine is shipped with
problem is resolved. one terminating resistor that is installed between
the ECM and the customer connector.
STOP.
Refer to the appropriate electrical schematic in
Test Step 2. Check for Active Diagnostic order to determine the missing resistor. Replace
Codes the missing resistor. Verify that the problem is
resolved.
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to STOP.
Troubleshooting, “Electronic Service Tools”.
• Not OK – The resistance is less than 57 Ohms.
B. Turn the keyswitch to the ON position. Proceed to Test Step 4.
C. Observe the active diagnostic code screen on • Not OK – The resistance is greater than 126
Cat ET. Wait at least 15 seconds so that any Ohms. Proceed to Test Step 5.
diagnostic codes may become active. Check for a
247-09 diagnostic code. Test Step 4. Check for a Short Circuit
Expected Result: A. Disconnect the J1/P1 ECM connector.
No diagnostic codes are active. B. Remove the terminating resistors from the CAN
data link.
Results:
C. If a J1939 display is installed, disconnect the
• OK – No codes are active. display.
Repair: The problem may be intermittent. If the D. Measure the resistance between the points that
problem is intermittent, refer to Troubleshooting, are listed in Table 15. Be sure to wiggle the wires
“Electrical Connectors - Inspect”. in the harnesses as you make each resistance
measurement.
STOP.
Table 15
• Not OK – A 247-09 diagnostic code is active. Resistance Measurements for the CAN Data Link
Proceed to Test Step 3.
Connector and Terminal
Test Step 3. Verify the Proper Installation Terminal
of the CAN Data Link P1-50 (CAN data link +) All of the other terminals on
the P1 connector
A. Disconnect the J1939 display.
Engine ground
B. Disconnect the P1 connector and measure the P1-34 (CAN data link -) All of the other terminals on
resistance between terminals P1-50 (CAN data the P1 connector
link +) and P1-34 (CAN data link -).
Engine ground
Expected Result:
Expected Result:
The resistance is between 57 and 63 Ohms.
Each check of the resistance indicates an open
Results: circuit.
• Not OK – At least one check of the resistance If the display does not operate correctly on the
does not indicate an open circuit. There is a short original engine, there may be a problem with the
circuit in a harness. There may be a problem with ECM.
a connector.
It is unlikely that the ECM has failed. Perform
Repair: Repair the wiring and/or the connector. this entire procedure again. Replace the ECM if
Replace part, if necessary. Verify that the problem the display does not operate correctly. Refer to
is resolved. Troubleshooting, “Replacing the ECM”.
STOP. STOP.
Test Step 5. Check for an Open Circuit • Not OK – The J1939 display does not operate
properly on another engine.
A. Verify that all of the connections are disconnected.
Repair: Replace the J1939 display. Verify that the
B. Fabricate a jumper wire. Use the jumper wire in problem is resolved.
order to create a short circuit between terminals G
and F on the service tool connector. STOP.
Expected Result:
Results:
g01167488
Illustration 35
Engine view (typical example)
(1) J1/P1 ECM connectors
g01202018
Illustration 37
P1 terminals that are associated with the Cat Data Link
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −
g01149983
Illustration 36
Engine view (typical example)
(2) P61 customer connector
(3) P63 service tool connector
STOP.
Table 16
Resistance Measurements for the Cat Data Link
Connector and Terminal
Terminal
P1-8 (Cat Data Link +) All of the other terminals on
the P1 connector
Ground stud
g01119122
Illustration 38 P1-9 (Cat Data Link -) All of the other terminals on
J61 and P61 terminals that are associated with the Cat Data Link the P1 connector
(6) Cat Data Link − Ground stud
(7) Cat Data Link +
STOP.
STOP.
i02434663
g01216335
Illustration 39
Schematic of the engine coolant level sensor
Expected Result:
Results:
STOP.
g01121173
Illustration 40
• Not OK – The coolant is at the proper level. Engine components for the engine coolant level sensor
Proceed to Test Step 2.
(1) P61 customer connector
(2) J1/P1 connectors
Test Step 2. Inspect the Electrical
Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
106 RENR5042-03
Troubleshooting Section
g01119186
Illustration 41
Rear view of a typical radiator with a engine coolant level sensor
g01216336
Illustration 42
P1 terminals that are associated with the engine coolant level
sensor
(P1-5) Return
(P1-4) +8 VDC (digital sensor supply)
(P1-49) Engine coolant level
RENR5042-03 107
Troubleshooting Section
STOP.
g01199118
Illustration 44
Location of the compression brake solenoid (typical example)
g01239503
Illustration 45
Schematic for the compression brake circuit
g01239528
Illustration 47
Left side engine view (typical example)
(4) Valve cover entry connector
g01239527
Illustration 46
Left side engine view (typical example)
(1) J2/P2 ECM connectors
(2) P61 connector
(3) J1/P1 ECM connectors
RENR5042-03 111
Troubleshooting Section
g01239521
Illustration 49
P1 ECM connector
(P1-5) Digital return
(P1-23) Compression brake solenoid low/high
(P1-40) Compression brake med/high
g01141312
Illustration 48
P2 ECM connector
(P2-1) Compression brake solenoid low/high
(P2-8) Compression brake solenoid med/high
(P2-14) Digital return
112 RENR5042-03
Troubleshooting Section
Expected Result:
Results:
• OK – No diagnostic codes are active. If a problem C. Inspect the terminals on the J2 and P2 ECM
is suspected with the “Compression Brake Switch”, connectors for damage.
proceed to Test Step 9.
Note: Refer to the Figure 48 for pin locations.
• Not OK – A low current diagnostic code (05) is
active at this time. Proceed to Test Step 3. D. Remove the return wire and the supply wire for
the suspect compression brake solenoid from the
• Not OK – A high current diagnostic code (06) is P2 ECM connector.
logged at this time. Proceed to Test Step 5.
E. Fabricate a jumper wire in order to short the two
Test Step 3. Short the Wires of the pins for the suspect compression brake solenoid
Suspect Compression Brake Solenoid at at the ECM. Crimp a socket to each end of the
the Valve Cover Connector jumper wire. Insert the jumper wire into the P2
ECM connector.
A. Turn the keyswitch to the OFF position.
F. Reconnect the P2 ECM connector.
B. Disconnect the valve cover connector for the
suspect compression brake solenoid. G. Turn the keyswitch to the ON position.
C. Fabricate a jumper wire in order to create a short H. Access the “Special Tests” under the “Diagnostics”
between the supply and the return for the suspect menu.
compression brake solenoid.
I. Start the “Compression Brake Solenoid Test” on
D. Turn the keyswitch to the ON position. Cat ET.
E. Access the “Special Tests” under the “Diagnostics” J. Once Cat ET displays the status of the
menu. compression brake solenoid, stop the
“Compression Brake Solenoid Test”.
F. Start the “Compression Brake Solenoid Test” on
Cat ET. K. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the
G. Once Cat ET displays the status of the compression brake solenoids.
compression brake solenoid, stop the
“Compression Brake Solenoid Test”. Expected Result:
H. Check for active diagnostic codes and/or logged A high current diagnostic code (06) is logged at this
diagnostic codes that are associated with the time.
compression brake solenoids.
Note: Disconnecting the supply wire for the suspect
Expected Result: compression brake solenoid will cause an “Open”
in the compression brake solenoid that shares the
A high current diagnostic code (06) is logged at this supply wire with the suspect compression brake
time. solenoid.
Results: Results:
• OK – A high current diagnostic code (06) is logged • OK – A high current diagnostic code (06) is logged
at this time. The harness wiring between the valve at this time. The ECM detected the short.
cover connector for the suspect compression brake
solenoid and ECM connector P2 is OK. Proceed Repair: Check continuity of the supply wire for the
to Test Step 7. suspect compression brake solenoid between the
valve cover connector for the suspect compression
• Not OK – A low current diagnostic code 05 is brake solenoid and P2. If the wire is open, replace
active at this time. The ECM did not detect the short the wire.
at the valve cover connector for the compression
brake solenoid. Proceed to Test Step 4.
Check continuity of the return wire for the suspect • Not OK – A high current diagnostic code (06)
compression brake solenoid between the valve is logged at this time. The ECM did not detect
cover connector for the suspect compression brake the open at the valve cover connector for the
solenoid and P2. If the wire is open, replace the compression brake solenoid. Proceed to Test Step
wire. 6.
Repair: Replace the ECM. Refer to C. Inspect the terminals on the J2 and P2 ECM
Troubleshooting, “Replacing the ECM”. connectors for damage.
Verify that the problem is resolved.
Note: Refer to the Figure 48 for pin locations.
STOP.
D. Remove the return wire and the supply wire for
Test Step 5. Open the Wires of the the suspect compression brake solenoid from the
Suspect Compression Brake Solenoid at P2 ECM connector.
the Valve Cover Connector
E. Reconnect the P2 ECM connector.
A. Turn the keyswitch to the OFF position.
F. Turn the keyswitch to the ON position.
B. Disconnect the valve cover connector for the
suspect compression brake solenoid. G. Access the “Special Tests” under the “Diagnostics”
menu.
C. Turn the keyswitch to the ON position.
H. Start the “Compression Brake Solenoid Test” on
D. Access the “Special Tests” under the “Diagnostics” Cat ET.
menu.
I. Once Cat ET displays the status of the
E. Start the “Compression Brake Solenoid Test” on compression brake solenoid, stop the
Cat ET. “Compression Brake Solenoid Test”.
F. Once Cat ET displays the status of the J. Check for active diagnostic codes and/or logged
compression brake solenoid, stop the diagnostic codes that are associated with the
“Compression Brake Solenoid Test”. compression brake solenoids.
Measure the resistance between the return wire for Expected Result:
the suspect compression brake solenoid and every
terminal on ECM connector P1 and ECM connector A high current diagnostic code (06) is logged at this
P2. If the wire is shorted, replace the wire. time.
STOP. Results:
• Not OK – A high current diagnostic code (06) is • OK – A high current diagnostic code (06) is logged
logged at this time. The ECM did not detect the at this time. The harness wiring between the
open. solenoid connector for the suspect compression
brake solenoid and ECM connector P2 is OK.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Repair: Temporarily connect a new compression
Verify that the problem is resolved. brake solenoid to the harness, but do not install the
new compression brake solenoid in the engine.
STOP. Verify that there are no active diagnostic codes for
the compression brake solenoid. If there are no
Test Step 7. Create a Short Circuit at the active diagnostic codes for the compression brake
Compression Brake Solenoid solenoid, permanently install the new compression
brake solenoid. Clear any logged diagnostic codes.
A. Turn the keyswitch to the OFF position.
STOP.
B. Remove the valve cover.
• Not OK – A low current diagnostic code (05) is
C. Reconnect the valve cover connector. active at this time. The ECM did not detect the
short circuit.
D. Disconnect the connector on the suspect
compression brake solenoid. Repair: Repair the harness between the connector
for the compression brake solenoid and the valve
E. Inspect the terminals on the solenoid connector cover connector for the suspect compression brake
for damage. solenoid.
