Renr9313 04 00 - Manuals Service Modules - Troubleshooting

RENR9313-04
June 2009
Troubleshooting
C7 and C9 Marine Engines
M7A1-Up (Engine)
C7D1-Up (Engine)
X9X1-Up (Engine)
Z9X1-Up (Engine)
X9Y1-Up (Engine)
C7Z1-Up (Engine)
SAFETY.CAT.COM
i03602780
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
RENR9313-04 3
Table of Contents
Table of Contents Troubleshooting with a Diagnostic Code

Flash Codes .......................................................... 49
Diagnostic Codes .................................................. 49
Diagnostic Code Cross Reference ....................... 50
Troubleshooting Section CID 0001 FMI 11 Cylinder #1 Injector fault ........... 53
CID 0002 FMI 11 Cylinder #2 Injector fault ........... 53
Electronic Troubleshooting
System Overview .................................................... 5
Electronic Service Tools .......................................... 6
Replacing the ECM ................................................. 9
Self-Diagnostics .................................................... 10
CID 0042 FMI 11 Inject Actuation Control Valve
Sensors and Electrical Connectors ....................... 10
open/short ........................................................... 55
Engine Wiring Information .................................... 14
CID 0091 FMI 08 Throttle Position signal
abnormal ............................................................. 55
Programming Parameters
CID 0091 FMI 13 Throttle Position calibration
Programming Parameters ..................................... 16
required ............................................................... 55
Customer Passwords ............................................ 16
CID 0094 FMI 03 Fuel Pressure open/short to
Factory Passwords ............................................... 16
+batt .................................................................... 56
Flash Programming .............................................. 17
CID 0094 FMI 04 Fuel Pressure short to ground .. 56
Injector Trim File ................................................... 17
CID 0096 FMI 03 Fuel Level Sensor open/short to
Service Information Report ................................... 18
+batt .................................................................... 56
CID 0096 FMI 04 Fuel Level Sensor short to
System Configuration Parameters
ground ................................................................. 56
System Configuration Parameters ........................ 19
CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt .................................................................... 57
Troubleshooting without a Diagnostic Code
CID 0100 FMI 04 Engine Oil Pressure short to
Alternator (Charging Problem and/or Noisy
ground ................................................................. 57
Operation) ........................................................... 24
CID 0102 FMI 03 Boost Pressure Sensor short to
Battery .................................................................. 24
+batt .................................................................... 57
Can Not Reach Top Engine RPM ......................... 24
CID 0102 FMI 04 Boost Pressure Sensor short to
Coolant in Engine Oil ............................................ 26
ground ................................................................. 57
Coolant Temperature Is Too High ......................... 26
CID 0105 FMI 03 Inlet Manifold Temp Sensor
ECM Will Not Accept Factory Passwords ............. 27
open/short to +batt .............................................. 58
ECM Will Not Communicate with Other Systems or
CID 0105 FMI 04 Inlet Manifold Temp Sensor short to
Display Modules .................................................. 28
ground ................................................................. 58
Electronic Service Tool Will Not Communicate with
CID 0110 FMI 03 Engine Coolant Temperature
ECM .................................................................... 28
Engine Cranks but Will Not Start .......................... 29
CID 0110 FMI 04 Engine Coolant Temperature short
Engine Has Early Wear ........................................ 31
to ground ............................................................. 59
Engine Misfires, Runs Rough or Is Unstable ........ 31
CID 0127 FMI 03 Transmission Oil Pressure
Engine Oil in Cooling System ............................... 32
Engine Oil in Exhaust System .............................. 33
CID 0127 FMI 04 Transmission Oil Pressure short to
Engine Oil Temperature Is Too High ..................... 33
ground ................................................................. 59
Engine Stalls at Low RPM .................................... 34
CID 0164 FMI 00 High Injector Actuation
Engine Vibration ................................................... 35
Pressure .............................................................. 59
Engine Will Not Crank ........................................... 35
CID 0164 FMI 02 Injector Actuation Pressure signal
Excessive Black Smoke ........................................ 36
erratic .................................................................. 60
Excessive Engine Oil Consumption ...................... 37
CID 0164 FMI 03 Injector Actuation Pressure voltage
Excessive Fuel Consumption ............................... 37
high ..................................................................... 60
Excessive Valve Lash ........................................... 38
Excessive White Smoke ....................................... 39
low ....................................................................... 61
Exhaust Temperature Is Too High ......................... 40
CID 0164 FMI 11 Injector Actuation Pressure system
Fuel Dilution of Engine Oil .................................... 40
fault ..................................................................... 61
Intermittent Engine Shutdown ............................... 41
CID 0168 FMI 00 System Voltage High ................ 61
Intermittent Low Power or Power Cutout .............. 42
CID 0168 FMI 01 System Voltage Low ................. 62
Low Engine Oil Pressure ...................................... 43
CID 0168 FMI 02 System Voltage intermittent/
Low Power/Poor or No Response to Throttle ....... 43
erratic .................................................................. 62
Marine Transmission Oil Pressure Is Too High ..... 45
CID 0174 FMI 03 Fuel Temperature open/short to
Marine Transmission Oil Temperature Is Too
+batt .................................................................... 62
High ..................................................................... 45
CID 0174 FMI 04 Fuel Temperature short to
Mechanical Noise (Knock) in Engine .................... 46
ground ................................................................. 63
Noise Coming from Cylinder ................................. 46
CID 0177 FMI 03 Transmission Oil Temperature
Poor Acceleration or Response ............................ 47
4 RENR9313-04
Table of Contents
CID 0177 FMI 04 Transmission Oil Temperature short Engine Pressure Sensor Open or Short Circuit -
to ground ............................................................. 63 Test ................................................................... 120
CID 0190 FMI 11 Engine Speed Sensor mechanical Engine Speed/Timing Sensor Circuit - Test ........ 125
failure .................................................................. 64 Engine Synchronize Switch Circuit - Test ........... 130
CID 0253 FMI 02 Personality Module mismatch .. 64 Engine Temperature Sensor Open or Short Circuit -
CID 0254 FMI 12 Electronic Control Module Test ................................................................... 139
Error .................................................................... 64 Fuel Level Sensor Circuit - Test .......................... 143
CID 0261 FMI 13 Engine Timing Calibration Indicator Lamp Circuit - Test ............................... 146
required ............................................................... 65 Injection Actuation Pressure - Test ..................... 150
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Injection Actuation Pressure Control Valve Circuit -
short to +batt ....................................................... 65 Test ................................................................... 161
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Injection Actuation Pressure Sensor - Test ......... 165
short to ground .................................................... 65 Injector Solenoid Circuit - Test ............................ 169
CID 0263 FMI 03 Digital Sensor Supply short to Switch Circuits - Test .......................................... 178
+batt .................................................................... 66 Throttle Position Sensor Circuit - Test ................ 181
CID 0263 FMI 04 Digital Sensor Supply short to Transmission Oil Temperature Sensor Open or Short
ground ................................................................. 66 Circuit - Test ...................................................... 187
CID 0268 FMI 02 Check Programmable
Parameters ......................................................... 66 Calibration Procedures
CID 0342 FMI 11 Secondary Engine Speed Sensor Engine Speed/Timing Sensor - Calibrate ............ 192
mechanical failure ............................................... 66 Throttle Position Sensor - Calibrate .................... 195
CID 0535 FMI 08 Exhaust Temperature Sensor noisy
signal ................................................................... 67 Index Section
CID 0617 FMI 05 Air Inlet Heater Relay open/current
below normal ....................................................... 67 Index ................................................................... 197
CID 0617 FMI 06 Air Inlet Heater Relay
grounded/current above norm ............................. 67
CID 1249 FMI 08 Secondary Throttle Position signal
abnormal ............................................................. 68
CID 1249 FMI 13 Secondary Throttle Position
calibration required ............................................. 68
Troubleshooting with an Event Code

Event Codes ........................................................ 69
E015 High Engine Coolant Temperature Derate .. 73
E017 High Engine Coolant Temperature
Warning ............................................................... 74
E025 High Inlet Air Temperature Derate ............... 75
E027 High Inlet Air Temperature Warning ............ 76
E030 High Transmission Oil Temperature
Warning ............................................................... 76
E039 Low Engine Oil Pressure Derate ................. 77
E053 Low Fuel Pressure Warning ........................ 78
E056 High Fuel Temperature Warning .................. 78
E057 Low Engine Coolant Level Derate ............... 79
E059 Low Engine Coolant Level Warning ............ 79
E096 High Fuel Pressure ...................................... 80
E100 Low Engine Oil Pressure Warning ............... 80
E113 High Transmission Oil Pressure .................. 81
E119 Low Fuel Level ............................................ 82
E173 High Exhaust Temperature Warning ............ 82
E190 Engine Overspeed Warning ........................ 82
Diagnostic Functional Tests

Air Inlet Heater Circuit - Test ................................. 83
Analog Sensor Supply Circuit - Test ..................... 90
CAN Data Link Circuit - Test ................................. 95
Cat Data Link Circuit - Test ................................. 100
Coolant Level Sensor Circuit - Test .................... 103
Digital Sensor Supply Circuit - Test .................... 107
Electrical Connectors - Inspect ............................ 111
Electrical Power Supply Circuit - Test .................. 116
RENR9313-04 5
Troubleshooting Section
Troubleshooting Section Fuel Injection

The ECM controls the amount of fuel that is
injected by varying the signals to the injectors. The
Electronic Troubleshooting injectors will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal to
the solenoid. This high voltage signal energizes the
i02439954 solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
System Overview timing and the amount of fuel that is injected.
SMCS Code: 1900 The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
System Operation during cold mode operation. Cold mode operation
provides the following benefits:
The engine utilizes a Hydraulic Electronic Unit
Injector (HEUI) fuel system. A solenoid on each • Increased cold weather starting capability
injector meters the amount of fuel that is delivered
by the injector. An axial piston pump that is referred • Reduced warm-up time
to as the unit injector hydraulic pump pressurizes
oil in order to activate the injector. An Electronic • Reduced white smoke
Control Module (ECM) sends a signal to the injection
actuation pressure control valve in order to control Cold mode is activated whenever the engine coolant
injection pressure. Another electrical signal is sent to temperature falls below 18 °C (64 °F). Cold mode
each injector solenoid in order to inject fuel. remains active until the engine coolant temperature
rises above 20 °C (68 °F) or until the engine has
Electronic Controls been running for 14 minutes.
The electronic system for the engine consists of the The flash file inside the ECM sets certain limits on
ECM, the wiring harness, the engine sensors, the the amount of fuel that can be injected. The “FRC
switches, the injection actuation pressure control Fuel Limit” is used to control the air/fuel ratio for
valve, the unit injector hydraulic pump, the HEUI control of emissions. The “FRC Fuel Limit” is a limit
injectors and the interface for a particular application. that is based on the turbocharger outlet pressure.
The ECM is the computer. The flash file is the A higher turbocharger outlet pressure indicates that
software for the computer. The flash file contains there is more air in the cylinder. When the ECM
the operating maps. The operating maps define the senses a higher turbocharger outlet pressure, the
following characteristics of the engine: ECM increases the “FRC Fuel Limit”. When the ECM
increases the “FRC Fuel Limit”, the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
• Horsepower programmed into the flash file at the factory. The
“FRC Fuel Limit” cannot be changed.
• Torque curves
The ECM determines the timing and the amount The “Rated Fuel Limit” is a limit that is based on the
of fuel that is delivered to the cylinders. This power rating of the engine and on the engine speed.
determination is based on the actual conditions and The “Rated Fuel Limit” is similar to the rack stops
the desired conditions at any given time. and the torque spring on a mechanically governed
engine. The “Rated Fuel Limit” provides the power
The ECM compares the desired engine speed to curves and the torque curves for a specific engine
the actual engine speed. The actual engine speed is family and for a specific engine rating. The “Rated
determined via a signal from the engine speed/timing Fuel Limit” is programmed into the flash file at the
sensor. If the desired engine speed is greater than factory. The “Rated Fuel Limit” cannot be changed.
the actual engine speed, the ECM injects more fuel
in order to increase the actual engine speed. Once the ECM determines the amount of fuel that
is required, the ECM must determine the timing
of the fuel injection. The ECM determines the top
center position of each cylinder from the engine
speed/timing sensor's signal. The ECM calculates
when fuel injection should occur relative to the top
center position. The ECM also provides the signal
to the injector at the desired time. The ECM adjusts
timing for optimum engine performance, optimum
fuel economy, and optimum control of white smoke.
6 RENR9313-04
Injection Actuation Pressure Control Required Service Tools

System
The tools that are listed in Table 1 are required in
The injection actuation pressure control valve order to enable a service technician to perform the
(IAPCV) that is internal to the unit injector hydraulic test procedures that are found in this manual.
pump is a precision displacement control actuator.
Table 1
This actuator changes the pump outlet flow that
is based on the control current that is supplied by Required Service Tools
the ECM. The variable displacement unit injector
Part Description
hydraulic pump pressurizes only the amount of high Number
pressure oil that is needed by the injectors.
N/A 4 mm Allen Wrench
Starting Aids 6V-2197 Transducer
The following devices (if equipped) are used in order 7X-1171 Transducer Adapter
to improve the starting of the engine in cold weather 7X-1695 Cable As
conditions.
146-4080 Digital Multimeter Gp (RS232)
• Air inlet heater 7X-1710 Multimeter Probes
7X-6370 Adapter Cable As (3-PIN BREAKOUT)
• Ether injection
208-0059 Adapter Cable As (70-PIN BREAKOUT)
The ECM controls the air inlet heater. The ether
injection system can be controlled by the ECM or by 257-8718 Adapter Cable As (120-PIN BREAKOUT)
the operator. 167-9225 Harness (SERVICE TOOL ADAPTER)
1U-5804 Crimp Tool (12−AWG TO 18−AWG)
Programmable Parameters
175-3700 Connector Repair Kit (DEUTSCH DT)
Certain parameters that affect the engine operation
may be changed with electronic service tools. Two short jumper wires are needed to check the
The parameters are stored in the ECM, and the continuity of some wiring harness circuits by shorting
parameters are protected from unauthorized changes two adjacent terminals together in a connector. A
by passwords. long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Passwords
Optional Service Tools
Several system configuration parameters and
most logged events are protected by passwords. Table 2 lists the optional service tools that may be
Refer to programming parameters Troubleshooting, needed during testing or repair.
“Customer Passwords” and refer to programming
parameters Troubleshooting, “Factory Passwords”.
i02728769
Electronic Service Tools

SMCS Code: 0785
Caterpillar electronic service tools are designed to

help the service technician perform the following
tasks:
• Information access
• System diagnostics
• System calibrations
• System configurations
• Data link communications
RENR9313-04 7
Table 2 Note: For more information regarding the use of

Optional Service Tools
Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
Part Number Description software.
198-4240 Digital Pressure Indicator
or Connecting Cat ET
1U-5470 Engine Pressure Group
4C-4075
Connecting with the Communication Adapter II
Crimp Tool (4−AWG TO 10−AWG)
4C-4911(1) Battery Load Tester Table 4 lists the standard hardware that is required in
5P-7277
order to connect Cat ET.
Voltage Tester
6V-9130(2) Temperature Adapter (MULTIMETER) Table 4
8T-5319 Connector Tool Group Standard Hardware for the Use of Cat ET
155-5176 AC/DC Current Probe Part Number Description
285-0910 Multi-Tool Gp N/A Personal Computer (PC)

(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries”
Communication Adapter
and Special Instructions, SEHS7633, “Battery Test Procedure”. 275-5120 Gp (CAT ET TO ECM
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130 INTERFACE)
Temperature Adapter Group”.
237-7547(2) Adapter Cable As
Parallel Port Cable
Caterpillar Electronic Technician 225-5985(3) (COMMUNICATION
(ET) ADAPTER)
(2) The 237-7547 Adapter Cable As is required to connect to the
Cat ET can display the following information: Universal Serial Bus (USB) on computers that are not equipped
with a RS232 serial port.
(3) The 225-5985 Parallel Port Cable is required to connect to
• Parameters the parallel port.
• Event codes
• Diagnostic codes
• Engine configuration
Cat ET can be used by the technician to perform the
following functions:
• Diagnostic tests
• Calibrations
• Flash programming
• Configuration of the Electronic Control Module
(ECM)
Table 3 lists the software that is required in order to

use Cat ET. Always use the latest version of Cat ET
that is available.
g01255306
Illustration 1
Table 3 Connecting the Communication Adapter II
Software Requirements for Cat ET (1) Personal Computer (PC)
(2) 237-7547 Adapter Cable As
Part Description (3) 196-0055 Adapter Cable As
Number (4) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)
(5) 275-5121 Communication Adapter As
JERD2124 Single user license for Cat ET (6) 207-6845 Adapter Cable As
Data subscription for all engines and Note: Items (3), (5), and (6) are part of the 275-5120
JERD2129
machines Communication Adapter Gp.
8 RENR9313-04
Use the following procedure in order to connect Cat

ET and the Communication Adapter II.
1. Remove the electrical power from the ECM.
2. Connect communications adapter (5) to a

communications port on the PC by using one of
the following methods:
a. Connect cable (4) between the “COMPUTER”

end of communications adapter (5) and the
parallel port of PC (1). Be sure to configure
Cat ET for the parallel port. This configuration
provides the fastest connection.
b. Connect cable (3) between the “COMPUTER”

end of communication adapter (5) and the
RS232 serial port of PC (1).
c. Connect cables (2) and (3) between the

“COMPUTER” end of communication adapter
(5) and the USB port of PC (1). Illustration 2
g01297379
(1) Personal computer (PC)

3. Connect cable (6) to communication adapter (5). (7) 261-4867 Card (PCMCIA)
(8) 239-9955 Communication Radio Gp
4. Connect cable (6) to a service tool connector. (9) 259-3183 Data Link Cable As
5. Verify that the “POWER” indicator on the Note: Items (7), (8), and (9) are part of the 261-3363
communication adapter is illuminated. Wireless Communication Adapter Gp.
6. Establish communication between Cat ET and the Use the following procedure in order to connect the
ECM. wireless communication adapter for use with Cat ET.
7. If Cat ET and the communication adapter 1. Remove the electrical power from the ECM.
do not communicate with the ECM, refer to
troubleshooting without a diagnostic code 2. Ensure that the computer has been correctly
Troubleshooting, “Electronic Service Tool Will Not configured for the 261-4867 Card (PCMCIA).
Communicate with ECM”. Verify that the PC card is installed in the
computer's PCI expansion slot.
Communicating with the Wireless Communication
Adapter 3. Connect cable (9) between communication radio
(8) and the service tool connector.
Table 5 lists the optional hardware that is needed
in order to connect Cat ET by using a wireless 4. Restore the electrical power to the ECM. If Cat ET
connection. and the communication radio do not communicate
with the ECM, refer to troubleshooting without
Table 5 a diagnostic code Troubleshooting, “Electronic
Optional Hardware for the Use of Cat ET Service Tool Will Not Communicate with ECM”.
Part Number Description
N/A Personal Computer (PC)
Wireless Communication
261-3363(1)
Adapter Gp
(1) Refer to Tool Operating Manual, “Using the 261-3363
Wireless Communication Adapter Gp” for information that is
related to the installation and the configuration.
RENR9313-04 9
i02488890 b. Print the parameters from the “Configuration”

screen on Cat ET. If a printer is unavailable,
Replacing the ECM record all of the parameters. Record any logged
diagnostic codes and logged event codes for
SMCS Code: 1901-510 your records. Record the injector codes from
the “Calibrations” screen in the “Service” menu
NOTICE on Cat ET.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- c. Use the “Copy Configuration/ECM
ing, adjusting and repair of the product. Be prepared to Replacement” feature that is found under the
collect the fluid with suitable containers before open- “Service” menu on Cat ET. Select “Load from
ing any compartment or disassembling any compo- ECM” in order to copy the configuration data
nent containing fluids. from the suspect ECM.
Refer to Special Publication, NENG2500, “Caterpillar Note: If the “Copy Configuration” process fails and
Dealer Service Tool Catalog” for tools and supplies the parameters were not obtained in Step 1.b, the
suitable to collect and contain fluids on Caterpillar parameters must be obtained elsewhere. Some of the
products. parameters are stamped on the engine information
plate. Most of the parameters must be obtained from
Dispose of all fluids according to local regulations and the factory.
mandates.
2. Remove the ECM:
NOTICE a. Remove electrical power from the ECM.
Keep all parts clean from contaminants.
b. Disconnect the P1 and P2 connectors from the
Contaminants may cause rapid wear and shortened ECM.
component life.
NOTICE
The Electronic Control Module (ECM) contains no Use a suitable container to catch any fuel that might
moving parts. Replacement of the ECM can be spill. Clean up any spilled fuel immediately.
costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this
manual in order to ensure that replacing the ECM will NOTICE
correct the problem. Verify that the suspect ECM is Do not allow dirt to enter the fuel system. Thoroughly
the cause of the problem. clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
Note: Ensure that the ECM is receiving power nected fuel system component.
and that the ECM is properly wired to the negative
battery circuit before a replacement of the ECM is
c. Remove the fuel lines (if equipped) from the
attempted. Refer to the diagnostic functional test
ECM.
Troubleshooting, “Electrical Power Supply Circuit -
Test”.
d. Disconnect the ECM ground strap.
NOTICE e. Remove the mounting bolts from the ECM.
If the flash file and engine application are not matched,
engine damage may result. 3. Install the replacement ECM:
Perform the following procedure in order to replace a. Use the old mounting hardware to install the
the ECM: replacement ECM.
1. Record the configuration data: b. Connect the fuel lines (if equipped).
a. Connect Cat ET to the service tool Note: Verify that the fuel lines are installed correctly.
connector. Refer to electronic troubleshooting The fuel lines must not put tension on the ECM.
Troubleshooting, “Electronic Service Tools”. Rubber grommets are used to protect the ECM from
excessive vibration. The ECM should move slightly in
the rubber grommets. If the ECM cannot be moved
slightly, check that the fuel lines are not pulling the
ECM against one side of the grommets.
c. Connect the ECM ground strap.

10 RENR9313-04
d. Connect the P1 and P2 connectors. Tighten • Active

the allen head screw for each of the ECM
connectors to the proper torque. Refer to the • Logged
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. Active Code
4. Configure the replacement ECM: An active diagnostic code indicates that an active
problem has been detected. Active codes require
a. Flash program the flash file into the ECM. Refer immediate attention. Always service active codes
to programming parameters Troubleshooting, prior to servicing logged codes.
“Flash Programming”.
Logged Code
b. Use Cat ET to match the engine application
and the interlock code if the replacement ECM Every generated code is stored in the permanent
was used for a different application. memory of the ECM. The codes are logged.
c. If the “Copy Configuration” process from Logged codes may not indicate that a repair is
Step 1.b was successful, return to the “Copy needed. The problem may have been temporary. The
Configuration/ECM Replacement” screen on problem may have been resolved since the logging
Cat ET and select “Program ECM”. Proceed to of the code. If the system is powered, it is possible
Step 4.e when programming is complete. to generate an active diagnostic code whenever a
component is disconnected. When the component is
d. If the “Copy Configuration” process from Step reconnected, the code is no longer active. Logged
1.b was unsuccessful, manually program the codes may be useful to help troubleshoot intermittent
ECM parameters. The parameters must match problems. Logged codes can also be used to review
the parameters from Step 1.b. the performance of the engine and of the electronic
system.
e. Program the engine monitoring system, if
necessary. Event Code
f. Load the injector trim files for the injectors. Refer An event code is generated by the detection of an
to programming parameters Troubleshooting, abnormal engine operating condition. For example,
“Injector Trim File” for instructions. an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the
g. Use Cat ET to check for an active 261-13 symptom of a problem.
Engine Timing Calibration required. If the
diagnostic code is active, calibrate the engine
i02457219
speed/timing. Refer to calibration procedures
Troubleshooting, “Engine Speed/Timing Sensor
- Calibrate” for the correct procedure.
Sensors and Electrical
Connectors
i02378227 SMCS Code: 1439; 7553-WW
Self-Diagnostics
SMCS Code: 1901
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:
• Diagnostic
• Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
Diagnostic codes can have two different states:

RENR9313-04 11
g01226319
Illustration 3
Block diagram
12 RENR9313-04
C9 Marine Engines
g01226497
Illustration 4
Typical left side engine view
(1) Coolant temperature sensor (9) Inlet manifold temperature sensor (16) Secondary engine speed/timing sensor
(2) Fuel temperature sensor (10) Service tool connector (17) Timing calibration port
(3) Fuel pressure sensor (11) Injector valve cover entry connector (18) Engine oil pressure sensor
(4) Injection actuation pressure control valve (12) Connector for the transmission oil (19) Timing calibration probe connector
(5) Injection actuation pressure sensor temperature sensor (option) (20) ECM connector J1/P1
(6) Connector for the coolant level sensor (13) Connector for the transmission oil (21) J1939 termination resistor
(option) pressure sensor (option) (22) ECM connector J2/P2
(7) Intake manifold (boost) pressure sensor (14) Connector for the fuel level sensor (23) Customer connector
(8) Connector for the exhaust temperature (option)
sensor (option) (15) Primary engine speed/timing sensor
RENR9313-04 13
C7 Marine Engine
g01226356
Illustration 5
(1) Unit injector wiring harness connector (8) Fuel pressure sensor (15) ECM connector J2/P2
(2) Injection actuation pressure sensor (9) Injection actuation pressure control valve (16) Connector for the transmission
(3) Intake manifold (boost) pressure sensor (10) Connector for the transmission pressure temperature sensor (option)
(4) Intake manifold temperature sensor sensor (option) (17) ECM connector J1/P1
(5) Engine oil pressure sensor (11) Primary engine speed/timing sensor (18) Electronic Control Module (ECM)
(6) Timing calibration probe connector (12) Customer connector
(7) Connector for the air inlet heater relay (13) Secondary engine speed/timing sensor
(option) (14) Service tool connector
g01226481
Illustration 6
Typical top engine view
(19) Coolant temperature sensor (21) Connector for the fuel temperature (22) Connector for the fuel level sensor
(20) Coolant level sensor (option) sensor (option) (option)
14 RENR9313-04
i02433503 Table 7
Engine Wiring Information Metric Equivalents for AWG Numbers

AWG Diameter AWG Diameter
SMCS Code: 1408 Number (mm) Number (mm)
The wiring schematics are revised periodically. 20 0.8 14 1.6

The wiring schematics will change as updates are 18 1.0 12 2.0
made to the engine's harness. For the most current
information, always check the revision number of the 16 1.3 4 3.2
schematic. Use the schematic with the latest revision
number. Welding on Applications that are
Equipped with an Electronic Control
Harness Wire Identification Module (ECM)
Caterpillar identifies all wires with eleven solid colors. Proper welding procedures are necessary in order
The circuit number is stamped on the wire at a 25 mm to avoid damage to the engine's electronic control
(1 inch) spacing. Table 6 lists the wire colors and the module, sensors, and associated components.
color codes. Remove the component that requires welding. When
Table 6
welding on an application that is equipped with an
ECM and removal of the component is not possible,
Color Codes for the Harness Wire the following procedure must be followed. This
Color Code Color Color Code Color procedure provides the minimum amount of risk to
the electronic components.
BK Black GN Green
BR Brown BU Blue NOTICE
RD Red PU Purple
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
OR Orange GY Gray cause damage to the drive train bearings, hydraulic
YL Yellow WH White
components, electrical components, and other com-
ponents.
PK Pink
Clamp the ground cable from the welder to the com-
For example, a wire identification of A701-GY on the ponent that will be welded. Place the clamp as close
schematic would signify a gray wire with the circuit as possible to the weld. This will help reduce the pos-
number A701. A701-GY identifies the power circuit sibility of damage.
for the No. 1 Injector solenoid.
1. Stop the engine. Remove the electrical power
Another wire identification on the schematic is the from the ECM.
size of the wire. The size of the wire will follow the
wire color. Wire size or gauge is referred to as AWG 2. Disconnect the negative battery cable from the
(American Wire Gauge). AWG is a description of the battery. If a battery disconnect switch is installed,
diameter of the wire. open the switch.
For example, a code of 150-OR-14 on the schematic
would indicate that the orange wire in circuit 150 is a
14 AWG wire.
If the gauge of the wire is not listed, the wire is 16

AWG.
Conversion of AWG Numbers to Metric

Measurements
Table 7 shows the various AWG numbers that are
used for the wires. The metric equivalent for the
diameter of each AWG number are also shown.
RENR9313-04 15
g01143634
Illustration 7
Service welding guide (typical diagram)
3. Connect the welding ground cable as close

as possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
electrical/electronic components.
4. Protect the wiring harness from welding debris

and spatter.
5. Weld the materials by using standard welding

methods.
16 RENR9313-04
Programming Parameters 4. From the “Factory Password” screen, enter the

factory passwords.
i03312021 5. When the “Read Customer Passwords” screen

appears, record the customer passwords. The
Programming Parameters customer passwords may then be used to change
parameters that are customer programmable.
SMCS Code: 1901
The electronic service tool can be used to view i02433393

certain parameters that can affect the operation of the
engine. The electronic service tool can also be used Factory Passwords
to change certain parameters. The parameters are
stored in the Electronic Control Module (ECM). Some SMCS Code: 0785
of the parameters are protected from unauthorized
changes by passwords. Parameters that can be NOTICE
changed have a tattletale number. The tattletale Operating the engine with a flash file not designed for
number shows if a parameter has been changed. that engine will damage the engine. Be sure the flash
file is correct for your engine.
i03502923
Note: Factory passwords are provided only to
Customer Passwords Caterpillar dealers.
SMCS Code: 0785 Factory passwords are required to perform each of

the following functions:
Customer passwords may be used to protect
customer parameters from being changed. Caterpillar • Program a new Electronic Control Module (ECM).
Electronic Technician (ET) can be used to change
certain parameters. There are some parameters that When an ECM is replaced, the system configuration
cannot be changed and there are some applications parameters must be programmed into the new
that do not allow any changes to the programmable ECM. A new ECM will allow these parameters to
monitoring system. The passwords are programmed be programmed once without factory passwords.
into the Electronic Control Module (ECM) with After the initial programming, some parameters are
the Cat ET. One password may be programmed protected by factory passwords.
or both passwords may be programmed. If
customer passwords are not programmed, customer • Clear event codes.
parameters may be changed by anyone.
Most event codes require the use of factory
To obtain customer passwords, contact the owner of passwords to clear the code once the code has
the engine. If the owner has forgotten the customer been logged. Clear these codes only when you are
passwords, customer passwords may be read by certain that the problem has been corrected.
using Cat ET. Factory passwords are required in
order to read customer passwords. • Unlock parameters.
Use the following procedure in order to read customer Factory passwords are required in order to
passwords with Cat ET: unlock certain system configuration parameters.
Refer to Troubleshooting, “System Configuration
1. Select the “Information” menu. Then select Parameters”.
“Passwords”.
Since factory passwords contain alphabetic
2. When the “Factory Password” screen appears, characters, the Caterpillar Electronic Technician (ET)
record the information that is listed on the “Factory must be used to perform these functions. In order to
Passwords Worksheet”. Refer to programming obtain factory passwords, proceed as if you already
parameters Troubleshooting, “Factory Passwords have the password. If factory passwords are needed,
Worksheet” for additional information. Cat ET will request the factory passwords and Cat ET
will display the information that is required to obtain
3. Obtain the factory passwords. The information the passwords. For the worksheet that is used for
that is recorded on the “Factory Passwords acquiring factory passwords, refer to programming
Worksheet” must be provided. When you obtain parameters Troubleshooting, “Factory Passwords
the factory passwords, a permanent record of your Worksheet”.
access is generated at Caterpillar.
RENR9313-04 17
i02419726 “WinFlash” Error Messages

Flash Programming If you receive any error messages during flash
programming, click on the “Cancel” button in order
SMCS Code: 1901-591 to stop the process. Access the information about
the “ECM Summary” under the “Information” menu.
Flash Programming – This is a method of Make sure that you are flashing the correct file for
programming or updating the flash file in an engine's your engine.
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to flash i02431150

program a file into the memory of the engine's ECM.
Injector Trim File
If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench SMCS Code: 1290
(STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature The Caterpillar Electronic Technician (ET) is used to
on SIS Web to obtain the flash file for your engine. load the injector trim files into the Electronic Control
You must have the engine serial number in order to Module (ECM).
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write The injector trim files must be loaded into the ECM if
down the name of the flash file for future reference. any of the following conditions occur:
• An injector is replaced.
Programming a Flash File
• The ECM is replaced.
1. Establish communication between Cat ET and the
engine's ECM. • A 253-02 diagnostic code is active (if applicable).
2. Select “WinFlash” from the “Utilities” menu on Cat • A 268-02 diagnostic code is active (if applicable).
ET.
• Injectors are exchanged between cylinders.
Note: If “WinFlash” will not communicate with the
ECM, refer to troubleshooting without a diagnostic Exchanging Injectors
code Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM”. Exchanging injectors can help determine if a
combustion problem is in the injector or in the
3. Program the flash file into the ECM. cylinder. If two injectors that are currently installed
in the engine are exchanged between cylinders,
a. Select the engine ECM under the “Detected the injector trim files can also be exchanged. Press
ECMs”. the “Exchange” button at the bottom of the “Injector
Trim Calibration” screen on Cat ET. Select the two
b. Press the “Browse” button in order to select the injectors that will be exchanged and press the “OK”
name of the flash file that will be programmed button. The tattletale for the injectors that were
into the ECM. exchanged will increase by one.
c. When the correct flash file is selected, press Note: The injector serial number and the injector
the “Open” button. confirmation code are located on the injector.
d. Verify that the “File Values” match the 1. Record the injector serial number and the injector
application. If the “File Values” do not match confirmation code for each injector.
the application, obtain the correct flash file.
2. Click on “Service Software Files” in SIS Web.
e. When the correct flash file is selected, press
the “Begin Flash” button. 3. Enter the serial number for the injector in the
search field.
f. Cat ET will indicate when flash programming
has been successfully completed. 4. Download the injector trim file to the PC. Repeat
this procedure for each injector, as required.
4. Start the engine and check for proper operation.
Repair any active diagnostic or event codes. 5. Connect Cat ET to the service tool connector. Refer
to electronic troubleshooting Troubleshooting,
“Electronic Service Tools”.
18 RENR9313-04
6. Restore the electrical power to the ECM. Cause of Failure

7. Select the following menu options on Cat ET: Comments on the cause of failure should include
the number of diagnostic codes that were logged.
• Service Comments should also indicate if the code was an
active code. Indicate the source of the problem. Also
• Calibrations indicate the method that was used to discover the
problem. Examples of the methods that were used to
• Injector Trim Calibration discover the problem could be one of the following
methods:
8. Select the appropriate cylinder.
• A specific procedure in the manual was followed.
9. Click on the “Change” button.
• A visual inspection indicated that wire abrasion on
10. Select the appropriate injector trim file from the the engine harness existed.
PC.
• An engine dynamometer test indicated that the
11. Click on the “Open” button. power was below the specification at 1700 rpm
due to the loss of the no. 4 injector and an engine
12. If you are prompted by Cat ET enter the injector dynamometer test indicated that the power was
confirmation code into the field. below the specification at all engine speeds above
1700 rpm due to the loss of the no. 4 injector.
13. Click on the “OK” button.
Be as specific as possible.
The injector trim file is loaded into the ECM.
Repair Procedure
14. Repeat the procedure for each cylinder, as
required. Comments on the repair procedure should include
the following types of information:
i02278907
• The wiring harness was repaired.
Service Information Report
• The Full Load Setting (FLS) was changed per the
SMCS Code: 0336 factory's instructions.
After verifying the correct repair has been performed Be as specific as possible.
on the engine, it is critical to provide brief, detailed
information. This information helps Caterpillar better
serve you and the customer.
Recommendations
Customer's Complaint
Obtain as much information from the customer
as possible. Investigate any written information
that is available and document any information
that is gathered from the customer. The following
information is of particular importance:
• Indicate if the diagnostic lamp was flashing.

• Indicate if the warning lamp was flashing, or if the
lamp was on continuously.
• Indicate the symptoms of engine operation that are

present.
Be as specific as possible.
RENR9313-04 19
System Configuration
Parameters
i02457488
System Configuration
Parameters
SMCS Code: 1901
System configuration parameters are parameters

that affect the emissions and the power of the engine.
Default values for the parameters are programmed
at the factory. The values for certain configuration
parameters are stamped on the engine information
plate.
Some values may be changed by the customer in

order to suit the needs of the specific application.
The values are programmed with the Caterpillar
Electronic Technician (ET).
If the parameters that are protected with the factory

passwords are changed, the Caterpillar warranty
may be voided.
Note: The “Electronic Control Module (ECM)

Identification Parameters” must be programmed if the
ECM is replaced and/or you reprogram the engine
rating. It is not necessary to reprogram the “ECM
Identification Parameters” if a new flash file is flash
programmed into the ECM.
The system configuration parameters are arranged in

groups. Refer to Table 8.
Table 8
Parameter Available Range or Options Default Password
Selected Engine Rating
Rating Number Software Dependent Factory
Rated Power Software Dependent Read Only (1)
Rated Peak Torque Software Dependent Read Only (1)
Top Engine Speed Range Software Dependent Read Only (1)
Test Specification Software Dependent Read Only (1)
ECM Identification Parameters
Equipment ID 17 alphanumeric characters “NOT PROGRAMMED” Customer
Engine Serial Number 0XX00000 or XXX00000 “0XX00000” Factory
ECM Serial Number Hardware Dependent Read Only (1)
Software Group Part Number (2) Software Dependent Read Only (1)
Software Group Release Date (2) Software Dependent Read Only (1)
Software Group Description (2) Software Dependent Read Only (1)
(continued)
20 RENR9313-04
(Table 8, contd)
Parameter Available Range or Options Default Password
Engine/Gear Parameters
Port, Center, Starboard,
Engine Location Port Customer
1, 2, 3, 4, 5
Number of Synchronized Engines Configuration 1, 2, 3, 4, 5 1 Customer
FLS Programmed at the Factory Factory
FTS Programmed at the Factory Factory
Low Idle Speed 550 rpm to 750 rpm 600 rpm Customer
Maximum Trolling Engine Speed 751 rpm to 1200 rpm 900 rpm Customer
Secondary Throttle Enable Status Enabled or Disabled Disabled Customer
Optional Parameters
Transmission Oil Temperature Sensor
Installed or Not Installed Not Installed Customer
Installation Status
Transmission Oil Pressure Sensor Installation
Installed or Not Installed Not Installed Customer
Status
Fuel Level Sensor Installation Status Installed or Not Installed Not Installed Customer
Coolant Level Sensor Installation Status Installed or Not Installed Not Installed Customer
Exhaust Temperature Sensor Installation Status Installed or Not Installed Not Installed Customer
Air Inlet Heater Installation Status Installed or Not Installed Not Installed Customer
Maintenance Parameters
Engine Oil Capacity N/A N/A Customer
Fuel Correction Error -63.5 to +63.5 0 Customer
Off, Man Hour, Auto Hour,

Maintenance Indicator Mode N/A Customer
Man Fuel, or Auto Fuel
PM1 Interval N/A N/A Customer
Passwords
Customer Password #1 8 alphanumeric characters Blank Customer
Customer Password #2 8 alphanumeric characters Blank Customer
Security Access Parameters
Total Tattletale 0 to 65535 0 Read Only (1)
(1) This parameter can only be viewed. No changes are allowed.
(2) The Software Group is the flash file.
Parameter Descriptions ECM Identification Parameters
Selected Engine Rating Equipment ID
Rating Number The “Equipment ID” parameter allows the customer

to enter a description into the ECM in order to identify
The “Rating Number” corresponds to the selected the engine's application. A maximum of 17 characters
set of performance maps for the application. The can be entered in the field.
selected set of performance maps are derived from
several unique sets of maps that are in the flash file.
The dealer and/or the OEM will need to select the
appropriate rating tier, if more than one rating tier is
present. The rating tiers are A through E.
RENR9313-04 21
Engine Serial Number FTS (Full Torque Setting)
Program the “Engine Serial Number” to match the This parameter is similar to “FLS”. Factory passwords
engine serial number that is stamped on the engine are required in order to change this parameter.
information plate. The engine serial number is not
preprogrammed on a replacement ECM. Compare the values of the FLS and the FTS from the
ECM with the values that are listed on the engine
Engine/Gear Parameters information plate. The FLS and the FTS should only
be changed after a mechanical change is made to
Engine Location the engine. Entering the wrong values can cause
damage to the engine. Entering the wrong values
Note: The “Number of Synchronized Engines may also void the Caterpillar warranty.
Configuration”, “Engine Location”, and “Secondary
Throttle Enable Status” must be programmed in the Low Idle Speed
following order:
This parameter is the engine's minimum allowable
• Number of synchronized engines configuration operating speed. The allowable range is from 550
to 750 rpm.
• Engine location
Maximum Trolling Engine Speed
• Secondary throttle enable status
The ECM must limit the engine speed when the
This parameter can be set to one of the following engine is in trolling mode. This prevents damage to
values: the clutch. The maximum engine speed is set to the
value of this parameter when the engine is in trolling
• Port mode. The value of this parameter must be higher
than the value of the “Low Idle Speed” parameter.
• Starboard
• Center
• Engine #X (X is the engine number)
Number of Synchronized Engines Configuration
Note: The “Number of Synchronized Engines

Throttle Enable Status” must be programmed in the
following order:
• Number of synchronized engines configuration

• Engine location
• Secondary throttle enable status
Program this parameter to the number of
synchronized engines that are used in the
application. The allowable range is from 1 to 5. The Illustration 8
g01126434
default value is 1. Engine speed versus throttle position
(X) Throttle position
If this parameter is programmed for more than one (Y) Engine speed
engine, the “Secondary Throttle Enable Status”
parameter is automatically set to “Enabled”. Secondary Throttle Enable Status
FLS (Full Load Setting) Note: The “Number of Synchronized Engines
This parameter represents the adjustment to the Throttle Enable Status” must be programmed in the
fuel system that was made at the factory in order following order:
to fine tune the fuel system. The correct value for
this parameter is stamped on the engine information
plate. Factory passwords are required in order to
• Number of synchronized engines configuration
change this parameter.
22 RENR9313-04
• Engine location Maintenance Parameters

• Secondary throttle enable status Engine Oil Capacity
This parameter can be programmed to “Enabled” or Program this parameter to match the actual engine
“Disabled”. If the “Number of Synchronized Engines oil capacity in quarts.
Configuration” parameter is programmed to more
than one engine, this parameter is automatically set Fuel Correction Error
to “Enabled”.
The Fuel Correction Factor (FCF) fine tunes all of the
Refer to Troubleshooting, “Engine Synchronize fuel data that will be stored in the future by the ECM.
Switch Circuit - Test” for more information on the Caterpillar recommends changing the FCF only
secondary throttle. after an operating interval that allows a comparison
of actual fuel economy to the fuel economy that
Optional Parameters is calculated by the ECM for typical operating
conditions. The allowable range is −63.5 to +63.5.
Transmission Oil Temperature Sensor
Calculating the Error
This parameter can be set to “Installed” or to “Not
Installed”. Setting this parameter to “Not Installed” Error = [(Actual fuel economy − Economy calculated
disables monitoring of the circuit for the transmission by the ECM) ÷ Actual fuel economy] × 100
oil temperature sensor.
Calculating the New Fuel Correction Factor
Transmission Oil Pressure Sensor
New FCF = Old FCF + [(100 + Old FCF) × Error] ÷
This parameter can be set to “Installed” or to “Not 100
Installed”. Setting this parameter to “Not Installed”
disables fault monitoring of the circuit for the Note: The old FCF is the FCF that is currently
transmission oil pressure sensor. programmed in the ECM.
Fuel Level Sensor Installation Status Maintenance Indicator Mode
This parameter can be programmed to “Installed” or The ECM records data that is related to equipment
to “Not Installed”. If this parameter is programmed maintenance. The ECM will activate the maintenance
to “Installed”, the monitoring system can be indicator lamp when scheduled maintenance is due.
programmed to alert the operator when the fuel level The maintenance indicator lamp can be reset by
is low. activating the maintenance clear switch or via Cat ET.
Coolant Level Sensor Installation Status The maintenance interval can be based on operating
hours or on fuel consumption. This parameter can be
This parameter can be programmed to “Installed” or set to one of the following values:
to “Not Installed”. If this parameter is programmed
to “Installed”, the monitoring system can be • Off
programmed to alert the operator when the coolant
level is low. • Man Hour
Exhaust Temperature Sensor Installation Status • Auto Hour
This parameter can be programmed to “Installed” or • Man Fuel

to “Not Installed”. Setting this parameter to “Installed”
enables monitoring of the circuit for the exhaust • Auto Fuel
temperature sensor.
PM1 Interval
Air Inlet Heater Installation Status
This parameter allows the customer to define the
This parameter can be programmed to “Installed” or maintenance interval if the “Maintenance Indicator
to “Not Installed”. If this parameter is programmed to Mode” parameter is programmed to a manual option.
“Installed”, the cold start capability of the engine is Refer to the Operation and Maintenance Manual for
improved and white smoke is reduced. additional information.
RENR9313-04 23
Passwords (Table 9, contd)

Maximum Trolling Engine
Customer Password #1 Speed
This parameter allows the customer to lock out Secondary Throttle Enable
certain parameters by entering a password. Customer Status
passwords must be used to unlock any parameters Transmission Oil
that are protected by customer passwords before the Temperature Sensor
parameter can be changed. Factory passwords are
Transmission Oil Pressure
required if this password is lost.
Sensor
Customer Password #2 Fuel Level Sensor
Installation Status
This parameter allows the customer to lock out Coolant Level Sensor
certain parameters by entering a password. Customer Installation Status
passwords must be used to unlock any parameters
that are protected by customer passwords before the Exhaust Temperature
parameter can be changed. Factory passwords are Sensor Installation Status
required if this password is lost. Air Inlet Heater Installation
Status
Parameter Worksheet Engine Oil Capacity
Record the values of the parameters in Table 9. Save
the Table for future reference. Fuel Correction Error
Table 9 Maintenance Indicator

Mode
Engine Parameters
Rating Number PM1 Interval
Rated Power
Customer Password #1
Rated Peak Torque
Customer Password #2
Top Engine Speed Range
Total Tattletale
Test Specification Information from the Engine Information Plate
Equipment ID Engine Serial Number
Engine Serial Number

FTS
ECM Serial Number
Software Group Part FLS
Number
Injector Codes
Software Group Release
Date Injector Code (1)
Software Group
Description Injector Code (2)
Engine Location
Injector Code (3)
Number of Synchronized
Engines Configuration
Injector Code (4)
FLS
Injector Code (5)
FTS
Injector Code (6)
Low Idle Speed
(continued)
24 RENR9313-04
Troubleshooting without a Charging Circuit

Diagnostic Code Inspect the battery cables, wiring, and connections in
the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts.
i02476459
Alternator Alternator or Regulator

(Charging Problem and/or Verify that the alternator or the regulator is operating
Noisy Operation) correctly. Refer to Special Instruction, REHS0354,
“Charging System Troubleshooting” for the proper
SMCS Code: 1405-035 testing procedures. Repair the alternator or replace
the alternator, as needed.
Probable Causes
i02475244
• Alternator drive belts Battery

• Alternator drive pulley SMCS Code: 1401-035
• Alternator bearings Refer to Special Instruction, SEHS7633, “Battery
Test Procedure” for the proper testing procedures.
• Charging circuit
• Regulator Probable Causes
• Alternator • Worn battery
Recommended Actions • Switched battery circuit
Alternator Drive Belts Recommended Actions

1. Inspect the condition of the alternator drive belts. Worn Battery
If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and 1. Verify that the battery is no longer able to hold a
Assembly. charge.
2. Check the belt tension. Refer to the engine's 2. Replace the battery.
Specifications manual.
Switched Battery Circuit
3. If the engine is equipped with an automatic belt
tensioner, check the automatic belt tensioner. If 1. Verify that a switched battery circuit drained the
necessary, replace the automatic belt tensioner. battery by being left in the ON position.
Note: Excessive belt tension can result in damage to 2. Charge the battery.
the alternator.
3. Verify that the battery is able to maintain a charge.
Alternator Drive Pulley
i02451211
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the
pulley by the belt. If there is excessive wear, replace
Can Not Reach Top Engine
the pulley. Check that the nut for the pulley has not RPM
become loose. If necessary, tighten the nut.
SMCS Code: 1915-035
Note: Make sure that the alignment is correct.
Note: If this problem occurs only under load,
Alternator Bearings refer to troubleshooting without a diagnostic code
Troubleshooting, “Low Power/Poor or No Response
Check the alternator bearings for signs of wear. to Throttle”.
Repair the alternator or replace the alternator, as
needed.
RENR9313-04 25
Probable Causes Starting Aids

• Diagnostic codes Verify the correct operation of the air inlet heater
(if equipped). For additional information on the
• Event codes air inlet heater, refer to diagnostic functional tests
Troubleshooting, “Air Inlet Heater Circuit - Test”.
• Throttle signal
Fuel Supply
• Cold mode
1. Check the fuel lines for the following problems:
• Starting aids restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
• Intake manifold (boost) pressure lines and/or replace the lines.
• Fuel supply 2. Check the fuel tank for foreign objects which may
block the fuel supply.
• Air inlet and exhaust system
3. Prime the fuel system if any of the following
• Accessory equipment procedures have been performed:
• Specific conditions • Replacement of the fuel filters

Recommended Actions • Service on the low pressure fuel supply circuit
Diagnostic Codes and Event Codes • Replacement of unit injectors

Note: A sight glass in the low pressure supply line is
Certain diagnostic codes and/or event codes may
helpful in diagnosing air in the fuel.
cause poor performance. Connect Caterpillar
Electronic Technician (ET) and check for active codes
4. Cold weather adversely affects the characteristics
and/or logged codes. Troubleshoot any codes that
of the fuel. Refer to the Operation and
are present before continuing with this procedure.
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Throttle Signal operation.
Monitor “Throttle Position” on Cat ET. Verify that 5. Check the fuel pressure during engine cranking.
the appropriate parameter is programmed to the Check the fuel pressure on the outlet side of
correct value. Verify that you can achieve full throttle. the fuel filter. Refer to Testing and Adjusting for
Refer to Troubleshooting, “System Configuration correct pressure values. If the fuel pressure is low,
Parameters”. Refer to diagnostic functional tests replace the fuel filters. If the fuel pressure is still
Troubleshooting, “Throttle Position Sensor Circuit - low, check the following items: fuel transfer pump,
Test”. fuel transfer pump coupling, and fuel pressure
regulating valve.
Intake Manifold (Boost) Pressure
Air Inlet and Exhaust System
1. Monitor “Fuel Position” and “Rated Fuel Limit” on
the electronic service tool. If “Fuel Position” does 1. Clean plugged air filters or replace plugged air
not equal “Rated Fuel Limit”, then check the intake filters. Refer to the Operation and Maintenance
manifold pressure. Manual.
2. Monitor the status of the intake manifold pressure 2. Check the air inlet and exhaust system for
on the electronic service tool for normal operation. restrictions and for leaks. Refer to Testing and
Adjusting.
Cold Mode
Accessory Equipment
Use the electronic service tool to verify that the
engine has exited cold mode. A status flag will Check all accessory equipment for problems that
appear if the engine is operating in cold mode. This may create excessive load on the engine. Repair
may limit engine speed. any damaged components or replace any damaged
components.
26 RENR9313-04
Check the actual size of the prop. An oversized 3. Install a new cylinder head gasket and new water
prop can cause an engine overload. Install the seals in the spacer plate. Refer to the Disassembly
recommended prop if an oversized prop is being and Assembly manual.
used.
Cylinder Head
Specific Conditions
Check for cracks in the cylinder head. If a crack
An engine overload may be caused by specific is found, repair the cylinder head and/or replace
conditions which may exist. The following two the cylinder head. Refer to the Disassembly and
conditions can cause this problem. Assembly manual.
• Obstructions on the hull may have buildup which Cylinder Liner

can cause the engine to be overloaded. Refer to
Operation and Maintenance Manual. Check for cracked cylinder liners. Replace any
cracked cylinder liners. Refer to the Disassembly and
• Check the water line on the vessel. The water line Assembly manual.
may indicate a condition of excessive weight. The
water line may also indicate an improper weight
distribution. Refer to Operation and Maintenance
Cylinder Block
Manual.
Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
i02381103 block.
Coolant in Engine Oil

i02451330
SMCS Code: 1348-035; 1395-035
Coolant Temperature Is Too
Probable Causes High
SMCS Code: 1395-035
• Engine oil cooler core
• Cylinder head gasket Probable Causes
• Cylinder head • Parameters
• Cylinder liner • Coolant level
• Cylinder block • Combustion gases in the cooling system
Recommended Actions • Water temperature regulators
Engine Oil Cooler Core • Restriction in the cooling system
1. Check for leaks in the oil cooler core. If a leak is

• Coolant temperature gauge
found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
• Water pump
2. Drain the crankcase and refill the crankcase with

• Excessive load on the system
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual. Recommended Actions
Cylinder Head Gasket Parameters
1. Remove the cylinder head. Refer to the Verify that the values for the programmable monitoring
Disassembly and Assembly manual. system are correct. Refer to Troubleshooting, “System
Configuration Parameters”.
2. Check the cylinder liner projection. Refer to the
Systems Operation/Testing and Adjusting manual.
RENR9313-04 27
Coolant Level Keel Cooler
1. Visually inspect the circuit for collapsed hoses

and/or other restrictions.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, 2. Clean the circuit and make the necessary repairs
stop the engine and wait until the cooling system to the circuit.
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Coolant Temperature Gauge
sure.
Compare the reading for the coolant temperature
from the Caterpillar Electronic Technician (ET) to
Note: Low coolant level can be the result of the reading for the coolant temperature from a
overheating rather than the cause. mechanical gauge. The temperature should rise
steadily as the engine is warmed. Ensure that
Check the coolant level. the temperature is reasonable. Refer to Systems
Operation/Testing and Adjusting.
Run the engine to operating temperature.
If the reading on Cat ET for the coolant temperature
Inspect the cooling system for leaks. Check for the is not reasonable, troubleshoot the circuit and the
presence of coolant in the engine oil. This would coolant temperature sensor. Refer to the diagnostic
indicate an internal coolant leak. functional test Troubleshooting, “Engine Temperature
Sensor Open or Short Circuit - Test”.
Determine whether the leak occurs before the engine
overheats.
Water Pump
Add coolant, if necessary. If leaking is found, make
the necessary repairs. Inspect the water pump impeller for damage and/or
erosion. If necessary, repair the water pump or
replace the water pump.
Combustion Gases in the Cooling System
Inspect the coolant for presence of bubbles. If Excessive Load on the System
bubbles are present, combustion gases may be
entering the cooling system. Reduce the load and verify that the condition does
not reoccur.
Water Temperature Regulators
i02826488
Check the water temperature regulators for proper
operation. Refer to Systems Operation/Testing and ECM Will Not Accept Factory
Adjusting. Passwords
Replace the water temperature regulators, if SMCS Code: 1901-035
necessary.
Restriction in the Cooling System

Probable Causes
One of the following items may not be recorded
The following cooling systems may not be operating correctly on the Caterpillar Electronic Technician
properly. (ET):
• Raw water circuit for the heat exchanger • Passwords
• Keel cooler • Serial numbers
Raw Water Circuit for the Heat Exchanger
• Total tattletale
1. Visually inspect the circuit for collapsed hoses
and/or other restrictions.
• Reason code
2. Clean the circuit and make the necessary repairs

to the circuit.
28 RENR9313-04
Recommended Actions 4. Troubleshoot the CAN data link (if equipped)

for possible problems. Refer to the diagnostic
1. Verify that the correct passwords were entered. functional test Troubleshooting, “CAN Data Link
Check every character in each password. Remove Circuit - Test”.
the electrical power from the engine for 30
seconds and then retry.
i02429900
2. Verify that Cat ET is displaying the “Enter Factory

Passwords” dialog box.
Electronic Service Tool Will
Not Communicate with ECM
3. Use Cat ET to verify that the following information
has been entered correctly: SMCS Code: 0785-035; 1901-035
• Engine serial number Probable Causes

• Serial number for the electronic control module • Configuration for the communications adapter
• Serial number for Cat ET • Electrical connectors
• Total tattletale • Communication adapter and/or cables
• Reason code • Electrical power supply to the service tool
connector
For additional information, refer to Troubleshooting,
“Factory Passwords”.
• Caterpillar Electronic Technician (ET) and related
hardware
i02480112
• Electrical power supply to the Electronic Control
ECM Will Not Communicate Module (ECM)
with Other Systems or Display • Flash file
Modules
• Cat Data Link
SMCS Code: 1901-035
Recommended Actions
Probable Causes
Start the engine. If the engine starts, but the ECM
• Wiring and/or electrical connectors will not communicate with Cat ET, continue with
this procedure. If the engine will not start, refer
• Cat Data Link to the troubleshooting without a diagnostic code
procedure Troubleshooting, “Engine Cranks but Will
• CAN data link (if equipped) Not Start”. If the engine will not crank, refer to the
troubleshooting without a diagnostic code procedure
• Electronic Control Module (ECM) Troubleshooting, “Engine Will Not Crank”.
Recommended Actions Configuration for the Communications

Adapter
1. Check for correct installation of the connectors for
the Electronic Control Module (ECM) J1/P1, J2/P2 1. Access “Preferences” under the “Utilities” menu
and J3/P3. Refer to the diagnostic functional test on Cat ET.
Troubleshooting, “Electrical Connectors - Inspect”.
2. Verify that the correct “Communications Interface
2. Connect the electronic service tool to the Device” is selected.
service tool connector. If the ECM does not
communicate with the electronic service tool, 3. Verify that the correct port is selected for use by
refer to troubleshooting without a diagnostic code the communication adapter.
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”. Note: The most commonly used port is “COM 1”.
3. Troubleshoot the Cat Data Link for possible

problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
RENR9313-04 29
4. Check for any hardware that is utilizing the Note: A new ECM is not programmed to any specific
same port as the communications adapter. If any engine until a flash file has been installed. The engine
devices are configured to use the same port, exit will not start and the engine will not communicate
or close the software programs for that device. with Cat ET until the flash file has been downloaded.
Refer to programming parameters Troubleshooting,
Electrical Connectors “Flash Programming”.
Check for correct installation of the J1/P1 and Cat Data Link
J2/P2 ECM connectors and of the service tool
connector. Refer to the diagnostic functional test Troubleshoot the Cat Data Link for possible
Troubleshooting, “Electrical Connectors - Inspect”. problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
Communication Adapter and/or Cables
i02377759
1. If you are using a “Communication Adapter II”,
ensure that the firmware and driver files for the Engine Cranks but Will Not
communication adapter are the most current files
that are available. If the firmware and driver files Start
do not match, the communication adapter will not
communicate with Cat ET. SMCS Code: 1000-035
2. Disconnect the communication adapter and the Probable Causes

cables from the service tool connector. Reconnect
the communication adapter to the service tool • Diagnostic codes
connector.
• Event codes
3. Verify that the correct cable is being used between
the communication adapter and the service tool • Flash file
connector. Refer to electronic troubleshooting
Troubleshooting, “Electronic Service Tools”. • Power supply for the Electronic Control Module
(ECM)
Electrical Power Supply to the Service
Tool Connector • Starting circuit
Verify that battery voltage is present between • Starting aids (if applicable)
terminals A and B of the service tool connector. If the
communication adapter is not receiving power, the • Engine shutdown switches (if applicable)
display on the communication adapter will be blank.
• Air shutoff system (if applicable)
Cat ET and Related Hardware • Engine speed/timing
In order to eliminate Cat ET and the related hardware • Unit injectors
as the problem, connect Cat ET to a different engine.
If the same problem occurs on a different engine, • Fuel supply
check Cat ET and the related hardware in order to
determine the cause of the problem. • Combustion
Electrical Power Supply to the Electronic Recommended Actions
Control Module (ECM)
Check power to the ECM. Refer to the diagnostic
Diagnostic Codes, Event Codes, and
functional test Troubleshooting, “Electrical Power ECM Power Supply
Supply Circuit - Test”.
Note: If the ECM is not receiving battery voltage, the prevent the engine from starting. Connect the
ECM will not communicate. Caterpillar Electronic Technician (ET) and check for
active codes and/or for logged codes. Troubleshoot
any codes that are present before continuing with
Flash File this procedure.
Ensure that the correct flash file is properly installed
in the ECM.
30 RENR9313-04
Note: If Cat ET will not communicate with the ECM, 2. Ensure that the timing reference gear is installed
the problem is most likely with the electrical power correctly. The engine will not start if the gear was
supply to the ECM. Refer to the diagnostic functional installed backward. Check for proper orientation
test Troubleshooting, “Electrical Power Supply Circuit between the crankshaft and camshaft drive gears.
- Test”. Correct the orientation and/or replace the drive
gear, if necessary. Refer to Disassembly and
Starting Circuit Assembly.
Test the operation of the starting motor and Unit Injectors

associated circuit components. Refer to the Systems
Operation/Testing and Adjusting manual. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids are
Flash File being energized by the ECM. Refer to the diagnostic
functional test Troubleshooting, “Injector Solenoid
Verify that the correct flash file has been flashed Circuit - Test”.
into the ECM. Refer to programming parameters
Troubleshooting, “Flash Programming”. Verify that the injection system is delivering the
correct pressure. Refer to the diagnostic functional
test Troubleshooting, “Injection Actuation Pressure -
Starting Aids Test”.
Air Inlet Heater (if applicable)
Fuel Supply
Make sure that the air inlet heater is programmed
to the On position. For additional information on the 1. Visually check the fuel level. Do not rely on the fuel
air inlet heater, refer to the diagnostic functional test gauge only. If necessary, add fuel. If the engine
Troubleshooting, “Air Inlet Heater Circuit - Test”. has been run out of fuel, it will be necessary to
prime the fuel system. Refer to Operation and
Maintenance Manual.
Engine Shutdown Switches (If
Applicable) 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
The engine shutdown switches should be in the problems are found with the fuel lines, repair the
OFF position. Use Cat ET to verify the status of the lines and/or replace the lines.
shutdown switches. When a shutdown occurs, the
engine control must be in the OFF/RESET mode for 3. Check the fuel tank for foreign objects which may
at least 15 seconds before restarting the engine. block the fuel supply.
Air Shutoff System (If Applicable) 4. Check for air in the low pressure fuel supply
system if any of the following procedures have
Check the air shutoff mechanism. If an engine been performed:
overspeed has occurred, the keyswitch must be
cycled. There may be a manual reset for the air • Replacement of the fuel filters
shutoff mechanism that is on the engine.
• Service on the low pressure fuel supply circuit
Engine Speed/Timing
• Replacement of unit injectors
1. Crank the engine and observe the engine speed
on the Cat ET status screen. If Cat ET indicates Note: A sight glass in the low pressure supply line is
zero rpm, refer to the diagnostic functional test helpful in diagnosing air in the fuel. Refer to Testing
Troubleshooting, “Engine Speed/Timing Sensor and Adjusting.
Circuit - Test”.
NOTICE
Note: Upon initial cranking, the status for engine Do not crank the engine continuously for more than
speed may indicate that the engine speed signal is 30 seconds. Allow the starting motor to cool for two
abnormal. This message will be replaced with an minutes before cranking the engine again.
engine speed once the ECM is able to calculate a
speed from the signal.
5. Prime the low pressure fuel supply circuit. Refer
to Operation and Maintenance Manual, “Fuel
System - Prime”.
RENR9313-04 31
6. Check fuel quality. Cold weather adversely If the oil filter bypass valve is open, the oil will not be
affects the characteristics of the fuel. Refer to the filtered. Check the oil filter bypass valve for a weak
applicable Operation and Maintenance Manual for spring or for a broken spring. If the spring is broken,
information on improving the characteristics of the replace the spring. Refer to the engine's Disassembly
fuel during cold weather operation. and Assembly manual. Make sure that the oil bypass
valve is operating correctly.
7. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to Testing and Low Oil Pressure
Adjusting. If the fuel pressure is low, replace the
fuel filters. If the fuel pressure is still low, check the When some components of the engine show bearing
following items: fuel transfer pump, fuel transfer wear in a short time, the cause can be a restriction in
pump coupling, and fuel pressure regulating valve. a passage for engine oil.
Refer to Testing and Adjusting.
An indicator for the engine oil pressure may indicate
Combustion sufficient pressure, but a component is worn due
to a lack of lubrication. In such a case, look at the
Check for combustion problems. passage for the engine oil supply to the component.
i03506600
Leaks in Air Intake System
Engine Has Early Wear A leak in the air intake system may allow unfiltered
air into the engine. Inspect the air intake system for
SMCS Code: 1000-035 streaks which may indicate a leakage of unfiltered air.
Inspect all of the gaskets and the connections. Repair
any leaks. Refer to Systems Operation, Testing and
Probable Causes Adjusting for more information.
Engine Oil Inspect the air filter. Replace the air filter, if necessary.
• Incorrect maintenance intervals Inspect the Fuel Filters for Contamination

• Contaminated engine oil 1. Remove the fuel filters. Inspect the fuel filters for
contamination. Install new fuel filters. Refer to the
• Low oil pressure Operation and Maintenance Manual. Determine
the cause of the contamination.
Contaminated Air
2. Contaminants in the fuel such as hydrogen sulfide
• Leaks in air intake system and sulfur can lead to the formation of acids in the
crankcase. Obtain a fuel analysis.
Contaminated Fuel
i02487955
• Inspect the fuel filters for contamination.
Engine Misfires, Runs Rough
Recommended Actions or Is Unstable
Incorrect Maintenance Intervals SMCS Code: 1000-035
Use engine oil that is recommended and change the Note: If the symptom is intermittent and the symptom
engine oil at the interval that is recommended by the cannot be repeated, refer to troubleshooting without
engine's Operation and Maintenance Manual. a diagnostic code Troubleshooting, “Intermittent Low
Power or Power Cutout”. If the symptom is consistent
Contaminated Engine Oil and the symptom can be repeated, continue with this
procedure.
Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Refer to Probable Causes
the engine's Operation and Maintenance Manual.
• Electrical connectors
• Cold mode
32 RENR9313-04
• Injection actuation pressure 3. Compare the actual actuation pressure and

the desired actuation pressure on Cat ET. If
• Throttle signal these readings do not agree within 2000 kPa
(290 psi), refer to the diagnostic functional test
• Unit injectors Troubleshooting, “Injection Actuation Pressure -
Test”.
• Fuel supply
Unit Injectors
1. Perform the “Injector Solenoid Test” on Cat
Recommended Actions ET in order to determine if all of the injector
solenoids are being energized by the ECM. Refer
Note: If the symptom only occurs under certain to the diagnostic functional test Troubleshooting,
operating conditions (high idle, full load, engine “Injector Solenoid Circuit - Test”.
operating temperature, etc), test the engine under
those conditions. Troubleshooting the symptom 2. Perform the “Cylinder Cutout Test” on Cat ET in
under other conditions can give misleading results. order to identify any misfiring cylinder(s). Refer
to the diagnostic functional test Troubleshooting,
“Injector Solenoid Circuit - Test”.
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar Fuel Supply
Electronic Technician (ET). Troubleshoot any
active diagnostic codes before continuing with this 1. Check the fuel lines for the following problems:
procedure. restrictions, collapsed lines, and pinched lines. If
Electrical Connectors lines and/or replace the lines.
2. Check the fuel tank for debris which may block

Check the condition of the connectors at the
Electronic Control Module (ECM). Check for the the fuel supply.
correct installation of the J2/P2 and J1/P1 ECM
3. Check for air in the low pressure fuel supply
connectors. Check the J300/P300 injector solenoid
harness connector. Refer to the diagnostic functional circuit. Refer to Systems Operation/Testing and
Adjusting. If air is present in the low pressure fuel
test Troubleshooting, “Electrical Connectors -
supply circuit, prime the fuel system. Refer to
Inspect”.
Systems Operation/Testing and Adjusting.
Cold Mode
Use Cat ET to verify that the engine has exited cold
1. Check for an air filter restriction. Clean plugged air
mode. Cold mode operation may cause the engine to
filters or replace plugged air filters. Refer to the
run rough and engine power may be limited.
Operation and Maintenance Manual.
Throttle Signal 2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Use Cat ET to view the status for the throttle position Operation/Testing and Adjusting.
on the status screen. Operate the throttle from the
low idle position to the high idle position. The status
should be 0 percent at low idle and the status should i02549498
be 100 percent at high idle.
Engine Oil in Cooling System
Injection Actuation Pressure SMCS Code: 1348-035; 1350-035
1. Check the engine oil level. Engine oil supplies the
injection actuation pressure circuit. The engine oil Probable Causes
must be kept at the proper level.
• Engine oil cooler core
2. If service has recently been performed on the
engine, air may be present in the injection • Cylinder head gasket
actuation pressure circuit. Allow the engine to fully
warm up and operate the engine under load in • Water pump
order to ensure that the air has been purged from
the injection actuation pressure circuit.
RENR9313-04 33
Recommended Actions Worn Valve Guides
Engine Oil Cooler Core Inspect the valve guides for wear. Refer to the
Specification manual for the maximum permissible
1. Inspect the engine oil cooler core for leaks. If a wear of the valve guides. If necessary, recondition
leak is found, replace the oil cooler core. Refer to the cylinder head.
Disassembly and Assembly.
Worn Piston Rings
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Piston rings that have excessive wear can cause
Refer to Operation and Maintenance Manual. too much pressure in the crankcase. The additional
pressure in the crankcase will cause more than
Cylinder Head Gasket the normal amount of crankcase blowby from the
crankcase breather. Use the 8T-2700 Blowby/Air
1. Remove the cylinder head. Refer to Disassembly Flow Indicator to check the amount of crankcase
and Assembly. blowby. The test procedure is in Special Instruction,
SEHS8712. Inspect piston rings and install new
2. Check the cylinder liner projection. Refer to parts, as required.
Scored Cylinder Walls or Worn Cylinder
3. Install a new cylinder head gasket and new water Walls
seals in the spacer plate. Refer to Disassembly
and Assembly. Inspect the cylinder liners for damage. Hone the
cylinder liners in order to remove the scoring. If
Water Pump necessary, install new liners.
Check the weep hole in the water pump for blockage.

i02424562
Check the water pump seals.
Engine Oil Temperature Is Too
i02234636 High
Engine Oil in Exhaust System SMCS Code: 1348-035-TA
SMCS Code: 1050-035; 1348-035
Probable Causes
Probable Causes
• Oil specifications
• Failed turbocharger seals
• Engine oil temperature reading
• Worn valve guide seals or faulty valve guide seals
• Engine oil cooler bypass valve
• Worn valve guides
• High coolant temperature
• Worn piston rings
• Engine oil cooler
• Scored cylinder liners or worn cylinder liners
Recommended Actions
Recommended Actions
Oil Specifications
Failed Turbocharger Seals
Inspect the engine oil level. If necessary, add the
correct engine oil. Check the condition of the engine
Check the inlet manifold and the exhaust manifold for
oil. If oil is present, replace the turbocharger. oil.
For information on oil specifications and/or

Worn Valve Guide Seals or Faulty Valve information on oil analysis, refer to the Operation and
Guide Seals Maintenance manual .
Inspect the valve guide seals for wear and for

damage. Replace the valve guide seals, if necessary.
34 RENR9313-04
Engine Oil Temperature Reading 2. Perform the “Injector Solenoid Test” with the
Caterpillar Electronic Technician (ET) in order to
Compare the engine oil temperature reading from determine if all of the injector solenoids are being
the Caterpillar Electronic Technician (ET) to the energized by the ECM.
temperature from a 6V-9130 Temperature Adapter.
Verify that the readings are reasonably close. 3. Perform the “Cylinder Cutout Test” with Cat ET
in order to identify any injectors that might be
Engine Oil Cooler Bypass Valve misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Clean the engine oil cooler bypass valve and inspect
the engine oil cooler bypass valve. Clean the bore for Fuel Supply
the valve. Ensure that the bypass valve is not stuck
in the open position. Replace the bypass valve, if 1. Check the fuel pressure. Refer to Systems
necessary. Refer to Disassembly and Assembly. Operation/Testing and Adjusting.
High Coolant Temperature 2. Check the fuel lines for the following problems:
Check for a high coolant temperature. Resolve problems are found with the fuel lines, repair the
any problems with active event codes before lines and/or replace the lines.
proceeding. If necessary, refer to troubleshooting
without a diagnostic code Troubleshooting, “Coolant 3. Check the fuel tank for foreign objects which may
Temperature Is Too High”. block the fuel supply.
Engine Oil Cooler NOTICE

Do not crank the engine continuously for more than
Check for a damaged engine oil cooler or for 30 seconds. Allow the starting motor to cool for two
blockage in the engine oil cooler. Look for a restriction minutes before cranking the engine again.
in the passages for engine oil in the engine oil cooler.
Clean the engine oil cooler core or replace the engine
oil cooler core.
procedures have been performed:
i02455784 • Replacement of the fuel filters

Engine Stalls at Low RPM • Service on the low pressure fuel supply circuit
SMCS Code: 1915-035 • Replacement of unit injectors
Probable Causes Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
• Unit injectors
• Fuel supply 5. Cold weather adversely affects the characteristics
• Air supply Maintenance Manual.
6. Check the fuel pressure after the fuel filter

• Engine idle
while the engine is being cranked. For the
• Accessory equipment correct pressure values, refer to the Systems
Operation/Testing and Adjusting manual. If the
fuel pressure is low, replace the fuel filters. If the
Recommended Actions fuel pressure is still low, check the following items:
fuel transfer pump, fuel transfer pump coupling,
Unit Injectors and fuel pressure regulating valve.
1. Check for correct installation of the J1/P1 and Air Supply

J2/P2 connectors for the Electronic Control
Module (ECM). Check for correct installation of the Check for restrictions in the air inlet system. Refer to
J300/P300 connectors for the unit injectors. Refer Systems Operation/Testing and Adjusting.
“Electrical Connectors - Inspect”.
RENR9313-04 35
Engine Idle i02377768
Check the parameter for the low engine idle (if Engine Will Not Crank
applicable). Refer to Troubleshooting, “System
Configuration Parameters”. SMCS Code: 1000-035
Accessory Equipment Probable Causes