F. Fabricate a jumper wire in order to short the two Verify that the repair eliminates the problem.
wires for the suspect solenoid on the solenoid
connector. Crimp a pin to each end of the jumper STOP.
wire.
Test Step 8. Create an Open Circuit at the
G. Make sure that the solenoid connector securely Compression Brake Solenoid
holds the jumper wire.
A. Turn the keyswitch to the OFF position.
Note: Worn terminals and/or damaged terminals on
the solenoid connector could cause an intermittent B. Reconnect the valve cover connector.
“Open”.
C. Remove the valve cover.
H. Turn the keyswitch to the ON position.
D. Disconnect the connector on the suspect
I. Access the “Special Tests” under the “Diagnostics” compression brake solenoid.
menu.
E. Inspect the terminals on the solenoid connector
J. Start the “Compression Brake Solenoid Test” on for damage.
Cat ET.
F. Turn the keyswitch to the ON position.
K. Once Cat ET displays the status of the
compression brake solenoid, stop the G. Access the “Special Tests” under the “Diagnostics”
“Compression Brake Solenoid Test”. menu.
L. Check for active diagnostic codes and/or logged H. Start the “Compression Brake Solenoid Test” on
diagnostic codes that are associated with the Cat ET.
compression brake solenoids.
I. Once Cat ET displays the status of the
compression brake solenoid, stop the
“Compression Brake Solenoid Test”.
116 RENR5042-03
Troubleshooting Section
• OK – A low current diagnostic code (05) is active Repair: If the problem is intermittent, refer to
at this time. The ECM detected the open at the Troubleshooting, “Electrical Connectors - Inspect”.
compression brake solenoid. The harness wiring
between the solenoid connector for the suspect STOP.
compression brake solenoid and ECM connector
P2 is OK. • Not OK – There is a problem in the circuit for the
compression brake switch. Proceed to Test Step
Repair: Temporarily connect a new compression 10.
brake solenoid to the harness, but do not install the
new compression brake solenoid in the engine. Test Step 10. Check the Switch Circuits
Verify that there are no active diagnostic codes for at the J61/P61 Connector
the compression brake solenoid. If there are no
active diagnostic codes for the compression brake A. Turn the keyswitch to the OFF position.
solenoid, permanently install the new compression
brake solenoid. Clear any logged diagnostic codes. B. Disconnect the J61/P61 connector.
C. Operate the compression brake switch in the I. Check the status for the compression brake switch
following positions: on Cat ET.
• High
RENR5042-03 117
Troubleshooting Section
The status for the compression brake switch indicates Test Step 1. Check the Operation of the
“Medium” when a wire jumper is installed between Diagnostic Lamp
terminal 9 and terminal 35.
A. Turn the keyswitch to the ON position.
Results:
B. Monitor the diagnostic lamp.
• OK – The status changed accordingly. There
is a problem in the wiring between J61 and the Expected Result:
compression brake switch.
The diagnostic lamp turns on for five seconds. Then,
Repair: Repair the harness or replace the the diagnostic lamp turns off. If a diagnostic code is
compression brake switch. active, the diagnostic lamp will flash.
STOP. Results:
• Not OK – There is a problem in the wiring between • Yes – The diagnostic lamp turns on for five
P61 and the ECM. seconds. Then, the diagnostic lamp turns off. The
diagnostic lamp appears to be operating correctly
Repair: Repair the harness or replace the harness at this time. STOP.
between P61 and the ECM.
• No – The diagnostic lamp did not turn on for five
STOP. seconds. Check the bulb. Replace the bulb if the
bulb is not OK. If the bulb is OK, proceed to Test
Step 2.
i02433636
g01123371
Illustration 52
Schematic for the diagnostic lamp
118 RENR5042-03
Troubleshooting Section
g01119456 g01215717
Illustration 53 Illustration 54
Left side view P1 terminals that are associated with the diagnostic lamp
(1) P61 customer connector (P1-28) Diagnostic lamp
(2) J1/P1 ECM connectors (P1-65) −Battery
STOP.
Expected Result:
E. Check the allen head screw on the customer Test Step 4. Test the Diagnostic Lamp
connector for the proper torque. Refer to Circuit at the Diagnostic Lamp
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. A. Disconnect wire F404-RD from the diagnostic
lamp.
F. Check the harness and wiring for abrasions and
for pinch points from the diagnostic lamp to the B. Connect a jumper wire between the diagnostic
ECM. lamp’s open terminal and engine ground.
B. Remove the wire from the terminal R of the C. Insert the jumper into P1-28.
keyswitch.
D. Connect the J1/P1 connectors.
C. Turn the keyswitch to the ON position.
E. Connect one probe of a voltage test lamp to the
D. Measure the voltage on terminal B of the jumper wire in P1-28.
keyswitch to engine ground.
F. Connect the other probe of the voltage test lamp
E. Measure the voltage on terminal R of the to +Battery.
keyswitch to engine ground.
G. Turn the keyswitch to the ON position. Wait for
F. Turn the keyswitch to the OFF position. ten seconds.
STOP.
i02433728
g01146754
Illustration 56
Schematic for the digital sensor supply
g01121173 g01215738
Illustration 57 Illustration 58
Left side view P1 ECM connector
(1) P61 customer connector (P1-4) +8 VDC (digital sensor supply)
(2) J1/P1 ECM connectors (P1-5) Return
STOP.
g01119753
One of the above diagnostic codes is active.
Illustration 59
J61 and P61 customer connectors Results:
(8) +8 VDC (digital sensor supply)
(9) Return • Active 041-03 code – A 041-03 diagnostic code is
active. Proceed to Test Step 3.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the digital sensor • Active 041-04 code – A 041-04 diagnostic code is
supply. active. Proceed to Test Step 4.
D. Check the allen head screw on each ECM • No active codes – None of the above codes are
connector for the proper torque. Refer to active.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. Repair: If any of the above codes are logged
and the engine is not running properly, refer to
E. Check the harness and wiring for abrasions and Troubleshooting, “Troubleshooting Without a
for pinch points from the battery to the ECM. Diagnostic Code”.
• Not OK – There is a problem with a connector B. Disconnect the harness connectors for the engine
and/or the wiring. coolant level sensor J800/P800.
D. Measure the voltage between terminals A and B C. Verify that all of the digital sensors are
at the harness connector for the sensor. disconnected.
Repair: Connect the sensor connectors. Clear E. Measure the resistance between P1-4 (+8 VDC
all diagnostic codes. Check for active diagnostic supply) and the engine ground.
codes. If the problem is intermittent, refer to
Troubleshooting, “Electrical Connectors - Inspect”. Expected Result:
Connect all of the connectors. Verify that the B. Measure the resistance between terminals A and
problem is resolved. B at the harness connector for each digital sensor.
B. Remove terminal 5 from the P1 connector. Install This procedure covers the following diagnostic codes:
a jumper wire with socket terminals on both ends
into P1-5. • 253-02 Personality Module mismatch
D. Turn the keyswitch to the ON position. Also, use this procedure to troubleshoot the following
conditions:
E. Measure the voltage between the jumper wires
in P1-4 and P1-5. • The integrity of the customer parameters or the
system parameters in the Electronic Control
F. Turn the keyswitch to the OFF position. Module (ECM) is questionable.
G. Restore all wiring to the original configuration. • The data for the engine lifetime totals is
questionable.
Expected Result:
Test Step 1. Inspect the Electrical
The voltage measurement is 8.0 ± 0.4 VDC. Connectors and the Wiring
STOP.
STOP.
g01120020
Illustration 60
ECM
(1) J2/P2 connectors
(2) J1/P1 connectors
126 RENR5042-03
Troubleshooting Section
C. Check the allen head screw on each ECM • Active 268-02 code – A 268-02 diagnostic code is
connector for the proper torque. Refer to the active. Proceed to Test Step 4.
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. • Scrambled parameters – The configuration
parameters are scrambled. Proceed to Test Step 5.
D. Check the harnesses and the wiring for abrasion
and for pinch points. Test Step 3. Check the Part Number of
the Flash File
Expected Result:
A. Verify that the flash file agrees with the original
All connectors, pins and sockets are completely engine arrangement.
coupled and/or inserted and the harnesses and wiring
are free of corrosion, of abrasion or of pinch points. Expected Result:
The 253-02 or 268-02 codes are not active. The The configuration parameters and the injector trim
configuration parameters are not scrambled. files are correct.
RENR5042-03 127
Troubleshooting Section
Test Step 5. Review the Parameters and • Always use a 1U-5804 Crimp Tool to service
Deutsch HD and DT connectors. Never solder the
Data terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
A. Review the system configuration parameters and
the engine lifetime totals.
• Always use a 147-6456 Wedge Removal Tool to
remove wedges from DT connectors. Never use a
Expected Result: screwdriver to pry a wedge from a connector.
The parameters and totals are correct.
• Always use a breakout harness for a voltmeter
probe or a test light. Never break the insulation
Results: of a wire in order to access to a circuit for
measurements.
• OK – The parameters and totals are correct.
Repair: Return the engine to service.
• If a wire is cut, always install a new terminal for
the repair.
STOP.
Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If any
Moisture and Corrosion of the plugs are missing, replace the plug. Ensure
that the plugs are inserted correctly into the
connector. Refer to Illustration 62.
g01131019
Illustration 63
Seal for a three-pin connector (typical example)
g01131211
Illustration 61
Leaky seal at the connector (typical example)
g01131165
Illustration 64
Seal for ECM connector (typical example)
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.
STOP.
g01131604
Illustration 66
Diagram for testing pin retention (typical example)
A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.
Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.
STOP.
RENR5042-03 131
Troubleshooting Section
Results:
STOP.
g01133047
Illustration 70
Allen head screw for the 40 pin customer connector and the 70 pin
g01132827
Illustration 67 customer connector (typical example)
Allen head screw for the 120 pin ECM connector (typical example)
B. Connect the customer connector.
a. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Torque the allen head screw for the 40 pin
customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
Expected Result:
Results:
Repair: Repair the connector or replace the • 168-02 System Voltage intermittent/erratic
connector, as required. Verify that the repair
eliminates the problem. This procedure tests whether proper voltage is being
supplied to the Electronic Control Module (ECM).
STOP.
Unswitched battery voltage is supplied through the
Test Step 8. Perform the “Wiggle Test” on customer connector to the ECM at P1-48, P1-52, and
the Caterpillar Electronic Technician (ET) P1-53. The negative battery is supplied to the ECM
at P1-61, P1-63, and P1-65. The ECM receives the
A. Select the “Wiggle Test” from the diagnostic tests input from the keyswitch at P1-70 when the keyswitch
on Cat ET. is in the ON position or the START position. When
the ECM detects battery voltage at this input, the
B. Choose the appropriate group of parameters to ECM will power up. When battery voltage is removed
monitor. from this input, the ECM will power down.
C. Press the “Start” button. Wiggle the wiring harness The cause of an intermittent power supply to the ECM
in order to reproduce intermittent problems. can occur on either the positive side or the negative
side of the battery circuit. Both sides are routed from
If an intermittent problem exists, the status will be the ECM to the battery. The three connections for
highlighted and an audible beep will be heard. the unswitched +Battery should be routed through a
dedicated protective device (circuit breaker).
Expected Result:
The engine ECM requires the keyswitch to be in the
No intermittent problems were indicated during the ON position in order to maintain communications with
“Wiggle Test”. the electronic service tool.
Results:
STOP.
i02434665
g01216339
Illustration 71
Schematic diagram for the electrical power supply
g01120079 g01104383
Illustration 72 Illustration 73
Left side view P1 terminals that are associated with the electrical power supply
(1) P61 customer connector (P1-44) Shutdown
(2) J1/P1 ECM connectors (P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
D. Thoroughly inspect connectors (1) and (2). (P1-61) −Battery
Inspect the connections for the battery and (P1-63) −Battery
the connections to the keyswitch. Refer to (P1-65) −Battery
Troubleshooting, “Electrical Connectors - Inspect” (P1-70) Keyswitch
for details.
RENR5042-03 135
Troubleshooting Section
STOP.
Expected Result:
g01216338
Illustration 74 The measured voltage is between 11.0 VDC and 13.5
J61 and P61 terminals that are associated with the electrical VDC for a 12 volt system and between 22.0 VDC and
power supply 27.0 VDC for a 24 volt system with no suspected
(1) +Battery intermittent problems at this time.
(26) Keyswitch
(27) Shutdown
(31) +Battery
Results:
(32) +Battery
• OK – The ECM is receiving the correct voltage.
E. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the electrical power Repair: If an intermittent condition is suspected,
supply. refer to Troubleshooting, “Electrical Connectors
- Inspect”.
F. Check the allen head screw on each ECM
connector for the proper torque. Refer to STOP.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. • Battery voltage is out of range – Proceed to Test
Step 3.
G. Check the harness and wiring for abrasions and
for pinch points from the battery to the ECM. Also, • Keyswitch voltage out of range
check the harness and wiring for abrasions and
for pinch points from the keyswitch to the ECM. Repair: Check the circuit protection for the
circuit and for the wiring. Trace the wiring for the
Expected Result: keyswitch from the ECM through the keyswitch
circuit to the batteries. Find the problem and repair
All connectors, pins, and sockets are completely the problem.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. Verify that the repairs eliminate the problem.
Results: STOP.
• OK – The connectors and wiring are OK. Proceed Test Step 3. Check the Batteries
to Test Step 2.
A. Measure the no-load battery voltage at the battery
• Not OK – There is a problem with the connectors posts.
or wiring.
136 RENR5042-03
Troubleshooting Section
B. Load test the batteries. Use the 4C-4911 • 100-03 Engine Oil Pressure open/short to +batt
Battery Load Tester. Refer to Special Instruction,
SEHS9249, “Use of 4C-4911 Battery Load Tester • 100-04 Engine Oil Pressure short to ground
for 6, 8 and 12 Volt Lead Acid Batteries” and
Special Instruction, SEHS7633, “Battery Test • 102-03 Boost Pressure Sensor short to +batt
Procedure”.
• 102-04 Boost Pressure Sensor short to ground
Expected Result:
• 274-03 Atmospheric Pressure open/short to +batt
The batteries pass the load test. The measured
voltage is the minimum specification for a 12V or 24V • 274-04 Atmospheric Pressure short to ground
system.
The troubleshooting procedures for the diagnostic
Results: codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 volt supply
• OK – The batteries are OK. to terminal A of each sensor. The sensor common
connection is connected to terminal B of each sensor.
Repair: Check the wiring between the batteries The signal voltage from terminal C of each sensor is
and the ECM for shorts. sent to the appropriate terminal at the J2/P2 ECM
connector.
Check the connectors between the batteries and
the ECM for moisture and/or corrosion. Pull-up Voltage
Repair the wiring and/or the connectors. The ECM continuously outputs a pull-up voltage
on the circuit for the sensor signal wire. The ECM
Verify that the repair eliminates the problem. uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
STOP. presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
• Not OK – The battery voltage is low or the battery diagnostic code (03) for the sensor.
did not pass the load test.
If the sensor is disconnected at the sensor connector,
Repair: Recharge or replace the faulty batteries. the presence of pull-up voltage at the sensor
Verify that the repair eliminates the problem. connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
STOP. ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
i02433757
or a short to ground. If the sensor is disconnected at
Engine Pressure Sensor Open the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
or Short Circuit - Test wire is shorted to another wire in the harness.
g01216615
Illustration 75
Schematic for the engine pressure sensors
138 RENR5042-03
Troubleshooting Section
g01094844
Illustration 77
Sensor connector
(A) +5 VDC
(B) Common
(C) Signal
Expected Result:
Repair: Repair the connectors or wiring and/or C. Monitor the active diagnostic code screen on the
replace the connectors or wiring. Ensure that all of electronic service tool. Check and record any
the seals are properly in place and ensure that the active diagnostic codes.
connectors are completely coupled.
Note: Wait at least 15 seconds in order for the
Verify that the repair eliminates the problem. diagnostic codes to become active.
The voltage is 5.0 ± 0.16 VDC. B. Disconnect the sensor connector of the sensor
with the short circuit diagnostic code (04).
Results:
C. Turn the keyswitch to the ON position. Wait at
• OK – The voltage is 5.0 ± 0.16 VDC. The voltage least 15 seconds for activation of the diagnostic
is correct. Proceed to Test Step 3. codes.
• Not OK – The voltage is not 5.0 ± 0.16 VDC. The D. Access the “Active Diagnostic Code” screen on
voltage is incorrect. the electronic service tool. Check for an active
open circuit diagnostic code (03).
Repair: Perform the diagnostic functional test
Troubleshooting, “5 Volt Engine Pressure Sensor E. Turn the keyswitch to the OFF position.
Supply Circuit - Test”.
Expected Result:
STOP.
An open circuit diagnostic code 03 is now active for
Test Step 3. Check for Active Diagnostic the disconnected sensor.
Codes
Results:
A. Connect the electronic service tool to the service
tool connector. • OK – A short circuit diagnostic code (04) was
active before disconnecting the sensor. An open
B. Turn the keyswitch to the ON position. circuit diagnostic code (03) became active after
disconnecting the sensor.
140 RENR5042-03
Troubleshooting Section
Repair: Temporarily connect a new sensor to the E. Measure the resistance between the terminal for
harness, but do not install the new sensor in the the sensor signal wire at the ECM and engine
engine. Verify that there are no active diagnostic ground.
codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently F. Reconnect P1 and P2.
install the new sensor. Clear any logged diagnostic
codes. Expected Result:
B. Disconnect the suspect sensor. Repair: The low resistance measurement indicates
a low resistance between two or more wires.
C. Measure the voltage between terminal C (signal) Repair the connectors or wiring and/or replace the
and terminal B (sensor return) at the sensor connectors or wiring.
connector.
STOP.
D. Turn the keyswitch to the OFF position.
Test Step 7. Create a Short at the Suspect
Expected Result: Sensor Connector
The voltage is 11 ± 2 VDC. A. Turn the keyswitch to the OFF position.
Test Step 6. Check the Signal Wire for a F. Turn the keyswitch to the OFF position.
Short Circuit
Expected Result:
A. Turn the keyswitch to the OFF position.
A short circuit diagnostic code 04 is active when the
B. Disconnect ECM connectors P1 and P2. jumper wire is installed. An open circuit diagnostic
code 03 is active when the jumper wire is removed.
C. Disconnect the connector for the suspect sensor.
Results:
D. Measure the resistance between the terminal
for the sensor signal wire at the ECM and • OK – The engine harness and the ECM are OK.
every terminal on ECM connector P1 and ECM
connector P2.
RENR5042-03 141
Troubleshooting Section
STOP. Results:
• Not OK – The open circuit diagnostic code 03 • OK – The ECM is operating properly. The problem
remains active with the jumper in place. The is in the wiring between the ECM and the sensor
open circuit is between the ECM and the sensor connector.
connector. Proceed to Test Step 8.
Repair: If the code is active for more than one
Test Step 8. Check the Operation of the sensor, the problem is most likely in the return wire
ECM for the sensor. Repair the return wire for the sensor
or replace the harness.
A. Turn the keyswitch to the OFF position.
If the code is only active for one sensor, the
B. Check the operation of the ECM by creating an problem is most likely in the signal wire for the
open at the ECM. sensor. Repair the signal wire for the sensor.
A short circuit diagnostic code (04) should be • 190-08 Engine Speed abnormal
active when the wire jumper is installed.
• 342-08 Secondary Engine Speed signal abnormal
d. Remove the wire jumper and reconnect all
wires.
142 RENR5042-03
Troubleshooting Section
The engine uses two engine speed/timing sensors. If a replacement of the ECM is required, the ECM
The primary engine speed/timing sensor detects the parameters and the timing calibration can be
unique pattern of crankshaft gear and the secondary transferred from the suspect ECM to the replacement
engine speed/timing sensor picks up the unique ECM. Timing calibration will not be necessary. This
pattern of the camshaft gear. Both of the engine feature requires the Caterpillar Electronic Technician
speed/timing sensors detect the reference for engine (ET) and this feature is only possible if the existing
speed and timing from a unique pattern on the gear. ECM can communicate with Cat ET. Use the “Copy
The Engine Control Module (ECM) measures the Configuration - ECM Replacement” feature on Cat
time between the pulses that are created by the ET.
sensors as the gears rotate in order to determine rpm.
Complete all of the following tasks when you
Under normal operation, the secondary engine install a speed/timing sensor:
speed/timing sensor is used to determine timing
for starting purposes. The secondary engine • Lubricate the O-ring with oil.
speed/timing sensor is used to determine when
the piston in the No. 1 cylinder is at the top of the • Ensure that the sensor has a face seal inside the
compression stroke. When the timing has been connector body. If a seal is damaged or missing,
established, the primary engine speed/timing sensor replace the seal.
is then used to determine engine speed.
• Ensure that the sensor is fully seated into the
After locating the No. 1 cylinder, the ECM triggers engine before tightening the bracket bolt.
each injector in the correct firing order and at the
correct unit injector timing. The actual timing and • Ensure that the connector is latched on both sides.
duration of each injection is based on engine rpm and
load. If the engine is running and the signal from the • Ensure that the harness is properly secured, and
primary engine speed/timing sensor is lost, a slight ensure that the tie-wraps are placed in the correct
change in engine performance will be noticed when location.
the ECM performs the changeover to the secondary
engine speed/timing sensor. Loss of the signal from
the secondary engine speed/timing sensor during
engine operation will not result in any noticeable
change in engine performance. However, if the signal
from the secondary engine speed/timing sensor is
not present during start-up the following conditions
may exist:
The engine will start and the engine will run when only
one sensor signal is present. The loss of the signal
from both of the sensors during engine operation will
result in the termination of injection and the shutting
down the engine by the ECM. The loss of the signal
from both of the sensors during start-up will prevent
the engine from starting.
g01142626
Illustration 78
Schematic for engine speed/timing sensors
144 RENR5042-03
Troubleshooting Section
• 190-08
• 342-08
Expected Result:
Results:
g01099116
Illustration 79
P2 ECM connector
(P2-25) Primary engine speed/timing −
(P2-26) TDC probe +
(P2-35) Primary engine speed/timing +
(P2-36) TDC probe −
(P2-46) Secondary engine speed/timing +
(P2-47) Secondary engine speed/timing −
B. Visually inspect the sensor without removing the 5. Ensure that the harness is properly secured,
sensor from the engine. Flange (2) must be flush and ensure that the tie-wraps are placed in the
against the engine in order to ensure proper correct location.
operation. Inspect bracket (1) in order to ensure
that the installation allows the flange of the sensor Verify that the repair eliminates the problem.
to be flush against the engine. Verify that the
bracket is not bent. STOP.