Check all accessory equipment for problems that • Circuit breakers
may create excessive load on the engine. Repair
any damaged components or replace any damaged • Battery cables
components.
• Batteries
i02419766
• Starting circuit
Engine Vibration • Flywheel ring gear
SMCS Code: 1000-035
• Driven equipment
Probable Causes • Engine accessories
• Vibration damper • Hydraulic cylinder lock
• Engine supports • Internal engine problem
• Driven equipment Recommended Actions
• Engine misfiring or running rough
Circuit Breakers
Recommended Actions Check the state of each of the circuit breakers. Reset
the circuit breakers if the circuit breakers are tripped.
Vibration Damper Prior to returning the engine to service, determine
the condition that caused the circuit breaker to trip.
Check the vibration damper for damage. Install a Make the necessary repairs.
new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace Battery Cables and/or Batteries
any damaged bolts. Refer to the Disassembly and
Assembly manual. 1. Inspect the battery disconnect switch, bus bars,
battery posts, and battery cables for loose
Engine Supports connections and corrosion. If the battery cables
are corroded, remove the battery cables and clean
Inspect the mounts and the brackets while you run the battery cables. Tighten any loose connections.
the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten 2. Inspect the batteries.
all of the mounting bolts. Install new components, if
necessary. a. Charge the batteries. Refer to Special
Instruction, SEHS7633, “Battery Test
Driven Equipment Procedure”.
Check the alignment and the balance of the driven b. Load test the batteries. Refer to Special
equipment. Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
Engine Misfiring or Running Rough
Refer to troubleshooting without a diagnostic code Starting Circuit
Troubleshooting, “Engine Misfires, Runs Rough or
Is Unstable”. Test the operation of the starting motor and
associated circuit components. Refer to the Systems
Operation/Testing and Adjusting manual.
36 RENR9313-04
Driven Equipment and/or Engine • Valve lash

Accessories
• Electronic unit injector
1. Ensure free movement of the driveline.
• Intake manifold (boost) pressure sensor, rated fuel
2. Ensure that the timing pin was not left in the position and/or FRC fuel position
flywheel housing.
• Flash file
3. Remove any engine accessories that may lock
up the engine. Inspect the condition of the • Fuel quality
accessories.
Recommended Actions
The following list illustrates examples of engine
accessories that may lock up the engine: Air Inlet System or Exhaust System
• Fuel transfer pump 1. Check the air inlet system for restrictions and/or
for leaks.
• Air compressor
a. Check for an air filter restriction.
• Engine oil pump
b. Check for derates and for alarms.
• Engine shutdown switches
c. Perform a visual inspection of the system for
• Start interlock restrictions and/or for leaks.
• Prelubrication system 2. Ensure that the turbocharger has not failed.
• Crank enable switch 3. Check the exhaust system for restrictions.
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 Sensors
Note: Be sure to drain the fuel from the cylinder head
prior to removing the injectors. Fuel will flow from the
1. Check the calibration of the engine speed/timing
cylinder head into the cylinders when the unit injector
sensor. Refer to calibration procedures
is removed. Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate”.
Internal Engine Problem
2. Verify that the crankshaft and the camshaft drive
Inspect the internal components for the following gears are set with the proper orientation. Refer to
conditions: the Disassembly and Assembly manual.
• Seizure Valve Lash

• Broken components Check the valve lash. Refer to Systems
• Bent components
Electronic Unit Injector
i02455931
1. Ensure that the electronic unit injector connectors
Excessive Black Smoke (J300/P300) are fully connected and free of
corrosion.
SMCS Code: 1088-035
2. Ensure that the ECM connector (J2/P2) is fully
Probable Causes connected and free of corrosion.
• Air inlet system or exhaust system 3. Connect the Caterpillar Electronic Technician
(ET). Run the cylinder cutout test in order to
• Engine speed/timing sensors identify any misfiring cylinders.
RENR9313-04 37
Refer to the diagnostic functional test Recommended Actions

Oil Leaks
Intake Manifold (Boost) Pressure Sensor,
Rated Fuel Position and/or FRC Fuel Check the engine compartment for oil leaks. Repair
any oil leaks that are identified.
Position
1. Monitor the status of “Fuel Position” and “Rated Oil Level
Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit” Check the engine oil level. Too much oil in the engine
and “Fuel Position” is less than “FRC Fuel Limit”, crankcase can cause the engine to consume oil.
the Electronic Control Module (ECM) is providing Remove excessive engine oil from the crankcase.
the correct control. Otherwise, proceed to the next
Step. Ensure that the dipstick is properly calibrated
and/or that the dipstick is correct for the application.
2. Verify that there are no active diagnostic codes. Calibrate the dipstick and/or replace the dipstick.
3. Monitor the status of “Intake Manifold (Boost) Turbocharger

Pressure” and “Atmospheric Pressure” on the
Caterpillar Electronic Technician (ET). When the Check for turbocharger shaft seal leakage. Remove
engine is not running, “Boost Pressure” should be the air inlet piping and the exhaust outlet piping from
0 kPa (0 psi). the turbocharger. Check the compressor wheel and
the turbine for evidence of an oil leak. If necessary,
Note: A problem with the FRC will only cause black repair the turbocharger or replace the turbocharger.
smoke during acceleration. A problem with the FRC Refer to Systems Operation/Testing and Adjusting.
will not cause black smoke during steady state
operation. Internal Engine Wear
Flash File Internal engine wear can cause excessive oil leakage
into the combustion area of the cylinders. Excessive
Verify that the correct flash file is installed. Refer to wear on the following components may cause oil
programming parameters Troubleshooting, “Flash consumption:
Programming”.
• Piston rings
Fuel Quality
• Valve guides
1. Check fuel quality.
Check for excessive crankcase blowby at the
2. Cold weather adversely affects the characteristics engine crankcase breather. Refer to Systems
of the fuel. For information on improving the Operation/Testing and Adjusting.
characteristics of the fuel during cold weather
operation, refer to the Operation and Maintenance i02430014
Manual.
Excessive Fuel Consumption
i02410997
SMCS Code: 1250-035
Excessive Engine Oil
Consumption Probable Causes
SMCS Code: 1348-035 • Engine operation
• Fuel leaks
Probable Causes
• Fuel quality
• Oil leaks
• Engine speed/timing
• Oil level
• Unit injectors
• Turbocharger seal
• Internal engine wear
38 RENR9313-04
• Accessory equipment 2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Recommended Actions
Engine Operation Accessory Equipment
Check all accessory equipment for problems that
Use the Caterpillar Electronic Technician (ET) to
check the “Current Totals” for excessive idle time may create excessive load on the engine. Repair
any damaged components or replace any damaged
and/or for a high load factor which would be indicative
components.
of poor operating habits.
Note: Engine operation may also be affected by i02424626

environmental conditions such as wind and snow.
Excessive Valve Lash
Fuel Leaks
SMCS Code: 1105-035
Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer Probable Causes
to Systems Operation/Testing and Adjusting for the
correct pressure values. If the fuel pressure is low, • Lubrication
replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel • Valve lash
transfer pump coupling, and fuel pressure regulating
valve. • Valve train components
Fuel Quality Recommended Actions
Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Maintenance Lubrication
Manual for information on improving the
1. Remove the valve mechanism covers. Refer to
characteristics of the fuel during cold weather
operation. the engine's Disassembly and Assembly manual.
2. Check the lubrication in the valve compartment.

Engine Speed/Timing Ensure that there is adequate engine oil flow in
the valve compartment. The passages for the
Perform a speed/timing sensor calibration. Refer to engine oil must be clean.
the calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Valve Lash
Unit Injectors Adjust the engine valve lash. Refer to the engine's
Systems Operation/Testing and Adjusting manual.
1. Check for correct installation of the J1/P1
and J2/P2 Electronic Control Module (ECM)
connectors and the unit injector connectors. Refer Valve Train Components
1. Inspect the following components of the valve
train:
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids • Rocker arms
are being energized by the ECM.
• Pushrods
3. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that might be • Valve lifters
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”. • Camshaft
• Valve stems
• Rocker shafts
1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
or replace the air filter.
RENR9313-04 39
2. Check the components for the following conditions: If a problem with the operation of the air inlet
abnormal wear, excessive wear, straightness, and heater circuit is suspected, refer to the diagnostic
cleanliness. Replace parts, if necessary. functional test Troubleshooting, “Air Inlet Heater
Circuit - Test”.
Note: If you replace the camshaft, you must also
replace the valve lifters. Coolant Temperature Sensor
3. Adjust the engine valve lash. Refer to the engine's 1. Use the Caterpillar Electronic Technician (ET) to
Systems Operation/Testing and Adjusting manual. verify that the engine has exited cold mode.
i02456160
2. Ensure that the coolant temperature that is
reported from Cat ET is reasonable. If this
Excessive White Smoke coolant temperature is suspect, use a 6V-9130
Temperature Adapter (MULTIMETER) to confirm
SMCS Code: 1088-035 the accuracy.
Note: Some white smoke may be present during Water Temperature Regulators
cold start-up conditions when the engine is operating
normally. If the white smoke persists, there may be Check the water temperature regulators for correct
a problem. operation. Refer to Systems Operation/Testing and
Adjusting.
Probable Causes
Engine Speed/Timing
• Air inlet restriction
1. Check the calibration of the engine speed/timing
• Starting aids sensor. Refer to calibration procedures
Troubleshooting, “Engine Speed/Timing Sensor -
• Coolant temperature sensor Calibrate”.
• Water temperature regulators 2. Verify that the crankshaft and camshaft drive
gears are set with the proper orientation. Refer to
• Engine speed/timing the Disassembly and Assembly.
• Unit injectors Unit Injectors

• Flash file Perform the “Cylinder Cutout Test” on Cat ET in order
to check the unit injectors and the performance of
• Fuel supply each cylinder. Refer to the diagnostic functional test
• Component wear
Flash File
• Cooling system
Verify that the latest version of the ECM flash file
Recommended Actions has been installed. Refer to system configuration
parameters Troubleshooting, “System Configuration
Air Inlet Restriction Parameters”.
Check the air inlet system for restrictions. Refer to Fuel Supply
1. Inspect the condition of the fuel system
Starting Aids components. Inspect each component for leakage
and damage.
1. If the engine application is equipped with a jacket
water heater, check for the proper operation of 2. Check the fuel pressure during engine cranking.
the heater control and the heater element. If Check the filtered fuel pressure. Refer to Systems
necessary, repair the jacket water heater. Operation/Testing and Adjusting for the correct
pressure values. If the fuel pressure is low,
2. Check for the proper operation of the air inlet replace the fuel filters. If the fuel pressure is still
heater. Check for the proper operation of the low, check the following items: fuel transfer pump,
heater control, the heater element, and the heater fuel transfer pump coupling, and fuel pressure
relay. If necessary, repair the air inlet heater. regulating valve.
40 RENR9313-04
3. Check the fuel quality. Low cetane fuel can create 2. Check for leaks between the exhaust manifold and
white smoke. If necessary, replace the fuel with a the turbocharger. Check for exhaust restrictions.
higher cetane fuel. Refer to Systems Operation/Testing and Adjusting,
“Air Inlet and Exhaust System”.
4. Cold weather adversely affects the characteristics
i02119587
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
Fuel Dilution of Engine Oil
SMCS Code: 1348-035
Component Wear
Check the engine for the following problems: Probable Causes
Excessive valve wear, piston wear, ring wear, liner
wear, and reduced compression pressure. • Leaking seals on the case of the unit injector or on
the barrel of the unit injector
Cooling System • Leaking seals on the fuel line adapter for the
cylinder head
Check for an internal coolant leak into the
cylinder and/or the exhaust. Refer to Systems • Excessive leakage from the unit injector tip or
Operation/Testing and Adjusting. breakage of the unit injector tip
i02514091 • Cracked fuel supply manifold

Exhaust Temperature Is Too • Leaking seal on the fuel transfer pump
High
Recommended Actions
SMCS Code: 1088-035-TA
Leaking Seals on the Case of the Unit
Probable Causes Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit
• Electrical connectors injectors. Replace any seals that are leaking.
• Air inlet and exhaust system Leaking Seals on the Fuel Line Adapter
for the Cylinder Head
Recommended Actions
Look for signs of damage to the seals on the fuel line
Diagnostic Codes adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
Connect the Caterpillar Electronic Technician (ET) lines or components.
and check for active diagnostic codes. Troubleshoot
any active diagnostic codes before continuing with Excessive Leakage from the Unit Injector
this procedure.
Tip or Breakage of the Unit Injector Tip
Electrical Connectors Look for signs of damage to the unit injectors. If
necessary, repair the unit injectors or replace the unit
Check for correct installation of the J2/P2 Electronic injectors.
Control Module (ECM) connector and of the
J300/P300 connector that is for the injectors. Refer
Cracked Fuel Supply Manifold
Look for signs of damage to the fuel supply manifold.
Leaking Fuel Transfer Pump Seal
1. Check the air inlet manifold pressure. Check for
Ensure that the weep hole is not plugged. If
air inlet restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and necessary, repair the fuel transfer pump or replace
the fuel transfer pump.
Exhaust System”.
RENR9313-04 41
i02477276 3. Check the state of each of the circuit breakers.

Reset the circuit breakers if the circuit breakers
Intermittent Engine Shutdown are tripped. Prior to returning the engine to
service, determine the condition that caused the
SMCS Code: 1000-035 circuit breaker to trip. Make the necessary repairs.
Note: Use this procedure only if the engine shut 4. Aftermarket engine protection devices usually
down completely and it was necessary to restart the interrupt power to the ECM. Check for correct
engine. installation and operation of aftermarket engine
protection devices. It may be necessary to bypass
Probable Causes aftermarket devices in order to continue testing.
• Diagnostic codes Unit Injector Connectors

• Event codes Check the unit injector connectors J300/P300 and
associated wiring for damage, or for intermittent
• Electrical connections problems. Refer to the diagnostic functional test
• Unit injector connectors
Fuel Supply
• Fuel supply
1. Check the fuel lines for the following problems:
• Engine shutdown switch (if applicable) restrictions, collapsed lines, and pinched lines. If
Note: If the problem only occurs under certain lines and/or replace the lines.
conditions such as full load or engine operating
temperature, then perform the test under those 2. Check the fuel tank for foreign objects which may
operating conditions. block the fuel supply.
Recommended Actions NOTICE

Diagnostic Codes or Event Codes 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Certain diagnostic codes or event codes may cause
the engine to shutdown. Connect the Caterpillar
Electronic Technician (ET) and check for active codes 3. Prime the fuel system if any of the following
and/or logged codes. Troubleshoot any codes that procedures have been performed:
are present before continuing with this procedure.
• Replacement of the fuel filters
Electrical Connections • Service on the low pressure fuel supply circuit
1. Inspect the wiring from the Electronic Control
Module (ECM) to the breaker panel. Refer to the
Schematic for the engine. Inspect any device that Refer to the Operation and Maintenance Manual.
has been installed for circuit protection. Ensure
that battery power is present at the ECM. Ensure Note: A sight glass in the fuel supply line is helpful in
that the ground circuits are providing electrical diagnosing air in the fuel.
continuity to the ECM. Refer to the diagnostic
functional test Troubleshooting, “Electrical Power 4. Cold weather adversely affects the characteristics
Supply Circuit - Test”. of the fuel. Refer to the Operation and
Maintenance Manual.
2. Check the circuit between the ECM and the
keyswitch. Refer to the Schematic for the engine. 5. Check the fuel pressure during engine cranking.
Also, ensure that all electrical connectors are in Check the fuel pressure after the fuel filter. Refer
good repair. Refer to the diagnostic functional to the Systems Operation/Testing and Adjusting.
test Troubleshooting, “ Electrical Connectors - If the fuel pressure is low, replace the fuel filters.
Inspect”. If the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve.
42 RENR9313-04
Engine Shutdown Switch (If Applicable) • Troubleshooting, “Throttle Switch Circuit - Test”
Use Cat ET to monitor the status of the engine • Troubleshooting, “Speed Control - Test”
shutdown switches. Check for status indicators
that are active due to the engine shutdown switch. ECM Power Supply
Determine the cause for the shutdown and make any
repairs necessary. 1. Inspect the circuit between the ECM and the
batteries for poor connections and damage.
i02424639
Inspect the wiring, the connectors, and the power
relay. Refer to the Electrical System Schematic.
Intermittent Low Power or
2. Inspect the circuit between the ECM and the
Power Cutout keyswitch. Inspect the wires, the connectors, and
the keyswitch. Refer to the diagnostic functional
SMCS Code: 1000-035 test Troubleshooting, “Electrical Power Supply
Circuit - Test”.
Note: Use this procedure only if the engine does not
shut down completely during operation.
Injection Actuation Pressure
Probable Causes Ensure that the injection actuation system is
operating properly. Refer to the diagnostic functional
• Diagnostic codes test Troubleshooting, “Injection Actuation Pressure -
Test”.
• Event codes
Fuel Supply
• Throttle signal
1. Visually check the fuel level. Do not rely on the fuel
• Power supply to the Electronic Control Module gauge only. If necessary, add fuel. If the engine
(ECM) has been run out of fuel, it will be necessary to
prime the fuel system. Refer to the Operation and
• Injection actuation pressure Maintenance Manual.
• Fuel supply 2. Check the fuel lines for the following problems:
Recommended Actions problems are found with the fuel lines, repair the
lines and/or replace the lines.
Note: If the problem only occurs under certain
conditions, test the engine under those conditions. 3. Check the fuel tank for foreign objects which may
Examples of certain conditions are high engine block the fuel supply.
idle, full load, or a specific operating temperature.
Troubleshooting the symptoms under other NOTICE
conditions may give misleading results. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
Diagnostic Codes and Event Codes minutes before cranking the engine again.

cause poor performance. Connect the Caterpillar 4. Prime the fuel system if any of the following
Electronic Technician (ET) and check for active codes procedures have been performed:
and/or logged codes. Troubleshoot any codes that
are present before continuing with this procedure. • Replacement of the fuel filters
Throttle Signal • Service on the low pressure fuel supply circuit
Monitor the status for “Throttle Position” on Cat ET. • Replacement of unit injectors
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
helpful in diagnosing air in the fuel. Refer to Testing
Refer to the appropriate diagnostic functional test for
and Adjusting.
your application:
5. Check the fuel filters.
• Troubleshooting, “Throttle Position Sensor Circuit -
Test”
RENR9313-04 43
6. Cold weather adversely affects the characteristics Engine Oil Pump

Maintenance Manual. Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil
7. Check the fuel pressure during engine cranking. pump for excessive wear. If necessary, repair the oil
Check the fuel pressure after the fuel filter. Refer pump or replace the oil pump.
to Systems Operation/Testing and Adjusting. If the
fuel pressure is low, replace the fuel filters. If the Oil Cooler
fuel pressure is still low, check the following items:
fuel transfer pump, fuel transfer pump coupling, Check the engine's oil cooler for plugging or
and fuel pressure regulating valve. blockage. Clean the engine oil cooler core(s) and/or
install new engine oil cooler core(s).
i02430113
Fuel Dilution
Low Engine Oil Pressure
Check for presence of fuel in lubricating oil. Refer
SMCS Code: 1348-035-LP to the troubleshooting without a diagnostic code
procedure Troubleshooting, “Fuel Dilution of Engine
NOTICE Oil”.
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure is Engine Wear
low, discontinue engine operation until the problem is
corrected. Inspect the camshaft and/or camshaft bearings
for excessive wear. Inspect the crankshaft and/or
crankshaft bearings. Excessive wear to discrete
Probable Causes components may be an indication of a blocked oil
passage. Use an oil pressure gauge to check the
• Engine oil level oil pressure at the main oil gallery. This will help
determine if the excessive wear is from low system
• Engine oil filters and oil filter bypass valve pressure or from passages that are blocked.
• Engine oil pump
i02466495
• Engine oil cooler
Low Power/Poor or No
• Fuel dilution Response to Throttle
• Engine wear SMCS Code: 1000-035
Recommended Actions Probable Causes

Engine Oil Level • Active engine derate
Inspect the engine oil level. If engine oil is low add • Diagnostic codes
engine oil. Refer to the Operation and Maintenance
Manual. • Event codes
Engine Oil Filters and Oil Filter Bypass • Programmable parameters

Valve
• Cold mode
Check the service records of the engine for
information that is related to the last oil change. If
necessary, perform an oil change on the engine and
replace the engine oil filters. • Throttle signal
Check the operation of oil filter bypass valve. Clean

• Circuit for electronic unit injectors
the bypass valve and the housing. If necessary,
install new parts.
• Injection actuation pressure
• Fuel supply
• Intake manifold (boost) pressure sensor
44 RENR9313-04
• Air inlet and exhaust system Electrical Connectors

Check the associated wiring for damage, for
Recommended Actions abrasion, for corrosion or for incorrect attachment on
Note: If the problem only occurs under certain the following connectors: Electronic Control Module
(ECM) connectors and customer connector. Refer
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature. “Electrical Connectors - Inspect”.
Troubleshooting the symptoms under other
conditions can give misleading results. Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may and that the engine is able to reach high idle speed.
cause poor performance. Connect the Caterpillar
your application:
and/or logged codes. Wait at least 30 seconds in
order for any codes to become active. Troubleshoot • Troubleshooting, “Throttle Position Sensor Circuit -
Test”
any codes that are present before continuing with
this procedure.
• Troubleshooting, “Throttle Switch Circuit - Test”
Note: Although a sensor's signal may be in the
operational range of the sensor, certain failure modes • Troubleshooting, “Speed Control - Test”
of a sensor may produce an output signal that does
not represent an accurate measurement. Use Cat ET Unit Injectors
to check that the pressures and the temperatures are
fluctuating normally. Also check that the values are 1. Use Cat ET to perform the injector solenoid test
reasonable for the conditions that are present. in order to determine if all of the injector solenoids
are being energized by the ECM.
Programmable Parameters
2. Perform the cylinder cutout test on Cat ET in order
If the Electronic Control Module (ECM) has been to check the performance of each cylinder. Refer
replaced, compare the values on the engine
“Injector Solenoids Circuit - Test”.
information plate to the following parameters from
Cat ET:
• FRC offset
• Full Load Setting (FLS) injection actuation pressure circuit. The engine oil
must be kept at the proper level for fuel injection.
• Full Torque Setting (FTS)
2. If service has recently been performed on the
Determine the type of throttle that is used in the engine, air may be present in the injection
application. Program any parameters that may be actuation pressure circuit. Allow the engine to fully
associated with the throttle. Program any parameters warm up and operate the engine under load in
that may be associated with this troubleshooting order to purge the air from the injection actuation
procedure. pressure circuit.
Note: If the parameters are not programmed 3. Check the injection actuation pressure. Refer to
correctly, then the engine will have poor performance. the diagnostic functional test Troubleshooting,
“Injection Actuation Pressure - Test”.
Cold Mode
4. Check the operation of the injection actuation
pressure control valve. Refer to the diagnostic
Verify that the engine has exited cold mode. If the
functional test Troubleshooting, “Injection
engine is operating in cold mode, an indicator will
be displayed on the top of any of the status screens Actuation Pressure Control Valve Circuit - Test”.
on the electronic service tool. Cold mode operation
may slow throttle response.
RENR9313-04 45
Fuel Supply Air Inlet and Exhaust System

1. Visually check the fuel level in the fuel tank. Do not Check the air inlet and exhaust systems for
rely on the fuel gauge only. If necessary, add fuel restrictions and for leaks. Refer to the Operation
to the fuel tank. If the engine has been run out of and Maintenance Manual. Look for an indication of
fuel, it will be necessary to prime the fuel system. the warning lamp or restriction indicators that are
Refer to the Operation and Maintenance Manual. tripped if the filters are equipped with these devices.
These indicators are associated with plugged filters.
2. Check the fuel lines for the following problems: Replace the plugged air filters or clean the plugged
restrictions, collapsed lines, and pinched lines. If air filters per the guidelines of the Operation and
problems are found with the fuel lines, repair the Maintenance Manual. Repair any leaks that are
lines and/or replace the lines. found in the system.
3. Check the fuel tank for debris or foreign objects

i02456375
which may block the fuel supply.
Marine Transmission Oil
NOTICE
Pressure Is Too High
SMCS Code: 3080-035-HQ
Probable Causes
procedures have been performed: Relief valve failure
Recommended Actions
Relief Valve Failure
1. Locate the relief valve for the transmission oil.
helpful in diagnosing air in the fuel. Refer to Testing 2. Remove any blockages and check the operation
and Adjusting. of the relief valve.
5. Check fuel quality. Cold weather adversely 3. Repair the relief valve or replace the relief
affects the characteristics of the fuel. Refer to the valve. Refer to the vessel's Original Equipment
Operation and Maintenance Manual. Manufacturer (OEM) service literature for
additional information on the transmission for the
6. Check the filtered fuel pressure while the engine vessel.
is being cranked. Refer to Testing and Adjusting.
If the fuel pressure is low, replace the fuel filters.
If the fuel pressure is still low, check the following i02456379
items: fuel transfer pump, fuel transfer pump

coupling, and fuel pressure regulating valve. Refer
Marine Transmission Oil
to Testing and Adjusting. Temperature Is Too High
Intake Manifold (Boost) Pressure Sensor SMCS Code: 3080-035-TA
1. With the engine at full load, monitor “Fuel Position” Probable Causes
and “Rated Fuel Limit” on the status screen. If
“Fuel Position” does not equal “Rated Fuel Limit”, • Oil is leaking from the transmission.
then check intake manifold (boost) pressure.
• Excessive oil in the transmission
2. Monitor intake manifold (boost) pressure and
atmospheric pressure for normal operation on the • Transmission oil cooler
status screen.
Recommended Actions
Oil Leaks
Locate all oil leaks and repair the leaks.
46 RENR9313-04
Excessive Oil in the Transmission Inspect the flywheel and the flywheel bolts.
1. Remove excess oil. Locate the source of the extra Inspect the engine oil filters for nonferrous material.
oil and make the necessary repairs. Flaking of nonferrous material could indicate worn
gear train bearings.
2. Check for restrictions in the relief valve and make
the necessary repairs. Crankshaft
3. Check for high coolant temperature. Refer Inspect the crankshaft and the related components.
to troubleshooting without a diagnostic code Inspect the connecting rod bearings and the bearing
Troubleshooting, “Coolant Temperature is Too surfaces on the crankshaft. Make sure that the
High”. bearings are in the correct position. Look for worn
thrust plates and wear on the crankshaft. Check the
4. Refer to the vessel's Original Equipment counterweight bolts. Replace any damaged parts.
Manufacturer (OEM) service literature for
additional information on the transmission for the
vessel, if necessary.
Piston
Inspect the condition of the pistons. Make sure that
i02514294 the piston pins are correctly installed. Replace any
damaged parts.
Mechanical Noise (Knock) in
Engine i02477338
SMCS Code: 1000-035 Noise Coming from Cylinder

SMCS Code: 1000-035
Probable Causes
• Faulty accessory Probable Causes
• Cylinder head and related components • Diagnostic codes
• Gear train • Fuel quality
• Crankshaft and related components • Unit injectors
• Piston • Valve lash
Recommended Repairs • Cylinder head and related components
Faulty Accessory Recommended Actions

Isolate the source of the noise. Remove the suspect Diagnostic Codes
engine accessories. Inspect the suspect engine
accessories. Repair the engine accessories and/or Check for active diagnostic codes on the Caterpillar
replace the engine accessories. Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
Cylinder Head and Related Components
Fuel Quality
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear Refer to Operation and Maintenance Manual for
to the valves, cylinder head gasket, springs, lifters, information on the characteristics of the fuel.
pushrods, etc. Inspect the condition of the camshafts.
If a camshaft is replaced, new valve lifters must be
installed. Replace any damaged parts.
Gear Train
Inspect the condition of the gear train. Replace any
damaged parts.
RENR9313-04 47
Unit Injectors Recommended Actions

1. Check the connectors at the Electronic Control Note: If the problem only occurs under certain
Module (ECM). Check for correct installation conditions, test the engine under those conditions.
of the J1/P1 and J2/P2 ECM connectors. Also, Examples of certain conditions are high engine
thoroughly inspect the unit injector wiring harness idle, full load, or a specific operating temperature.
from the ECM to the J300/P300 valve cover entry Troubleshooting the symptoms under other
connector. Refer to the diagnostic functional test conditions may give misleading results.
Diagnostic Codes and Event Codes
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids Certain diagnostic codes and/or event codes may
are being energized by the ECM. cause poor performance. Connect the Caterpillar
3. Perform the “Cylinder Cutout Test” on Cat ET and/or logged codes. Troubleshoot any codes that
in order to identify any injectors that may be are present before continuing with this procedure.
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”. Note: Although a sensor's signal may be in the
operational range of the sensor, certain failure modes
Valve Lash of a sensor may produce an output signal that does
not represent an accurate measurement. Use Cat ET
Check the engine valve lash settings. Inspect the to check that the pressures and the temperatures are
valve train for sufficient lubrication. Check damage to fluctuating normally. Also check that the values are
valve train components which may cause excessive reasonable for the conditions that are present.
valve lash. Repair any problems that are found.
Refer to troubleshooting without a diagnostic code Cold Mode Operation and Cold Cylinder
Troubleshooting, “Excessive Valve Lash”.
Cutout
Cylinder Head and Related Components Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may cause a slow
Check for signs of damage and/or wear to the valves, throttle response. Some engines use a feature such
cylinder head gasket, etc. Inspect the condition of as the cold cylinder cutout in order to warm the
the camshafts. engine during cold mode. Again, ensure that the
engine has exited cold mode operation.
i02488012
Flash File
Poor Acceleration or Response
Verify that the latest flash file has been installed into
SMCS Code: 1000-035 the Electronic Control Module (ECM).
Probable Causes Throttle Signal

• Diagnostic codes and event codes Monitor the status for “Throttle Position” on Cat ET.
• Cold mode operation and cold cylinder cutout and that the engine is able to reach high idle speed.
• Flash file your application:
• Throttle signal • Troubleshooting, “Throttle Position Sensor Circuit -

Test”
• Injection actuation pressure
• Troubleshooting, “Throttle Switch Circuit - Test”
• Troubleshooting, “Speed Control - Test”
• Unit injectors
• Air inlet and exhaust system injection actuation pressure circuit. The engine oil
must be kept at the proper level for fuel injection.
• Fuel supply
48 RENR9313-04
2. If service has recently been performed on the Air Inlet and Exhaust System
engine, air may be present in the injection
actuation pressure circuit. Allow the engine to fully 1. Check the air filter restriction indicator for a
warm up and operate the engine under load in plugged filter. If necessary, service the engine.
order to purge the air from the injection actuation Refer to the Operation and Maintenance Manual.
pressure circuit.
2. Check the air inlet and exhaust system for
3. Check the injection actuation pressure. Refer to restrictions and/or leaks. Refer to Testing and
the diagnostic functional test Troubleshooting, Adjusting.
“Injection Actuation Pressure - Test”.
Fuel Supply
4. Check the operation of the injection actuation
pressure control valve. Refer to the diagnostic 1. Visually check the fuel level in the fuel tank. Do not
functional test Troubleshooting, “Injection rely on the fuel gauge only. If necessary, add fuel
Actuation Pressure Control Valve Circuit - Test”. to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system.
Electrical Connectors Refer to the Operation and Maintenance Manual.
Disconnect the J1/P1 and J2/P2 ECM connectors. 2. Check the fuel lines for the following problems:
Inspect each connector for moisture and corrosion. restrictions, collapsed lines, and pinched lines. If
Also, inspect the harness and connectors for the unit problems are found with the fuel lines, repair the
injectors from the ECM to the valve cover. Refer lines and/or replace the lines.
“Electrical Connectors - Inspect”. 3. Check the fuel tank for debris or foreign objects
which may block the fuel supply.
Unit Injectors
NOTICE
1. Use Cat ET to perform the injector solenoid test Do not crank the engine continuously for more than
in order to determine if all of the injector solenoids 30 seconds. Allow the starting motor to cool for two
are being energized by the ECM. minutes before cranking the engine again.
2. Perform the cylinder cutout test on Cat ET in order

to check the performance of each cylinder. Refer 4. Prime the fuel system if any of the following
to the diagnostic functional test Troubleshooting, procedures have been performed:
“Injector Solenoids Circuit - Test”.
Intake Manifold (Boost) Pressure Sensor
1. Monitor the status of “Fuel Position”, “Rated Fuel
Limit”, and “FRC Fuel Limit” on Cat ET while • Replacement of unit injectors
the engine is operating under full load. These
parameters should agree with the information
helpful in diagnosing air in the fuel. Refer to Testing
below.
and Adjusting.
Table 10
5. Check fuel quality. Cold weather adversely
“Fuel Position” = “Rated Fuel Limit” affects the characteristics of the fuel. Refer
and to the Operation and Maintenance Manual for
“Fuel Position” < “FRC Fuel Limit”
information on improving the characteristics of the
fuel during cold weather operation.
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit”, the 6. Check the filtered fuel pressure while the engine
electronics are operating correctly. Otherwise, is being cranked. Refer to Testing and Adjusting
proceed with the next Step. for the correct pressure values. If the fuel pressure
is low, replace the fuel filters. If the fuel pressure
2. Monitor the status of “Intake Manifold (Boost) is still low, check the following items: fuel transfer
Pressure” and “Atmospheric Pressure” for normal pump, fuel transfer pump coupling, and fuel
operation on Cat ET. When the engine is not pressure regulating valve. Refer to Testing and
running, “Intake Manifold (Boost) Pressure” should Adjusting.
be 0 kPa (0 psi).
RENR9313-04 49
Troubleshooting with a Refer to Troubleshooting, “Diagnostic Code Cross

Reference” for the complete list of the diagnostic
Diagnostic Code codes and a description of each code. There is a
troubleshooting procedure for every diagnostic code.
Refer to Troubleshooting, “Troubleshooting With A
i02085761 Diagnostic Code”.
Flash Codes When a diagnostic code is activated, the Electronic
Control Module (ECM) transmits information about
SMCS Code: 1900 the code over the J1939 data link. Some J1939
devices may display the code. However, the code
Flash codes are a simple way to alert the operator will be displayed with a SPN-FMI code. Refer to
that a problem exists with the engine's control system Troubleshooting, “Diagnostic Code Cross Reference”
or with the engine's operation. Each flash code is for a cross-reference between SPN-FMI codes and
a two digit number. The diagnostic lamp flashes in diagnostic codes.
order to identify the flash code.
Do not confuse diagnostic codes with event codes.
EXAMPLE Event codes alert the operator that an abnormal
operating condition such as low oil pressure or high
Note: Flash Code 27 would flash on the diagnostic coolant temperature has been detected. Refer to
lamp in the following manner: Troubleshooting, “Troubleshooting with an Event
Code” for additional information on event codes.
• Two short flashes
Illustration 9 is an example of the operating range
• Hesitation of a sensor.
• Seven short flashes
For the descriptions of the flash codes, refer to
Troubleshooting, “Diagnostic Code Cross Reference”.
i02769238
Diagnostic Codes
SMCS Code: 1900
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes are also used by the service technician
to identify the nature of the problem. Caterpillar
Electronic Technician (ET) is a software program
that is designed to run on a personal computer.
The software can be used by the service technician
in order to view the diagnostic code information
for an ECM. Diagnostic codes may consist of the
component identifier (CID), and the failure mode
identifier (FMI).
Component Identifier (CID) – The CID indicates the

component that generated the code. For example,
the CID number 1 identifies the fuel injector for the
number one cylinder.
Failure Mode Identifier (FMI) – The FMI indicates

the type of failure.
Suspect Parameter Number (SPN) – The SPN is a

three digit code which is assigned to each component
in order to identify data via the data link to the ECM.
This is used on the diagnostics for the CAN data link.
50 RENR9313-04
Logged Diagnostic Codes

When the ECM generates a diagnostic code, the
ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. Each ECM
will record the following information when a code is
generated:
• The hour of the first occurrence of the code

• The hour of the last occurrence of the code
• The number of occurrences of the code
This information is a valuable indicator for
troubleshooting intermittent problems.
A code is cleared from memory when one of the

following conditions occur:
• The service technician manually clears the code.

• The code does not recur for 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
Some diagnostic codes may be easily triggered.

Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
Illustration 9
g01365757 of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs
Example of the typical operating range of a sensor
special investigation.
(1) This area represents the normal operating range of the engine
parameter.
(2) In these areas, the engine is operating in an unsafe operating
Note: Always clear logged diagnostic codes after
range of the monitored parameter. An event code will be investigating and correcting the problem which
generated for the monitored parameter. The sensor circuit generated the code.
does not have an electronic problem. Refer to Troubleshooting,
“Troubleshooting with an Event Code” for additional information
on event codes. i02377790
(3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for
Diagnostic Code Cross
the sensor circuit. Reference
Active Diagnostic Codes SMCS Code: 1900
An active diagnostic code represents a problem with Problems with the electronic control system are
the electronic control system. Correct the problem reported via these types of codes: flash codes,
as soon as possible. SPN/FMI codes, diagnostic codes, and event codes.
When the ECM generates an active diagnostic code, For information on flash codes, refer to
the “Active Alarm” indicator (“Engine Control Alarm troubleshooting with a diagnostic code
Status” on Cat ET) is activated in order to alert the Troubleshooting, “Flash Codes”.
operator. If the condition that generated the code
is momentary, the message disappears from the For information on SPN/FMI codes, refer
list of active diagnostic codes. The diagnostic code to troubleshooting with a diagnostic code
becomes logged. Troubleshooting, “Diagnostic Codes”.
RENR9313-04 51
For information on diagnostic codes, refer

to troubleshooting with a diagnostic code
Troubleshooting, “Diagnostic Codes”.
For information on event codes, refer to

troubleshooting with an event code Troubleshooting,
“Event Codes”.
Cross-Reference for Flash Code

to SPN-FMI Code to CID-FMI
(Diagnostics) or EID (Events)
Table 11
Cross-Reference for Flash Code to SPN-FMI Code to CID-FMI (Diagnostics) or EID (Events)
Flash SPN-FMI or
CID-FMI or EID Description of Code
Code EID
174-03 174-03 Fuel Temperature open/short to +batt
13
174-04 174-04 Fuel Temperature short to ground
168-00 168-00 System Voltage High
17 168-01 168-01 System Voltage Low
168-02 168-02 System Voltage intermittent/erratic
620-03 262-03 5 Volt Sensor DC Power Supply short to +batt
620-04 262-04 5 Volt Sensor DC Power Supply short to ground
21
678-03 263-03 Digital Sensor Supply short to +batt
678-04 263-04 Digital Sensor Supply short to ground
100-03 100-03 Engine Oil Pressure open/short to +batt
24
100-04 100-04 Engine Oil Pressure short to ground
102-03 102-03 Boost Pressure Sensor short to +batt
25
102-04 102-04 Boost Pressure Sensor short to ground
110-03 110-03 Engine Coolant Temperature open/short to +batt
27
110-04 110-04 Engine Coolant Temperature short to ground
91-13 91-13 Throttle Position Calibration required
28
29-13 1249-13 Secondary Throttle Position calibration required
91-08 91-08 Throttle Position signal abnormal
32
29-08 1249-08 Secondary Throttle Position signal abnormal
190-11 190-11 Engine Speed Sensor mechanical failure
34
723-11 342-11 Secondary Engine Speed Sensor mechanical failure
35 190-00 E190 Engine Overspeed Warning
94-03 94-03 Fuel Pressure open/short to +batt
37
94-04 94-04 Fuel Pressure short to ground
172-03 105-03 Inlet Manifold Temp Sensor open/short to +batt
38
172-04 105-04 Inlet Manifold Temp Sensor short to ground
42 228-13 261-13 Engine Timing Calibration required
100-18 E039 Low Engine Oil Pressure Derate
46
100-17 E100 Low Engine Oil Pressure Warning
(continued)
52 RENR9313-04
(Table 11, contd)

Cross-Reference for Flash Code to SPN-FMI Code to CID-FMI (Diagnostics) or EID (Events)
Flash SPN-FMI or
CID-FMI or EID Description of Code
Code EID
53 N/A 254-12 Electronic Control Module Error
56 111-02 268-02 Check Programmable Parameters
111-18 E057 Low Engine Coolant Level Derate
58
111-17 E059 Low Engine Coolant Level Warning
59 253-02 253-02 Personality Module mismatch
111-16 E015 High Engine Coolant Temperature Derate
61
111-15 E017 High Engine Coolant Temperature Warning
94-07 E053 Low Fuel Pressure Warning
63
94-15 E096 High Fuel Pressure
172-16 E025 High Inlet Air Temperature Derate
64
172-015 E027 High Inlet Air Temperature Warning
65 174-15 E056 High Fuel Temperature Warning
66 177-15 E030 High Transmission Oil Temperature Warning
177-03 177-03 Transmission Oil Temperature open/short to +batt
67
177-04 177-04 Transmission Oil Temperature short to ground
127-03 127-03 Transmission Oil Pressure open/short to +batt
68
127-04 127-04 Transmission Oil Pressure short to ground
69 127-15 E113 High Transmission Oil Pressure
71 651-11 1-11 Cylinder #1 Injector fault
164-00 164-00 High Injector Actuation Pressure
164-02 164-02 Injector Actuation Pressure signal erratic
137 164-03 164-03 Injector Actuation Pressure voltage high
164-04 164-04 Injector Actuation Pressure voltage low
164-11 164-11 Injector Actuation Pressure system fault
138 679-11 42-11 Inject Actuation Control Valve open/short
185 173-18 535-08 Exhaust Temperature Sensor noisy signal
729-05 617-05 Air Inlet Heater Relay open/current below normal
49
729-06 617-06 Air Inlet Heater Relay grounded/current above norm
N/A 96-17 E119 Low Fuel Level
N/A N/A E173 High Exhaust Temperature Warning
RENR9313-04 53
i02457823 System Response:

CID 0001 FMI 11 Cylinder #1 The ECM will log the diagnostic code. The ECM will
Injector fault continue to attempt to operate the injector after the
code has been logged.
SMCS Code: 1290-038
The injector may not operate while the condition
Conditions Which Generate This Code: exists.
The Electronic Control Module (ECM) is attempting Possible Performance Effect:

to operate the injector. The ECM detects an open or
a short in the circuit for the injector. • The engine may misfire.
If the cause of the diagnostic code is a problem in the • The engine may experience low power.
common wire, two cylinders will be affected because
of the shared common wire for the injectors. 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:
• OK – STOP.
exists. i02457905
Possible Performance Effect: CID 0003 FMI 11 Cylinder #3

• The engine may misfire. Injector fault
SMCS Code: 1290-038
• The engine may experience low power.
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Injector The Electronic Control Module (ECM) is attempting
Solenoid Circuit - Test” to operate the injector. The ECM detects an open or
a short in the circuit for the injector.
Results:
If the cause of the diagnostic code is a problem in the
• OK – STOP. of the shared common wire for the injectors.
i02457853 System Response:

CID 0002 FMI 11 Cylinder #2 The ECM will log the diagnostic code. The ECM will
Injector fault continue to attempt to operate the injector after the
SMCS Code: 1290-038
Conditions Which Generate This Code: exists.
The Electronic Control Module (ECM) is attempting Possible Performance Effect:

to operate the injector. The ECM detects an open or
a short in the circuit for the injector. • The engine may misfire.
If the cause of the diagnostic code is a problem in the • The engine may experience low power.
of the shared common wire for the injectors. Troubleshooting:
Perform the following diagnostic procedure: “Injector

Solenoid Circuit - Test”
54 RENR9313-04
Results: System Response:
• OK – STOP. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
i02457916
CID 0004 FMI 11 Cylinder #4 The injector may not operate while the condition
exists.
Injector fault
Possible Performance Effect:
SMCS Code: 1290-038
• The engine may misfire.
Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open or Troubleshooting:
If the cause of the diagnostic code is a problem in the Solenoid Circuit - Test”
of the shared common wire for the injectors. Results:
System Response: • OK – STOP.

continue to attempt to operate the injector after the i02458033

CID 0006 FMI 11 Cylinder #6
The injector may not operate while the condition Injector fault
exists.
SMCS Code: 1290-038
• The engine may experience low power. to operate the injector. The ECM detects an open or
Troubleshooting:
If the cause of the diagnostic code is a problem in the
Perform the following diagnostic procedure: “Injector common wire, two cylinders will be affected because
Solenoid Circuit - Test” of the shared common wire for the injectors.
Results: System Response:
• OK – STOP. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
i02458023
CID 0005 FMI 11 Cylinder #5 The injector may not operate while the condition
exists.
Injector fault
SMCS Code: 1290-038
to operate the injector. The ECM detects an open or Troubleshooting:
If the cause of the diagnostic code is a problem in the Solenoid Circuit - Test”
of the shared common wire for the injectors.
RENR9313-04 55
Results: i02440965
• OK – STOP. CID 0091 FMI 08 Throttle

Position signal abnormal
i02377733
SMCS Code: 1439-038; 1913-038
CID 0042 FMI 11 Inject
Actuation Control Valve
open/short The Electronic Control Module (ECM) detects an
incorrect frequency on the throttle signal or the
SMCS Code: 1714-038 throttle position sensor is out of the acceptable range.
Conditions Which Generate This Code: System Response:
The Electronic Control Module (ECM) detects one of The code is logged. The ECM flags the throttle
the following conditions: position as invalid data and a default value of zero
percent is used.
• Open circuit
• Short to ground
• The engine speed is limited to low idle.
• Short to +Battery
Troubleshooting:
• Short across the solenoid when the engine is
running. Perform the following diagnostic procedure: “Throttle
Position Sensor Circuit - Test”
System Response:
Results:
The ECM will cycle the control valve for the injection
actuation system on and off. The ECM will cycle the • OK – STOP.
control valve several times in a second when the
engine is running.
i02426246
Possible Performance Effect: CID 0091 FMI 13 Throttle

The engine will stop running if the signal line for the Position calibration required
control valve for the injection actuation system is
shorted to ground. SMCS Code: 1439-038; 1913-038
If the return line for the control valve is shorted to Conditions Which Generate This Code:
ground, the following conditions may exist:
The duty cycle of the signal from the throttle that is
• The engine may continue to run. connected to the primary throttle input is incorrect.
• The idle may be unstable. System Response:
Troubleshooting: The Electronic Control Module (ECM) will log the

diagnostic code. The ECM flags the throttle position
Perform the following diagnostic procedure: “Injection as invalid data and a default value of zero percent
Actuation Pressure Control Valve Circuit - Test” is used.
Results: Possible Performance Effect:
• OK – STOP. • The engine speed is limited to low idle.

Troubleshooting:
Perform the following diagnostic procedure: “Throttle

Position Sensor - Calibrate”
56 RENR9313-04
Results: Results:
• OK – STOP. • OK – STOP.
i02424760 i02458070
CID 0094 FMI 03 Fuel Pressure CID 0096 FMI 03 Fuel Level
open/short to +batt Sensor open/short to +batt
SMCS Code: 1439-038; 1718-038 SMCS Code: 1439-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The voltage on the signal wire for the fuel level
voltage that is above normal. sensor is above normal.
System Response: System Response:
The ECM will log the diagnostic code. The ECM flags The Electronic Control Module (ECM) will log the
fuel pressure as invalid data and a default value is diagnostic code.
used.
• There are no performance effects.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Fuel
Perform the following diagnostic procedure: “Engine Level Sensor Circuit - Test”
Pressure Sensor Open or Short Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02458075
CID 0096 FMI 04 Fuel Level

i02424763
CID 0094 FMI 04 Fuel Pressure Sensor short to ground

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

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

Level Sensor Circuit - Test”
Perform the following diagnostic procedure: “Engine
RENR9313-04 57
Results: Results:
i02424766 i02458098
CID 0100 FMI 03 Engine Oil CID 0102 FMI 03 Boost

Pressure open/short to +batt Pressure Sensor short to +batt
SMCS Code: 1439-038-OC; 1924-038 SMCS Code: 1439-038; 1917-038
The Electronic Control Module (ECM) detects signal The signal voltage from the boost pressure sensor is
voltage that is above normal. above normal.
System Response: System Response:
The ECM will log the diagnostic code. The ECM flags The Electronic Control Module (ECM) will log the
oil pressure as invalid data. diagnostic code. The ECM will flag the boost pressure
as invalid data and a default value is used.
Troubleshooting:
Troubleshooting:
Pressure Sensor Open or Short Circuit - Test” Perform the following diagnostic procedure: “Engine
Results:
Results:
• OK – STOP.
• OK – STOP.
i02424648
CID 0100 FMI 04 Engine Oil

i02458100
Pressure short to ground CID 0102 FMI 04 Boost

Pressure Sensor short to
SMCS Code: 1439-038-OC; 1924-038
ground
SMCS Code: 1439-038; 1917-038
The Electronic Control Module (ECM) detects a
signal voltage that is below normal.
System Response: The signal voltage from the boost pressure sensor is
below normal.
The code is logged. The ECM flags oil pressure as
invalid data and a default value is used. System Response:

diagnostic code. The ECM will flag the boost pressure
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: “Engine • The engine may experience low power.
58 RENR9313-04
Perform the following diagnostic procedure: “Engine • The engine may experience low power.
Troubleshooting:
Results:
• OK – STOP. Temperature Sensor Open or Short Circuit - Test”
Results:
i02458652
CID 0105 FMI 03 Inlet Manifold • OK – STOP.

Temp Sensor open/short to
i02427669
+batt
CID 0110 FMI 03 Engine
SMCS Code: 1439-038-AI; 1921-038
Coolant Temperature
Conditions Which Generate This Code: open/short to +batt
The Electronic Control Module (ECM) detects signal SMCS Code: 1439-038-CLT; 1906-038
voltage that is above normal.
System Response:
The signal voltage from the engine coolant
The ECM will log the diagnostic code. The ECM flags temperature sensor is above normal.
inlet air temperature as invalid data and a default
value is used. System Response:
Possible Performance Effect: The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags coolant temperature
• The engine may experience low power. as invalid data and a default value is used. The
engine will not go into cold mode.
Troubleshooting:
Temperature Sensor Open or Short Circuit - Test” • The engine may misfire.
Results: • The engine may experience reduced speed (rpm)
and/or low power.
• OK – STOP.
Troubleshooting:
i02458657
CID 0105 FMI 04 Inlet Manifold Temperature Sensor Open or Short Circuit - Test”
Temp Sensor short to ground Results:
SMCS Code: 1439-038-AI; 1921-038 • OK – STOP.

The Electronic Control Module (ECM) detects signal

System Response:
The ECM will log the diagnostic code. The ECM flags
Inlet air temperature as invalid data and a default
value is used.
RENR9313-04 59
i02427678 Troubleshooting:
CID 0110 FMI 04 Engine Perform the following diagnostic procedure: “Engine
Coolant Temperature short to Pressure Sensor Open or Short Circuit - Test”
ground Results:
SMCS Code: 1439-038-CLT; 1906-038 • OK – STOP.

i02458670
The signal voltage from the engine coolant
temperature sensor is below normal. CID 0127 FMI 04 Transmission
Oil Pressure short to ground
System Response:
SMCS Code: 1439-038-T3
diagnostic code. The ECM flags coolant temperature Conditions Which Generate This Code:
as invalid data and a default value is used. The
engine will not go into cold mode. The signal from the marine transmission oil pressure
sensor is below normal.
System Response:
• The engine may experience reduced speed (rpm) diagnostic code. The ECM flags marine transmission
and/or low power. oil pressure as invalid data and a default value is
used.
Troubleshooting:
Temperature Sensor Open or Short Circuit - Test” • There are no performance effects.
Results: Troubleshooting:
• OK – STOP. Perform the following diagnostic procedure: “Engine

i02458663
Results:
CID 0127 FMI 03 Transmission
• OK – STOP.
Oil Pressure open/short to
+batt i02458675
SMCS Code: 1439-038-T3 CID 0164 FMI 00 High Injector

Actuation Pressure
SMCS Code: 1439-038-UIN; 1925-038
The signal from the marine transmission oil pressure
sensor is above normal.
System Response:
The Electronic Control Module (ECM) detects all of
The Electronic Control Module (ECM) will log the the following conditions:
diagnostic code. The ECM flags marine transmission
oil pressure as invalid data and a default value is • Engine speed is greater than zero rpm.
used.
• Cold mode is not active.
• Actual injection actuation pressure is above
26.5 MPa (3850 psi) for at least six seconds.
60 RENR9313-04
System Response: Possible Performance Effect:
The ECM will log the diagnostic code. The status of • The engine may experience low power.
“Injector Actuation Current” on Caterpillar Electronic
Technician (ET) will ramp to zero percent. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure: “Injection

Actuation Pressure Sensor - Test”
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injection
Actuation Pressure - Test”
i02427705
Results: CID 0164 FMI 03 Injector

• OK – STOP. Actuation Pressure voltage
high
i02468990
SMCS Code: 1439-038-UIN; 1925-038
CID 0164 FMI 02 Injector
Actuation Pressure signal Conditions Which Generate This Code:
erratic The signal from the injection actuation pressure

sensor is above normal. Cold mode is not active.
SMCS Code: 1439-038-UIN; 1925-038
System Response:
The Electronic Control Module (ECM) detects the diagnostic code. The ECM will flag injection actuation
following conditions: pressure as invalid data and a default value is used.
The ECM will set the current for the control valve to a
If the engine is not running, the following fixed value.
conditions must be met.
• The actual injection actuation pressure remains
above 3 MPa (435 psi) for at least three seconds. • The engine may experience low power.
• Cold mode is not active. • The engine may experience poor idle quality.
If the engine is running, the following conditions Troubleshooting:
must be met.
• The actual injection actuation pressure and the Pressure Sensor Open or Short Circuit - Test”
desired injection actuation pressure differ by more
than 2 MPa (290 psi) for at least ten seconds. Results:
• The change in injection actuation pressure was not • OK – STOP.

consistent with the change in the current to the
control valve.
• Cold mode is not active.

System Response:
The ECM will log the diagnostic code. The status

of “Injection Actuation Pressure” on Caterpillar
Electronic Technician (ET) will revert to a default
value.
RENR9313-04 61
i02427714 • Engine speed is detected and there is plenty of

fuel.
CID 0164 FMI 04 Injector
Actuation Pressure voltage • The current to the injection actuation pressure
control valve is at the maximum output for an
low excessive period of time or the current to the
injection actuation pressure control valve is at the
SMCS Code: 1439-038-UIN; 1925-038 maximum output for at least three seconds while
the engine is being cranked.
• The injection actuation pressure control valve is
The signal from the injection actuation pressure at minimum output for an excessive period of
sensor is below normal. Cold mode is not active. time and engine speed is less than 1900 RPM
or engine speed is greater than 1900 RPM and
System Response: injection actuation pressure is greater than 15 MPa
(2175 psi).
diagnostic code. The ECM will flag injection actuation Note: The diagnostic code indicates a mechanical
pressure as invalid data and a default value will be problem. The ECM and the electronic control system
used. The ECM will set the current for the control are operating correctly.
valve to a fixed value.
System Response:
The ECM will log the diagnostic code.
• The engine may experience poor idle quality.
• The engine may experience low power and/or
Troubleshooting: unstable idle.
Perform the following diagnostic procedure: “Engine • The engine may be difficult to start at normal
Pressure Sensor Open or Short Circuit - Test” operating temperatures and/or easy to start below
normal operating temperatures.
Results:
Troubleshooting:
• OK – STOP.
Note: The problem may only exist at operating
i02458683
temperature. Air may be trapped in the injection
actuation system if the system has been serviced
CID 0164 FMI 11 Injector recently. Start the engine and run the engine at 1500
rpm for a few minutes in order to remove the trapped
Actuation Pressure system air.
fault
Perform the following diagnostic procedure: “Injection
SMCS Code: 1439-038-UIN; 1925-038 Actuation Pressure - Test”
Conditions Which Generate This Code: Results:
The Electronic Control Module (ECM) detects the • OK – STOP.

following conditions:
i02424772
• The engine oil temperature is greater than 18 °C
(64 °F) and the desired injection actuation pressure CID 0168 FMI 00 System
and actual injection actuation pressure differ by
more than 3 MPa (435 psi). Voltage High
SMCS Code: 1401-038
• There are no active diagnostics for the injection
actuation pressure sensor and/or the 5 VDC
supply. Conditions Which Generate This Code:
While the above mentioned conditions are true the The Electronic Control Module (ECM) detects the
ECM detects one of the following conditions: following condition:
62 RENR9313-04
• For 12 volt systems, the ECM reads battery voltage Troubleshooting:

that is above 16 VDC.
Perform the following diagnostic procedure:
• For 24 Volt systems, the ECM reads battery “Electrical Power Supply Circuit - Test”
voltage that is above 32 VDC.
Results:
Note: Excessive voltage to the ECM may damage
the ECM. • OK – STOP.
System Response:
i02458713
The ECM will log the diagnostic code. CID 0168 FMI 02 System
Possible Performance Effect: Voltage intermittent/erratic
• There are no performance effects. SMCS Code: 1401-038
Perform the following diagnostic procedure: While the engine is running, the battery voltage drops
“Electrical Power Supply Circuit - Test” below 9 VDC intermittently, or the battery voltage
drops below 9 VDC three times in a seven second
Results: period.
• OK – STOP. System Response:

i02480880 diagnostic code.
CID 0168 FMI 01 System Possible Performance Effect:
Voltage Low
• The engine may misfire and/or shutdown
SMCS Code: 1401-038
Troubleshooting:
The Electronic Control Module (ECM) has been “Electrical Power Supply Circuit - Test”
powered for at least three seconds. The ECM detects
the following condition: Results:
• For 12 volt systems, the ECM reads battery voltage • OK – STOP.

that is below 9 VDC.
i02424795
• For 24 volt systems, the ECM reads battery voltage
that is below 18 VDC. CID 0174 FMI 03 Fuel
System Response: Temperature open/short to
The ECM will log the diagnostic code.
+batt
SMCS Code: 1439-038; 1922-038
• The engine may shut down.
• The engine may have hard starting and/or misfire. signal voltage from the sensor that is above normal.
• The contacts for the starting motor solenoid may System Response:
be chatter during cranking. This can damage the
contacts.
The ECM will log the diagnostic code. The ECM flags
fuel temperature as invalid data and fuel temperature
is set to a default value.
RENR9313-04 63
Possible Performance Effect: System Response:
• There are no performance effects. The Electronic Control Module (ECM) will log the
diagnostic code. The transmission oil temperature
Troubleshooting: will be set to a default value.
Perform the following diagnostic procedure: “Engine Possible Performance Effect:

Temperature Sensor Open or Short Circuit - Test”
Results:
Troubleshooting:
• OK – STOP.
“Transmission Oil Temperature Sensor Open or Short
i02424798
Circuit - Test”
CID 0174 FMI 04 Fuel Results:
Temperature short to ground
• OK – STOP.
SMCS Code: 1439-038; 1922-038
Conditions Which Generate This Code: i02460864
The Electronic Control Module (ECM) detects signal

CID 0177 FMI 04 Transmission
voltage that is below normal. Oil Temperature short to
System Response:
ground
The ECM will log the diagnostic code. The ECM flags SMCS Code: 1439-038-T3; 3194-038-OC
fuel temperature as invalid data and a default value
is used.
The signal voltage from the transmission oil
temperature sensor is below normal.
• There are no performance effects. System Response:
Troubleshooting:
diagnostic code. The transmission oil temperature
will be set to a default value.
Temperature Sensor Open or Short Circuit - Test”
Results:
• OK – STOP. • There are no performance effects.

Troubleshooting:
i02460862
CID 0177 FMI 03 Transmission “Transmission Oil Temperature Sensor Open or Short
Oil Temperature open/short to Circuit - Test”
+batt Results:
SMCS Code: 1439-038-T3; 3194-038-OC • OK – STOP.

The signal voltage from the transmission oil

temperature sensor is above normal.
64 RENR9313-04
i02460929 Possible Performance Effect:

CID 0190 FMI 11 Engine Speed • The fuel injection system is disabled and the
Sensor mechanical failure engine will not start.
SMCS Code: 1439-038-VF; 1907-038 Troubleshooting:
Conditions Which Generate This Code: Check the Part Number of the Flash File
The Electronic Control Module (ECM) detects the A. Restore the electrical power to the Electronic
following conditions: Control Module (ECM).
• The pattern of the timing ring from the primary B. Verify that the part number for the flash file agrees
engine speed/timing sensor is lost for more than with the latest update that is available on Service
one second. Technician Workbench (STW), or on SIS Web.
• The signal from the secondary engine speed/timing Expected Result:

sensor is good.
The correct flash file is installed in the ECM.
System Response:
Results:
use the secondary engine speed/timing sensor. • OK – The correct flash file is installed in the ECM.
Possible Performance Effect: Repair: The engine will not start until the 253-02
diagnostic code is cleared. Clearing this code
• The engine may misfire and/or shutdown requires factory passwords.
Note: The engine will shut down only if the primary Acquire factory passwords. Clear the 253-02
engine speed/timing sensor and the secondary diagnostic code. Return the engine to service.
engine speed/timing sensor fail.
STOP.
Troubleshooting:
• Not OK – The correct flash file is not installed in
Perform the following diagnostic procedure: “Engine the ECM.
Speed/Timing Sensor Circuit - Test”
Repair: Flash program the ECM with the correct
Results: flash file. Refer to programming parameters
Troubleshooting, “Flash Programming”. Verify that
• OK – STOP. the problem is resolved.
STOP.
i02428636
CID 0253 FMI 02 Personality i02125661
Module mismatch CID 0254 FMI 12 Electronic

SMCS Code: 1902-038 Control Module Error
Conditions Which Generate This Code: SMCS Code: 1901-038
The flash file that is used for replacement is for Conditions Which Generate This Code:
a different engine family or for a different engine
application. The Electronic Control Module (ECM) has detected
an internal fault.
System Response:
System Response:
Caterpillar Electronic Technician (ET) will not be able
to clear the code. The ECM will log the diagnostic code.
RENR9313-04 65
Possible Performance Effect: i02468995
• Engine power and engine performance may be CID 0262 FMI 03 5 Volt Sensor
affected. DC Power Supply short to
• Any normal ECM function may be affected. +batt
• Engine shutdown SMCS Code: 1439-038
Replace the ECM. Ensure that the new ECM serial The Electronic Control Module (ECM) reads supply
number ends with the same two characters as the voltage that is above normal.
old ECM serial number. Refer to Troubleshooting,
“Replacing the ECM” before replacing the ECM. System Response:
Results: The ECM will log the diagnostic code. The ECM flags
all analog sensors as invalid data and default values
• OK – STOP. are used.

i02445663
CID 0261 FMI 13 Engine Timing • The engine may experience low power.
Calibration required Troubleshooting:
SMCS Code: 1439-038; 1912-038 Perform the following diagnostic procedure: “Analog
Sensor Supply Circuit - Test”
Results:
The Electronic Control Module (ECM) detects an
incorrect engine timing. • OK – STOP.
Note: A timing calibration is required for a new
i02468997
engine, replacing an ECM that fails to communicate
or following work on the front gear train, the camshaft, CID 0262 FMI 04 5 Volt Sensor
or the crankshaft.
DC Power Supply short to
System Response: ground
The check engine lamp will illuminate while this SMCS Code: 1439-038
diagnostic code is active. The ECM uses default
timing. Timing may be off as much as three degrees. Conditions Which Generate This Code:
Possible Performance Effect: The Electronic Control Module (ECM) reads supply
• The engine may run rough and/or the engine may
emit white smoke in the exhaust. System Response:
Troubleshooting: The ECM will log the diagnostic code. The ECM flags
all analog sensors as invalid data and default values
Perform the following diagnostic procedure: “Engine are used.
Speed/Timing Sensor - Calibrate”
Results:
• OK – STOP.
Troubleshooting:
Perform the following diagnostic procedure: “Analog

66 RENR9313-04
Results: Results:
i02461066 i02445689
CID 0263 FMI 03 Digital Sensor CID 0268 FMI 02 Check

Supply short to +batt Programmable Parameters
SMCS Code: 1439-038 SMCS Code: 1901-038
The Electronic Control Module (ECM) detects supply The Electronic Control Module (ECM) detects one of
voltage that is above normal. the following conditions:
System Response: • At least one system configuration parameter is not

programmed.
The ECM will log the diagnostic code. The ECM
flags all digital sensors as invalid data and all digital • At least one injector trim file is not programmed.
sensors are set to the respective default values.
System Response:
The diagnostic code will only be active. The check
• The engine may experience low power. engine lamp will illuminate while this diagnostic code
is active. Any unprogrammed parameters are set to
Troubleshooting: the default value.
Perform the following diagnostic procedure: “Digital Possible Performance Effect:

• The unprogrammed parameters determine the
Results: action that is taken by the ECM.
• OK – STOP. Troubleshooting:
Program the missing parameter.

i02461080
CID 0263 FMI 04 Digital Sensor If a system configuration parameter has not been
programmed, refer to Troubleshooting, “System
Supply short to ground Configuration Parameters”.
SMCS Code: 1439-038 If an injector trim file has not been programmed,
refer to programming parameters Troubleshooting,
Conditions Which Generate This Code: “Injector Trim File”.
The Electronic Control Module (ECM) detects supply Results:

• OK – STOP.
System Response:
The ECM will log the diagnostic code. The ECM i02120367
flags all digital sensors as invalid data and all digital

sensors are set to the respective default values.
CID 0342 FMI 11 Secondary
Engine Speed Sensor
mechanical failure
• The engine may experience low power. SMCS Code: 1439-038-VF; 1907-038
Troubleshooting:
Perform the following diagnostic procedure: “Digital
The signal for the secondary speed/timing sensor is
intermittent or lost.
RENR9313-04 67
System Response: i02424828
The Electronic Control Module (ECM) will log the CID 0617 FMI 05 Air Inlet
diagnostic code. Heater Relay open/current
Possible Performance Effect: below normal
There should not be a noticeable change in engine SMCS Code: 4493-038
response unless the signal for the primary sensor
is also lost. The loss of both sensors will shut down Conditions Which Generate This Code:
the engine.
Troubleshooting: open circuit while attempting to energize the air inlet
heater relay.
Speed/Timing Sensor Circuit - Test” System Response:
Results: The ECM logs the diagnostic code. The air inlet
heater will be disabled or the air inlet heater will run
• OK – STOP. continuously.

i02461141
CID 0535 FMI 08 Exhaust • The engine may experience hard starting and/or
the engine may emit excessive white smoke.
Temperature Sensor noisy
Troubleshooting:
signal
Perform the following diagnostic procedure: “Air Inlet
SMCS Code: 1439-038-TA; 1919-038 Heater Circuit - Test”
Conditions Which Generate This Code: Results:
The Electronic Control Module (ECM) detects sensor
frequency that is outside the acceptable range.
• OK – STOP.
The ECM will set engine exhaust temperature to a CID 0617 FMI 06 Air Inlet Heater
default value. Relay grounded/current above
Possible Performance Effect: norm
• There are no performance effects. SMCS Code: 4493-038
Perform the following diagnostic procedure: “Digital The Electronic Control Module (ECM) detects
Sensor Supply Circuit - Test” excessive current while attempting to energize the
air inlet heater relay.
Results:
System Response:
• OK – STOP.
The ECM logs the diagnostic code. The air inlet
heater will be disabled.
• The engine may experience hard starting and/or

the engine may emit excessive white smoke.
68 RENR9313-04
Perform the following diagnostic procedure: “Air Inlet • The engine speed is limited to low idle.
Heater Circuit - Test”
Troubleshooting:
Results:
• OK – STOP. Position Sensor - Calibrate”
Results:
i02461161
CID 1249 FMI 08 Secondary • OK – STOP.

Throttle Position signal
abnormal
SMCS Code: 1439-038; 1913-038-SE
The frequency or the duty cycle of the signal from the

secondary throttle input is incorrect.
System Response:

• The engine speed is limited to low idle.

Troubleshooting:

Position Sensor Circuit - Test”
Results:
• OK – STOP.
i02461164
CID 1249 FMI 13 Secondary

Throttle Position calibration
required
SMCS Code: 1439-038; 1913-038-SE
The frequency or the duty cycle of the signal from the

secondary throttle input is incorrect.
System Response:

RENR9313-04 69
Troubleshooting with an
Event Code
i02461632
Event Codes
SMCS Code: 1901
Event codes alert the operator that an abnormal

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

An event code represents a problem with engine
operation. Correct the problem as soon as
possible.
Event codes are listed in ascending numerical order.

The code with the lowest number is listed first.
Illustration 10 is an example of the operating range of

a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.
g01138880
Illustration 10
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.
Events are represented in two formats. In the first

format, the “E” means that the code is an event
code. The “XXX” represents a numeric identifier for
the event code. This is followed by a description of
the code. If a warning, a derate, or a shutdown is
applicable, the numeric identifiers are different. Refer
to the following example:
• E004 Engine Overspeed Shutdown

In the second format, the “E” means that the code is
an event code. The “XXX-X” represents a numeric
identifier for the event code. The fourth “X” identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
70 RENR9313-04
• E360-1 Low Oil Pressure Warning Troubleshooting

• E360-2 Low Oil Pressure Derate For basic troubleshooting of the engine, perform the
following steps in order to diagnose a malfunction:
• E360-3 Low Oil Pressure Shutdown
1. Obtain the following information about the
The definition for a warning, a derate, and a shutdown complaint:
are defined below:
• The event and the time of the event
Warning – This condition represents a serious
problem with engine operation. However, this • Determine the conditions for the event. The
condition does not require a derate or a shutdown. conditions will include the engine rpm and the
load.
Derate – For this condition, the Electronic Control
Module (ECM) reduces the engine's power in order • Determine if there are any systems that were
to help prevent possible engine damage. installed by the dealer or by the customer that
could cause the event.
Shutdown – For this condition, the ECM shuts down
the engine in order to help prevent possible engine • Determine whether any additional events
damage. occurred.
Logged Event Codes 2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
When the ECM generates an event code the ECM due to error of the operator.
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record 3. Narrow the probable cause. Consider the operator
the following information when an event code is information, the conditions of operation, and the
generated: history of the engine.
4. Perform a visual inspection. Inspect the following

• The hour of the first occurrence of the code items:
• The hour of the last occurrence of the code
• Fuel supply
• The number of occurrences of the code
• Oil level
Logged events are listed in chronological order. The
most recent event code is listed first. • Oil supply
This information can be helpful for troubleshooting • Wiring

intermittent problems. Logged codes can also be
used to review the performance of the engine. • Connectors
Be sure to check the connectors. This is very
Clearing Event Codes important for problems that are intermittent.
Refer to troubleshooting with a diagnostic code
A code is cleared from memory when one of the Troubleshooting, “Electrical Connectors - Inspect”.
following conditions occur:
If these steps do not resolve the problem, identify
• The code does not recur for 100 hours. the procedures in this manual that best describe the
event. Check each probable cause according to the
• A new code is logged and there are already ten tests that are recommended.
codes in memory. In this case, the oldest code is
cleared.
Trip Points for the Monitoring
• The service technician manually clears the code. System
Always clear logged event codes after investigating The monitoring system determines the level of action
and correcting the problem which generated the that is taken by the ECM in response to a condition
code. that can damage the engine. When any of these
conditions occur, the appropriate event code will trip.
RENR9313-04 71
Table 12 contains the conditions that are monitored

and the default trip points for each condition. Each
condition has an associated parameter. The settings
for each parameter can be viewed with the Caterpillar
Electronic Technician (ET). The trip points for some
of the parameters can be adjusted with Cat ET.
72 RENR9313-04
Table 12
Trip Points for the Monitoring System
Delay Time in Seconds Trip Point
Condition Action Default
Min Max Default Min Max Default State
Map
E100-(1) Low Engine Oil
Warning N/A N/A 30 N/A N/A dependent On
Pressure Warning
value(1)
E039-(2) Low Engine Oil Map
Pressure Derate Derate N/A N/A 30 N/A N/A dependent On
value (2)
E017-(1) High Engine
103 °C
Coolant Temperature Warning N/A N/A 30 N/A N/A On (3)
(217 °F)
Warning
E015-(2) High Engine
111 °C
Coolant Temperature Derate N/A N/A 30 N/A N/A On
(232 °F)
Derate
115% of
E190-(1) Engine Overspeed Rated
Warning N/A N/A 0 N/A N/A On(3)
Warning Engine
Speed (4)
E027-(1) High Engine Inlet 70 °C
Warning N/A N/A 30 N/A N/A On(3)
Air Temperature Warning (158 °F)
E025-(2) High Engine Inlet 79 °C
Derate N/A N/A 30 N/A N/A Off
Air Temperature Derate (174 °F)
E030-(1) High Transmission 50 °C 120 °C 95 °C
Warning 1 60 10 On
Oil Temperature Warning (122 °F) (248 °F) (203 °F)
E113-(1) High Transmission 689 kPa 3600 kPa 2412 kPa
Warning 0 60 10 On
Oil Pressure Warning (100 psi) (522 psi) (350 psi)
E059-(1) Low Coolant Level
Warning 4 60 30 N/A N/A Low On
Warning
E057-(2) Low Coolant Level
Derate 4 60 30 N/A N/A Low On
Derate
E056-(1) High Fuel 50 °C 80 °C 70 °C
Warning N/A N/A 30 On
Temperature Warning (122 °F) (176 °F) (158 °F)
Map
E096-(1) High Fuel Pressure
Warning 1 30 2 N/A N/A dependent On
Warning
value (5)
Map
E053-(1) Low Fuel Pressure
Warning 1 30 2 N/A N/A dependent On
Warning
value (6)
E119-(1) Low Fuel Level
Warning 60 900 300 5 percent 95 percent 12.5 percent Off
Warning
E173-(1) High Exhaust 800 °C
Warning 1 60 5 N/A N/A On
Temperature Warning (1472°F)
(1) Refer to Table 2.
(3) This event is permanently enabled.
(4) Fuel injection is disabled when the engine speed exceeds 115% of rated engine speed. Fuel injection is enabled when the engine speed
drops below the high idle engine speed.
RENR9313-04 73
Table 13 Troubleshooting:
Trip Points for Low Oil Pressure Warning
Check the Engine's Cooling System
0 rpm 0 kPa (0 psi)
500 rpm 0 kPa (0 psi)
A. Verify that the cooling system is filled to the proper
level. If the coolant level is too low, air will get into
1600 rpm 154 kPa (22 psi) the cooling system. Air in the cooling system will
2400 rpm 154 kPa (22 psi)
cause a reduction in coolant flow.
B. Check the quality of the coolant. Follow