Note: The bracket cannot be replaced separately. Test Step 3. Measure the Sensor
Resistance through the Engine Harness
C. Remove the sensor. Ensure that one O-ring (3)
is installed on the sensor. Check the O-ring for A. Turn the keyswitch to the OFF position.
damage. Replace the O-ring, if necessary.
B. Thoroughly inspect the J2/P2 ECM connector.
Expected Result: Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.
The sensor’s components are OK.
C. Perform a 45 N (10 lb) pull test on the wires
Results: that are associated with the engine speed/timing
sensors.
• OK – The sensor’s components are OK.
D. Ensure that the latch tab on each sensor
Repair: Perform the following procedure in order connector is properly latched.
to properly install the sensor:
E. Check the allen head screw on each ECM
1. Lubricate the O-ring with engine oil. connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
2. Fully seat the sensor in the engine. for the correct torque values.
Note: If the sensor will not fully seat into the engine, F. Repair the harness or repair the connector if a
replace the sensor. problem is found.
3. Tighten the bracket bolt. G. Ensure that the wiring harness is correctly routed
and secured at the correct locations.
4. Connect the sensor’s electrical connector. Verify
that the connector is latched on both sides. H. Ensure that the harness wiring is not pulled
too tightly. When the harness wiring is pulled
5. Ensure that the harness is properly secured, too tightly, vibrations or movement can cause
and ensure that the tie-wraps are placed in the intermittent connections.
correct location.
I. Inspect the harness wiring for nicks and abrasions.
Proceed to Test Step 3.
J. If the harness and the connector are OK,
• Not OK – At least one of the sensor’s components disconnect the J2/P2 ECM connector.
is not OK.
K. If you are troubleshooting a problem with the
Repair: Obtain a new sensor. Perform the following primary engine speed/timing sensor, perform the
procedure in order to properly install the new following procedure:
sensor:
a. Measure the sensor’s resistance between
1. Lubricate the O-ring with engine oil. P2-35 (Primary engine speed/timing positive)
and P2-25 (Primary engine speed/timing
2. Fully seat the sensor in the engine. negative).
Note: If the sensor will not fully seat into the engine, b. Check for an intermittent open circuit or for a
replace the sensor. short circuit by moving the harness while you
take the resistance measurement. Pull the
3. Tighten the bracket bolt. wires that are directly behind the sensor or
shake the wires that are directly behind the
4. Connect the sensor’s electrical connector. Verify sensor.
that the connector is latched on both sides.
Resistance ............................ 75 to 230 Ohms
146 RENR5042-03
Troubleshooting Section
L. If you are troubleshooting a problem with the a. Measure the sensor’s resistance between
secondary engine speed/timing sensor, perform J402-2 (Secondary engine speed/timing
the following procedure: positive) and J402-1 (Secondary engine
speed/timing negative).
a. Measure the sensor’s resistance between
P2-46 (Secondary engine speed/timing Resistance ........................ 600 to 1800 Ohms
positive) and P2-47 (Secondary engine
speed/timing negative). Expected Result:
b. Check for an intermittent open circuit or for a The readings are within the specifications.
short circuit by moving the harness while you
take the resistance measurement. Pull the Results:
wires that are directly behind the sensor or
shake the wires that are directly behind the • OK – The readings are within the specifications.
sensor. Proceed to Test Step 5.
Resistance ........................ 600 to 1800 Ohms • Not OK – The readings are not within the
specifications.
Expected Result:
Repair: Perform the following procedure in order
The readings are within the specifications. to check and install the new sensor:
A. Disconnect the suspect sensor from the engine c. Lubricate the O-ring.
harness.
d. Seat the sensor and tighten the bolt.
B. Thoroughly inspect the sensor’s connectors.
Refer to Troubleshooting, “Electrical Connectors - If the sensor will not seat, repair the sensor
Inspect” for details. or replace the sensor, as required.
C. If you are troubleshooting a problem with the Note: Do not remove the sensor from the bracket.
primary engine speed/timing sensor, perform the
following procedure: e. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
a. Measure the sensor’s resistance between location.
J401-2 (Primary engine speed/timing positive)
and J401-1 (Primary engine speed/timing 2. Verify that the repair eliminates the problem.
negative).
STOP.
Resistance ............................. 75 to 230 Ohms
Test Step 5. Install the Bypass Harness
D. If you are troubleshooting a problem with the for the Engine Speed/Timing Sensors
primary engine speed/timing sensor, perform the
following procedure: A. Turn the keyswitch to the OFF position.
C. Use the following procedure for the primary engine B. Temporarily connect a test ECM.
speed/timing sensor:
C. Start the engine. Run the engine in order to repeat
a. Fabricate a harness from two wires. The the conditions when the problem occurs.
wires must reach between the primary engine
speed/timing sensor and the P2 connector. D. If the problem is resolved with the test ECM,
Twisted pair wiring is required. Ensure that the reconnect the suspect ECM.
wires have at least one twist per inch.
E. If the problem returns with the suspect ECM,
b. Connect one wire of the harness between replace the ECM.
P2-35 and P401-2.
Verify that the repair eliminates the problem.
c. Connect the other wire between P2-25 and
P401-1. Expected Result:
D. Use the following procedure for the primary engine The problem remains with the suspect ECM.
speed/timing sensor:
Results:
a. Fabricate a harness from two wires. The wires
must reach between the secondary engine • OK
speed/timing sensor and the P2 connector.
Twisted pair wiring is required. Ensure that the Repair: If the problem is resolved with the test
wires have at least one twist per inch. ECM and the problem returns with the suspect
ECM, replace the ECM.
b. Connect one wire of the harness between
P2-46 and P402-2. Verify that the repair eliminates the problem.
Results:
Engine Temperature Sensor
Open or Short Circuit - Test
• OK
SMCS Code: 5574-038-TA
Repair: Permanently install a new section of
harness. System Operation Description:
Pull-up Voltage
g01239916
Illustration 81
Schematic for the engine temperature sensors
g01216577
Illustration 83
P1 terminals that are associated with the auxiliary temperature
sensor
(P1-3) Return
(P1-16) Auxiliary temperature
g01146245
Illustration 82
P2 ECM connector
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature
(P2-62) Fuel temperature
RENR5042-03 151
Troubleshooting Section
Results:
STOP.
B. Turn the keyswitch to the ON position. Repair: The low resistance measurement indicates
a short circuit between two or more wires. Repair
C. Measure the voltage between terminal 1 (signal) the connectors or wiring and/or replace the
and terminal 2 (sensor common) at the sensor connectors or wiring.
connector.
STOP.
D. Turn the keyswitch to the OFF position.
Test Step 5. Create a Short at the Suspect
Expected Result: Sensor Connector
The voltage is 5.5 ± 0.5 VDC. A. Turn the keyswitch to the OFF position.
A. Turn the keyswitch to the OFF position. An 04 diagnostic code is active when the jumper wire
is installed. An 03 diagnostic code is active when the
B. Disconnect the P2 connector. jumper wire is removed.
Each check of the resistance is greater than 20,000 • Not OK – The 03 diagnostic code remains active
Ohms. with the jumper in place. There is an open circuit
between the ECM and the sensor connector.
Results: Proceed to Test Step 7.
• OK – Each check of the resistance is greater than Test Step 6. Disconnect the Suspect
20,000 Ohms. Proceed to Test Step 5. Sensor in Order to Create an Open Circuit
• Not OK – At least one check of the resistance is A. Turn the keyswitch to the OFF position.
less than 20,000 Ohms.
RENR5042-03 153
Troubleshooting Section
B. Disconnect the suspect sensor from the harness An 03 diagnostic code should be active for the
at the sensor connector. suspect sensor.
C. Turn the keyswitch to the ON position. Wait at C. Check the operation of the ECM by creating a
least 15 seconds for activation of the diagnostic short at the ECM.
codes.
a. Install a wire jumper between the terminals for
D. Access the “Active Diagnostic Codes” screen on the sensor signal and the sensor return.
the electronic service tool and check for an active
03 diagnostic code for the suspect sensor. b. Monitor the “Active Diagnostic Code” screen
on the electronic service tool. Wait at least 15
E. Turn the keyswitch to the OFF position. seconds for activation of the code.
Verify that the repair eliminates the problem. Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire
STOP. for the sensor. Repair the return wire for the sensor
or replace the harness.
• Not OK – The 04 diagnostic code is still present.
Leave the sensor disconnected. Proceed to Test If the code is only active for one sensor, the
Step 7. problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.
Test Step 7. Check the Operation of the
ECM STOP.
A. Turn the keyswitch to the OFF position. • Not OK – One of the following conditions exists:
The 03 diagnostic code is not active when the
B. Check the operation of the ECM by creating an sensor signal wire is disconnected. The 04
open at the ECM. diagnostic code is not active when the wire jumper
is installed.
a. Remove the signal wire for the suspect sensor
from the P2connector. Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
b. Remove the sensor return from terminal P2-30. Verify that the problem is resolved.
g01121249
Illustration 85
Schematic of the ether injection system
Expected Result:
Results:
STOP.
g01120529
Illustration 88
J61/P61 terminals for the ether injection system
(22) Ether relay
(38) Ether starting aid switch
Expected Result:
Results:
• Not OK – The connectors and/or wiring are not Repair: Replace the empty ether canister with a
OK. full ether canister. Verify that the original problem
is resolved.
Repair: Repair the wiring and/or the connectors.
Replace parts, if necessary. STOP.
Verify that the original problem is resolved. Test Step 5. Check the Voltage at the
Ether Start Relay
STOP.
A. Turn the keyswitch to the OFF position.
Test Step 3. Check for Active Diagnostic
Codes B. Connect Cat ET to the service tool connector.
A. Connect the Caterpillar Electronic Technician C. Remove the ether canister from the ether valve.
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. D. Remove the wire from terminal 87 of the normally
open contacts of the ether relay that goes to the
B. Turn the keyswitch to the ON position. ether injection solenoid.
C. Monitor the active diagnostic code screen on Cat E. Connect a voltmeter between terminal 87 of the
ET. Check and record any active diagnostic codes. ether relay and ground.
Note: Wait at least 15 seconds in order for the F. Turn the keyswitch to the ON position.
diagnostic codes to become active.
G. Select the “Diagnostic Tests” on Cat ET.
D. Determine if the problem is related to an open
circuit diagnostic code 05 or to a short circuit H. Select the “Override Parameters” screen on Cat
diagnostic code 06. ET.
Expected Result: I. Activate the ether override. The ECM will activate
the ether injection system for ten seconds.
No active codes are present.
J. Measure the voltage at the ether relay while the
Results: ether injection system is activated.
• OK – No active codes are present. However, the K. Deactivate the ether override.
ether injection system does not inject ether. Check
that ether injection is configured “ON” in Cat ET. L. Turn the keyswitch to the OFF position.
Check for tripped breakers. Proceed to Test Step 4.
M. Reconnect the wire to terminal 87 of the ether
• Not OK – There is an active diagnostic code for relay.
the ether injection system. Proceed to Test Step 5.
Expected Result:
Test Step 4. Check the Ether Canister
The voltage at the ether relay is 24 ± 3 VDC.
A. Turn the keyswitch to the OFF position.
Results:
B. Remove the ether canister from the ether valve.
Determine if the canister is empty. • OK – The voltage at the ether relay is 24 ± 3 VDC.
Proceed to Test Step 6.
Expected Result:
• Not OK - 24 VDC – The voltage at the ether relay
The ether canister is not empty. is not 24 ± 3 VDC. Proceed to Test Step 7.
• Not OK – The ether canister is empty. B. Disconnect the electrical connector for the ether
injection solenoid.
158 RENR5042-03
Troubleshooting Section
C. At the harness connector for the ether injection E. Select the “Diagnostic Tests” on Cat ET.
solenoid, connect a voltmeter between terminal 1
and engine ground. F. Select the “Override Parameters” screen on Cat
ET.
D. Turn the keyswitch to the ON position.
G. Activate the ether override. The ECM will activate
E. Select the “Diagnostic Tests” on Cat ET. the override for ten seconds. Observe the
voltmeter while the ether injection system is
F. Select the “Override Parameters” screen on Cat activated.
ET.
H. Deactivate the ether override.
G. Activate the ether override. The ECM will activate
the override for ten seconds. Observe the I. Turn the keyswitch to the OFF position.
voltmeter while the ether injection system is
activated. J. Connect the wire to terminal 86 of the ether start
relay.
H. Deactivate the ether override.
Expected Result:
I. Turn the keyswitch to the OFF position.
The voltage measures 24 ± 3 VDC.
J. Connect all of the connectors.
Results:
Expected Result:
• OK – The voltage was 24 ± 3 VDC. Proceed to
The voltage at the ether injection solenoid is 24 ± 3 Test Step 8.
VDC.
• Not OK – The voltage was not 24 ± 3 VDC.
Results: Proceed to Test Step 10.
• OK – The voltage at the ether injection solenoid Test Step 8. Check the Voltage to the
is 24 ± 3 VDC. Normally Open Contacts of the Ether
Relay from the Keyswitch
Repair: Verify that the wire from the ether injection
solenoid to the −Battery has continuity. If the wire A. Turn the keyswitch to the ON position.
is OK, replace the ether injection solenoid.
B. Measure the voltage between terminal 30 of the
STOP. ether relay and ground.
• Not OK – The voltage at the ether injection C. Turn the keyswitch to the OFF position.
solenoid is not 24 ± 3 VDC.
Expected Result:
Repair: Inspect the wiring and connectors between
the normally open contacts of the ether relay The voltage is 24 ± 3 VDC.
and the connector at the ether injection solenoid.
Repair the connectors or wiring and/or replace the Results:
connectors or wiring.
• OK – The voltage is 24 ± 3 VDC.
STOP.
Repair: Verify that the wire from terminal 85 of the
Test Step 7. Check the Voltage at the Coil ether relay has continuity to the −Battery. If the
of the Ether Relay wire is OK, replace the ether relay. Verify that the
original problem is resolved.
A. Turn the keyswitch to the OFF position.
If the wire from terminal 85 of the ether start relay
B. Disconnect the wire from terminal 86 of the ether does not have continuity to the −Battery, repair the
relay. wire. Replace the wire, if necessary. Verify that the
original problem is resolved.
C. Connect a voltmeter between the end of the wire
and engine ground. STOP.
• Not OK – The voltage is not 24 ± 3 VDC. Proceed B. Remove wire 382-PK from terminal P1-10. Install
to Test Step 9. a jumper wire into terminal P1-10.
Test Step 9. Check the Voltage from the C. Connect a voltmeter between the −Battery and
Keyswitch to the Ether Relay the other end of the jumper wire.
A. Turn the keyswitch to the OFF position. D. Turn the keyswitch to the ON position.
B. Remove the wire from terminal R of the keyswitch. E. Select the “Diagnostic Tests” on Cat ET.
C. Turn the keyswitch to the ON position. F. Select the “Override Parameters” screen on Cat
ET.
D. Measure the voltage between terminal B of the
keyswitch and engine ground. G. Activate the ether override. The ECM will activate
the override for ten seconds. Observe the
E. Measure the voltage between terminal R of the voltmeter while the ether injection system is
keyswitch and engine ground. activated.
F. Turn the keyswitch to the OFF position. H. Deactivate the ether override.
Voltage is present on terminal B and terminal R at J. Remove the wire jumper and install wire 382-PK
the keyswitch. into P1-10.
Repair: If voltage is present on terminal B of the B. Disconnect the wire on terminal 86 of the ether
keyswitch but not present on terminal R, replace relay.
the keyswitch. Return all wiring to the original
configuration. Verify that the problem is resolved. C. Disconnect ECM connector J1/P1.
Repair: Repair the wire between terminal 86 of Use this procedure for the following diagnostic codes:
the ether relay and terminal P1-10. Verify that the
original problem is resolved. • 1-05 Cylinder #1 Injector open circuit
A. Turn the keyswitch to the OFF position. • 3-05 Cylinder #3 Injector open circuit
B. Disconnect the wire on terminal 86 of the ether • 3-06 Cylinder #3 Injector short
relay.
• 4-05 Cylinder #4 Injector open circuit
C. Disconnect the J1/P1 and J2/P2 connectors.
• 4-06 Cylinder #4 Injector short
D. Measure the resistance between terminal P1-10
and all of the other terminal in the P1 and P2 • 5-05 Cylinder #5 Injector open circuit
connectors. Measure the resistance between wire
P1-10 and engine ground. • 5-05 Cylinder #5 Injector short
E. Return the wiring to the original configuration. • 1-06 Cylinder #6 Injector open circuit
Each check of the resistance indicates an open • You have been directed to this procedure from
circuit. Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
Results:
Perform this procedure under conditions that are
• OK – Each check of resistance indicates an open identical to the conditions that exist when the problem
circuit. occurs. Typically, problems with an injector solenoid
occur when the engine is warm and/or when the
Repair: The problem may be intermittent. If the engine is under vibration (heavy loads).
problem is intermittent, refer to Troubleshooting,
“Electrical Connectors - Inspect”. These engines have Electronic Unit Injectors (EUI)
that are mechanically actuated and electronically
STOP. controlled. The Engine Control Module (ECM) sends
a 105 volt pulse to each injector solenoid. The pulse
• Not OK – At least one check of the resistance does is sent at the proper time and at the correct duration
not indicate an open circuit. There is a problem for a given engine load and speed. The solenoid
with the wiring. There may be a problem with a is mounted on top of the fuel injector body. The
connector. 105 volt pulse can be individually cut out to aid in
troubleshooting misfire problems.
Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the original
problem is resolved.
STOP.
RENR5042-03 161
Troubleshooting Section
g01216792
Illustration 90
Schematic diagram for the injector solenoids
RENR5042-03 163
Troubleshooting Section
g01001203
Illustration 92
Harness connector for the injectors
Expected Result:
• OK – The harness and wiring are OK. Proceed F. Select the start button at the bottom of the screen
to Test Step 2. for the cylinder cutout test on Cat ET.
• Not OK – There is a problem in the connectors G. Select the “4 Cylinder Cutout Test” which is the
and/or wiring. default test.
Repair: Repair the connectors or wiring and/or H. Follow the instructions that are provided in the
replace the connectors or wiring. Ensure that all of cylinder cutout test. The cylinder cutout tests
the seals are properly in place and ensure that the are interactive so you will be guided through the
connectors are completely coupled. procedure.
Verify that the repair eliminates the problem. Note: The “Manual Cylinder Cutout Test” is also
available. Access the manual test by selecting the
STOP. “Change” button on the screen for the cylinder
cutout test. The “4 Cylinder Cutout Test” is the
Test Step 2. Check for Logged Diagnostic recommended starting procedure. The automated
Codes for the Injector Solenoids tests run twice collecting data.
A. Connect Cat ET to the service tool connector. I. As the test is running, check the “Fuel Position” for
the cylinders.
B. Turn the keyswitch to the ON position.
Expected Result:
C. Check for logged diagnostic codes that are related
to the injector solenoids. The “Fuel Position” for the cylinders does not change
during the test.
Expected Result:
Results:
One or more diagnostic codes that are related to the
injector solenoids have been logged. • OK – The “Fuel Position” for the cylinders does
not change during the test. The cylinders seem to
Results: be OK.
• OK – One or more diagnostic codes are logged. Repair: If the engine was misfiring or if the
Proceed to Test Step 4. engine has low power, refer to Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”
• Not OK – No diagnostic codes are logged. and Troubleshooting, “Low Power/Poor or No
Proceed to Test Step 3. Response to Throttle”.
Test Step 3. Check the Variation of the If a diagnostic code results from running the
Injectors Between Cylinders Cylinder Cutout test, proceed to Test Step 4.
A. Start the engine. • Not OK – The “Fuel Position” for one or more
cylinders increased during the test. At least one of
B. Allow the engine to warm up to the normal the injectors is not firing properly. Proceed to Test
operating temperature. Step 4.
C. After the engine is warmed up to the operating Test Step 4. Use the “Injector Solenoid
temperature, access the “Cylinder Cutout Test” by Test” to Test the Injector Solenoids
accessing the following display screens in order:
A. Start the engine.
• “Diagnostics”
B. Allow the engine to warm up to normal operating
• “Diagnostic Tests” temperature.
D. Shut off all parasitic loads such as air compressors D. Turn the keyswitch to the ON position.
which could affect the results of the test.
RENR5042-03 165
Troubleshooting Section
E. Access the “Injector Solenoid Test” by accessing C. Turn the keyswitch to the ON position.
the following display screens in order:
D. Fabricate a jumper wire 100 mm (4 inch) long with
• “Diagnostics” Deutsch pins on both ends of the wire.
• “Diagnostic Tests” E. Insert one end of the jumper wire into the common
socket for the suspect injector on the harness
• “Injector Solenoid Test” connector. Insert the other end of the jumper wire
into the socket for the suspect injector on the
F. Activate the test. harness connector.
Note: Do not confuse the “Injector Solenoid Test” F. Perform the “Injector Solenoid Test” at least two
with the “Cylinder Cutout Test”. The “Cylinder Cutout times.