Table 14 the recommendations in the Operation and
Trip Points for Low Oil Pressure Derate Maintenance Manual.
0 rpm 0 kPa (0 psi) C. Check for air in the cooling system. Air can enter
500 rpm 0 kPa (0 psi) the cooling system in different ways. The most
common causes of air in the cooling system are
1600 rpm 104 kPa (15 psi) the incorrect filling of the cooling system and
2400 rpm 104 kPa (15 psi) combustion gas leakage into the cooling system.
Combustion gas can get into the system through
Table 15
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket.
Trip Points for High Fuel Pressure Warning
500 rpm 759 kPa (110 psi) D. Check the cooling system hoses and clamps.
Damaged hoses with leaks can normally be seen.
2000 rpm 794 kPa (115 psi) Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
Table 16 kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses
Trip Points for Low Fuel Pressure Warning
become soft and/or get cracks after a period of
500 rpm 350 kPa (51 psi) time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
700 rpm 380 kPa (55 psi)
flow.
980 rpm 390 kPa (57 psi)
E. Check the sea water strainer for plugging.
1100 rpm 400 kPa (58 psi)
2300 rpm 400 kPa (58 psi) F. Check the heat exchanger for a restriction to the
flow of sea water.
2600 rpm 410 kPa (59 psi)
G. Check the water pump. A water pump with a
damaged impeller does not pump enough coolant.
i02456918
Remove the water pump and check for damage
E015 High Engine Coolant to the impeller.
Temperature Derate H. Check the water temperature regulator. A water

temperature regulator that does not open, or a
SMCS Code: 1395-038-TA water temperature regulator that only opens part
of the way can cause overheating.
I. If the cooling system for this application is
The temperature of the engine coolant has exceeded equipped with an expansion tank, check the shunt
the trip point. Refer to Troubleshooting, “Event line for the expansion tank. The shunt line must be
Codes” for the trip point. submerged in the expansion tank. A restriction of
the shunt line from the expansion tank to the inlet
System Response: of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump
The Electronic Control Module (ECM) will log the efficiency will result in low coolant flow.
event.
J. If the cooling system for this application
Possible Performance Effect: is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the air
• Engine power is reduced. to air aftercooler can cause overheating. Check
for debris or deposits which would prevent the free
flow of air through the aftercooler.
74 RENR9313-04
K. Check for a restriction in the air inlet system. A Possible Performance Effect:
restriction of the air that is coming into the engine
can cause high cylinder temperatures. High • There are no performance effects.
cylinder temperatures cause higher than normal
temperatures in the cooling system. Troubleshooting:
L. Check for a restriction in the exhaust system. Check the Engine's Cooling System
A restriction of the air that is coming out of the
engine can cause high cylinder temperatures. A. Verify that the cooling system is filled to the proper
level. If the coolant level is too low, air will get into
M. Consider high ambient temperatures. When the cooling system. Air in the cooling system will
ambient temperatures are too high for the rating cause a reduction in coolant flow.
of the cooling system, there is not enough of a
temperature difference between the ambient air B. Check the quality of the coolant. Follow
and coolant temperatures. the recommendations in the Operation and
Maintenance Manual.
N. Consider high altitude operation. The cooling
capability of the cooling system is reduced at C. Check for air in the cooling system. Air can enter
higher altitudes. A pressurized cooling system that the cooling system in different ways. The most
is large enough to keep the coolant from boiling common causes of air in the cooling system are
must be used. the incorrect filling of the cooling system and
combustion gas leakage into the cooling system.
O. The engine may be running in the lug condition. Combustion gas can get into the system through
When the load that is applied to the engine is inside cracks, a damaged cylinder head, or a
too large, the engine will run in the lug condition. damaged cylinder head gasket.
When the engine is running in the lug condition,
engine rpm does not increase with an increase of D. Check the cooling system hoses and clamps.
fuel. This lower engine rpm causes a reduction in Damaged hoses with leaks can normally be seen.
coolant flow through the system. Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
Expected Result: kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses
A thorough inspection of the cooling system revealed become soft and/or get cracks after a period of
a problem. time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
Results: flow.
• OK – There is a problem with the cooling system. E. Check the sea water strainer for plugging.
Repair: Repair the problem. Ensure that the repair F. Check the heat exchanger for a restriction to the
eliminates the problem. flow of sea water.
STOP. G. Check the water pump. A water pump with a

damaged impeller does not pump enough coolant.
Remove the water pump and check for damage
i02456909
to the impeller.
E017 High Engine Coolant H. Check the water temperature regulator. A water
Temperature Warning temperature regulator that does not open, or a
water temperature regulator that only opens part
SMCS Code: 1395-038-TA of the way can cause overheating.
Conditions Which Generate This Code: I. If the cooling system for this application is
equipped with an expansion tank, check the shunt
The temperature of the engine coolant has exceeded line for the expansion tank. The shunt line must be
the trip point. Refer to Troubleshooting, “Event submerged in the expansion tank. A restriction of
Codes” for the trip point. the shunt line from the expansion tank to the inlet
of the jacket water pump will cause a reduction in
System Response: water pump efficiency. A reduction in water pump
efficiency will result in low coolant flow.
event.
RENR9313-04 75
J. If the cooling system for this application i02450055

is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the air E025 High Inlet Air
to air aftercooler can cause overheating. Check Temperature Derate
for debris or deposits which would prevent the free
flow of air through the aftercooler. SMCS Code: 1050-038-TA
K. Check for a restriction in the air inlet system. A Conditions Which Generate This Code:
can cause high cylinder temperatures. High The Electronic Control Module (ECM) detects inlet air
cylinder temperatures cause higher than normal temperature that exceeds the trip point temperature.
temperatures in the cooling system. Information on default settings and ranges for this
event can be found in Troubleshooting, “Event
L. Check for a restriction in the exhaust system. Codes”.
A restriction of the air that is coming out of the
engine can cause high cylinder temperatures. System Response:
M. Consider high ambient temperatures. When The ECM will log the event.
ambient temperatures are too high for the rating
of the cooling system, there is not enough of a Possible Performance Effect:
temperature difference between the ambient air
and coolant temperatures. • The engine power is derated.
N. Consider high altitude operation. The cooling Troubleshooting:
capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that There may be a problem with the engine.
is large enough to keep the coolant from boiling
must be used. Test Step 1. Check the Engine's Air Inlet
and Exhaust Systems
O. The engine may be running in the lug condition.
When the load that is applied to the engine is A. Check for a restriction in the air inlet system. A
too large, the engine will run in the lug condition. restriction of the air that is coming into the engine
When the engine is running in the lug condition, can cause high cylinder temperatures. High
engine rpm does not increase with an increase of cylinder temperatures cause higher than normal
fuel. This lower engine rpm causes a reduction in temperatures in the cooling system.
coolant flow through the system.
B. Check for a restriction in the exhaust system.
Expected Result: A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
A thorough inspection of the cooling system revealed
a problem. Continue to the next test step.
Results: Test Step 2. Check for an Extreme
Operating Environment
• OK – There is a problem with the cooling system.
A. Consider high ambient temperatures. When
Repair: Repair the problem. Ensure that the repair ambient temperatures are too high for the rating
eliminates the problem. of the cooling system, there is not enough of a
temperature difference between the ambient air
STOP. and coolant temperatures.
B. Consider high altitude operation. The cooling

capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that
must be used.
76 RENR9313-04
C. The engine may be running in the lug condition. Test Step 2. Check for an Extreme
When the load that is applied to the engine is Operating Environment
too large, the engine will run in the lug condition.
When the engine is running in the lug condition, A. Consider high ambient temperatures. When
engine rpm does not increase with an increase of ambient temperatures are too high for the rating
fuel. This lower engine rpm causes a reduction in of the cooling system, there is not enough of a
coolant flow through the system. temperature difference between the ambient air
and coolant temperatures.
Expected Result:
B. Consider high altitude operation. The cooling
A thorough inspection of the engine revealed a capability of the cooling system is reduced at
problem. higher altitudes. A pressurized cooling system that
Results: must be used.
• OK – There is a problem with the engine. C. The engine may be running in the lug condition.
When the load that is applied to the engine is
Repair: Repair the problem. Ensure that the repair too large, the engine will run in the lug condition.
eliminates the problem. When the engine is running in the lug condition,
engine rpm does not increase with an increase of
STOP. fuel. This lower engine rpm causes a reduction in
coolant flow through the system.
i02450081
Expected Result:
E027 High Inlet Air A thorough inspection of the engine revealed a
Temperature Warning problem.
SMCS Code: 1050-038-TA Results:
Conditions Which Generate This Code: • OK – There is a problem with the engine.
The Electronic Control Module (ECM) detects inlet air Repair: Repair the problem. Ensure that the repair
temperature that exceeds the trip point temperature. eliminates the problem.
Information on default settings and ranges for this
event can be found in Troubleshooting, “Event STOP.
Codes”.
The ECM will log the event.

E030 High Transmission Oil
Temperature Warning
Troubleshooting:
The transmission oil temperature has exceeded the
Test Step 1. Check the Engine's Air Inlet trip point. Refer to Troubleshooting, “Event Codes”
and Exhaust Systems for the trip point.
A. Check for a restriction in the air inlet system. A System Response:

can cause high cylinder temperatures. High The Electronic Control Module (ECM) will log the
cylinder temperatures cause higher than normal event.
temperatures in the cooling system.
B. Check for a restriction in the exhaust system.
A restriction of the air that is coming out of the • There are no performance effects.
engine can cause high cylinder temperatures.
Continue to the next test step.

RENR9313-04 77
Troubleshooting: b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the
Check the Transmission engine oil pump.
Refer to the information that is provided by the OEM c. If the engine is equipped with a scavenge
for the transmission. pump, the scavenge pump may not be
supplying oil to the main engine oil pump.
Results:
C. The inlet screen of the oil suction tube for the
• OK – There is a problem with the transmission. engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of
Repair: Make the necessary repairs. Verify that engine oil pressure. Check the inlet screen on
the problem is resolved. the oil pickup tube and remove any material that
may be restricting engine oil flow. Low engine oil
STOP. pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
oil pickup tube for cracks or a damaged O-ring
i02450088
seal.
E039 Low Engine Oil Pressure D. If the engine oil bypass valves are held in the open
Derate position, a reduction in the oil pressure can be the
result. This may be due to debris in the engine
SMCS Code: 1348-038-LP oil. If the engine oil bypass valves are stuck in
the open position, remove each engine oil bypass
Conditions Which Generate This Code: valve and clean each bypass valve in order to
correct this problem. You must also clean each
The Electronic Control Module (ECM) detects an bypass valve bore.
engine oil pressure that falls below the trip point.
Information on default settings and ranges for this E. Engine oil that is contaminated with fuel or coolant
event can be found in Troubleshooting, “Event will cause low engine oil pressure. High engine
Codes”. oil level in the crankcase can be an indication of
contamination.
System Response:
F. Excessive clearance at engine bearings will
The ECM will log the code. cause low engine oil pressure. Check the engine
components for excessive bearing clearance.
G. An oil line that is open, broken, or disconnected
• The engine power is derated. will cause low engine oil pressure.
Troubleshooting: Expected Result:
There may be a problem with the engine. 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:
a. Air leakage in the supply side of the oil pump

will also cause cavitation and loss of oil
pressure. Check the supply side of the oil pump
and make necessary repairs.
78 RENR9313-04
i02456968 i02456970
E053 Low Fuel Pressure E056 High Fuel Temperature

Warning Warning
SMCS Code: 1250-038-LP SMCS Code: 1250-038-TA
The fuel pressure is below the trip point. Refer to The fuel temperature has exceeded the trip point.
Troubleshooting, “Event Codes” for the trip point. Refer to Troubleshooting, “Event Codes” for the trip
point.
System Response:
System Response:
event. The Electronic Control Module (ECM) will log the
event.
Troubleshooting:
Troubleshooting:
Check the Fuel System's Components
Check the Fuel System
A. Check the fuel level in the fuel tank. Ensure that
the vent in the fuel cap is not filled with dirt. A. Check the heat exchanger (if equipped). Verify
that the heat exchanger is free of debris and of
B. Check all fuel lines for fuel leakage. The fuel lines obstructions.
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed. Expected Result:
C. Install a new fuel filter. A thorough inspection of the heat exchanger revealed
a problem.
D. Cut the old filter open with the 175-7546 Oil
Filter Cutter Gp. Inspect the filter for excess Results:
contamination. Determine the source of the
contamination. Make the necessary repairs. • OK – There is a problem with the heat exchanger.
E. Service the primary fuel filter (if equipped). Repair: Make the necessary repairs. Verify that
the repair eliminates the problem.
F. Operate the hand priming pump (if equipped).
If excessive resistance is felt, inspect the fuel STOP.
pressure regulating valve. If uneven resistance is
felt, test for air in the fuel. • Not OK – There is a problem with the fuel system.
Expected Result: Repair: Repair the problem.
There is a problem with the fuel system. Ensure that the repair eliminates the problem.
Results: STOP.
• OK – There is a problem with the fuel system.

Repair: Make the necessary repairs. Verify that
STOP.
RENR9313-04 79
i02515083 Repair: Check the cooling system for leaks. Repair

any problems that are found. Refill the cooling
E057 Low Engine Coolant system to the proper level.
Level Derate
STOP.
SMCS Code: 1395-038-LO
• Not OK – The coolant level is not low.
Repair: There may be air in the cooling system.
The coolant level is below the coolant level sensor. For information on checking the cooling system,
Information on default settings and ranges for this refer to the engine's Systems Operation/Testing
event code can be found in Troubleshooting, “Event and Adjusting manual.
Codes”.
Ensure that any repairs eliminate the problem.
System Response:
STOP.
event. • Not OK – The coolant level is not low.
Possible Performance Effect: Repair: There may be a problem with the coolant
level sensor. Refer to the diagnostic functional test
E057(2) Troubleshooting, “Coolant Level Sensor Circuit -
Test”.
• Engine power is derated.
Troubleshooting:
STOP.
• The coolant level is most likely low.
i02515107
• Air may be trapped in the cooling system.
E059 Low Engine Coolant
• There may be a problem with the coolant level Level Warning
sensor.
Check the Coolant Level SMCS Code: 1395-038-LO

Pressurized System: Hot coolant can cause seri- problem with the engine's cooling system. Information
ous burns. To open the cooling system filler cap, on default settings and ranges for this event code
stop the engine and wait until the cooling system can be found in Troubleshooting, “Event Codes”.
pressure cap slowly in order to relieve the pres- System Response:
sure.
The event code will be logged.
A. Stop the engine.
B. After allowing the engine to cool, check the coolant
level. Refer to the Operation and Maintenance E059(1)
Manual.
Expected Result:
Troubleshooting:
The coolant level is low.
• The coolant level is most likely low.
Results:
• Air may be trapped in the cooling system.
• OK – The coolant level is low.
• There may be a problem with the coolant level
sensor.
80 RENR9313-04
Check the Coolant Level i02416641
E096 High Fuel Pressure

SMCS Code: 1250-038-HQ
ous burns. To open the cooling system filler cap, Conditions Which Generate This Code:
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system The Electronic Control Module (ECM) detects a
pressure cap slowly in order to relieve the pres- high fuel pressure. Information on default settings
sure. and ranges for these event codes can be found in
troubleshooting with an event code Troubleshooting,
A. Stop the engine. “Event Codes”.
B. After allowing the engine to cool, check the coolant System Response:
level. Refer to the Operation and Maintenance
Manual. The ECM will log the code.
Expected Result: Possible Performance Effect:
The coolant level is low. • Engine performance is not affected.

Results: Troubleshooting:
• OK – The coolant level is low. Check the Fuel System
Repair: Check the cooling system for leaks. Repair Check the fuel system's components.
any problems that are found. Refill the cooling
system to the proper level. Check the pressure of the fuel system.
STOP. Expected Result:
• Not OK – The coolant level is not low. There is a problem with the fuel system.
Repair: Air may be trapped in the cooling system. Results:

For information on checking the cooling system,
refer to the engine's Systems Operation/Testing • OK – There is a problem with the fuel system.
and Adjusting manual.
Repair: Make the necessary repairs. Verify that
Ensure that any repairs eliminate the problem. the repair eliminates the problem.
STOP. STOP.
• Not OK – The coolant level is not low. i02450095
Repair: There may be a problem with the coolant E100 Low Engine Oil Pressure
level sensor. Refer to the diagnostic functional test
Troubleshooting, “Coolant Level Sensor Circuit - Warning
Test”.
SMCS Code: 1348-038-LP
STOP.
engine oil pressure that falls below the trip point.
Information on default settings and ranges for this
event can be found in Troubleshooting, “Event
Codes”.
System Response:

RENR9313-04 81
Possible Performance Effect: Expected Result:
• There are no performance effects. An inspection of the engine's lubrication system

indicated a problem.
Troubleshooting:
Results:
Check the Engine's Lubrication System
• OK – There is a problem in the engine's lubrication
A. Check the engine oil level. If the oil level is below system.
the oil pump's supply tube, the oil pump will not
have the ability to supply enough lubrication to Repair: Repair the problem. Ensure that the repair
the engine components. If the engine oil level is eliminates the problem.
low, add engine oil in order to obtain the correct
engine oil level. STOP.
B. Check the following problems that may occur to

i02456991
the engine oil pump:
a. Air leakage in the supply side of the oil pump

E113 High Transmission Oil
will also cause cavitation and loss of oil Pressure
pressure. Check the supply side of the oil pump
and make necessary repairs. SMCS Code: 3080-038-HQ
b. Oil pump gears that have too much wear will Conditions Which Generate This Code:
cause a reduction in oil pressure. Repair the
engine oil pump. The transmission oil pressure has exceeded the trip
point. Refer to Troubleshooting, “Event Codes” for
c. If the engine is equipped with a scavenge the trip point.
pump, the scavenge pump may not be
supplying oil to the main engine oil pump. System Response:
C. The inlet screen of the oil suction tube for the The Electronic Control Module (ECM) will log the
engine oil pump can have a restriction. This event.
restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on Possible Performance Effect:
the oil pickup tube and remove any material that
may be restricting engine oil flow. Low engine oil • There are no performance effects.
pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the Troubleshooting:
oil pickup tube for cracks or a damaged O-ring
seal. Check the Transmission
D. If the engine oil bypass valves are held in the open Refer to the information that is provided by the OEM
position, a reduction in the oil pressure can be the for the transmission.
result. This may be due to debris in the engine
oil. If the engine oil bypass valves are stuck in Results:
the open position, remove each engine oil bypass
valve and clean each bypass valve in order to • OK – There is a problem with the transmission.
correct this problem. You must also clean each
bypass valve bore. Repair: Make the necessary repairs. Verify that
the problem is resolved.
E. Engine oil that is contaminated with fuel or coolant
will cause low engine oil pressure. High engine STOP.
oil level in the crankcase can be an indication of
contamination.
F. Excessive clearance at engine bearings will

cause low engine oil pressure. Check the engine
components for excessive bearing clearance.
G. An oil line that is open, broken, or disconnected

will cause low engine oil pressure.
82 RENR9313-04
i02456997 Expected Result:

E119 Low Fuel Level The reason for the high exhaust temperature was
determined.
SMCS Code: 1250-038-FLV
Results:
• OK – The reason for the high exhaust temperature
The fuel level is below the trip point. Refer to was determined. STOP.
Troubleshooting, “Event Codes” for the trip points.
The Electronic Control Module (ECM) will log the E190 Engine Overspeed
event. Warning
Possible Performance Effect: SMCS Code: 7427-038
• There are no performance effects. Conditions Which Generate This Code:

Troubleshooting: The Electronic Control Module (ECM) detects an
engine overspeed condition. Information on default
Add fuel to the fuel tank. Refer to the literature that settings and ranges for this event can be found in
is provided by the OEM of the vessel for the correct Troubleshooting, “Event Codes”.
procedure.
System Response:
Results:
• OK – STOP.
i02457000
E173 High Exhaust
Troubleshooting:
Temperature Warning
The operator may be operating the engine incorrectly.
Interview the Operator
Determine the events that caused the overspeed of
The temperature of the engine exhaust has exceeded the engine. Make corrections in order to prevent the
the trip point. Refer to Troubleshooting, “Event overspeed from recurring.
Codes” for the trip point.
Results:
System Response:
• OK – STOP.
The event code is logged.

Evaluate the Air Inlet and Exhaust
System
Check the air inlet manifold pressure. Check for leaks
between the exhaust manifold and the turbocharger.
Check for exhaust restrictions. Refer to Testing and
Adjusting, “Air Inlet and Exhaust System”.
RENR9313-04 83
Diagnostic Functional Note: When you convert the “SUM” of two

temperatures that are in degrees Celsius,
Tests the resulting value in degrees Fahrenheit will
be incorrect. The two temperatures must be
converted prior to the addition of the two values.
i02907627
Air Inlet Heater Circuit - Test • Convert the reading for the coolant temperature
from degrees Celsius to degrees Fahrenheit.
SMCS Code: 1090-038
• Convert the reading for the inlet manifold air
System Operation Description: temperature from degrees Celsius to degrees
Fahrenheit.
Use this procedure to troubleshoot any suspect
problems with the air inlet heater circuit. • Add the two conversions together in order to arrive
at the correct conversion for the sum in degrees
This procedure covers the following diagnostic codes: Fahrenheit. Refer to the example that is in Table
17.
• 617-05 Air Inlet Heater Relay open/current below Table 17
normal
Example
• 617-06 Air Inlet Heater Relay grounded/current Reading °C °F
above norm
Coolant Temperature 15 °C 59 °F
The air inlet heater improves the engine's ability to Inlet Manifold Air Temperature 10 °C 50 °F
start when the engine is cold. The air inlet heater also
reduces white smoke when the engine is cold. “SUM”(1) 25 °C 109
°F
The Electronic Control Module (ECM) controls the (1) The sum cannot be directly converted. The direct conversion
operation of the air inlet heater via the air inlet heater of 25 °C is 77 °F.
relay.
The operation of the air inlet heater is determined

by the following cycles:
Power Up Cycle – The air inlet heater is turned on

for two seconds after the ECM is first powered up.
This will happen regardless of temperatures and
engine speed.
Preheat Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
less than 25 °C (109 °F), then the heater will remain
on up to 30 seconds. If the engine speed is zero after
30 seconds, the heater is turned off regardless of the
temperature.
Crank Cycle – If the “SUM” of the coolant

still less than 25 °C (109 °F), the air inlet heater will
remain on while the engine is being cranked.
Running Cycle – If the “SUM” of the coolant

less than 35 °C (127 °F), then the air inlet heater will
remain on for seven minutes.
Postheat Cycle – The air inlet heater is cycled on

and off for an additional 13 minutes if the “SUM” of
the coolant temperature and the inlet manifold air
temperature is still less than 35 °C (127 °F). The air
inlet heater will turn on for ten seconds and the air
inlet heater will turn off for ten seconds.
84 RENR9313-04
g01228563
Illustration 11
Schematic of the air inlet heater
Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.
RENR9313-04 85
g01208064
Illustration 12
Typical component locations for the air inlet heater
(1) Air inlet heater (3) Ground connection for the air inlet heater
(2) Air inlet heater relay (4) J2/P2 connectors
B. Thoroughly inspect the connector for the air inlet

heater and connector (4). Inspect the connections
on air inlet heater relay (2) and air inlet heater
(1). Refer to the diagnostic functional test
86 RENR9313-04
Results:
• OK – The harness and the connectors appear to

be OK. Proceed to Test Step 2.
• Not OK – There is a problem with the connectors

and/or the wiring.
Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.
STOP.
Test Step 2. Check for Active Diagnostic

Codes
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic
Service Tools”.
B. Restore the electrical power to the ECM.
C. Observe the “Active Diagnostic” screen on Cat ET.

Wait at least 30 seconds so that any codes may
become active. Look for these codes:
• 617-05
• 617-06
Illustration 13
g01208070 Expected Result:
P2 terminals that are associated with the air inlet heater
One of the above codes is active.
(P2-5) Air inlet heater
(P2-79) Air inlet heater
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the connectors that are associated with • Active 05 code – A 05 diagnostic code is active.
Proceed to Test Step 3.
the circuit.
D. Check the torque of the allen head screws for the • Active 06 code – A 06 diagnostic code is active.
ECM connectors. Refer to the diagnostic functional
Inspect” for the correct torque values. • No active codes – None of the above codes are
active. There may be a problem with the high
power circuit. Proceed to Test Step 6.
E. Check the harness and wiring for abrasion and
for pinch points from the air inlet heater back to
the ECM and from the air inlet heater back to the
battery.
Expected Result:
All connectors, pins and sockets are completely

coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
RENR9313-04 87
Test Step 3. Check for an Open Circuit B. Measure the resistance between terminal P2-5
to the Relay and terminal 1 of the connector for the air inlet
heater.
C. Measure the resistance between terminal P2-79

and terminal 2 of the connector for the air inlet
heater.
Expected Result:
Both of the resistance measurements are less than

ten Ohms.
Results:
• OK – Both of the resistance measurements are

less than ten Ohms.
g01118589
Illustration 14
Small terminals for the typical air inlet heater relay Repair: Perform the following repair:
A. Disconnect the wires from the small terminals of 1. Temporarily connect a spare ECM.
the air inlet heater relay.
2. Reconnect all connectors and wires.
B. Install a test lamp across the wires.
3. Recheck the system for active diagnostic codes.
C. Start the “Air Inlet Heater Override” on Cat ET and
observe the test lamp. 4. Repeat this test step.
Note: Do not leave the “Air Inlet Heater Override” 5. If the problem is resolved with the spare ECM,
ON. This prevents unnecessary cycling of the air inlet reconnect the suspect ECM.
heater and the battery from discharging. The “Air
Inlet Heater Override” has a one minute timer that 6. If the problem returns with the suspect ECM,
disables the test when the time expires. replace the ECM.
D. Stop the “Air Inlet Heater Override” and restore 7. Verify that the repair eliminates the problem.
electrical power to the ECM.
STOP.
Expected Result:
• Not OK – At least one of the resistance
The test lamp turned on while the override was active. measurements is more than ten Ohms. There is a
problem with the wiring between the ECM and the
Results: air inlet heater relay. There may be a problem with
a connector.
• OK – The test lamp turned on while the override
was active. The open circuit is in the relay. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
Repair: Replace the air inlet heater relay. Clear that the problem is resolved.
any diagnostic codes. Verify that the problem is
resolved. STOP.
STOP.
• Not OK – The test lamp did not turn on while the

override was active. Proceed to Test Step 4.
Test Step 4. Check the Wiring Between

the ECM and the Relay
A. Disconnect the J2/P2 connectors.
Note: Be sure to wiggle the harness during the

following measurements in order to reveal an
intermittent condition.
88 RENR9313-04
Test Step 5. Check for a Short Circuit in Test Step 6. Check for Battery Voltage at
the Wiring to the Relay the Relay
A. Connect a test lamp between the +Battery side of
the air inlet heater relay and the engine ground.
Expected Result:
The test lamp turns ON.
Results:
• OK – The test lamp turns ON. Battery voltage is

reaching the relay. Proceed to Test Step 7.
• Not OK – The test lamp does not turn ON. Battery

voltage is not reaching the relay.
g01118589
Illustration 15
Small terminals for the typical air inlet heater relay Repair: There is an open circuit in the wiring
between the battery and the relay. There may be a
A. Disconnect the wires from the small terminals for problem with a connection.
the air inlet heater relay.
Repair the wire and/or the connection, when
B. Restore the electrical power to the ECM. possible. Replace parts, if necessary. Verify that
the problem is resolved.
C. Observe the “Active Diagnostic” screen on Cat ET.
Wait at least 30 seconds so that any codes may STOP.
become active.
Test Step 7. Check for Voltage Output at
D. Remove the electrical power from the ECM. the Relay
Expected Result: A. Connect a test lamp between the output terminal
of the air inlet heater relay and the engine ground.
The short circuit diagnostic code (06) changed to an
open circuit diagnostic code (05) when the wires to Note: Observe the test lamp. The test lamp should
the relay were disconnected. be off, since the relay is not energized. If the test
lamp is on, ensure that the test lamp is connected to
Results: the output side of the relay.
• OK – The short circuit diagnostic code (06) B. Restore the electrical power to the ECM.
changed to an open circuit diagnostic code (05)
when the wires to the relay were disconnected. C. Run the “Air Inlet Heater Override” on Cat ET and
The short circuit is in the relay. observe the test lamp.
Repair: Replace the relay. Clear the diagnostic Note: Do not leave the “Air Inlet Heater Override”
codes. ON. This prevents unnecessary cycling of the air inlet
heater and the battery from discharging. The “Air
Verify that the problem is resolved. Inlet Heater Override” has a one minute timer that
disables the test when the time expires.
STOP.
D. Stop the “Air Inlet Heater Override” and remove
• Not OK – The short circuit diagnostic code electrical power from the ECM.
(06) remained when the wires to the relay were
disconnected. There is a problem in the wiring Expected Result:
between the ECM and the relay. There may be a
problem with a connector. The test lamp turned on when the “Air Inlet Heater
Override” was enabled.
Repair: Repair the wire and/or the connector,
that the problem is resolved.
STOP.
RENR9313-04 89
Results: Repair: Repair the wire and/or the connector,

• OK – The test lamp turned on when the “Air Inlet that the problem is resolved.
Heater Override” was enabled. The air inlet heater
relay and the +Battery connection to the air inlet STOP.
heater relay are operating correctly. Proceed to
Test Step 8. Test Step 9. Measure the Current through
the Heater
• Not OK – The test lamp did not turn on when the
“Air Inlet Heater Override” was enabled.
Repair: Replace the relay.
Verify that the problem is resolved.
STOP.
Test Step 8. Check the Wiring Between

the Relay and the Heater and Between
the Heater and the Engine Block
g01118617
Illustration 17
Typical left side view
(1) Wire
(2) Terminal
(3) Terminal
A. Connect a 155-5176 AC/DC Current Probe or an

equivalent inductive pickup clamp around wire (1)
between the relay and the air inlet heater.
B. Connect the current probe to a multimeter.
Illustration 16
g01143674 C. Restore the electrical power to the ECM.
D. Run the “Air Inlet Heater Override” on Cat ET and
(1) Wire
(2) Terminal
observe the current reading on the multimeter.
A. Measure the resistance of wire (1) that connects Note: Do not leave the “Air Inlet Heater Override”
the relay to the air inlet heater. On. Avoid unnecessary cycling of the air inlet heater
in order to prevent the battery from discharging. The
B. Measure the resistance of the ground strap that is “Air Inlet Heater Override” has a one minute timer in
connected between terminal (2) and the engine order to disable the test when the time expires.
block.
E. While the override is active, measure the voltage
Expected Result: between terminals (2) and (3).
Both of the resistance measurements are less than F. Stop the “Air Inlet Heater Override” and remove
ten Ohms. the electrical power from the ECM.
Results: Expected Result:
The current reading is between 84 and 104 Amperes.

• OK – Both of the resistance measurements are The voltage reading is approximately 22 VDC.
less than ten Ohms. Proceed to Test Step 9.
Note: If the voltage reading does not match the
• Not OK – At least one of the resistance specified value, you will need to adjust the current
measurements is more than ten Ohms. There is an
open circuit in the wiring. There may be a problem value accordingly. For slightly lower voltages, the
with a connector. current value will be slightly lower. For slightly higher
voltages, the current value will be slightly higher.
90 RENR9313-04
Results: The 5 volt sensor supply provides power to all 5 volt

sensors. The ECM supplies 5.0 ± 0.2 VDC to terminal
• OK – The readings are within the specified ranges. A of each sensor connector. The sensor common
from the ECM connector goes to terminal B of each
Repair: The readings are within the specified sensor connector. The sensor supply is output short
ranges. The air inlet heater circuit appears to be circuit protected. A short circuit to the battery will not
operating correctly at this time. If an intermittent damage the circuit inside the ECM.
problem is suspected, refer to diagnostic functional
tests Troubleshooting, “Electrical Connectors - Note: The sensors are not protected from
Inspect”. overvoltage. A short from the supply line to the
+Battery may damage the sensors. If the CID-FMI
STOP. 262-03 is logged, it is possible that all of the sensors
have been damaged. Repair the sensor supply and
• Not OK – The voltage reading and/or the current check for any “ACTIVE” sensor diagnostic codes in
reading is not within the specified ranges. order to determine if a sensor has failed.
Repair: Replace the air inlet heater.
STOP.
i02462439
Analog Sensor Supply Circuit

- Test
SMCS Code: 1439-038
System Operation Description:
Use this procedure to troubleshoot the system when

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

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

ground
The Electronic Control Module (ECM) supplies a

regulated voltage of 5.0 ± 0.2 VDC to the following
sensors:
• Intake air (boost) pressure sensor

• Engine oil pressure sensor
• Fuel pressure sensor
• Injection actuation pressure sensor
• Transmission oil pressure sensor
• Transmission oil temperature sensor
RENR9313-04 91
g01228600
Illustration 18
Schematic
92 RENR9313-04
g01180108
Illustration 19
Typical location of the engine's 5 volt sensors
(1) Fuel pressure sensor
(2) Injection actuation pressure sensor
(3) Boost pressure sensor
(4) Connector for the optional marine transmission oil temperature
sensor
(5) Connector for the optional marine transmission oil pressure
sensor
(6) Engine oil pressure sensor
(7) J2/P2 ECM connector
g01149132
Illustration 20
P2 terminals that are associated with the 5 volt supply
(P2-17) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
(P2-54) Return
(P2-81) +5 VDC
(P2-93) Return
Test Step 1. Inspect Electrical Connectors

and Wiring
RENR9313-04 93
B. Thoroughly inspect the J1/P1 ECM connector • 262-04

and the J2/P2 ECM connector. Inspect all of the
connectors that are associated with the circuit. Results:
Refer to the diagnostic functional test • OK – A 03 diagnostic code is active. Proceed to

Troubleshooting, “Electrical Connectors - Inspect”. Test Step 4.
C. Perform a 45 N (10 lb) pull test on each of the • OK – A 04 diagnostic code is active. Proceed to
wires in the ECM connectors that are associated Test Step 3.
with the circuit.
• Not OK – No diagnostic code is active.
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to the diagnostic Repair: The problem is no longer present. If the
functional test Troubleshooting, “Electrical problem is intermittent, refer to the diagnostic
Connectors - Inspect” for details. functional test Troubleshooting, “Electrical
Connectors - Inspect”.
E. Check the harness and wiring for abrasion and
pinch points from the sensors back to the ECM. STOP.
Expected Result: Test Step 3. Disconnect the +5 V Sensors

while you Monitor the Active Diagnostic
All connectors, pins and sockets are completely Codes
are free of corrosion, of abrasion and of pinch points. A. Monitor the active diagnostic code screen on the
electronic service tool. Check and record any
Results: active diagnostic codes.
• OK – The harness and connectors appear to be Note: Wait at least 30 seconds in order for the
OK. Proceed to Test Step 2. diagnostic codes to become active.
• Not OK – There is a problem with the connectors B. Disconnect the following sensors one at a time
and/or wiring. and observe Cat ET.
Repair: Repair the connectors or wiring and/or • Intake air (boost) pressure sensor
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the • Engine oil pressure sensor
connectors are completely coupled.
Verify that the repair eliminates the problem.
• Transmission oil pressure sensor
STOP.
• Transmission oil temperature sensor
Codes C. Wait for 30 seconds after each sensor is
disconnected. Check for an active diagnostic code
A. Connect the Caterpillar Electronic Technician (ET) on Cat ET.
to the service tool connector.
Expected Result:
The 04 diagnostic code deactivates.
C. Monitor the active diagnostic code screen on the
electronic service tool. Check and record any Results:
active diagnostic codes.
• OK – The 04 diagnostic code deactivates. The
Note: Wait at least 30 seconds in order for the diagnostic code is not active after a specific sensor
diagnostic codes to become active. is disconnected.
Expected Result:
One of the following diagnostic codes is active:
• 262-03
94 RENR9313-04
Repair: Reconnect the sensor that is suspected Repair: Repair the wire or replace the wire. Clear
of causing the problem. If the problem returns all logged diagnostic codes. Reconnect all wires
after the reconnection of the sensor, disconnect to the original configuration. Verify that the repair
the sensor. If the problem disappears after the eliminates the problem.
disconnection of the sensor, replace the sensor.
Reconnect all wires to the original configuration. STOP.
Clear all diagnostic codes. Verify that the repair
eliminates the problem. Test Step 5. Check the +5 V Supply and
the Sensor Common for an Open Circuit
STOP.
A. Install a wire jumper between terminal P2-80 (+5
• Not OK – The 04 diagnostic code stays active. V Supply) and terminal P2-54 (Sensor Return).
Leave the sensors disconnected. Proceed to Test
Step 4. B. Install a wire jumper between terminal P2-81 (+5
V Supply) and terminal P2-93 (Sensor Return).
Test Step 4. Check the +5 V Supply Wire
for a Short to Engine Ground or a Short C. Install a wire jumper between terminal P2-72 (+5
to another Wire in the Harness V Supply) and terminal P2-17 (Sensor Return).
A. Remove the electrical power from the ECM. Note: Wiggle the harness during the following
measurements in order to reveal any intermittent
B. Disconnect the J2/P2 ECM connector. short condition.
C. Leave the sensors disconnected at the sensor D. Record the resistance at each analog sensor
connectors. connector between terminal A and terminal B.
Note: Wiggle the harness during the following E. Remove the wire jumpers.
short condition. Expected Result:
D. Measure the resistance from the ECM connector The resistance is less than 5 Ohms for each
P2-80 (+5 V Supply) to every terminal on ECM measurement.
connector P2 and ECM connector P1. Measure
the resistance from the ECM connector P2-80 to Results:
the ECM ground strap.
• OK – The resistance check does not indicate an
E. Measure the resistance from the ECM connector open circuit in the engine harness. Proceed to Test
P2-81 (+5 V Supply) to every terminal on ECM Step 6.
connector P2 and ECM connector P1. Measure
the resistance from the ECM connector P2-81 to • Not OK – A resistance measurement is greater
the ECM ground strap. than 5 Ohms. The +5 V supply wire or the sensor
return has excessive resistance.
F. Measure the resistance from the ECM connector
P2-72 (+5 V Supply) to every terminal on ECM Repair: Repair the wires or replace the wires.
connector P2 and ECM connector P1. Measure Clear all logged diagnostic codes. Reconnect all
the resistance from the ECM connector P2-72 to wires to the original configuration. Verify that the
the ECM ground strap. repair eliminates the problem.
Expected Result: STOP.
Each resistance measurement is more than 20,000 Test Step 6. Check the +5 V Supply at the
Ohms. ECM
Results: A. Remove the wire G828-WH from ECM connector
P2-72 (+5 V Supply). Install a wire jumper with
• OK – The resistance check does not indicate a socket terminals on both ends into P2-72.
short in the engine harness or a short to engine
ground. Proceed to Test Step 5. B. Remove the 993-BR or G829-GN wire from ECM
connector P2-17 (Sensor Return). Install a wire
• Not OK – A resistance measurement is less than jumper with socket terminals on both ends into
20,000 Ohms. The +5 V supply wire is shorted P2-17.
in the engine harness or the +5 V supply wire is
shorted to engine ground.
RENR9313-04 95
C. Remove the wire N940-BU from ECM connector Repair: Replace the ECM. Refer to electronic
P2-81 (+5 V Supply). Install a wire jumper with troubleshooting Troubleshooting, “Replacing the
socket terminals on both ends into P2-81. ECM”.
D. Remove the wire N941-YL from ECM connector STOP.