Test” is used to shut off fuel to a specific cylinder
while the engine is running. The “Injector Solenoid G. Repeat this test for each suspect injector. Stop
Test” is used to actuate the injector solenoids. This the “Injector Solenoid Test” before handling the
allows the click of the injector solenoids to be heard jumper wires.
when the engine is not running in order to determine
that the circuit is functioning properly. Expected Result:
G. As each solenoid is energized by the ECM, an Cat ET displays “Short” for the cylinder with the
audible click can be heard at the valve cover. jumper wire.
All cylinders indicate “OK”. • Not OK – There is a problem between the ECM
and the valve cover base. Proceed to Test Step 7.
Results:
Test Step 6. Check the Injector Harness
• OK – There is not an electronic problem with the under the Valve Cover
injectors at this time.
• Short – Note the cylinders that indicate “Short”. B. Remove the valve cover.
Proceed to Test Step 8.
C. Disconnect the harness from the suspect injector.
Test Step 5. Check the Harness Between Disconnect the harness from the injector that
the ECM and the Valve Cover Base for an shares the same supply wire.
Open Circuit
Note: If both injectors that share a wire indicate
“Open”, inspect the common wire under the valve
cover for problems. The open circuit is probably
caused by an open in the shared wire.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts. D. Thoroughly clean the terminals on both injectors
and the harness connectors.
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch E. Exchange the harness between the two injectors
is not turned off. that share the supply wire.
B. Disconnect the connector from the valve cover F. Turn the keyswitch to the ON position.
base.
166 RENR5042-03
Troubleshooting Section
• Yes – Exchanging the harness between the two Repair: Repair the engine harness or replace the
injectors caused the problem to move to the other engine harness, as required.
injector. The problem is in the harness that was
exchanged. Verify that the repair eliminates the problem.
Perform the “Injector Solenoid Test”. • Not OK – Cat ET does not display “Short” for the
cylinder with the jumper wire. The ECM is not OK.
Verify that the repair eliminates the problem.
Repair: Perform the following procedure:
STOP.
1. Remove the jumper wire and return the P2
• No – Exchanging the harness between the two wiring to the original configuration.
injectors does not cause the problem to move to
the other injector. There is a problem with the 2. Temporarily connect a test ECM.
injector.
3. Perform the “Injector Solenoid Test”.
Repair: Replace the malfunctioning injector.
If the test ECM fixes the problem, reconnect the
Verify that the repair eliminates the problem. suspect ECM. If the problem returns with the
suspect ECM, replace the ECM. Verify that the
STOP. repair eliminates the problem.
STOP.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts. Test Step 10. Check the Engine Harness
under the Valve Cover for a Short Circuit
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
is not turned off.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
B. Disconnect the P2 connector. Check the P2 and
J2 connectors for evidence of moisture entry.
A. Turn the keyswitch to the OFF position. A strong
C. Turn the keyswitch to the ON position. electrical shock hazard is present if the keyswitch
is not turned off.
D. Perform the “Injector Solenoid Test” at least two
times. B. Remove the valve cover.
Note: When the engine harness is disconnected, D. Turn the keyswitch to the ON position.
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of E. Perform the “Injector Solenoid Test” at least two
these diagnostic codes after completing this test step. times.
• OK – All cylinders indicate “Open” when the P2 All of the injectors that were disconnected indicate
connector is disconnected. The short circuit is in “Open”.
the engine harness.
Results:
Repair: The problem is most likely in the shared
supply wire to the injector. Inspect the connectors • OK – All of the injectors that were disconnected
for moisture and for corrosion. Also, check the indicate “Open”. The shared wire is not shorted.
common wire for exposed wires.
Repair: Leave the injector wires disconnected.
Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes Proceed to Test Step 11.
after completing this test step.
• Not OK – One or more of the injectors that were
Verify that the repair eliminates the problem. disconnected indicate “Short”.
Repair the injector harness or replace the injector Repair the injector harness or replace the injector
harness under the valve cover. harness.
Verify that the repair eliminates the problem. Perform the “Injector Solenoid Test”.
Results:
STOP.
Expected Result:
Results:
a. Turn the keyswitch to the ON position. The • OK – The connectors and wiring are OK. Proceed
lamp should turn on for five seconds. Then, the to Test Step 3.
lamp should turn off.
• Not OK – There is a problem in the connectors
Note: The lamp will only turn off if a condition that and/or wiring.
requires maintenance does not exist. Ensure that the
maintenance interval has not been exceeded.
170 RENR5042-03
Troubleshooting Section
Repair: Repair the connectors or wiring and/or Repair: Repair wire F424-YL between the lamp
replace the connectors or wiring. Ensure that all of and terminal P1-30.
the seals are properly in place and ensure that the
connectors are completely coupled. STOP.
Verify that the repair eliminates the problem. • Not OK – The lamp did not turn on. The lamp
circuit is not functioning properly. Proceed to Test
STOP. Step 5.
Test Step 3. Test the Lamp Circuit Test Step 5. Check the Voltage from the
Keyswitch to the Maintenance Due Lamp
A. Disconnect the P1 connector.
A. Turn the keyswitch to the OFF position.
B. Connect a jumper wire between wire F424-YL in
terminal P1-30 and engine ground. B. Remove the wire from the terminal R of the
keyswitch.
C. Turn the keyswitch to the ON position. Observe
the lamp. C. Turn the keyswitch to the ON position.
D. Remove the jumper wire and observe the lamp. D. Measure the voltage on terminal B of the
keyswitch to engine ground.
Expected Result:
E. Measure the voltage on terminal R of the
The maintenance due lamp turns on while the jumper keyswitch to engine ground.
is connected. The maintenance due lamp turns off
when the jumper is removed. F. Turn the keyswitch to the OFF position.
• OK – The maintenance due lamp circuit is Voltage is present on terminal B and terminal R at
functioning properly. Proceed to Test Step 6. the keyswitch.
• Not OK – The lamp did not turn on. The lamp Results:
circuit is not functioning properly. Proceed to Test
Step 4. • OK – Voltage is present on terminal B and terminal
R at the keyswitch.
Test Step 4. Test the Circuit at the
Maintenance Due Lamp Repair: If voltage is present on terminal R,
repair the wire between the keyswitch and the
A. Disconnect wire F424-YL from the lamp. maintenance due lamp. Verify that the breaker
is not tripped. Return all wiring to the original
B. Connect a jumper wire between the lamp’s empty configuration. Verify that the problem is eliminated.
terminal and engine ground.
STOP.
C. Turn the keyswitch to the ON position. Observe
the lamp. • Not OK – Voltage is not present on terminal B at
the keyswitch.
D. Disconnect the jumper wire and observe the lamp.
Repair: If voltage is not present on terminal B,
Expected Result: repair the wire between the +Battery and the
keyswitch. Verify that the breaker is not tripped.
The lamp turns on while the jumper is connected. Check the battery’s no-load voltage. Return all
The lamp turns off when the jumper is disconnected. wiring to the original configuration. Verify that the
problem is eliminated.
Results:
STOP.
• OK – The circuit for the lamp is functioning
properly. • Not OK – Voltage is not present on terminal R at
the keyswitch.
RENR5042-03 171
Troubleshooting Section
C. Insert one end of the jumper wire into terminal The Electronic Control Module (ECM) provides the
P1-30. PTO speed control function. The PTO speed control
function requires the following inputs:
D. Connect one probe of a voltage test lamp to the
wire jumper in terminal P1-30. • PTO switches
E. Connect the other probe of the voltage test lamp • The “PTO Mode” parameter
to +Battery.
The PTO switches enable the PTO speed control
F. Turn the keyswitch to the ON position. function and the PTO switches control the desired
engine speed.
Expected Result:
The “PTO Mode” parameter determines the mode
The test lamp turns ON for five seconds. Then, the of operation. There are two modes of operation:
test lamp turns OFF. “Ramp Up/Ramp Down” and “Set/Resume”. Use
the Caterpillar Electronic Technician (ET) in order to
Results: change the value of the parameter.
• OK – The ECM is operating correctly. The circuit “Ramp Up/Ramp Down” Mode
appears to be operating correctly.
This mode uses three inputs. The inputs are provided
Repair: The problem may be intermittent. If the by two switches. Refer to Illustration 95.
problem is intermittent, refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
STOP.
STOP.
172 RENR5042-03
Troubleshooting Section
g01121879
Illustration 95
Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation
“Set/Resume” Mode
g01105373
Illustration 96
Schematic for the PTO inputs for the “Set/Resume” mode of operation
A. Turn the keyswitch to the OFF position. (1) P61 customer connector
(1) J1/P1 ECM connectors
174 RENR5042-03
Troubleshooting Section
g01123458
Illustration 99
J61/P61 terminals that are associated with the PTO
(19) Input from the PTO interrupt switch
(29) Input from the PTO enable switch
(30) Input from the PTO ramp up switch or set switch
(39) Input for PTO ramp down switch or resume switch
Expected Result:
STOP.
i02433846
g01120532 g01121943
Illustration 101 Illustration 102
Left side view P1 terminals for the various switches
(1) P61 customer connector (P1-6) Maintenance clear switch
(2) J1/P1 Electronic Control Module (ECM) connectors (P1-7) Torque limit switch
(P1-22) Ether starting aid switch
(P1-41) PTO interrupt switch
B. Thoroughly inspect connectors (1) and (2). (P1-44) Remote shutdown switch
Thoroughly inspect the connections for the (P1-45) Intermediate engine speed switch
suspect switch. Refer to Troubleshooting, (P1-54) Overspeed verify switch
“Electrical Connectors - Inspect”. (P1-56) PTO enable switch
(P1-58) PTO ramp up switch or set switch
(P1-60) PTO ramp down switch or resume switch
178 RENR5042-03
Troubleshooting Section
Results:
STOP.
Table 19
Expected Result:
C. Connect a meter lead to the P1 terminal for the
suspect switch. Connect the other meter lead to
All connectors, pins, and sockets are completely
engine ground.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
RENR5042-03 179
Troubleshooting Section
Results:
If the switch does not operate correctly, there may Illustration 104
g01123466
be a short circuit between the circuit for the suspect Electronic throttle position sensor
switch and another circuit. Carefully reinspect the
components. Refer to Troubleshooting, “Electrical
Inspectors - Inspect”. Locate the short circuit and
make repairs.
STOP.
STOP.
180 RENR5042-03
Troubleshooting Section
g01122050
Illustration 106
Throttle position sensor with a knob
g01122143
Illustration 107
Duty cycle versus throttle position
g01122222
Illustration 108
Schematic for the throttle position sensor
Test Step 1. Inspect the Electrical B. Thoroughly inspect connectors (1) and (2). Inspect
Connectors and the Wiring the connections on the throttle position sensor.
Refer to Troubleshooting, “Electrical Connectors
A. Turn the keyswitch to the OFF position. - Inspect”.
g01120532 g01122213
Illustration 109 Illustration 110
Left side view P1 terminal that is associated with the throttle position sensor
(1) P61 customer connector (P1-66) Throttle position
(2) J1/P1 connectors
182 RENR5042-03
Troubleshooting Section
STOP.
Expected Result:
g01122217
Results:
Illustration 111
J61 and P61 terminal that is associated with the throttle position • OK – The supply voltage is at least 11 VDC for a
(10) Throttle position 12 volt system. The supply voltage is at least 22
VDC for a 24 volt system. The supply voltage is
C. Perform a 45 N (10 lb) pull test on each of the reaching the sensor. Proceed to Test Step 3.
wires that are associated with the throttle position
sensor. • Not OK – The supply voltage is incorrect.
D. Check the allen head screw on each ECM Repair: The configuration of the wiring between the
connector for the proper torque. Refer to +Battery and the throttle position sensor depends
Troubleshooting, “Electrical Connectors - Inspect” on the engine’s configuration. The problem could
for the correct torque values. be in the wiring or in a connector. There may be a
problem with the battery.
E. Check the allen head screw on the customer
connector for the proper torque. Refer to Perform the necessary repairs. Verify that the
Troubleshooting, “Electrical Connectors - Inspect” problem is resolved.
for the correct torque value.
STOP.
F. Check the harness and wiring for abrasions and
for pinch points from the throttle position sensor Test Step 3. Check the Signal Wire for a
to the ECM and from the throttle position sensor Short Circuit
to the battery.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect the P1 connector.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Note: Be sure to wiggle the harnesses during the
are free of corrosion, of abrasion or of pinch points. following measurements. Be sure to wiggle each
harness near each connector.
Results:
C. Measure the resistance between terminal P1-66
• OK – The wiring and the connectors are OK. and all of the other terminals in the P1 connector.
Proceed to Test Step 2.
RENR5042-03 183
Troubleshooting Section
• Not OK – At least one resistance measurement F. Observe the “Active Diagnostic” screen on Cat
does not indicate an open circuit. There is a ET. Slowly move the throttle from the low idle
problem with the signal wire for the throttle position position to the high idle position. Look for a 091-08
sensor. diagnostic code while you move the throttle.
Measure the resistance between terminal P1-66 and 1. Turn the keyswitch to the off position.
terminal P403-C.
2. Remove the 208-0059 Adapter Cable As
Expected Result: (70-PIN BREAKOUT).
The resistance measurement is less than ten Ohms. 3. Connect the J1/P1 connectors.
• OK – The resistance measurement is less than 5. Operate the throttle throughout the entire range.
ten Ohms. Connect the P403 connector. Proceed
to Test Step 5. If the problem does not recur, the problem is
resolved. The original problem was probably
• Not OK – The resistance measurement is greater caused by a poor electrical connection. Return
than ten Ohms. There is a problem with the signal the engine to service.
wire.
STOP.
Repair: The problem could be in the wiring or in a
connector. Repair the wiring and/or the connector, • Not OK – The frequency of the signal is incorrect.
when possible. Replace parts, if necessary. Verify A 091-08 diagnostic code is activated.
that the problem is resolved.
Repair: Perform the following procedure:
STOP.
1. Turn the keyswitch to the off position.
Test Step 5. Check the Frequency of the
Throttle Position Signal at the ECM 2. Replace the throttle position sensor. Check for
a 091-08 diagnostic code again.
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to If the diagnostic code does not recur, the
Troubleshooting, “Electronic Service Tools”. problem is resolved. Return the engine to
service.
B. Connect a 208-0059 Adapter Cable As (70-PIN
BREAKOUT) between the P1 connector and the
J1 connector.
184 RENR5042-03
Troubleshooting Section
If the diagnostic code recurs, replace the ECM. Note: The lamp will only turn off only if a “Warning”, a
Refer to Troubleshooting, “Replacing the ECM”. “Derate”, or a “Shutdown” condition does not exist.
Verify that the problem is resolved.
Expected Result:
STOP.
The warning lamp turns on and the warning lamp
turns off per the above description.
i02435122
Use this procedure to troubleshoot any suspect Test Step 2. Inspect the Electrical
problems with the circuit for the warning lamp. Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
g01122447
Illustration 112
Schematic for the warning lamp
g01216603
Illustration 115
J61 and P61 terminals that are associated with the warning lamp
(25) Warning lamp
Expected Result:
Results:
C. Turn the keyswitch to the ON position. Observe • Not OK – The warning lamp did not turn on when
the warning lamp. the jumper wire was connected. There is a problem
with the +Battery side of the circuit for the warning
D. Remove the jumper wire and observe the warning lamp. Proceed to Test Step 5.
lamp.
Test Step 5. Check the Voltage from the
Expected Result: Keyswitch to the Warning Lamp
The warning lamp turned on while the jumper was A. Turn the keyswitch to the OFF position.
connected. The warning lamp turned off when the
jumper was removed. B. Remove the wire from the terminal R of the
keyswitch.
Results:
C. Turn the keyswitch to the ON position.
• OK – The warning lamp turned on while the jumper
was connected. The warning lamp turned off when D. Measure the voltage on terminal B of the
the jumper was removed. The warning lamp circuit keyswitch to engine ground.
is functioning properly. Proceed to Test Step 6.
E. Measure the voltage on terminal R of the
• Not OK – The warning lamp did not turn on. There keyswitch to engine ground.
is a problem with the circuit for the warning lamp.
Proceed to Test Step 4. F. Turn the keyswitch to the OFF position.
Repair: If voltage is not present on terminal B, Repair: Temporarily connect a test ECM. Refer to
repair the wire between the +Battery and the Troubleshooting, “Replacing the ECM”. Check the
keyswitch. Check the battery’s no-load voltage. operation of the warning lamp when the test ECM
Return all wiring to the original configuration. Verify is installed.
that the problem is resolved.
If the problem is resolved with the test ECM,
STOP. reconnect the original ECM. If the problem returns
with the original ECM, replace the original ECM.
• Not OK – Voltage is not present on terminal R at Verify that the problem is resolved.
the keyswitch.
STOP.
Repair: If voltage is present on terminal B of the
keyswitch but not present on terminal R, replace
the keyswitch. Return all wiring to the original
configuration. Verify that the problem is resolved.
STOP.
Expected Result:
Results:
STOP.
Table 20
Required Special Tools
Part Number Description
7X-1171 Transducer Adapter
6V-2197 Transducer
7X-1695 Cable As
170-3519 Harness (1)
(1) This item is not required if the engine harness has a connector
for timing calibration.
E. Remove the plug from the timing calibration port. d. Install the white wire of the 170-3519 Harness
into the appropriate location.
F. Thread the transducer adapter into the port.
e. Install the yellow wire of the 170-3519
Continue to the next test step. Harness into the appropriate location.
Disregard the pin-outs on the label of the
Test Step 2. Install the Transducer harness.
A. If the engine harness is equipped with a connector B. Start the engine and run the engine until the
for timing calibration, connect the 7X-1695 Cable engine is at the normal operating temperature.
As to the connector for timing calibration and to
the transducer. C. Check for active diagnostic codes. Wait at least 30
seconds in order for the codes to become active.
B. If the engine harness is not equipped with a
connector for timing calibration, perform the The engine must not have any active diagnostic
following procedure: codes during the timing calibration except for a
261-13 Engine Timing Calibration required.
190 RENR5042-03
Troubleshooting Section
There are no active diagnostic codes or there is only 5. Remove the transducer and remove the
an active 261-13 diagnostic code. adapter.
• OK – There are no active diagnostic codes or 7. If you installed a 170-3519 Harness, you may
there is only an active 261-13 diagnostic code. remove the harness or you may permanently
Proceed to Test Step 5. install the harness for future use. If you remove
the harness, install the sealing plugs into the
• Not OK – There is at least one active code that unused cavities of the P2 connector. Otherwise,
is not 261-13. moisture and debris will enter the connector.
Repair: Troubleshoot and repair any active If you choose to permanently install the harness,
diagnostic codes before you continue with this fasten the harness to the existing engine wiring
procedure. harness with cable ties. Also, install a 3E-3364
Receptacle and two 8T-8737 Seal Plugs on
STOP. the P400 timing calibration probe connector
in order to prevent moisture and debris from
Test Step 5. Calibrate the Engine entering the connector.
Speed/Timing Sensor
8. Return the engine to service.
A. Set the engine speed to 1100 ± 50 rpm. The
engine speed must be steady within this rpm STOP.
range in order for the calibration to be successful.
• Not OK – The timing calibration was unsuccessful.
B. After the engine has warmed up, access the
“Timing Calibration” screen on the Cat ET. Access Repair: The following conditions can cause the
the following display screens in order: timing calibration to fail:
Note: When you adjust the high idle on some types 2. Verify that the “Throttle Position” is zero percent
of linkage, the low idle adjustment may change. when the throttle is at low idle.
B. Verify that low idle is correctly adjusted. Make Proceed to Test Step 6.
adjustments, if necessary.
Test Step 6. Configure the Calibration for
Expected Result: High Idle
When the throttle is at high idle, the “Throttle Position” A. Move the throttle to high idle.
is 100 percent. When the throttle is at low idle, the
“Throttle Position” is zero percent. B. Check the “Throttle Position” on the status screen
of Cat ET.
Results:
C. Verify that the “Throttle Position” is 100 percent.
• OK – When the throttle is at high idle, the “Throttle
Position” is 100 percent. When the throttle is at low Expected Result:
idle, the “Throttle Position” is 0 percent. Calibration
of the throttle is complete. STOP. The “Throttle Position” is 100 percent when the
throttle is in high idle.
• Not OK – The high idle position and/or the low idle
position cannot be adjusted to the specification. An Results:
electronic calibration is required. Proceed to Test
Step 5. • OK – The “Throttle Position” is 100 percent when
the throttle is at high idle. Calibration of the throttle
Test Step 5. Calibrate the Throttle at Low is complete. STOP.
Idle
• Not OK – The “Throttle Position” is not 100 percent
A. Connect Cat ET to the service tool connector. when the throttle is at high idle.
Refer to Troubleshooting, “Electronic Service
Tools”. Repair: Perform the following procedure:
B. Turn the keyswitch to the ON position. Do not start 1. Adjust the “Throttle Input High Idle Duty Cycle
the engine. Setpoint” on the “Configuration” screen on Cat
ET.
C. Move the throttle to low idle.
2. Verify that the “Throttle Position” is 100 percent
D. Observe the “Throttle Position” on the status when the throttle is at high idle.
screen of Cat ET.
STOP.