P2-93 (Sensor Return). Install a wire jumper with
socket terminals on both ends into P2-93.
i02462985
E. Remove the wire G826-BR from ECM connector

P2-80 (+5 V Supply). Install a wire jumper with
CAN Data Link Circuit - Test
socket terminals on both ends into P2-80. SMCS Code: 1901-038
F. Remove the wire G827-BU from ECM connector System Operation Description:
P2-54 (Sensor Return). Install a wire jumper with
socket terminals on both ends into P2-54. The CAN data link is used to communicate
information between the Electronic Control Module
Note: Disconnecting the common sensor wire from (ECM) and other modules. Use this procedure to
the ECM will generate an open circuit diagnostic troubleshoot any suspect problems with the CAN
code for all sensors that are connected to the sensor data link.
common. Troubleshoot the original diagnostic code.
Delete the logged diagnostic codes when you are This procedure identifies the following problems:
finished.
G. Reconnect ECM connector J2/P2.

• Faulty connectors
H. Restore the electrical power to the ECM.

• Missing termination resistors
I. Measure the voltage between the wire jumper in

• Short circuits
P2-72 and the wire jumper in P2-17.
• Open circuits
J. Measure the voltage between the wire jumper in
P2-81 and the wire jumper in P2-93.
• Faulty marine power display
A problem with the CAN data link is probably caused
K. Measure the voltage between the wire jumper in by a short circuit to ground or a short circuit to
P2-80 and the wire jumper in P2-54. another voltage source in the harness. The next likely
cause is a problem with a module that is connected
L. Remove the electrical power from the ECM. to the data link. The least likely cause is a problem
with the ECM.
M. Reconnect all wires to the original configuration.
Expected Result:
The voltage is 5.0 ± 0.2 VDC.
Results:
• OK – The voltage is 5.0 ± 0.2 VDC. The voltage is

correct.
Repair: Clear all diagnostic codes. Check

for active diagnostic codes. If the problem is
intermittent, refer to the diagnostic functional test
STOP.
• Not OK – The voltage is not 5.0 ± 0.2 VDC. The

voltage is incorrect.
96 RENR9313-04
g01149133
Illustration 21
Schematic for the CAN data link

RENR9313-04 97
g01150879
Illustration 22
(1) J60 service tool
(3) J1939 termination resistor
(4) J61 customer connector
B. Thoroughly inspect connectors (1), (2), and

(4). Also, thoroughly inspect the connector for
termination resistor (3). Refer to the diagnostic
functional test Troubleshooting, “Electrical
g01091318
Illustration 23
P1 terminals that are associated with the CAN data link
(34) CAN data link −
(42) CAN shield
(50) CAN data link +
98 RENR9313-04
Test Step 2. Verify the Proper Installation

of the Termination Resistors
B. Disconnect the Marine Power Display (MPD).
C. Disconnect any other display that is connected to

the CAN data link.
D. Disconnect the Caterpillar Electronic Technician

(ET) from the service tool connector.
E. Disconnect the P1 connector.
Note: Wiggle the harness during the following

measurements in order to reveal an intermittent
condition.
F. Measure the resistance between terminals P1-50

(CAN data link +) and P1-34 (CAN data link -).
g01180112
Illustration 24
P61 terminals that are associated with the CAN data link
Expected Result:
(16) Shield
(17) CAN data link +
The resistance is between 57 and 63 Ohms.
(18) CAN data link −
Results:
wires that are associated with the CAN data link. • OK – The resistance is between 57 and 63 Ohms.
D. Check the allen head screw on each ECM
connector and on the customer connector for the • Not OK – The resistance is between 114 Ohms
proper torque. Refer to the diagnostic functional and 126 Ohms. A termination resistor is missing.
Inspect”. Repair: Verify that two termination resistors are
connected to the data link. One resistor must be
E. Check the wiring harnesses for abrasion, for located on each end of the data link. The engine
corrosion and for pinch points. is shipped with one termination resistor that is
installed between the ECM and the customer
Expected Result: connector.
All connectors, pins and sockets are completely Refer to the appropriate electrical schematic in
coupled and/or inserted. The harness and wiring are order to determine the missing resistor. Replace
free of corrosion, of abrasion and of pinch points. the missing resistor. Verify that the problem is
resolved.
Results:
STOP.
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2. • Not OK – The resistance is less than 57 Ohms.
• Not OK – There is a problem in the wiring harness.
• Not OK – The resistance is greater than 126
Repair: Repair the connectors and/or the wiring. Ohms. Proceed to Test Step 4.
seals are properly in place and ensure that the Test Step 3. Check for a Short Circuit
problem is resolved. A. Remove both termination resistors from the CAN
data link.
STOP.
B. Measure the resistance between the points that
are listed in Table 18. Be sure to wiggle the wires
in the harnesses as you make each resistance
measurement.
RENR9313-04 99
Table 18 • Not OK – The resistance is more than ten Ohms.

Resistance Measurements for the CAN Data Link
There is an open circuit or excessive resistance in
the circuit. There may be a problem in a connector.
Connector and Terminal
Terminal Repair: Repair the wiring and/or the connector.
P1-50 (CAN data link +) All of the other terminals on Replace part, if necessary. Verify that the problem
the P1 connector is resolved.
Engine ground STOP.
P1-34 (CAN data link -) All of the other terminals on
the P1 connector Test Step 5. Check the Marine Power
Display
Engine ground
A. Connect the marine power display to another
Expected Result: engine.
Each check of the resistance indicates an open B. Operate the engine and monitor the marine power
circuit. display.
• OK – Each check of the resistance indicates an The marine power display operates properly.
open circuit. Proceed to Test Step 4.
Results:
• Not OK – At least one check of the resistance
does not indicate an open circuit. There is a short • OK – The marine power display operates properly
circuit in a harness. There may be a problem with on another engine.
a connector.
Repair: Connect the display to the original engine.
Repair: Repair the wiring and/or the connector. If the display operates correctly, there may be
Replace part, if necessary. Verify that the problem a problem with an electrical connector. Refer to
is resolved. the diagnostic functional test Troubleshooting,
STOP.
If the display does not operate correctly on the
Test Step 4. Check for an Open Circuit original engine, there may be a problem with the
ECM.
A. Remove both termination resistors from the CAN
data link. If the display does not operate correctly, replace
the ECM. Refer to electronic troubleshooting
B. Fabricate a jumper wire. Use the jumper wire in Troubleshooting, “Replacing the ECM”.
order to create a short circuit between terminals A
and B on the tee's connector for the termination STOP.
resistor. This will replace the termination resistor
with a short circuit. • Not OK – The marine power display does not
operate properly on another engine.
C. Measure the resistance between terminals P1-50
(CAN data link +) and P1-34 (CAN data link -). Repair: Replace the marine power display. Verify
D. Remove the jumper wire from the tee. Connect
the termination resistors to the data link. STOP.
E. Connect the J1/P1 connectors.
Expected Result:
The resistance is less than ten Ohms.
Results:
• OK – The resistance is less than ten Ohms. There

is not an open circuit. Proceed to Test Step 5.
100 RENR9313-04
i02463010
Cat Data Link Circuit - Test

SMCS Code: 1901-038
Note: This procedure checks for an open circuit

or a short circuit in the Cat Data Link. If you
are experiencing problems with communications
between the Caterpillar Electronic Technician
(ET) and the Electronic Control Module (ECM),
refer to troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM” before you use this
procedure.
The Cat Data Link is the standard data link that

is used by the ECM to communicate with Cat ET.
The ECM communicates with Cat ET in order to
share status information and diagnostic information.
Cat ET can also be used to configure the ECM
parameters. This information will not be available if
communication fails between the ECM and Cat ET.
g01179736
Illustration 25
Schematic for the Cat Data Link

RENR9313-04 101
g01180182
Illustration 26
Left side engine view (typical example)
(1) J60 service tool connector
(2) J1/P1 ECM connectors
(3) J61 customer connector
B. Thoroughly inspect connectors (1), (2), and

(3). Inspect all of the other connectors that are
associated with the circuit for the Cat Data Link.
Refer to the diagnostic functional test

C. Verify that the wiring for the Cat Data Link is Illustration 27
g01091329
installed correctly. Refer to Special Instruction, P1 terminals that are associated with the Cat Data Link
REHS1187, “Electronic Installation Guide”.
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −
D. Verify that each individual ECM is programmed to
the proper engine location.
g01130713
Illustration 28
Terminals on the service tool connectors that are associated with
the Cat Data Link
(D) Cat Data Link +
(E) Cat Data Link −
102 RENR9313-04
Test Step 2. Check for a Short Circuit

B. Disconnect any service tools from the Cat Data

Link.
C. Disconnect the P1 and P2 connectors from the

ECM.
D. Measure the resistance between the points that

are listed in Table 19. Be sure to wiggle the wires
measurement.
Table 19
Resistance Measurements for the Wiring Harness
Terminal
P1-8 (Cat Data Link +) All of the other terminals on
Illustration 29
g01179761 the P1 connector
Terminals on the customer connectors that are associated with All of the terminals on the P2
the Cat Data Link connector
(6) Cat Data Link +
(7) Cat Data Link − Engine ground
P1-9 (Cat Data Link −) All of the other terminals on
E. Perform a 45 N (10 lb) pull test on each of the the P1 connector
wires that are associated with the Cat Data Link.
All of the terminals on the P2
connector
F. Check the allen head screw on each ECM
connector and on the customer connector for the Engine ground
proper torque. Refer to the diagnostic functional
Expected Result:
Inspect”.
All of the resistance measurements indicate an open
G. Check the wiring harnesses for abrasion, for
circuit.
corrosion, and for pinch points.
Results:
Expected Result:
All connectors, pins and sockets are completely • OK – All of the resistance measurements indicate
an open circuit. Proceed to Test Step 3.
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion and of pinch points.
• Not OK – At least one resistance measurement
does not indicate an open circuit. There is a
Results:
problem with a wiring harness. There may be a
problem with a connector.
• OK – The harness and wiring appear to be OK.
Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the problem
• Not OK – There is a problem in the connectors is resolved.
and/or the wiring.
STOP.
Repair: Repair the connectors and/or the wiring.
Test Step 3. Check for an Open Circuit
problem is resolved.
B. Use a jumper wire to create a short circuit between
STOP.
terminals P1-8 and P1-9.
RENR9313-04 103

short condition.
C. Measure the resistance between the terminals for

the Cat Data Link at the service tool connectors.
Expected Result:
Each resistance measurement is less than ten Ohms.
Results:
• OK – Each resistance measurement is less than

ten Ohms. There is not an open circuit. g01132350
Illustration 30
Repair: The problem may be intermittent. If the Coolant level sensor
problem is intermittent, refer to the diagnostic (1) Sensor
functional test Troubleshooting, “Electrical (2) Brass rod
Connectors - Inspect”. (3) Plastic cover
STOP. Coolant level sensor (1) contains no moving parts.

The sensor detects variations in capacitance. The
• Not OK – At least one resistance measurement sensor's probe contains a brass rod (2) that is
is greater than ten Ohms. The wiring for the Cat covered with plastic (3). The brass rod is one plate
Data Link has excessive resistance. There may be of a capacitor. The plastic cover is the capacitor's
a problem in a connector. dielectric. The coolant is the other plate of the
capacitor.
Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify When the probe is immersed in coolant, the sensor
that the problem is resolved. senses a particular capacitance. The sensor
responds by creating a short circuit between the
STOP. signal wire and the ground wire.
When the probe is not immersed in coolant, the

i02463088 capacitance value changes. The change in the
capacitance value is detected by the sensor's
Coolant Level Sensor Circuit electronic circuits. The circuits apply approximately
- Test +5 VDC to the signal wire. The ECM detects the
voltage and the ECM activates either a E059 or a
SMCS Code: 1439-038-CLT E057 event code.
System Operation Description: The event codes are probably caused by a low
coolant level. The next likely cause is a problem with
Use this procedure to troubleshoot any suspect a wiring harness or with the sensor. The least likely
problems with the coolant level sensor. cause is a problem with the ECM.
The coolant level sensor monitors the engine coolant

level in order to warn the operator in the event that
the coolant level is low. The coolant level sensor is
located on the side of the expansion tank.
104 RENR9313-04
g01229002
Illustration 31
Schematic for the coolant level sensor

ous burns. To open the cooling system filler cap,
pressure cap slowly in order to relieve the pres-
sure.

g01228993
Illustration 33
g01132749
Illustration 32 P2 terminals that are associated with the coolant level sensor
Engine components for the coolant level sensor (P2-92) Return
(1) J1/P1 connectors (P2-29) +8 VDC
(2) J2/P2 connectors (P2-49) Coolant level
(3) Coolant level sensor
B. Thoroughly inspect connectors (1) and (2). wires that are associated with the circuit for the
Inspect the connectors for sensor (3). Refer to coolant level sensor.
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect” for details. D. Check the allen head screw on each ECM
connector for the proper torque. Refer to the
RENR9313-04 105
Expected Result: Repair: Refer to the diagnostic functional test

Troubleshooting, “Digital Sensor Supply Circuit -
All connectors, pins, and sockets are completely Test”.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion or of pinch points. STOP.
Results: Test Step 3. Check the Coolant Level

• OK – The connectors and wiring are OK. Proceed
to Test Step 2.
• Not OK – There is a problem with the connectors ous burns. To open the cooling system filler cap,
and/or the wiring.
Repair: Repair the wiring and connectors or components are cool. Loosen the cooling system
replace the wiring or the connectors. Ensure that pressure cap slowly in order to relieve the pres-
all of the seals are properly connected. Verify that sure.
A. Stop the engine.
B. After allowing the engine to cool, check the coolant
STOP. level. Refer to the Operation and Maintenance
Manual.
Test Step 2. Check the Supply Voltage at
the Sensor Connector Expected Result:
A. Disconnect the coolant level sensor. The coolant is at the proper level.
B. Restore the electrical power to the ECM. Results:
• OK – The coolant is at the proper level. Proceed

to Test Step 4.
• Not OK – The coolant level is low.

Repair: Add coolant according to the procedure in
the Operation and Maintenance Manual.
g01132478
Illustration 34
Harness connector for the coolant level sensor
Identify the source of the coolant leak and fix the
(A) +8 VDC
(B) Return
problem.
C. Measure the voltage between terminals A (+8 STOP.

VDC) and B (Return) at the harness connector for
the coolant level sensor. Test Step 4. Disconnect the Coolant
Level Sensor and Monitor the Status of
D. Remove the electrical power from the ECM. “Coolant Level”
Expected Result: A. Connect the Caterpillar Electronic Technician

(ET) to the service tool connector. Refer to
The voltage measurement is 8.0 ± 0.4 VDC. Troubleshooting, “Electronic Service Tools”.
Results: B. Disconnect the coolant level sensor connector.
C. Restore the electrical power to the ECM.

• OK – The voltage measurement is 8.0 ± 0.4 VDC.
The supply voltage is reaching the sensor. Proceed
to Test Step 3. D. Monitor the status of “Coolant Level” on Cat ET.
E. Remove the electrical power from the ECM.

• Not OK – The voltage measurement is not 8.0 ±
0.4 VDC. The digital sensor supply voltage is not
reaching the sensor.
106 RENR9313-04
Expected Result: If the status of the “Coolant Level” is “OK”,

replace the sensor. Verify that the problem is
The status changes from “OK” to “Low” when the resolved.
sensor is disconnected.
If the status for the coolant level is “Low”,
Results: connect the sensor. Fill the cooling system
according to the procedure in the Operation
• OK – The status is “Low” when the sensor is and Maintenance Manual. Return the engine
disconnected. Proceed to Test Step 5. to service.
• Not OK – The status is “OK” when the sensor is STOP.

disconnected. Proceed to Test Step 6.
• Not OK – Shorting the harness does not affect the
Test Step 5. Short the Harness and status on Cat ET. Proceed to Test Step 6.
Monitor the Status of “Coolant Level”
Test Step 6. Check the Wiring for an Open
A. Restore the electrical power to the ECM and Circuit
monitor the status of “Coolant Level” on Cat ET.
B. Install a jumper wire between terminals B (Return)
and C (Signal) on the harness connector for the B. Disconnect the J1/P1 and J2/P2 connectors.
coolant level sensor.
C. Monitor the status of “Coolant Level” on Cat ET measurements in order to reveal an intermittent
while the jumper wire is installed. condition.
D. Remove the jumper wire. C. Measure the resistance between the following
terminals:
• P2-29 (+8 VDC) to terminalA of the sensor
Expected Result: harness connector (+8 VDC)
The status changes from “Low” to “OK” when the • P2-92 (Return) to terminal B of the sensor
jumper wire is installed. harness connector (Return)
Results: • P2-49 (Engine Coolant Level) to terminal C of

the sensor harness connector (Engine Coolant
• OK – The status changes from “Low” to “OK” Level)
when the jumper wire is installed. The ECM and
the wiring to the coolant level sensor are OK. Expected Result:
Repair: Perform the following procedure: Each resistance measurement is less than ten Ohms.
Results:

• OK – Each resistance measurement is less than
ten Ohms. There are no opens in the wiring.
ous burns. To open the cooling system filler cap, Proceed to Test Step 7.
pressure cap slowly in order to relieve the pres-
• Not OK – At least one resistance measurement is
greater than ten Ohms. There is an open circuit or
sure. excessive resistance in the harness. There may be
a problem in a connector.
1. Drain the coolant below the level of the coolant
level sensor. Repair: Repair the wire and/or the connector,
2. Restore the electrical power to the ECM and that the problem is resolved.
STOP.
RENR9313-04 107
Test Step 7. Check the Wiring for a Short Expected Result:

Circuit
The status is “Low” when the jumper wire is not
A. Remove the electrical power from the ECM. connected. The status is “OK” when the jumper wire
is connected.
measurements in order to reveal an intermittent Results:
condition.
• OK – The status is “Low” when the jumper wire is
B. Measure the resistance between the points that not connected. The status is “OK” when the jumper
are listed in Table 20. Be sure to wiggle the wires wire is connected. The ECM is properly reading
in the harnesses as you make each resistance the switch input.
measurement.
Repair: Perform the following procedure:
Table 20
Resistance Measurements for the Circuit for 1. Remove the jumper wire from the ECM
the Coolant Level Sensor connector.
Connector and Terminal 2. Install the two terminals into the correct
Terminal
locations on the ECM connector. Pull on the two
P2-49 (Engine Coolant All of the other terminals on wires in order to verify proper installation of the
Level) the P2 connector terminals.
connector
The problem appears to be resolved. The
original problem was probably caused by a
Engine ground poor electrical connection. Return the engine
to service.
Expected Result:
STOP.
Each check of the resistance indicates an open
circuit. • Not OK – The status is “Low” when the jumper
wire is connected. The ECM is not reading the
Results: switch input.
Repair: Temporarily install a new ECM. Refer

• OK – Each check of the resistance indicates an to electronic troubleshooting Troubleshooting,
open circuit. Proceed to Test Step 8.
“Replacing the ECM”.
• Not OK – At least one check of the resistance If the new ECM works correctly, install the original
problem in the harness. There may be a problem ECM and verify that the problem returns. If the new
in a connector. ECM works correctly and the original ECM does
not work correctly, replace the original ECM. Verify
Repair: Repair the wire and/or the connector, that the problem is resolved.
that the problem is resolved. STOP.
STOP. i02463148
Test Step 8. Create a Short Circuit at the Digital Sensor Supply Circuit
ECM - Test
A. Remove the terminal from locations P2-46 and
SMCS Code: 1439-038
P2-92.
B. Install the ends of a jumper wire into locations
P2-46 and P2-92. This will create a short circuit
at the ECM connectors.
problems with the +8 V digital supply.
C. Restore the electrical power to the ECM and
This procedure covers the following diagnostic codes:
D. Remove the jumper wire. Monitor the status of • 263-03 8 Volt DC Supply short to +batt
“Coolant Level” on Cat ET.
108 RENR9313-04
• 263-04 8 Volt DC Supply short to ground

The digital sensor supply in the Electronic Control
Module (ECM) supplies 8.0 ± 0.4 VDC to the throttle
position sensor and the coolant level sensor.
A +8 V diagnostic code is probably caused by a short

circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
problem with the sensor. The least likely cause is a
problem with the ECM.
g01149135
Illustration 35
Schematic for the 8 volt supply

g01180117
Illustration 37
Typical component locations for the 8 volt supply
(2) Coolant level sensor (optional)
(3) Exhaust temperature sensor (optional)
B. Thoroughly inspect connector (1). Also, thoroughly

inspect each connector for sensors (2) and
g01229023
Illustration 36
RENR9313-04 109

E. Check the harness and wiring for abrasions and

for pinch points from the sensor to the ECM.
Expected Result:
All connectors, pins, and sockets are completely

Results:

to Test Step 2.

or wiring.
Repair: Repair the connectors or wiring and/or

the seals are properly in place and ensure that the
STOP.

Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
g01229035
Illustration 38
P2 terminals that are associated with the 8 volt supply
(P2-92) Return C. Monitor the active diagnostic code screen on Cat
(P2-29) +8 VDC
ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the

diagnostic codes to become active.
Expected Result:
One of the following diagnostic codes is active:
• 263-03
• 263-04
Results:
Illustration 39
g01159881 • OK – A 03 diagnostic code is active. Proceed to
Test Step 3.
Connector for the sensors
(A) +8 VDC
(B) Return
• OK – A 04 diagnostic code is active. Proceed to
(C) Signal
Test Step 4.

wires in the circuit for the digital sensor supply.
110 RENR9313-04
• Not OK – No diagnostic code for the digital supply Repair: Reconnect the sensor. If the problem
is active. A problem is suspected with a sensor returns after the reconnection of the sensor,
output signal. In order to verify that the sensor is disconnect the sensor. If the problem disappears
receiving the correct supply voltage, proceed to after the disconnection of the sensor, replace the
Test Step 3. sensor. Clear all diagnostic codes. Verify that the
Test Step 3. Check the Voltage on the +8
V Supply Wire STOP.
A. Remove the electrical power from the ECM. • Not OK – The 04 diagnostic code stays active.
Leave the sensors disconnected. Proceed to Test
B. Disconnect the digital sensors from the sensor Step 5.
connectors.
Test Step 5. Check the +8 V Supply Wire
C. Restore the electrical power to the ECM. for a Short to Engine Ground or a Short
to another Wire in the Harness
D. Measure the voltage between terminal A and
terminal B at each sensor connector. A. Remove the electrical power from the ECM.
Expected Result: B. Disconnect the J1/P1 ECM connector and the

J2/P2 ECM connector.
C. Leave the digital sensors disconnected.
Results:
• OK – The voltage is 8.0 ± 0.4 VDC. measurements in order to reveal any intermittent
short condition.
Repair: Reconnect the sensors. Clear all
diagnostic codes. Check for active diagnostic D. Measure the resistance between P2-29 (+8
codes. If the problem is intermittent, refer to V digital supply) and every terminal on ECM
the diagnostic functional test Troubleshooting, connector P1 and ECM connector P2.
a. Measure the resistance between P2-29 (+8 V
STOP. digital supply) and engine ground.
• Not OK – The voltage is not 8.0 ± 0.4 VDC. Expected Result:

Each resistance measurement indicates an open
Test Step 4. Disconnect the +8 V Sensors circuit.
and Check for an Active Diagnostic Code
Results:
A. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes. • OK – The resistance measurement does not
indicate a short in the engine harness or a short to
Note: Wait at least 30 seconds in order for the engine ground. Proceed to Test Step 6.
• Not OK – A resistance measurement does not
B. Disconnect the digital sensors one at a time from indicate an open circuit. The +8 V digital supply
the sensor connectors. Wait for 30 seconds after wire is shorted in the engine harness or the +8 V
each sensor is disconnected. Check for an active digital supply wire is shorted to engine ground.
diagnostic code on Cat ET.
Repair: Repair the wire or replace the wire. Clear
Expected Result: all logged diagnostic codes. Replace all wires to
the original configuration. Verify that the repair
The 04 diagnostic code deactivates. eliminates the problem.
Results: STOP.
• OK – The 04 diagnostic code deactivates after a Test Step 6. Check the +8 V Supply and
particular sensor is disconnected. the Sensor Return for an Open Circuit
A. Install a wire jumper between pin P2-29 (+8 V
digital supply) and pin P2-92 (digital return).
RENR9313-04 111
Note: Wiggle the harness during the following Repair: Clear all diagnostic codes. Check
measurements in order to reveal any intermittent for active diagnostic codes. If the problem is
short condition. intermittent, refer to the diagnostic functional test
B. Measure the resistance between terminal A and
terminal B at each of the sensor connectors. STOP.
C. Remove the wire jumper. • Not OK – The voltage is not 8.0 ± 0.4 VDC.
Expected Result: Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
The resistance is less than ten Ohms for each ECM”.
measurement.
STOP.
Results:
i02378207
• OK – The resistance check does not indicate an
open circuit in the engine harness. Proceed to Test
Step 7.
Electrical Connectors - Inspect
SMCS Code: 7553-040-WW
• Not OK – A resistance measurement is greater
than ten Ohms. The +8 V digital supply wire or the System Operation Description:
sensor common has excessive resistance.
Most electrical problems are caused by poor
Repair: Repair the wires or replace the wires. connections. The following procedure will assist in
Clear all logged diagnostic codes. Verify that the detecting problems with connectors and with wiring.
repair eliminates the problem. If a problem is found correct the condition and verify
STOP.
Intermittent electrical problems are sometimes
Test Step 7. Check the +8 V Supply at the resolved by disconnecting and reconnecting
ECM connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
A. Remove the wire R800-OR from ECM connector Also check for diagnostic codes after reconnecting
P2-29 (+8 V digital supply). Install a wire jumper the connector. If the status of a diagnostic code is
with socket terminals on both ends into P2-29. changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
B. Remove the wire J842-BK from ECM connector likely reasons are loose terminals, improperly crimped
P2-92 (digital return). Install a wire jumper with terminals, moisture, corrosion, and inadequate
socket terminals on both ends into P2-92. mating of a connection.
C. Reconnect ECM connector J1/P1 and J2/P2. Follow these guidelines:
D. Restore the electrical power to the ECM. • Always use a 1U-5804 Crimp Tool to service
Deutsch HD and DT connectors. Never solder the
E. Measure the voltage between the wire jumper in terminals onto the wires. Refer to “SEHS9615,
P2-29 and the wire jumper in P2-92. Servicing Deutsch HD and DT Style Connectors”.
F. Remove the electrical power from the ECM. • Always use a 147-6456 Wedge Removal Tool to
remove wedges from DT connectors. Never use a
G. Reconnect all wires to the original configuration. screwdriver to pry a wedge from a connector.
Expected Result: • Always use a breakout harness for a voltmeter
probe or a test light. Never break the insulation
The voltage is 8.0 ± 0.4 VDC. of a wire in order to access to a circuit for
measurements.
Results:
• If a wire is cut, always install a new terminal for
• OK – The voltage is 8.0 ± 0.4 VDC. the repair.
112 RENR9313-04
The connection of any electrical equipment and

the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
explosive atmosphere.
Test Step 1. Check Connectors for

Moisture and Corrosion
g01131276
Illustration 41
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
B. Ensure that the sealing plugs are in place. If

any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 41.
g01131211
Illustration 40
Leaky seal at the connector (typical example)
A. Inspect all wiring harnesses. Ensure that the

routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 40. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.
g01131019
Illustration 42
Seal for a three-pin connector (typical example)
RENR9313-04 113
Expected Result:
The harness wiring, connectors, and seals are in

good condition. There is no evidence of moisture in
the connectors.
Results:
• OK – The harness wiring, connectors, and seals

are in good condition. Proceed to Test Step 2.
• Not OK – A problem has been found with the

harness or the connectors.
Repair: Repair the connectors or the wiring, as

required. Ensure that all of the seals are properly
in place. Ensure that the connectors have been
reattached.
If corrosion is evident on the pins, sockets or the

connector, use only denatured alcohol to remove
Illustration 43
g01131165 the corrosion. Use a cotton swab or a soft brush
Seal for ECM connector (typical example)
to remove the corrosion.
C. Disconnect the suspect connector and inspect the If moisture was found in the connectors, run the
connector seal. Ensure that the seals are in good engine for several minutes and check again for
condition. If necessary, replace the connector. moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
D. Thoroughly inspect the connectors for evidence entry path is repaired, it may be necessary to
of moisture entry. replace the wires.
Note: It is normal to see some minor seal abrasion Verify that the repair eliminates the problem.
on connector seals. Minor seal abrasion will not allow
the entry of moisture. STOP.
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
• Missing seals • Exposed insulation
• Improperly installed seals • Rubbing of a wire against the engine
• Nicks in exposed insulation • Rubbing of a wire against a sharp point

B. Check all of the wiring harness fasteners in order
• Improperly mated connectors to verify that the harness is properly secured. Also
Moisture can also travel to a connector through check all of the fasteners in order to verify that the
the inside of a wire. If moisture is found in a harness is not compressed. Pull back the harness
connector, thoroughly check the connector's sleeves in order to check for a flattened portion
harness for damage. Also check other connectors of wire. A fastener that has been overtightened
that share the harness for moisture. flattens the harness. This damages the wires that
are inside the harness.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of Expected Result:
the moisture. Do not replace the ECM.
The wires are free of abrasion, of nicks, and of cuts
and the harness is properly clamped.
114 RENR9313-04
Results: A. Ensure that the locking wedge for the connector

is installed properly. Terminals cannot be retained
• OK – The harness is OK. Proceed to Test Step 3. inside the connector if the locking wedge is not
installed properly.
• Not OK – There is damage to the harness.
B. Perform the 45 N (10 lb) pull test on each wire.
Repair: Repair the wires or replace the wires, Each terminal and each connector should easily
as required. Verify that the repair eliminates the withstand 45 N (10 lb) of tension and each wire
problem. should remain in the connector body. This test
checks whether the wire was properly crimped
STOP. in the terminal and whether the terminal was
properly inserted into the connector.
Test Step 3. Inspect the Connector
Terminals Expected Result:
A. Visually inspect each terminal in the connector. Each terminal and each connector easily withstands
Verify that the terminals are not damaged. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are properly aligned in connector body.
the connector and verify that the terminals are
properly located in the connector. Results:
Expected Result: • OK – All terminals pass the pull test. Proceed to

Test Step 5.
The terminals are properly aligned and the terminals
appear undamaged. • Not OK – A wire has been pulled from a terminal
or a terminal has been pulled from the connector.
Results:
Repair: Use the 1U-5804 Crimp Tool to replace
• OK – The terminals are OK. Proceed to Test Step the terminal. Replace damaged connectors, as
4. required. Verify that the repair eliminates the
problem.
• Not OK – The terminals of the connector are
damaged. STOP.
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
STOP.
Test Step 4. Perform a Pull Test on Each

Wire Terminal Connection
g01131604
Illustration 45
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
pin by the socket.
g01131435
Illustration 44
Receptacle lock wedge (typical example) Expected Result:
The sockets provide good retention for the new pin.

RENR9313-04 115
Results:
• OK – The terminals are OK. Proceed to Test Step

6.
• Not OK – Terminals are damaged.

Repair: Use the 1U-5804 Crimp Tool to replace
the damaged terminals. Verify that the repair
eliminates the problem.
STOP.
Test Step 6. Check the Locking

Mechanism of the Connectors g01132827
Illustration 46
A. Ensure that the connectors lock properly. After Allen head screw for the 120 pin ECM connector (typical example)
locking the connectors, ensure that the two halves
cannot be pulled apart. a. Torque the allen head bolt for the 120 pin ECM
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).
B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
the connector returns to the locked position.
Expected Result:
The connector will securely lock. The connector and

the locking mechanism are without cracks or breaks.
Results:
• OK – The connectors are in good repair. Proceed

to Test Step 7.
• Not OK – The connector's locking mechanism is g01132849

damaged or missing. Illustration 47
Allen head screw for the 70 pin ECM connector (typical example)
Repair: Repair the connector or replace the
connector, as required. Verify that the repair b. Torque the allen head screw for the 70
eliminates the problem. pin ECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
STOP.
Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged.
A. Connect the ECM connectors.
g01132863
Illustration 48
Allen head screw for the 40 pin ECM connector (typical example)
c. Torque the allen head screw for the 40 pin ECM

connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
116 RENR9313-04
Expected Result:
No intermittent problems were indicated during the

“Wiggle Test”.
Results:
• OK – No intermittent problems were found. The

harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.
g01133047 • Not OK – At least one intermittent problem was

Illustration 49 indicated.
Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example) Repair: Repair the harness or the connector. Verify
that the repair eliminates the problem.
B. Connect the customer connector.
STOP.
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). i02463437
Expected Result: Electrical Power Supply Circuit

- Test
The ECM connector is secure and the allen head
screws are properly torqued. SMCS Code: 1401-038
Results: System Operation Description:
• OK – The ECM connectors and the customer Use this test to troubleshoot any suspect problems
connector is properly connected. Proceed to Test with power to the Electronic Control Module (ECM).
Step 8.
• Not OK – The allen head screws for the ECM
connector or the customer connector is damaged. • 168-00 “System Voltage High”
Repair: Repair the connector or replace the • 168-01 “System Voltage Low”
connector, as required. Verify that the repair
eliminates the problem. • 168-02 “System Voltage intermittent/erratic”
STOP. Use this test if there are intermittent engine
shutdowns or if a difficulty in starting is not
Test Step 8. Perform the “Wiggle Test” on accompanied by loss of electrical accessories.
the Caterpillar Electronic Technician (ET) Engine shutdowns that are accompanied by a loss of
other electrical accessories indicate a problem in the
A. Select the “Wiggle Test” from the diagnostic tests keyswitch. This does not indicate a problem in the
on Cat ET. wiring at the engine's ECM. Verify that there are no
problems with the starting system or the charging
B. Choose the appropriate group of parameters to system before you use this test.
monitor.
C. Press the “Start” button. Wiggle the wiring harness

in order to reproduce intermittent problems.
If an intermittent problem exists, the status will be

highlighted and an audible beep will be heard.
RENR9313-04 117
Unswitched battery voltage is supplied through the

J61/P61 machine connector to the ECM at P1-48,
P1-52, and P1-53. The negative battery is supplied
to the ECM at P1-61, P1-63, and P1-65. The ECM
receives the input from the keyswitch at P1-70 when
the keyswitch is in the ON position or the START
position. When the ECM detects battery voltage at
this input, the ECM will power up. When battery
voltage is removed from this input, the ECM will
power down. The ECM continuously receives battery
voltage through the 20 Amp fuse for the ECM.
The engine ECM requires the keyswitch to be in the

ON position in order to maintain communications with
the electronic service tool.
g01230328
Illustration 50
Schematic
118 RENR9313-04
E. Check the ECM connector (allen head screw)

for the proper torque. Refer to the diagnostic
F. Check the harness and the wiring for abrasion

and for pinch points.
Expected Result:

inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
All connections and grounds are tight and free of
corrosion.
Results:
• OK – The harness and wiring are OK. Proceed

to Test Step 2.
• Not OK – There is a problem in the connectors

and/or wiring.