E. Verify that the “Throttle Position” is zero percent.
Expected Result:
Results:
Index
Numerics CID 0100 FMI 04 Engine Oil Pressure short to
ground.................................................................. 60
5 Volt Engine Pressure Sensor Supply Circuit - CID 0100 FMI 10 Engine Oil Pressure Sensor
Test ...................................................................... 83 abnormal rate of change...................................... 60
CID 0102 FMI 03 Boost Pressure Sensor short to
+batt..................................................................... 60
A CID 0102 FMI 04 Boost Pressure Sensor short to
ground.................................................................. 61
Air Shutoff System - Test ....................................... 90 CID 0102 FMI 10 Boost Pressure Sensor abnormal
Alternator (Charging Problem)............................... 26 rate of change...................................................... 61
Probable Causes ............................................... 26 CID 0110 FMI 03 Engine Coolant Temperature
Recommended Actions...................................... 26 open/short to +batt............................................... 61
CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 62
B CID 0111 FMI 02 Engine Coolant Level Sensor Loss
of Signal............................................................... 62
Battery ................................................................... 26 CID 0168 FMI 00 System Voltage High................. 62
Probable Causes ............................................... 26 CID 0168 FMI 01 System Voltage Low.................. 62
Recommended Actions...................................... 26 CID 0168 FMI 02 System Voltage intermittent/
erratic................................................................... 63
CID 0172 FMI 03 Intake Manifold Air Temp open/short
C to +batt................................................................. 63
CID 0172 FMI 04 Intake Manifold Air Temp short to
Calibration Procedures ........................................ 188 ground.................................................................. 63
CAN Data Link Circuit - Test.................................. 97 CID 0174 FMI 03 Fuel Temperature open/short to
Can Not Reach Top Engine RPM .......................... 26 +batt..................................................................... 64
Probable Causes ............................................... 26 CID 0174 FMI 04 Fuel Temperature short to
Recommended Actions...................................... 27 ground.................................................................. 64
Cat Data Link Circuit - Test.................................. 101 CID 0190 FMI 08 Engine Speed signal abnormal.. 64
CID 0001 FMI 05 Cylinder #1 Injector open CID 0247 FMI 09 J1939 Data Link
circuit ................................................................... 54 communications................................................... 65
CID 0001 FMI 06 Cylinder #1 Injector short .......... 54 CID 0253 FMI 02 Personality Module mismatch ... 65
CID 0002 FMI 05 Cylinder #2 Injector open CID 0261 FMI 13 Engine Timing Calibration
circuit ................................................................... 55 required................................................................ 65
CID 0002 FMI 06 Cylinder #2 Injector short .......... 55 CID 0262 FMI 03 5 Volt Sensor DC Power Supply
CID 0003 FMI 05 Cylinder #3 Injector open short to +batt........................................................ 66
circuit ................................................................... 55 CID 0262 FMI 04 5 Volt Sensor DC Power Supply
CID 0003 FMI 06 Cylinder #3 Injector short .......... 56 short to ground..................................................... 66
CID 0004 FMI 05 Cylinder #4 Injector open CID 0268 FMI 02 Check Programmable
circuit ................................................................... 56 Parameters .......................................................... 66
CID 0004 FMI 06 Cylinder #4 Injector short .......... 56 CID 0274 FMI 03 Atmospheric Pressure open/short
CID 0005 FMI 05 Cylinder #5 Injector open to +batt................................................................. 67
circuit ................................................................... 56 CID 0274 FMI 04 Atmospheric Pressure short to
CID 0005 FMI 06 Cylinder #5 Injector short .......... 57 ground.................................................................. 67
CID 0006 FMI 05 Cylinder #6 Injector open CID 0342 FMI 08 Secondary Engine Speed signal
circuit ................................................................... 57 abnormal.............................................................. 67
CID 0006 FMI 06 Cylinder #6 Injector short .......... 57 CID 0545 FMI 05 Ether Start Relay open/short to
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 58 +batt..................................................................... 67
CID 0041 FMI 04 8 Volt DC Supply short to CID 0545 FMI 06 Ether Start Relay short to
ground.................................................................. 58 ground.................................................................. 68
CID 0091 FMI 08 Throttle Position signal CID 0791 FMI 05 Compression Brake Low/High
abnormal.............................................................. 58 Solenoid current low ............................................ 68
CID 0091 FMI 13 Throttle Position calibration CID 0791 FMI 06 Compression Brake Low/High
required................................................................ 59 Solenoid current high........................................... 68
CID 0094 FMI 03 Fuel Pressure open/short to CID 0792 FMI 05 Compression Brake Medium/High
+batt..................................................................... 59 Solenoid current low ............................................ 69
CID 0094 FMI 04 Fuel Pressure short to ground... 59 CID 0792 FMI 06 Compression Brake Medium/High
CID 0100 FMI 03 Engine Oil Pressure open/short to Solenoid current high........................................... 69
+batt..................................................................... 59 CID 1835 FMI 03 Auxiliary Pressure Sensor
open/short to +batt............................................... 69
194 RENR5042-03
Index Section
CID 1835 FMI 04 Auxiliary Pressure Sensor short to Electronic Service Tools .......................................... 6
ground.................................................................. 69 Caterpillar Electronic Technician (ET).................. 7
CID 1836 FMI 03 Auxiliary Temperature Sensor Optional Service Tools ......................................... 6
open/short to +batt............................................... 70 Required Service Tools ........................................ 6
CID 1836 FMI 04 Auxiliary Temperature Sensor short Electronic Troubleshooting ...................................... 5
to ground.............................................................. 70 Engine Cranks but Will Not Start ........................... 30
CID 2417 FMI 05 Ether Injection Control Solenoid Probable Causes ............................................... 30
current low ........................................................... 70 Recommended Actions...................................... 31
CID 2417 FMI 06 Ether Injection Control Solenoid Engine Has Early Wear ......................................... 32
current high.......................................................... 70 Probable Causes ............................................... 32
Compression Brake Solenoid Circuit - Test ......... 108 Recommended Actions...................................... 32
Coolant in Engine Oil............................................. 28 Engine Misfires, Runs Rough or Is Unstable......... 33
Probable Causes ............................................... 28 Probable Causes ............................................... 33
Recommended Actions...................................... 28 Recommended Actions...................................... 33
Coolant Level Sensor Circuit - Test ..................... 104 Engine Oil in Cooling System ................................ 34
Coolant Temperature Is Too High .......................... 28 Probable Causes ............................................... 34
Customer Passwords ............................................ 15 Recommended Actions...................................... 34
Engine Oil Temperature Is Too High...................... 34
Probable Causes ............................................... 34
D Recommended Actions...................................... 34
Engine Pressure Sensor Open or Short Circuit -
Diagnostic Code Cross Reference ........................ 51 Test .................................................................... 136
Diagnostic Codes .................................................. 50 Engine Speed/Timing Sensor - Calibrate ............ 188
Active Diagnostic Codes .................................... 51 Engine Speed/Timing Sensor Circuit - Test......... 141
Diagnostic Codes............................................... 50 Engine Stalls at Low RPM ..................................... 35
Logged Diagnostic Codes.................................. 51 Probable Causes ............................................... 35
Diagnostic Functional Tests................................... 83 Recommended Actions...................................... 35
Diagnostic Lamp Circuit - Test.............................. 117 Engine Temperature Sensor Open or Short Circuit -
Digital Sensor Supply Circuit - Test ..................... 121 Test .................................................................... 147
Engine Vibration .................................................... 35
Probable Causes ............................................... 35
E Recommended Actions...................................... 36
Engine Will Not Crank ........................................... 36
E057 Low Engine Coolant Level Derate................ 75 Probable Causes ............................................... 36
E058 Low Engine Coolant Level Shutdown .......... 76 Recommended Actions...................................... 36
E059 Low Engine Coolant Level Warning ............. 77 Engine Wiring Information ..................................... 13
E096 High Fuel Pressure ...................................... 77 Harness Wire Identification ................................ 13
E360 Low Engine Oil Pressure.............................. 78 Ether Injection System - Test............................... 154
E361 High Engine Coolant Temperature ............... 78 Event Codes .......................................................... 72
E362 Engine Overspeed ....................................... 80 Active Event Codes............................................ 72
E363 High Fuel Supply Temperature..................... 80 Clearing Event Codes ........................................ 73
E443 High Auxiliary Pressure................................ 81 Logged Event Codes ......................................... 73
E445 High Auxiliary Temperature .......................... 81 Trip Points for the Monitoring System................ 74
E539 High Intake Manifold Air Temperature.......... 81 Troubleshooting ................................................. 73
ECM Will Not Accept Factory Passwords.............. 29 Excessive Black Smoke ........................................ 37
Probable Causes ............................................... 29 Probable Causes ............................................... 37
Recommended Actions...................................... 29 Recommended Actions...................................... 37
ECM Will Not Communicate with Other Systems or Excessive Engine Oil Consumption....................... 38
Display Modules .................................................. 29 Probable Causes ............................................... 38
Probable Causes ............................................... 29 Recommended Actions...................................... 38
Recommended Actions...................................... 29 Excessive Fuel Consumption ................................ 38
ECM/Personality Module - Test ........................... 125 Probable Causes ............................................... 38
Electrical Connectors - Inspect............................ 127 Recommended Actions...................................... 38
Electrical Power Supply Circuit - Test.................. 132 Excessive Valve Lash............................................ 39
Electronic Display Module (If Equipped).................. 8 Probable Causes ............................................... 39
Electronic Service Tool Will Not Communicate with Recommended Actions...................................... 39
ECM..................................................................... 29 Excessive White Smoke ........................................ 39
Probable Causes ............................................... 29 Probable Causes ............................................... 39
Recommended Actions...................................... 30 Recommended Actions...................................... 40
RENR5042-03 195
Index Section
R
F
Replacing the ECM.................................................. 9
Factory Passwords ................................................ 15
Factory Passwords Worksheet.............................. 16
Flash Codes .......................................................... 50 S
Flash Programming ............................................... 16
Programming a Flash File.................................. 16 Self-Diagnostics..................................................... 10
Fuel Dilution of Engine Oil ..................................... 41 Sensors and Electrical Connectors ....................... 10
Probable Causes ............................................... 41 C11 and C13 Engines ........................................ 12
Recommended Actions...................................... 41 C15 and C18 Engines........................................ 13
Fuel in Cooling System.......................................... 41 Service Information Report.................................... 17
Probable Causes ............................................... 41 Recommendations ............................................. 17
Recommended Actions...................................... 41 Switch Circuits - Test ........................................... 176
System Configuration Parameters......................... 19
Monitoring System ............................................. 24
I Parameter Descriptions ..................................... 19
System Configuration Parameters ..................... 22
Important Safety Information ................................... 2 System Overview..................................................... 5
Injector Solenoid Circuit - Test............................. 160 Passwords ........................................................... 6
Injector Trim File .................................................... 17 Programmable Parameters.................................. 6
Intermittent Engine Shutdown ............................... 42 System Operation ................................................ 5
Probable Causes ............................................... 42
Recommended Actions...................................... 42
Intermittent Low Power or Power Cutout............... 43 T
Probable Causes ............................................... 43
Recommended Actions...................................... 43 Table of Contents..................................................... 3
Throttle Position Sensor - Calibrate..................... 191
Throttle Position Sensor Circuit - Test ................. 179
L Troubleshooting Section.......................................... 5
Troubleshooting with a Diagnostic Code ............... 50
Low Engine Oil Pressure ....................................... 44 Troubleshooting with an Event Code..................... 72
Probable Causes ............................................... 44 Troubleshooting without a Diagnostic Code .......... 26
Recommended Actions...................................... 44
Low Power/Poor or No Response to Throttle ........ 44
Probable Causes ............................................... 44 V
Recommended Actions...................................... 45
Valve Rotator or Spring Lock Is Free..................... 49
Probable Causes ............................................... 49
M Recommended Actions...................................... 49