STOP.
Test Step 2. Check the Battery Voltage at

Illustration 51
g01231248 the ECM
(22) Engine shutdown switch
(P1-48) +Battery
A. Turn the remote shutdown switch to the ON
(P1-52) +Battery position.
(P1-53) +Battery
(P1-61) −Battery B. Disconnect the J1/P1 ECM connector.
(P1-63) −Battery
(P1-65) −Battery
(P1-67) −Battery C. Restore the electrical power to the ECM.
(P1-70) Keyswitch
D. Measure the voltage between P1-48 (Unswitched
Test Step 1. Inspect Electrical Connectors Positive Battery) and P1-61 (Negative Battery).
and Wiring
E. Measure the voltage between P1-52 (Unswitched
A. Turn the remote shutdown switch to the OFF Positive Battery) and P1-63 (Negative Battery).
position.
F. Measure the voltage between P1-53 (Unswitched
B. Remove the electrical power from the ECM. Positive Battery) and P1-65 (Negative Battery).
C. Thoroughly inspect the ECM connectors J1/P1 G. Measure the voltage between P1-53 (Unswitched
and J2/P2. Inspect all of the connectors that are Positive Battery) and P1-67 (Negative Battery).
associated with this circuit. Refer to the diagnostic
functional test Troubleshooting, “Electrical H. Measure the voltage between P1-70 (Keyswitch)
Connectors - Inspect”. and P1-63 (Negative Battery).
D. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated
with the circuit.
RENR9313-04 119
Expected Result: Repair: Recharge or replace the faulty batteries.

The measured voltage is between 11.0 VDC and 13.5
VDC for a 12 volt system and between 22.0 VDC and STOP.
27.0 VDC for a 24 volt system with no suspected
intermittent problems at this time. Test Step 4. Check the Voltage from the
Keyswitch to the ECM
Results:
• OK – The ECM is receiving the correct voltage.
B. Remove the wire from the terminal R of the
Repair: If an intermittent condition is keyswitch.
suspected, refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”. C. Restore the electrical power to the ECM.
STOP. D. Measure the voltage on terminal B of the keyswitch

to engine ground.
• Not OK – The voltage is not correct at the ECM.
Proceed to Test Step 3. E. Measure the voltage on terminal R of the
keyswitch to engine ground.
• Keyswitch voltage out of range – Proceed to Test
Step 4. F. Remove the electrical power from the ECM.
Test Step 3. Check the Batteries Expected Result:
A. Measure the no-load battery voltage at the battery Voltage is present on terminal B and terminal R at
posts. the keyswitch.
B. Load test the batteries. Use the 4C-4911 Results:

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

voltage is the minimum specification for a 12V or 24V
system. • Not OK – Voltage is not present on terminal B at
the keyswitch.
Results:
Repair: If voltage is not present on terminal B,
• OK – The batteries are OK. repair the wire between the +Battery and the
keyswitch. Verify that the fuse for the keyswitch is
Repair: There is an open circuit or excessive not blown. Verify that the problem is eliminated.
resistance in the wiring or connections between the
batteries and the ECM. Verify that the 20 Amp fuse STOP.
for the ECM is not blown. Check the connections at
the customer connector. Verify that the connection • Not OK – Voltage is not present on terminal R at
for the engine ground is clean and tight and that the the keyswitch.
battery disconnect switch is functioning properly.
Repair the connectors or wiring and/or replace the Repair: If voltage is present on terminal B of the
connectors or wiring. keyswitch but not present on terminal R, replace
the keyswitch. Return all wiring to the original
STOP. configuration. Verify that the problem is eliminated.
• Not OK – The battery voltage is low or the battery STOP.

did not pass the load test.
120 RENR9313-04
i02463639 The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
Engine Pressure Sensor Open this pull-up voltage in order to detect a problem in the
or Short Circuit - Test signal circuit. When the ECM detects the presence
of a voltage that is above a threshold on the signal
SMCS Code: 1439-038-PX circuit, the ECM will generate a 03 diagnostic code
for the sensor.
If the sensor is disconnected at the sensor connector,
Use this procedure to troubleshoot any suspect the presence of pull-up voltage at the sensor
problems with the following sensors: connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
• Engine oil pressure sensor disconnected at the sensor connector, the absence
of pull-up voltage at the sensor connector indicates
• Intake manifold (boost) pressure sensor a problem in the signal wire. If the sensor is
disconnected at the sensor connector and the voltage
• Fuel pressure sensor at the sensor connector is different from pull-up
voltage, the signal wire may be shorted to another
• Injection actuation pressure sensor wire in the harness.
• Marine transmission oil pressure sensor

• 094-03 Fuel Pressure open/short to +batt

• 094-04 Fuel Pressure short to ground
• 100-03 Engine Oil Pressure open/short to +batt
• 100-04 Engine Oil Pressure short to ground
• 102-03 Boost Pressure Sensor short to +batt
• 102-04 Boost Pressure Sensor short to ground
• 127-03 Transmission Oil Pressure open/short to
+batt
• 127-04 Transmission Oil Pressure short to ground

• 164-03 Injection Actuation Pressure Sensor
Open/Short to +Batt
• 164-04 Injection Actuation Pressure Sensor short

to -Batt
The 5 volt sensor supply provides power to all

5 volt sensors. The Electronic Control Module
(ECM) supplies 5.0 ± 0.2 VDC to terminal A of
each sensor connector. The sensor return from the
ECM connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the ECM.
Pull-up Voltage
RENR9313-04 121
g01229164
Illustration 52
Schematic for the engine pressure sensors

g01180168
Illustration 53
(1) Fuel pressure sensor
(2) Injection actuation pressure sensor
(3) Intake manifold (boost) pressure sensor
(4) Connector for the optional marine transmission oil pressure
sensor
(5) Engine oil pressure sensor
122 RENR9313-04
B. Thoroughly inspect the connectors for engine

pressure sensors (1), (2), (3), and (5). Also,
thoroughly inspect connectors (4) and (6). Refer
g01159881
Illustration 55
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

wires that are associated with the engine pressure
sensors.


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

g01229206
Illustration 54 Results:
P2 terminals that are associated with the engine pressure sensors
(P2-15) Intake manifold (boost) pressure • OK – The harness and wiring are OK. Proceed
(P2-85) Injection actuation pressure to Test Step 2.
(P2-17) Return
(P2-72) +5 VDC • Not OK – There is a problem in the wiring and/or
(P2-16) Marine transmission oil pressure
(P2-93) Return
the connectors.
(P2-81) +5 VDC
(P2-28) Engine oil pressure Repair: Repair the wiring and/or the connectors.
(P2-40) Fuel pressure Replace parts, if necessary. Ensure that all of the
(P2-54) Return seals are properly in place and ensure that the
(P2-80) +5 VDC
STOP.

the Sensor Connector
RENR9313-04 123
B. Disconnect the harness connectors for the C. Monitor the active diagnostic code screen on Cat
following sensors: ET. Look for an active diagnostic code for an
engine pressure sensor.
D. Determine if the problem is related to an open
• Engine oil pressure sensor circuit diagnostic code 03 or a short circuit
diagnostic code 04.
Expected Result:
• Injection actuation pressure sensor
No diagnostic codes are active.
• Marine transmission oil pressure sensor
Results:
• OK – No diagnostic codes are active for the engine
Note: The original diagnostic code may not stay pressure sensors.
active. An open circuit diagnostic code for the sensor
supply may become active when all of the sensors Repair: The problem may have been related
are disconnected. Ignore the active codes at this time to a faulty connection in the harness. Carefully
and continue with this test step. reinspect the connectors and wiring. Refer to
Note: Be sure to wiggle the harness during the “Electrical Connectors - Inspect”.
following measurements in order to reveal an
intermittent condition. STOP.
D. Measure the voltage between terminals A and B • Not OK – A 03 diagnostic code is active at this
at each sensor connector on the engine harness. time. Proceed to Test Step 5.
E. Remove the electrical power from the ECM. • Not OK – A 04 diagnostic code is active at this
time. Proceed to Test Step 4.
F. Connect all of the sensors.
Test Step 4. Disconnect the Suspect
Expected Result: Sensor in Order to Create an Open Circuit
Each voltage measurement is 5.0 ± 0.2 VDC. A. Remove the electrical power from the ECM.
Results: B. Disconnect the harness connector of the sensor

with the 04 diagnostic code.
• OK – Each voltage measurement is 5.0 ± 0.2 VDC.
The voltage is correct at the sensor connectors. C. Restore the electrical power to the ECM.
D. Use Cat ET to check for active diagnostic
• Not OK – The voltage is not 5.0 ± 0.2 VDC. The codes. Wait at least 30 seconds for activation
voltage is incorrect. of the diagnostic codes. Check for an active 03
diagnostic code for the disconnected sensor.
Repair: Perform the diagnostic functional test
Troubleshooting, “Analog Sensor Supply Circuit - E. Remove the electrical power from the ECM.
Test”.
Expected Result:
STOP.
A 04 diagnostic code was active before the sensor
Test Step 3. Check for Active Diagnostic was disconnected. A 03 diagnostic code became
Codes active after the sensor was disconnected.
A. Connect Caterpillar Electronic Technician (ET) to Results:

the service tool connector.
• OK – A 04 diagnostic code was active before the
B. Restore the electrical power to the ECM. sensor was disconnected. A 03 diagnostic code
became active after the sensor was disconnected.
Note: Wait at least 30 seconds so that any codes
may become active.
124 RENR9313-04
Repair: Temporarily connect a new sensor to the Repair: The engine harness and the ECM are OK.
harness, but do not install the new sensor in the Temporarily connect a new sensor to the harness,
engine. Verify that there are no active diagnostic but do not install the new sensor in the engine.
codes for the sensor. If there are no active Verify that there are no active diagnostic codes for
diagnostic codes for the sensor, permanently the sensor. If there are no active diagnostic codes
install the new sensor. Clear any logged diagnostic for the sensor, permanently install the new sensor.
codes. Clear any logged diagnostic codes.
STOP. STOP.
• Not OK – When the sensor is disconnected, a 04 • Not OK – The 03 diagnostic code remains active
diagnostic code remains active for the suspect with the jumper in place. There is a problem in the
sensor. There is a short circuit between the sensor circuit between the ECM and the sensor connector.
harness connector and the ECM. Leave the sensor There may be a problem with the ECM. Proceed
disconnected. Proceed to Test Step 6. to Test Step 6.
Test Step 5. Create a Short at the Suspect Test Step 6. Test the Operation of the
Sensor Connector ECM
A. Remove the electrical power from the ECM. A. Remove the electrical power from the ECM.
B. Fabricate a jumper wire that is long enough to B. Fabricate a jumper wire that is long enough to
connect two terminals at the sensor connector. connect one of the terminals at the ECM connector
Crimp connector sockets to each end of the to the engine ground stud. Crimp a connector
jumper wire. socket to one end of the jumper wire.
C. Install the jumper wire between terminal B (sensor C. Disconnect the appropriate ECM connector for the
return) and terminal C (sensor signal) on the signal wire of the suspect sensor.
harness side of the connector for the suspect
sensor. D. Remove the signal wire for the suspect sensor
from the ECM connector.
D. Restore the electrical power to the ECM.
E. Install the jumper wire into the terminal location
Note: Wait at least 30 seconds for activation of the of the suspect sensor's signal wire at the ECM
diagnostic code. connector.
E. Monitor the “Active Diagnostic Codes” screen on F. Connect the ECM connectors.
Cat ET before installing the jumper wire and after
installing the jumper wire. G. Check the operation of the ECM by creating
an open at the ECM:
Check for an active short circuit diagnostic code
04 while the jumper wire is installed. a. Hold the loose end of the jumper wire away
from any components in order to create an
F. Remove the electrical power from the ECM. open circuit condition.
G. Remove the jumper wire. b. Restore the electrical power to the ECM.
Expected Result: Note: Wait at least 30 seconds so that any codes

may become active.
A 04 diagnostic code was active when the jumper
wire was installed. A 03 diagnostic code became c. Monitor the “Active Diagnostic Code” screen
active when the jumper wire was removed. on Cat ET.
Results: Check the suspect sensor for an active 03

diagnostic code.
• OK – A 04 diagnostic code was active when the
jumper wire was installed. A 03 diagnostic code d. Remove electrical power from the engine ECM.
became active when the jumper wire was removed.
H. Check the operation of the ECM by creating a
short circuit at the ECM:
a. Connect the jumper wire to the engine ground

stud.
RENR9313-04 125
b. Restore the electrical power to the ECM. i02378774
Note: Wait at least 30 seconds so that any codes Engine Speed/Timing Sensor
may become active. Circuit - Test
c. Monitor the “Active Diagnostic Code” screen SMCS Code: 1439-038-VF; 1912-038
on Cat ET.
d. Check the suspect sensor for an active 04
diagnostic code while the jumper wire is Use this procedure to troubleshoot any suspect
installed. problems with the following sensors:
e. Remove the electrical power from the ECM. • Primary engine speed/timing sensor
I. Remove the jumper wire. Return all wiring to the • Secondary engine speed/timing sensor
original configuration.
Expected Result:
• 190-11 Engine Speed Sensor mechanical failure
A 03 diagnostic code is active when the sensor
signal wire is removed from the ECM connector. A • 342-11 Secondary Engine Speed Sensor
04 diagnostic code is active when the signal wire is mechanical failure
connected to the engine ground stud.
The engine uses two engine speed/timing sensors.
Results: The primary engine speed/timing sensor and the
secondary engine speed/timing sensor are used to
• OK – A 03 diagnostic code is active when the detect the reference for engine speed and for engine
sensor signal wire is removed from the ECM timing from a unique pattern in the timing reference
connector. A 04 diagnostic code is active when the ring. The timing reference ring is located on the
signal wire is connected to the engine ground stud. back of the camshaft gear. To determine rpm, the
Electronic Control Module (ECM) counts the time
Repair: The ECM is operating properly. The between pulses that is created by the sensor as the
problem is in the harness wiring between the ECM gear rotates.
and the sensor connector. If the code is active for
more than one sensor, the problem is most likely Under normal operation, the secondary engine
in the return wire for the sensor. Repair the return speed/timing sensor is used to determine timing
wire for the sensor or replace the harness. for starting purposes. The secondary engine
speed/timing sensor is used to determine when
If the code is only active for one sensor, the the piston in the No. 1 cylinder is at the top of the
problem is most likely in the signal wire for the compression stroke. When the timing has been
sensor. Repair the signal wire for the sensor. established, the primary engine speed/timing sensor
is then used to monitor engine speed.
STOP.
When the timing has been established, the ECM
• Not OK – One of the following conditions exists: triggers each injector in the correct firing order at the
The 03 diagnostic code is not active when the correct time. The actual timing and duration of each
sensor signal wire is disconnected. The 04 injection is based on engine rpm and on load.
diagnostic code is not active when the wire jumper
is installed. If the engine is running and the signal from one
sensor is lost, no change in engine performance will
Repair: Replace the ECM. Refer to electronic be noticed. If the engine is running and the signals
troubleshooting Troubleshooting, “Replacing the from both sensors are lost, fuel injection will be
ECM”. Verify that the problem is resolved. terminated and the engine will be shut down by the
ECM.
STOP.
The engine will start when only one sensor signal is
present. The engine will not start if the signals from
both sensors are lost.
Both sensors are magnetic sensors. The two sensors

are not interchangeable.
126 RENR9313-04
If a replacement of the ECM is required, the ECM

parameters and the timing calibration can be
transferred from the suspect ECM to the replacement
ECM. This feature requires the Caterpillar Electronic
Technician (ET) and this feature is only possible if the
existing ECM can communicate with Cat ET. Use the
“Copy Configuration - ECM Replacement” feature
on Cat ET.
Note: Before replacing the ECM check the following

components for possible damage:
• Speed/timing sensors
• Camshaft
• Cam gear
Complete all of the following tasks when you
install a speed/timing sensor:
• Ensure that an O-ring is installed on the sensor.

If the O-ring is damaged or missing, replace the
O-ring.
• Lubricate the O-ring with oil.

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

• Ensure that the harness is properly secured, and
ensure that each tie-wrap is placed in the correct
location.
g01229299
Illustration 56
Schematic for the engine speed/timing sensors
Test Step 1. Check for Diagnostic Codes Note: If the engine will not start, monitor the engine
rpm on Cat ET while the engine is being cranked. Cat
A. Connect Cat ET to the service tool connector. Refer ET may need to be powered from another battery
to electronic troubleshooting Troubleshooting, while the engine is being cranked.
“Electronic Service Tools”.
D. Look for these codes on Cat ET:
Note: Wait at least 30 seconds in order for any codes
C. Start the engine and run the engine until the to become active.
engine is at the normal operating temperature.
RENR9313-04 127
• 190-11 Verify that the bracket is not bent. If the bracket is

bent or if an obstruction is preventing the sensor
• 342-11 assembly from being installed correctly, the engine
will not start.
Expected Result:
Note: The bracket cannot be replaced separately.
One or both of the diagnostic codes that are listed
above are logged or active. C. Remove the sensor assembly from the engine.
Inspect each sensor. Replace the sensor, if
Note: If the engine will not start and Cat ET displayed necessary.
0 rpm during cranking, select “No Engine rpm”.
Results:
• No Engine rpm – Engine rpm is not indicated on

Cat ET. Proceed to Test Step 2.
• Active or logged code – There is an active

diagnostic code or a logged diagnostic code for
an engine speed/timing sensor. Proceed to Test
Step 4.
• No codes – Neither code is active or logged.

Repair: Refer to troubleshooting without a
diagnostic code Troubleshooting.
STOP.
Test Step 2. Check the Installation of the

Sensor Assembly
g01180501
Illustration 58
Exploded view of the engine speed/timing sensors
(4) O-ring seals
D. Ensure that one O-ring (4) is installed on each

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

Repair: Perform the following procedure in order
to properly install the sensor assembly:
1. Lubricate each O-ring with engine oil.

g01180490
Illustration 57
Left side view 2. Fully seat the sensor assembly in the engine.
(1) Engine
(2) Mounting flange 3. Tighten the bracket bolt.
(3) Bracket
4. Connect the sensor's electrical connectors.
B. Visually inspect the sensor assembly without Verify that the connectors are latched on both
removing the sensor assembly from the engine. sides.
Flanges (2) must be flush against engine (1) in
order to ensure proper operation. 5. Ensure that the harness is properly secured,
and that the tie-wraps are placed in the correct
Inspect bracket (3). Verify that the bracket securely location.
holds the flanges of the sensors flush against the
engine. Proceed to Test Step 3.
128 RENR9313-04
• Not OK – At least one of the sensor assembly's

components is not OK.
Repair: Obtain a new sensor assembly. Perform

the following procedure in order to properly install
the sensor assembly:
1. Lubricate each O-ring with engine oil.
2. Fully seat the sensor assembly in the engine.
3. Tighten the bracket bolt.
4. Connect the sensor's electrical connectors.

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

and that the tie-wraps are placed in the correct
location.
STOP.

g01181800
Illustration 60
Left side view
(P2-46) Primary engine speed/timing sensor +
(P2-47) Primary engine speed/timing sensor -
(P2-35) Secondary engine speed/timing sensor +
(P2-25) Secondary engine speed/timing sensor -
g01181799
B. Perform a 45 N (10 lb) pull test on each of
Illustration 59 the wires that are associated with the engine
Typical left side engine view speed/timing sensors.
(5) connector for the primary engine speed/timing sensor
(6) connector for the secondary engine speed/timing sensor C. Check the allen head screw on each ECM
(7) J2/P2 ECM connector connector for the proper torque. Refer to the
A. Thoroughly inspect connectors (5), (6), and “Electrical Connectors - Inspect”.
Troubleshooting, “Electrical Connectors - Inspect”. D. Check the harness and the wiring for abrasion
and for pinch points from each sensor back to the
ECM.
Expected Result:
All of the connectors, pins and sockets are completely

RENR9313-04 129
Results: Results:
• OK – The harness and connectors appear to be • OK – The resistance measurement is within the
OK. Proceed to Test Step 4. specifications.
• Not OK – The connectors and/or wiring are not Repair: Perform the following procedure:
OK.
1. Temporarily install a new ECM. Refer to
Repair: Repair the wiring and/or the connectors. electronic troubleshooting Troubleshooting,
Replace parts, if necessary. Ensure that all of the “Replacing the ECM”.
connectors are completely coupled. Verify that the 2. Start the engine. Run the engine until the engine
repair eliminates the problem. is at normal operating temperature.
STOP. 3. If the problem is resolved with the test ECM,

connect the original ECM and verify that the
Test Step 4. Measure the Sensor problem recurs. If the problem returns with the
Resistance through the Engine Harness original ECM, replace the ECM.
A. Disconnect the J2/P2 ECM connector. Verify that the problem is resolved.
B. If you are troubleshooting a problem with the 4. If the problem is not resolved with the test ECM,
primary engine speed/timing sensor, perform the connect the original ECM. There may be a
following procedure: problem with the camshaft and/or the cam gear.
Refer to Disassembly and Assembly. There may
a. Measure the sensor's resistance between also be a problem with the sensors. Check the
P2-46 (primary engine speed/timing +) and sensors for damage.
P2-47 (primary engine speed/timing -).
b. Check for an intermittent open circuit or for
a short circuit by moving the harness while STOP.
you take the resistance measurement. Pull
the wires that are directly behind the sensor • Not OK – The readings are not within the
or shake the wires that are directly behind the specifications. The sensor resistance is not within
sensor. the acceptable range when the sensor resistance
is measured through the engine harness. Proceed
Resistance ............................ 75 to 230 Ohms to Test Step 5.
C. If you are troubleshooting a problem with the Test Step 5. Measure the Resistance of
secondary engine speed/timing sensor, perform the Sensor
the following procedure:
A. Disconnect the harness connector for the suspect
a. Measure the sensor's resistance between sensor.
P2-35 (secondary engine speed/timing +) and
P2-25 (secondary engine speed/timing -). B. Thoroughly inspect the sensor's connectors. Refer
b. Check for an intermittent open circuit or for “Electrical Connectors - Inspect”.
a short circuit by moving the harness while
you take the resistance measurement. Pull C. Measure the sensor's resistance between
the wires that are directly behind the sensor terminals A and B.
or shake the wires that are directly behind the
sensor. Expected Result:
Resistance ........................ 600 to 1800 Ohms For the primary engine speed/timing sensor, the
resistance measurement is between 75 and 230
Expected Result: Ohms. For the secondary engine speed/timing
sensor, the resistance measurement is between 600
The resistance measurement is within the and 1800 Ohms.
specifications.
130 RENR9313-04
Results: Use this procedure in order to troubleshoot any

suspect problems with engine synchronization. The
• OK – The reading is within the specification. There following items can cause problems with engine
is a problem with the wiring between the engine synchronization:
speed/timing sensor and the ECM. There may be
a problem with a connector. • Configuration parameters
Repair: Repair the wiring and/or the connector. • Vessel wiring or components
Replace parts, if necessary. Verify that the problem
is resolved. • ECM
STOP. The following configuration parameters affect engine
synchronization:
• Not OK – The reading is not within the
specification. There is an electrical problem with • Number of Synchronized Engines Configuration
the engine speed/timing sensor.
• Engine Location
Repair: Perform the following procedure in order
to check and install the new sensor assembly: • Secondary Throttle Enable Status
1. Before you install the new sensor assembly, These parameters must be programmed correctly
measure the resistance of the new sensors. in order for the engines to become synchronized.
Refer to Troubleshooting, “System Configuration
If the resistance measurements of the new Parameters” for additional information on these
sensors are within the specifications, install the parameters.
new sensor assembly in the engine according
to the following procedure: The synchronization inputs operate according to the
following conditions:
a. Loosen the bolt and remove the bolt that
holds the sensor to the engine. When neither of the synchronization inputs are
connected to the −Battery, the ECM will respond to
b. Ensure that an O-ring is installed on the new the primary throttle input.
sensor assembly. Verify that the O-ring is
free of damage. When Sync Input 1 is connected to the −Battery, the
ECM will respond to the primary throttle input.
c. Seat the sensor and tighten the bolt.
When Sync Input 2 is connected to the −Battery, the
d. Ensure that the harness is secured in the ECM will respond to the secondary throttle input.
proper location.
If Sync Input 1 and Sync Input 2 are connected to the
2. Verify that the repair eliminates the problem. −Battery at the same time, the ECM will respond to
the primary throttle input. The vessel's wiring should
STOP. be designed to prevent this condition from occurring.
Note: The ECM will not transfer control between the

i02363198
throttle inputs unless the throttle inputs are within 50
Engine Synchronize Switch rpm of each other.
Circuit - Test There are four possible configurations for engine

synchronization. The following information describes
SMCS Code: 7332-038-SY each configuration.
System Operation Description: Single Engine Configuration
The Electronic Control Module (ECM) has two

throttle inputs and two synchronization inputs. The
synchronization inputs allow the ECM to respond to
either of the throttle inputs. This capability allows all
of the engines on a vessel to respond to a single
throttle. This minimizes variations in speed and in
load between engines during cruise operations.
RENR9313-04 131
g01130005
Illustration 61
Single engine configuration
In this configuration, a single engine can be controlled

by two throttles. The secondary throttle is enabled by
activation of the “Secondary Throttle Enable” switch.
Twin Engine Configuration
g01130061
Illustration 62
Twin engine configuration
In this configuration, the position of the

synchronization switch determines the throttle input
that is recognized by each engine. Table 21 lists the
engine's response to each position of the switch.
132 RENR9313-04
Table 21
Engine Response to the Synchronization Switch
Position of the Engine Response
Synchronization Switch
Both engines respond to
Starboard
the starboard throttle.
Each engine responds to a
None
separate throttle.
Both engines respond to
Port
the port throttle.
Multiple Engine Configuration Without a

Dedicated Master Throttle
RENR9313-04 133
g01130062
Illustration 63
Multiple engine configuration with one throttle that is designated as a master throttle
134 RENR9313-04
In these configurations, one of the throttles has

been designated as the master throttle. When the
synchronization switch is not activated, each engine
will respond to the appropriate throttle. When the
synchronize switch is activated, all of the engines will
respond to the master throttle. Three engines and
three throttles are shown. As many as five engines
and five throttles can be connected in this manner.
Multiple Engine Configuration With a Dedicated

Master Throttle
g01130063
Illustration 64
Multiple engine configuration with a separate throttle that is used for the master throttle
In this configuration, the vessel is equipped with a Results:

master throttle in addition to a separate throttle for
each engine. When the synchronization switch is not • OK – The throttle positions are within 50 rpm of
activated, each engine will respond to the appropriate each other. Proceed to Test Step 2.
throttle. When the synchronize switch is activated, all
of the engines will respond to the master throttle. • Not OK – The throttle positions are not within 50
rpm of each other.
Test Step 1. Verify that the Throttle
Positions are Correct Repair: Adjust the throttles until the throttle
positions are within 50 rpm of each other. Try to
A. Determine the vessel's configuration for engine synchronize the engines.
synchronization. Identify the two throttles that are
connected to the throttle inputs for the ECM. If the engines become synchronized, the problem
is resolved. STOP.
Note: The ECM will not transfer control between the
throttles unless the throttle positions are within 50 If the engines do not become synchronized,
rpm of each other. proceed to Test Step 2.
B. Verify that the throttle positions are within 50 rpm Test Step 2. Check the Configuration
of each other. Parameters
Expected Result: A. Connect the Caterpillar Electronic Technician (ET)
The throttle positions are within 50 rpm of each other.
B. Verify that the following configuration parameters
are programmed correctly:
RENR9313-04 135
• Number of Synchronized Engines Configuration If the diagnostic code does not recur, attempt
to synchronize the engines. If the engines
• Engine Location become synchronized, the problem appears to
be resolved.
• Secondary Throttle Enable Status
The original problem may have been caused
Refer to Troubleshooting, “System Configuration by an intermittent problem in one of these
Parameters” for additional information on these components:
parameters.
• Throttle position sensor
Expected Result:
• Wiring for the throttle
The configuration parameters are programmed
correctly. • An electrical connector
Results: If the diagnostic code recurs, there is a problem
with the circuit for the throttle position sensor.
• OK – The configuration parameters are Refer to Troubleshooting, “Throttle Position
programmed correctly. Proceed to Test Step 3. Sensor - Calibrate” for the troubleshooting
procedure.
• Not OK – The configuration parameters are not
programmed correctly. STOP.
Repair: Program the correct value for each • Not OK – There is an active diagnostic code for a
parameter. throttle.
Verify that the problem is resolved. Repair: Troubleshoot the circuit for the throttle.
Refer to Troubleshooting, “Throttle Position Sensor
STOP. - Calibrate” for the troubleshooting procedure.
Test Step 3. Check for Diagnostic Codes Verify that the problem is resolved.
for the Throttle Inputs
STOP.
A. Check for the following diagnostic codes:
Test Step 4. Check the Synchronization
• 91-13 Throttle Position calibration required Inputs
• 1249-13 Secondary Throttle Position calibration A. Turn the keyswitch to the OFF position.
required
B. Disconnect the J1/P1 connectors for the suspect
Expected Result: ECM.
Neither diagnostic code is active or logged.
Results:
• OK – Neither diagnostic code is active or logged.

• Not OK – At least one of the diagnostic codes is

logged.
1. Clear the logged codes.
2. Slowly move the suspect throttle throughout the

entire range. Move the throttle several times.
Look for the diagnostic code to activate again.
136 RENR9313-04
g01134499
Illustration 65
ECM side of the P1 connector
(P1-35) Sync Input 1
(P1-44) Sync Input 2
C. Perform the resistance measurements that apply

to your vessel's configuration:
a. If the vessel has a single engine, measure the

resistance between the points that are listed in
Table 22. Be sure to wiggle the wires between
the Secondary Throttle Enable Switch and the
ECM as you make each measurement.
Table 22
Resistance Measurements for a Single
Engine Configuration
Secondary Terminals Expected Result
Throttle Enable
Switch Position
P1-35 P1-63 Open circuit
Disabled
Enabled P1-44 P1-63 Less than ten
Ohms
b. If the vessel has two engines, measure the

resistance between the points that are listed in
Table 23. Only perform the measurements on
the engine that will not become synchronized.
Be sure to wiggle the wires between the
Synchronization Switch and the ECM as you
make each measurement.
RENR9313-04 137
Table 23
Resistance Measurements for a Twin Engine Configuration
Engine Synchronization Switch Position Terminals Expected Result
None
P1-35 P1-63 Less than ten Ohms
Port Port
Starboard
None
Starboard Port
Starboard
c. If the vessel has two engines and one throttle

that is designated as the master throttle,
measure the resistance between the points
that are listed in Table 24. Only perform the
measurements that apply to the appropriate
engine and throttle configuration. Be sure to
wiggle the wires between the synchronization
switch and the ECM as you make each
measurement.
138 RENR9313-04
Table 24
Resistance Measurements for a Multiple Engine Configuration With One Throttle
that is Designated as a Master Throttle
Engine Master Throttle Synchronization Switch Terminals Expected Result
Position
Disabled
Port
Enabled
Disabled
Port Center
Enabled
Disabled
Starboard
Enabled
Disabled
Port
Enabled
Disabled
Center Center
Enabled
Disabled
Starboard
Enabled
Disabled
Port
Enabled
Disabled
Starboard Center
Enabled
Disabled
Starboard
Enabled
RENR9313-04 139
d. If the vessel has two engines and a dedicated i02464430

master throttle, measure the resistance
between the points that are listed in Table Engine Temperature Sensor
25. Only perform the measurements that Open or Short Circuit - Test
apply to the appropriate engine and throttle
configuration. Be sure to wiggle the wires SMCS Code: 1439-038-TA; 1906-038
between the Synchronization Switch and the
ECM as you make each measurement. System Operation Description:
Table 25
Resistance Measurements for a Multiple Engine problems with the following sensors:
Configuration With a Dedicated Master Throttle
Synchronization Terminals Expected • Engine coolant temperature sensor
Switch Position Result
• Inlet manifold temperature sensor
Disabled
P1-44 P1-63 Open circuit • Fuel temperature sensor
P1-35 P1-63 Open circuit Note: This application may be equipped with a
Enabled P1-44 P1-63 Less than ten transmission oil temperature sensor that requires
Ohms a different troubleshooting procedure. Refer to
“Transmission Oil Temperature Sensor Open or Short
Expected Result: Circuit - Test”.
The resistance measurements are correct. This procedure covers the following diagnostic codes:
Results: • 105-03 Inlet Manifold Temp Sensor open/short to
+batt
• OK – The resistance measurements are correct.
• 105-04 Inlet Manifold Temp Sensor short to ground
• 110-03 Engine Coolant Temperature open/short
1. Connect the J1/P1 connectors. to +batt
2. Attempt to synchronize the engines. • 110-04 Engine Coolant Temperature short to
ground
3. If the engines will not synchronize, there may
be a problem with the ECM. • 174-03 Fuel Temperature open/short to +batt
It is unlikely that the ECM has failed. Exit this • 174-04 Fuel Temperature short to ground
procedure and perform this entire procedure
again. If the engines will not synchronize, The troubleshooting procedures for the diagnostic
replace the ECM. Refer to Troubleshooting, codes of each temperature sensor are identical.
“Replacing the ECM”. The temperature sensors are passive sensors that
have two terminals. The temperature sensors do not
Verify that the problem is resolved. require supply voltage from the Electronic Control
Module (ECM).
STOP.
Pull-up Voltage
• Not OK – At least one resistance measurement
is incorrect. There is a problem with the circuit for The ECM continuously outputs a pull-up voltage
engine synchronization. There may be a problem on the circuit for the sensor signal wire. The ECM
with an electrical connector. uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
Repair: Carefully inspect the wiring between the presence of a voltage that is above a threshold on the
ECM and the Synchronization Switch. Refer to signal circuit, the ECM will generate an open circuit
Troubleshooting, “Electrical Connectors - Inspect”. diagnostic code (03) for the sensor.
Repair the wiring, when possible. Replace parts, if
necessary. Verify that the problem is resolved.
STOP.
140 RENR9313-04

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
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
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
g01200240
Illustration 66
Schematic for the engine temperature sensors
Test Step 1. Inspect the Electrical B. Inspect the connectors for sensors (1), (2), and
Connectors and the Wiring (3). Also, thoroughly inspect connectors (4). Refer
A. Remove the electrical power from the ECM. “Electrical Connectors - Inspect”.
g01153097
Illustration 67
(1) Engine coolant temperature sensor
(2) Fuel temperature sensor
(3) Intake manifold air temperature sensor
RENR9313-04 141

for pinch points from each sensor to the ECM.
Expected Result:

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


and/or wiring.
Repair: Repair the wiring and/or the connectors.

STOP.

Codes
C. Monitor the active diagnostic code screen on Cat

Illustration 68
g01229400 ET. Check and record any active diagnostic codes.
P2 terminals that are associated with the engine temperature
sensors
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature D. Look for a 03 diagnostic code or a 04 diagnostic
(P2-62) Fuel temperature code.
Expected Result:
Results:
• OK – No diagnostic codes are active. The problem

Illustration 69
g01155187 appears to be resolved.
Harness connector for the temperature sensors
Repair: The problem may have been related
(1) Signal to a faulty connection in the harness. Carefully
(2) Return
reinspect the connectors and wiring. Refer to
wires that are associated with the temperature
sensors.
STOP.
connector for the proper torque. Refer to the • Not OK – A 04 diagnostic code is active at this
142 RENR9313-04
• Not OK – A 03 diagnostic code is active at this D. Restore the electrical power to the ECM.
E. Access the “Active Diagnostic Code” screen on
Test Step 3. Disconnect the Suspect Cat ET. Check for an active 04 diagnostic code
Sensor in Order to Create an Open Circuit for the suspect sensor.
A. Remove the electrical power from the ECM. F. Remove the electrical power from the ECM.
B. Disconnect the suspect sensor from the engine Expected Result:

harness.
A 04 diagnostic code is now active for the suspect
C. Restore electrical power to the engine ECM. Wait sensor.
at least 30 seconds for activation of the diagnostic
codes. Results:
D. Access the “Active Diagnostic Codes” screen on • OK – A 03 diagnostic code was active before
Cat ET and check for an active 03 diagnostic code creating the short at the sensor connector. A 04
for the suspect sensor. diagnostic code became active after creating the
short at the sensor connector.
Repair: Temporarily connect a new sensor to the
Expected Result: harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
A 03 diagnostic code is now active for the suspect codes for the new sensor. If there are no active
sensor. diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic
Results: codes.
• OK – A 04 diagnostic code was active before STOP.

disconnecting the sensor. A 03 diagnostic code
became active after the sensor was disconnected. • Not OK – A 03 diagnostic code is still active for the
There may be a problem with the sensor. suspect sensors. Proceed to Test Step 5.
Repair: Temporarily connect a new sensor to the Test Step 5. Check the Operation of the
harness, but do not install the new sensor in the ECM
engine. Verify that there are no active diagnostic
codes for the new sensor. If there are no active A. Remove the electrical power from the ECM.
diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic B. Check the operation of the ECM by creating an
codes. Verify that the repair eliminates the problem. open at the ECM.
STOP. a. Disconnect the P2 ECM connector.
• Not OK – The 04 diagnostic code is still present. b. Fabricate a jumper wire that is long enough to
Leave the sensor disconnected. There may be reach from a terminal at the ECM connector
a problem with the harness or with the ECM. to the engine ground stud. Crimp a connector
Proceed to Test Step 5. socket to one end of the jumper wire.
Test Step 4. Create a Short at the Sensor c. Remove the signal wire for the suspect sensor
Connector from the P2 ECM connector. Install the jumper
wire into the terminal location for the signal wire
A. Disconnect the suspect sensor from the sensor of the suspect sensor.
connector.
d. Connect the ECM connectors.
B. Fabricate a jumper wire that can be used to create
a short between terminal 1 (signal) and terminal 2 e. Restore the electrical power to the ECM.
(sensor return) at the suspect sensor's connector.
Crimp connector pins to each end of the jumper f. Monitor the “Active Diagnostic Code” screen on
wire. Cat ET. Wait at least 30 seconds for activation
of the code.
C. Install the jumper into the harness side of the
sensor connector. An open circuit diagnostic code (03) will be
active for the suspect sensor.
RENR9313-04 143
C. Check the operation of the ECM by creating a i02378795

short at the ECM.
Fuel Level Sensor Circuit - Test
a. Short the jumper wire that is installed into the
P2 ECM connector to engine ground. SMCS Code: 1439-038
b. Monitor the “Active Diagnostic Code” screen on System Operation Description:

Cat ET. Wait at least 30 seconds for activation
of the code. Use this procedure to troubleshoot any suspect
problems with the fuel level sensor.
A short circuit diagnostic code (04) will be
active for the suspect sensor. This procedure covers the following diagnostic codes:
c. Remove the electrical power from the ECM. • 96-03 Inlet Manifold Temp Sensor open/short to
+batt
D. Remove the wire jumper. Reconnect all wires and
connectors. • 96-04 Inlet Manifold Temp Sensor short to ground
Expected Result: The fuel level sensor is a passive sensor. The fuel
level sensor does not require an operating voltage in
A 03 diagnostic code is active when the sensor signal order to provide a signal. This configuration utilizes
wire is open the ECM connector. A 04 diagnostic a fuel level buffer that helps to reduce the amount of
code is active when the jumper wire is shorted to indicator movement that is passed to the fuel gauge.
engine ground. The buffer is powered through a circuit that is wired
directly to a circuit breaker.
Results:
When the fuel tank is full, the fuel level sensor has a
• OK – The ECM is working properly. The problem resistance of 33 Ohms. When the fuel tank is empty,
is in the wiring between the ECM and the sensor the fuel level sensor has a resistance of 240 Ohms.
connector. The resistance from the fuel level sensor varies
between these values as the fuel level varies.
Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire An active diagnostic code for the fuel level sensor is
for the sensor. Repair the return wire for the sensor probably caused by a problem in the wiring harness.
or replace the harness. The next likely cause is a problem with the fuel level
sensor. The least likely cause is a problem with the
If the code is only active for one sensor, the Electronic Control Module (ECM).
problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. Verify
STOP.
• Not OK – One of the following conditions exists:

The 03 diagnostic code is not active when the
sensor signal wire is disconnected. The 04
is installed.
Repair: Replace the ECM. Refer to electronic

ECM”. Verify that the original problem is resolved.
STOP.
144 RENR9313-04
g01229426
Illustration 70
Schematic for the fuel level sensor

g01180987
Illustration 71
J1/P1 and J2/P2 ECM connectors (typical left side engine view)
(1) J60 Customer connector
(2) J2 ECM connector
(3) J803 Fuel level connector
B. Thoroughly inspect the J2/P2 ECM connectors.

Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors-Inspect”.
g01230525
Illustration 72
P2 terminals that are associated with the fuel level sensor
(P2-38) Fuel level sensor signal
(P2-93) Sensor return
g01155187
Illustration 73
Fuel level sensor connector
(1) Fuel level
(2) Sensor return
RENR9313-04 145
C. Perform a 45 N (10 lb) pull test on each of the B. Connect the Caterpillar Electronic Technician (ET)
wires that are associated with the fuel level sensor. to the service tool connector.
D. Check the allen head screw on the ECM C. Restore the electrical power to the ECM.
connectors for the proper torque. Refer to
the diagnostic functional test Troubleshooting, D. Observe the status of “Fuel Gauge” on Cat ET.
Note: The “Fuel Gauge” on Cat ET represents the
E. Check the harness and the wiring for abrasion percentage of fuel level in the tank.
and for pinch points from the fuel level sensor to
the ECM. E. Remove the electrical power from the ECM.
Expected Result: Expected Result:
All connectors, pins and sockets are completely The status of “Fuel Gauge” displays the correct fuel
coupled and/or inserted and the harness and wiring level.
Results:
Results:
• OK – Cat ET displays the correct fuel level.
• OK – The connectors and the wiring appear to be
OK. Proceed to Test Step 2. Repair: The fuel level sensor appears to be
operating correctly at this time. There may be
• Not OK – There is a problem in the connectors an intermittent problem in the harness or in a
and/or the wiring. connector. Refer to the diagnostic functional test
Repair: Repair the circuit. Verify that the repair
eliminates the problem. STOP.
STOP. • Not OK – Cat ET does not display the correct fuel

level. Proceed to Test Step 4.
Test Step 2. Confirm the Fuel Level in the
Tank Test Step 4. Check the Sensor's
Resistance at the Sensor
A. Visually check the fuel level in the tank.
A. Disconnect the fuel level sensor connector.
B. Compare the fuel level in the tank to the indicator
on the fuel level sensor. Note: Be sure to wiggle the harness during the
following measurement in order to reveal an
Expected Result: intermittent condition.
The fuel level in the tank agrees with the indicator B. Measure the sensor's resistance between 1 (fuel
on the fuel level sensor. level) and 2 (sensor return).
Results: The correct resistance is 33 Ohms when the

indicator is on “F”. The correct resistance is 240
• OK – The fuel level in the tank agrees with the Ohms when the indicator is on “E”.
indicator on the fuel level sensor. Proceed to Test
Step 3. Expected Result:
• Not OK – The indicator on the fuel level sensor The resistance measurement is between 33 Ohms
does not reflect the actual fuel level in the tank. and 240 Ohms.
Repair: Replace the fuel level sensor. Verify that Results:

• OK – The resistance of the sensor is between 33
STOP. Ohms and 240 Ohms. Record the measurement.
Connect the fuel level sensor connector. The
Test Step 3. Check the Status of the Fuel sensor's resistance is OK. Proceed to Test Step 5.
Level
• Not OK – The resistance measurement is greater
A. Remove the electrical power from the ECM. than 240 Ohms or the resistance measurement is
less than 33 Ohms.
146 RENR9313-04
Repair: Perform the following procedure: • Not OK – The resistance measurement is not
approximately equal to the resistance that was
1. Disconnect the fuel level sensor from the measured at the sensor connector. There is a
vessel's wiring. Verify that the fuel level sensor problem with the engine's wiring harness. There
is operating correctly. Refer to the literature that may be a problem with a connector.
is provided by the OEM for the sensor.
Repair: Repair the wiring, when possible. Replace
2. If the sensor is causing the high resistance, parts, if necessary. Verify that the problem is
adjust the sensor, when possible. Replace the resolved.
sensor, if necessary.
STOP.
STOP.
Test Step 5. Check the Sensor's i02379310
Resistance at the ECM Indicator Lamp Circuit - Test

A. Disconnect the J2/P2 connectors. SMCS Code: 7431-038
Note: Be sure to wiggle the harness during the System Operation Description:
following measurement in order to reveal an
intermittent condition. Use this procedure to troubleshoot any suspect
problems with the following indicator lamps:
B. Measure the resistance between P2-38 (fuel level
sensor) and P2-93 (sensor return) at the ECM • Low oil pressure lamp
connector.
• High coolant temperature lamp
Expected Result:
• Low coolant level lamp (optional)
The resistance measurement is approximately equal
to the resistance that was measured at the sensor • Diagnostic lamp
connector.
• Maintenance lamp
Results:
• Warning lamp
• OK – The resistance measurement is
approximately equal to the resistance The indicator lamps are activated by the Electronic
measurement that was recorded in the previous Control Module (ECM) in order to inform the operator
Test Step. of various engine events.
Repair: The fuel level sensor and the wiring are The most likely cause of a problem with an indicator
OK. Perform the following procedure: lamp is the bulb. The next most likely cause is a
problem with a wire or with a connector. The least
1. Connect the J2/P2 connectors. cause is a problem with the ECM.
2. Restore the electrical power to the ECM. Check
for a diagnostic code for the fuel level sensor
again. Wait at least 30 seconds in order for
codes to become active.
a. If the diagnostic code does not recur, the

problem is resolved. The original problem
was probably caused by a poor electrical
connection. Return the engine to service.
STOP.
b. If the diagnostic code recurs, Replace the

ECM. Refer to electronic troubleshooting
Troubleshooting, “Replacing the ECM”.
STOP.
RENR9313-04 147
g01229481
Illustration 74
Schematic for the indicator lamps

B. Thoroughly inspect connectors (1), and (2). Refer

148 RENR9313-04
g01187976
Illustration 75
J61/P61 terminals that are associated with the indicator lamps
(3) −Battery
(8) +Battery
(20) Low coolant level lamp (optional)
(21) High coolant temperature lamp
(23) Low oil pressure lamp
(24) Diagnostic lamp
(25) Warning lamp
(30) Keyswitch
(22) Maintenance lamp
g01149206
Illustration 76
P1 terminals that are associated with the indicator lamps
(P1-19) Diagnostic lamp
(P1-20) Warning lamp
(P1-28) Low oil pressure lamp
(P1-29) High coolant temperature lamp
(P1-30) Low coolant level lamp (optional)
(P1-53) +Battery
(P1-63) −Battery
(P1-70) Keyswitch
RENR9313-04 149
Results:

to Test Step 2.

and/or wiring.

STOP.
Test Step 2. Check for Normal Operation

of the Indicator Lamps
A. Restore the electrical power to the ECM and
monitor the indicator lamps.
Expected Result:
When the ECM is first powered up the indicator

lamps turn on for five seconds. Then, the indicator
lamps turn off.
Results:
• OK – The indicator lamps turn on for five seconds.

Then, the indicator lamps turn off.
Illustration 77
g01229616 Repair: The problem appears to be resolved. The
original problem was probably caused by a poor
P2 terminals that are associated with the indicator lamps
electrical connection. If an intermittent problem is
(P2-6) Maintenance lamp suspected, refer to the diagnostic functional test
wires that are associated with the indicator lamps. STOP.
D. Check the allen head screw on each ECM • Not OK – An indicator lamp does not turn on.
connector for the proper torque. Refer to the Proceed to Test Step 3.
“Electrical Connectors - Inspect”. Test Step 3. Measure the Voltage at the
Lamp Socket
E. Check the allen head screw on the customer
connector for the proper torque. Refer to the A. Use a test lamp to check for voltage at the suspect
diagnostic functional test Troubleshooting, lamp socket within the first five seconds after the
“Electrical Connectors - Inspect”. keyswitch is turned to the ON position.
F. Check the harness and wiring for abrasions and Expected Result:
for pinch points from the indicator lamps to the
ECM. The test lamp illuminates during the first five seconds
after the keyswitch is turned to the ON position.
Expected Result:
Results:
coupled and/or inserted. The harness and wiring are • OK – The test lamp illuminates during the first five
free of corrosion, of abrasion, and of pinch points. seconds after the keyswitch is turned to the ON
position.
150 RENR9313-04
Repair: Replace the bulb. The indicator lamps should illuminate for five
seconds. Then, the indicator lamps should turn
Verify that the repair eliminates the problem. off.
STOP. If the indicator lamps illuminate for five seconds,

the problem is resolved. Return the engine to
• Not OK – The test lamp did not illuminate during service. STOP.
the first five seconds after the keyswitch was
turned to the ON position. Proceed to Test Step 4. 3. If the indicator lamps do not illuminate for five
seconds, there may be a problem with the ECM.
Test Step 4. Test the Lamp Circuit It is unlikely that the ECM has failed. Exit this
procedure and perform this entire procedure
A. Disconnect the ECM connector for the suspect again.
lamp.
If the problem is not resolved, temporarily
B. Fabricate a jumper wire 100 mm (4 inch) long. connect a new ECM. Check the operation of the
Crimp a Deutsch pin to both ends of the wire. indicator lamps when the new ECM is installed.
If the problem is resolved with the new ECM,
C. Insert the ends of the jumper wire into the then reconnect the suspect ECM. If the problem
terminals for the suspect indicator lamp. Refer to returns with the suspect ECM, then replace
Table 26 for the appropriate terminals. the ECM. Refer to electronic troubleshooting
Troubleshooting, “Replacing the ECM”.
Table 26
P1 Terminals for the Connection of the Jumper Wire STOP.
Indicator Lamp Terminals • Not OK – The indicator lamp does not illuminate
Low coolant level P1-30 P1-63 while the jumper wire is connected to both
terminals. There is a problem in the wiring for
Low oil pressure P1-28 P1-63 the indicator lamp. There may be a problem in a
High coolant temperature P1-29 P1-63 connector.
Diagnostic lamp P1-19 P1-70 Repair: Repair the lamp circuit. Verify that the
Warning lamp P1-20 P1-70 repair eliminates the problem.
Maintenance lamp P2-6 P1-70 STOP.
D. Restore the electrical power to the ECM and

i03543132
observe the indicator lamp.
Injection Actuation Pressure -
E. Remove the jumper wire and observe the indicator
lamp. Test
Expected Result: SMCS Code: 1714-038
The indicator lamp illuminates while the jumper wire System Operation Description:
is connected to both terminals. The indicator lamp
turns off when the jumper wire is removed. Use the steps that follow to check the operation of
the HEUI fuel system. Circle the appropriate answers
Results: within the “Results” section of each step. Complete
the pages. Provide completed pages with any
• OK – The indicator lamp illuminates while the returned part. The parts should be returned through
jumper wire is connected to both terminals. The the part return system.
indicator lamp turns off when the jumper wire
is removed. The circuit for the indicator lamp is Results from the test must be included in the claim
functioning properly. story for related repairs. Failure to follow the proper
sequence of this procedure may result in incorrect
Repair: Perform the following procedure: results. The standard warranty may not cover repairs
performed while incorrectly using this procedure.
1. Connect the ECM connectors.
2. Restore the electrical power to the ECM and

monitor the indicator lamps.
RENR9313-04 151
Document all active diagnostic codes or logged

diagnostic codes.________________
Expected Result:
Diagnostic codes are not active or logged when

electrical power is restored to the ECM and the
engine is not running.
Results:
• OK – There are no active codes or logged codes.

• Not OK – Active codes or logged codes are

present.
Repair: Refer to Troubleshooting, “Engine

Pressure Sensor Open or Short Circuit - Test” if
164-03 or 164-04 is active or logged.
Illustration 78
g01181491 Refer to Troubleshooting, “Injection Actuation
Left side of engine (typical example)
Pressure Sensor - Test” if 164-02 is active or
logged.
(1) “J500/P500” Connector for the injection actuation pressure
control valve
(2) Injection actuation pressure sensor Refer to Troubleshooting, “Injection Actuation
Pressure Control Valve Circuit - Test” if 42-11 is
Test Step 1. Symptoms active or logged.
The following symptoms may occur if there is a Refer to System Operation, Test and Adjusting,
problem with the HEUI fuel system: “Fuel System Pressure - Test” if 94-1 is active or
logged.
• The engine cranks but the engine will not start.
Proceed to Test Step 2 if 164-00, 164-11 or 94-11
• The engine runs rough. is active or logged.
• The engine is erratic or unstable at idle or running. STOP.
• Low power Test Step 2. Start the Engine
• The following diagnostic codes might be active A. Inspect the engine for oil leaks in the HEUI oil rail.
codes or logged codes: 164-00, 164-02, 164-03, Repair leaks before proceeding. Clearly mark all
164-04, 164-11, 42-11, 94-1, and 94-11. leaks on returned parts.
A. Connect the Caterpillar Electronic Technician (ET) Note: Inspect the area near the high pressure oil rail
to the data link connector. and the unit injector hydraulic pump. If leakage is
found between the transfer pump and the hydraulic
B. Turn the keyswitch to the ON position. DO NOT pump, refer to Special Instruction, REHS3830 for
START THE ENGINE. details. If leakage is found between the hydraulic
pump and the front housing, refer to Special
C. Print the “Lifetime Totals” and the “Configuration” Instruction, REHS3830 for details on replacing the
screen. seal.
D. Check for active diagnostic codes or logged B. Check the engine oil level. If the engine oil level
diagnostic codes. The diagnostic codes should is low, add oil to the engine. Do not overfill the
become active within 30 seconds. engine.
E. Verify that the engine coolant temperature sensor C. Try to start the engine.
is operating properly. Verify through CAT ET. Refer
to Testing and Adjusting, “Cooling System - Test” Expected Result:
or Testing and Adjusting, “Test For The Water
Temperature Gauge” for the proper procedure. The engine starts.
152 RENR9313-04
• OK – The engine starts. Proceed to Test Step 10. The observed engine speed is above 100 rpm and
the actual injection actuation pressure is at least
• Not OK – The engine does not start. Proceed to 6 MPa (870 psi) while the engine is cranking.
Test Step 3.
Results:
Test Step 3. Verify the Operation of the
Injection Actuation Pressure Sensor • OK – The observed engine speed is above 100
rpm and the actual injection actuation pressure is at
A. Disconnect the connector for the injection least 6 MPa (870 psi) while the engine is cranking.
actuation pressure sensor. Check for evidence
of moisture in the connector. Refer to Repair: If a 94-11 code is active or logged, there
Troubleshooting, “Electrical Connectors - Inspect” is a problem with the fuel supply system. Refer
for troubleshooting details. to System Operation, Test and Adjusting, “Fuel
System Pressure - Test”.
B. Try to start the engine.
If a 94-11 code is not active or logged, refer to Test
Expected Result: Step 5.
The engine does not start. • Not OK – The observed engine speed is below
100 rpm.
Results:
Repair: Refer to Troubleshooting, “Engine Cranks
• OK – The engine does not start. Reconnect the but Will Not Start”.
connector for the actuation pressure sensor. Clear
all diagnostic codes. Proceed to Test Step 4. STOP.
• Not OK – The engine starts. • Not OK – The observed engine speed is above
100 rpm and the observed engine oil pressure is
Repair: The injection actuation pressure sensor below 14 kPa (2 psi).
may be faulty. Replace the sensor and reconnect
the connector. Clear all diagnostic codes. Verify Repair: There is a problem with the engine oil
that the repair eliminates the problem. supply. Refer to System Operation, Test and
Adjusting, “Engine Oil Pressure - Test”.
If the problem still exists, proceed to Test Step 4.
STOP.
Test Step 4. The Engine Cranks but the
Engine Will not Start • Not OK – The observed engine speed is above
100 rpm and the observed engine oil pressure
A. Observe the status for “Engine Speed”, “Actual is above 14 kPa (2 psi) and the actual injection
Injection Actuation Pressure” and “Engine Oil actuation pressure is below 6 MPa (870 psi).
Pressure” on Cat ET while the engine is cranking. Proceed to Test Step 7.
Record the following data:
Test Step 5. Verify Communication
________________ Engine Speed Between the ECM and the Fuel Injectors
________________ Actual injection actuation
pressure
________________ Desired injection actuation Electrical shock hazard. The electronic unit injec-
pressure tor system uses 90-120 volts.
________________ Engine oil pressure
________________ Fuel pressure
________________ Engine coolant temperature
________________ Observed “Injection Actuation

Output Percent”
RENR9313-04 153
C. Crank the engine for 15 seconds.
D. Check Cat ET for logged diagnostic codes that

are related to the injector solenoids.
Expected Result:
There are logged injector solenoid diagnostic codes

for all cylinders.
Results:
• OK – There are logged injector solenoid diagnostic

codes for all cylinders. Logged injector solenoid
codes indicate communication between the ECM
and the fuel injectors. Turn the key to the “OFF”
position. Reconnect the connector for the injector
harness. Clear all diagnostic codes. Proceed to
Test Step 6.
• Not OK – At least one cylinder does not indicate a

Illustration 79
g01330859 logged injector solenoid diagnostic code.
Location of the connectors for the injector solenoids (C7 engines)
Repair: There may be a problem with the engine
(1) Connector at the valve cover
harness or ECM. Record the numbers that do not
(3) Rubber grommet for the injector harness at the valve cover indicate a logged injector solenoid diagnostic code.
Turn the key to the “OFF” position. Reconnect
the connector for the injector harness. Clear
any diagnostic codes or event codes. Refer to
STOP.
Test Step 6. Check the Pressure of the

Low Pressure Fuel System
A. Observe the status for “Fuel Pressure” on Cat
ET while the engine is cranking. Record the fuel
pressure.
________________ Fuel Pressure
Expected Result:
Observed fuel pressure is above 175 kPa (25 psi)

while the engine is cranking.
g01330939
Results:
Illustration 80
Location of the connectors for the injector solenoids (C9 engines) • OK – Observed fuel pressure is above 175 kPa
(1) Connector at the valve cover (25 psi) while the engine is cranking.
A. Turn the key to the “OFF” position. An electrical

shock hazard is present if the key is not in the
“OFF” position.
B. Disconnect the connector for the injector

harness at the valve cover. Check for
evidence of moisture in the connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for troubleshooting details.
154 RENR9313-04
Repair: Access the “Injector Solenoid Test” in Cat Test Step 8. Check the High Pressure Oil
ET. Activate the test. As each solenoid is energized System for Leaks
by the ECM an audible click can be heard at the
valve cover. Listen for a click at the valve cover.
Cat ET will indicate the cylinder number as each
solenoid is being energized. Replace injectors
that do not produce an audible click. Verify the Hot oil and components can cause personal in-
repair. If all injectors produce an audible click and jury.
the engine will not start, refer to Troubleshooting,
“Engine Cranks but Will Not Start”. Do not allow hot oil or components to contact
skin.
STOP.
• Not OK – Observed fuel pressure is below 175 kPa

(25 psi) while the engine is cranking.
Electrical shock hazard. The electronic unit injec-
Repair: There is a problem with the fuel supply tor system uses 90-120 volts.
system. Refer to System Operation, Test and
Adjusting, “Fuel System Pressure - Test”. A. Remove the valve cover and inspect the high
pressure oil system for excessive oil leaks or
STOP. discharge.
Test Step 7. Use a Test Lamp to Check B. Look at the injector bores for any signs of oil
for the Presence of Current leakage while the engine is being cranked. Inspect
the spill ports on the injectors for an excessive
A. Disconnect the J500/P500 IAPCV connector from discharge of oil. All six injectors should discharge
the unit injector hydraulic pump. the same amount of oil. Excessive leakage or
discharge can cause issues with the system
Note: Do not insert any wire that is larger than pressure. Record the following data:
18 AWG into the P500 harness connector. Do not
insert the probe for the voltage test lamp into the ________________ Any injectors with excessive
P500 harness connector. These actions will spread leakage or discharge
the sockets of the connector which will damage
the connector. Damaged connectors could cause C. Turn the key to the “OFF” position. A electrical
intermittent connections. shock hazard is present if the key is not turned to
the “OFF” position.
B. Insert a 186-3735 Connector Pin into each of the
P500 harness connector sockets . D. Disconnect the connector for the injector
C. Connect a voltage test lamp to the connector pins evidence of moisture in the connector. Refer to
that are inserted in the P500 connector. Troubleshooting, “Electrical Connectors - Inspect”
D. Crank the engine and watch the test lamp.
E. Crank the engine. Observe the injector bores for
Expected Result: any signs of leakage. Inspect the spill ports on the
injectors for an excessive discharge of oil. The
The test lamp illuminates while the engine is cranking. injectors are now disabled and the injectors should
discharge very little oil, which is normal. Observe
Results: the status for the “Actual Injection Actuation
Pressure” on Cat ET while the engine is cranking.
• OK – The test lamp illuminates while the engine Record the following data:
is cranking. The ECM is operating correctly and
the wiring harness to the pump is OK. Proceed to ________________ Any injectors with excessive
Test Step 8. leakage or discharge
• Not OK – The test lamp does not illuminate while ________________Actual injection actuation pressure
the engine is cranking.
F. Clear any diagnostic codes that are logged.
Repair: Refer to Troubleshooting, “Injection
Actuation Pressure Control Valve Circuit - Test” for
information on troubleshooting the circuit.
STOP.
RENR9313-04 155
There are no excessive oil leaks around injector The engine starts.
bores. Also, there is no excessive oil discharge from
the spill ports of the injector. Results:
Results: • OK – The engine starts. STOP.

• OK – There are no excessive oil leaks around • Not OK – The engine does not start and actual
injector bores. Also, there is no excessive oil injection actuation pressure is above 6 MPa
discharge from the spill ports of the injector. (870 psi). Proceed to Test Step 5.
Repair: If the unit injector hydraulic pump has not • Not OK – The engine does not start and actual
been replaced during this procedure, replace the injection actuation pressure is below 6 MPa
pump and repeat steps “E” and “F”. The engine will (870 psi).
need to be cranked for a significant length of time
in order to fill the pump with oil after the pump is Repair: If the unit injector hydraulic pump has not
replaced. Clear all diagnostic codes. been replaced, replace the pump and try to start
the engine. The engine will need to be cranked for
If the unit injector hydraulic pump has been a significant length of time in order to fill the pump
replaced during this procedure, and the actual with oil after the pump has been replaced. Clear all
injection actuation pressure was at least 6 MPa diagnostic codes.
(870 psi) in Step “E”, proceed to Test Step 9.
If the engine does not start, proceed to Test Step 5.
• OK – If the unit injector hydraulic pump has
already been replaced during this procedure and • Not OK – If the unit injector hydraulic pump has
the actual injection actuation pressure was below already been replaced in a previous test, stop
6 MPa (870 psi) in Step “E”, consult your local and consult your local technical communicator for
technical communicator for assistance. assistance.
• Not OK – There are excessive oil leaks around the Test Step 10. Check the Low Pressure
injector bores or excessive oil discharge out of the Fuel and Oil System Pressures
spill port of the injector.
Extended oil drain intervals may cause elevated
Repair: Replace the O-ring on the injector(s) levels of soot in the engine oil. The elevated levels
that is leaking around the bore(s) or replace of soot may also deplete the additive package of the
the damaged injector(s) that is identified with oil. This can affect the operation of the high pressure
excessive discharge out of the spill ports. oil system.
Proceed to Test Step 9. Note: Refer to the engine's Operation and

Maintenance Manual for the recommended engine oil
Test Step 9. Try to Start the Engine change interval and refill capacities.
Electrical shock hazard. The electronic unit injec- Escaping fluid under pressure, even a pinhole size
tor system uses 90-120 volts. leak, can penetrate body tissue, causing serious
injury, and possible death. If fluid is injected into
your skin, it must be treated immediately by a doc-
A. Turn the key to the “OFF” position. A electrical tor familiar with this type of injury.
shock hazard is present if the key is not in the
“OFF” position. Always use a board or cardboard when checking
for a leak.
B. Reconnect the connector for the injector harness
at the valve cover and install the valve cover.
A. Start the Engine.
C. Try to start the engine. Observe the status for
“Actual Injection Actuation Pressure” on Cat ET B. Observe the status for “Fuel Pressure” and
while the engine is cranking. Record the actual “Engine Oil Pressure” on Cat ET while the engine
injection actuation pressure. is running. Record the following data:
________________ Actual injection actuation ________________ Observed fuel pressure from Cat
pressure ET
156 RENR9313-04
________________ Observed engine oil pressure Note: The “Injection Actuation Pressure Test” can
from Cat ET be used to increase the injection actuation pressure.
Also, the “Injection Actuation Pressure Test” can be
________________ Drain interval used to decrease the injection actuation pressure.
The test adjusts the injection actuation oil pressure in
________________ Miles or Kilometers since the last predefined steps. Step forward through all predefined
oil change steps in the test. Next, step backward through all
predefined steps in the test.
Expected Result:
D. Record the pressure readings from the pressure
The customer has not exceeded the suggested oil gauge and from Cat ET in Table27.
change interval.
Results:
• OK – The customer has not exceeded the

suggested oil change interval.
Repair: Refer to Systems Operation, Testing and

Adjusting, “Fuel System Pressure - Test” and
Systems Operation/Testing and Adjusting, “Engine
Oil Pressure - Test” in order to verify that the
observed fuel pressure and engine oil pressures
are acceptable.
If a 94-1 diagnostic code is active or a 94-1

diagnostic code is logged, a problem in the fuel
supply system has occurred, refer to Systems
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”. Make necessary repairs. Verify
• Not OK – The customer has exceeded the

suggested oil change interval.
Repair: If the customer has exceeded the

suggested oil change interval, ask the customer
to authorize an oil change with a new filter.
Oil changes are not covered by the warranty.
After the engine oil and the oil filter have been
changed, operate the engine until normal operating
temperature has been reached. Operate the engine
at 1200 to 1500 rpm for 15 minutes. This will purge
any trapped air or debris that is in the system.
If the problem still exists, or if the problem reoccurs

in a short period of time, repeat Test Step 10.
Test Step 11. Use “Injection Actuation

Pressure Test” on Cat ET to Check the
System
A. Install the 8T-0852 Pressure Gauge in an
accessible port in the high pressure injection
actuation oil system.
B. Start the engine.
C. Access the “Injection Actuation Pressure Test” in

the “Diagnostics Menu” of Cat ET and begin the
test.
RENR9313-04 157
Table 27
Step Manual pressure gauge Actual injection actuation Difference
pressure from Cat ET
1
2
3
4
3
2
1
Expected Result: Note: There may be a short lag in the reaction to

the injection pressure. The pressure change should
The pressure that is measured with the pressure occur within two seconds of each command.
gauge for each step and the pressure that is
displayed on Cat ET for each step are within B. Record the actual injection actuation pressure,
1379 kPa (200 psi). desired injection actuation pressure and injection
actuation output percent from Cat ET in Table 28.
Note: Under some situations, the injection actuation
pressure may not change. This step compares the
pressure reading from the pressure gauge to the
pressure reading that is displayed on Cat ET.
Results:
• OK – The pressure that is measured with the

pressure gauge for each step and the pressure
that is displayed on Cat ET for each step are
within 1379 kPa (200 psi). The injection actuation
pressure sensor is operating properly.
Repair: Do not replace the sensor.
• Not OK – The pressure that is measured with the

pressure gauge for each step and the pressure
that is displayed on Cat ET for each step are not
within 1379 kPa (200 psi).
Repair: The injection actuation pressure sensor

may be faulty. Replace the sensor and repeat this
test step.
If the problem still exists, verify the accuracy of the

pressure gauge. Reinstall the original sensor and
proceed to Test Step 12.
Test Step 12. Perform the “Injection

Actuation Pressure Test” at Low Idle
A. Start the engine. Run the “Injection Actuation
Pressure Test” at low idle only. Step forward
through all predefined steps in the test. Next, step
backward through all the predefined steps in the
test.
158 RENR9313-04
Table 28
Low Idle
Step Actual injection Desired injection Difference (A-B) Injection actuation output
actuation actuation pressure from percent from Cat ET
pressure from Cat ET (B)
Cat ET (A)
1
2
3
4
3
2
1
Expected Result: Test Step 13. Check the High Pressure

Oil System for Excessive Leaks
The actual injection actuation pressure is no more
than 1379 kPa (200 psi) above the desired injection
actuation pressure for each step. Also, the injection
actuation pressure does not fluctuate more than
±1000 kPa (±145 psi). Hot oil and components can cause personal in-
jury.
Results:
Do not allow hot oil or components to contact
• OK – The actual injection actuation pressure is no skin.
more than 1379 kPa (200 psi) above the desired
injection actuation pressure for each step. Also, A. Remove the valve cover and inspect the high
the actual injection actuation pressure does not pressure oil system for excessive oil leaks or
fluctuate more than ±1000 kPa (±145 psi). Low discharge.
pressure does not indicate a problem with the unit
injector hydraulic pump. Proceed to Test Step 13. B. Start the engine and allow the engine to idle. Look
at the injector bores for any signs of oil leakage.
• Not OK – One of the actual injection actuation Inspect the spill ports on the injectors for an
pressures is more than 1379 kPa (200 psi) above excessive discharge of oil. All six injectors should
the desired injection actuation pressure on at least discharge the same amount of oil. Excessive
one step, or the actual injection actuation pressure leakage or discharge can cause issues with the
fluctuates more than ±1000 kPa (±145 psi). Low system pressure.
pressure does not indicate a problem with the unit
injector hydraulic pump. C. While the engine is at low idle, perform the
“Injection Actuation Pressure Test” in Cat ET.
Repair: Replace the unit injector hydraulic pump. Run the test at the highest pressure in order to
After the pump has been replaced, the engine maximize any possible leaks. Observe the status
will need to be cranked for a significant length for “Actual Injection Actuation Pressure” on Cat
of time in order to fill the pump with oil. Clear all ET. Record the following data:
diagnostic codes or event codes. Verify that the
repair eliminates the problem. ________________ Any injectors with excessive
leakage or discharge
________________ Actual injection actuation
pressure at low idle
D. Turn the key to the “OFF” position. A electrical

shock hazard is present if the key is not turned to
the “OFF” position.
RENR9313-04 159
E. Disconnect the connector for the injector

evidence of moisture in the connector. Refer to
Escaping fluid under pressure, even a pinhole size
Troubleshooting, “Electrical Connectors - Inspect”
leak, can penetrate body tissue, causing serious
injury, and possible death. If fluid is injected into
your skin, it must be treated immediately by a doc-
F. Crank the engine. Observe the injector bores for
tor familiar with this type of injury.
any signs of leakage. Inspect the spill ports on
the injectors for an excessive discharge of oil.
Always use a board or cardboard when checking
The injectors are now disabled and the injectors
for a leak.
should discharge very little oil, which is normal.
G. While the engine is cranking, perform the “Injection C. Install the 8T-0852 Pressure Gauge in an
Actuation Pressure Test” in Cat ET. Run the test accessible port in the high pressure injection
at the highest pressure in order to maximize any actuation oil system.
possible leaks. Observe the status for “Actual
Injection Actuation Pressure” on Cat ET. Record D. Disconnect the connector for the injection
the following data: actuation pressure sensor and plug a spare
injection actuation pressure sensor into the engine
________________Any injectors with excessive harness. Allow the spare sensor to hang on the
leakage or discharge side of the engine.
________________ Actual injection actuation Note: This configuration allows the unit injector
pressure while the engine is cranking hydraulic pump to build maximum pressure. The
engine will not start in this configuration.
H. Clear any diagnostic codes that are logged.
E. Install a 224-9282 Adapter Cable As in
Expected Result: series with the P500 connector. Reconnect the
P500/J500 connector.
There are no excessive oil leaks around injector
bores. Also, there is no excessive oil discharge from Note: There must be a continuous electrical
the spill ports of the injector. connection between the ECM and the unit injector
hydraulic pump. The improper connection or the
Results: incomplete connection of the adapter cable may
provide incorrect results.
• OK – There are no excessive oil leaks around
injector bores. Also, there is no excessive oil F. Connect a multimeter that is capable of measuring
discharge from the spill ports of the injector. current that is 0 to 1,000 milliampere in series with
Proceed to Test Step 14. the adapter cable. Select the lowest current range
for the multimeter that is greater than one amp.
• Not OK – There are excessive oil leaks around
injector bores or excessive oil discharge from the Note: If the multimeter is not set to the correct scale,
spill ports of the injector. the following measurement may provide misleading
results.
Repair: Replace the O-ring on the injector(s)
that is leaking around the bore(s) or replace the G. Crank the engine and record the following data:
damaged injector(s) that is identified with excessive
discharge out of the spill ports. . ________________Observed pressure reading from
the pressure gauge
Verify that the repair eliminates the problem. If the
problem remains after the repair, proceed to Test Note: If the gauge fluctuates use the average.
Step 14.
________________ Observed engine speed from Cat
Test Step 14. Check the Oil Pressure at ET
the Pump (High Pressure Pump Test)
________________Observed “Injection Actuation
A. Turn the key to the “OFF” position. A electrical Output Percent” from Cat ET
shock hazard is present if the key is not turned to
the “OFF” position. ________________ Current reading from the
multimeter
B. Reconnect the connector for the injector harness
at the valve cover and install the valve cover.
160 RENR9313-04
Expected Result: Results:
The oil pressure is above 29.5 MPa (4278 psi) and • OK – The oil pressure is below 8 MPa (1160 psi).
the current is above 400 mA. Return the system to the original configuration and
proceed to Test Step 16.
Results:
• Not OK – The oil pressure is above 8 MPa
• OK – The oil pressure is above 29.5 MPa (1160 psi). The unit injector hydraulic pump is
(4278 psi) and the current is above 400 mA. faulty.
Leave the system in the present configuration and
proceed to Test Step 15. Repair: Replace the unit injector hydraulic pump.
After the pump has been replaced, the engine
• Not OK – The oil pressure is below 29.5 MPa will need to be cranked for a significant length
(4278 psi) and the current is above 400 mA. of time in order to fill the pump with oil. Clear all
diagnostic codes or event codes. Verify that the
Repair: Replace the unit injector hydraulic pump. If repair eliminates the problem. If the problem still
the drive gear on the pump is loose, do not attempt exists, consult your local technical communicator
to tighten the drive gear and reuse the pump. for assistance.
After the pump has been replaced, the engine
will need to be cranked for a significant length STOP.
of time in order to fill the pump with oil. Clear all
diagnostic codes or event codes. Verify that the Test Step 16. Use the “Cylinder Cutout
repair eliminates the problem. Test” on Cat ET to Check the Fuel
Injectors
If the problem still exists, consult your local
technical communicator for assistance. The troubleshooting indicates that the unit injector
hydraulic pump is working properly. Record the
STOP. following data:
• Not OK – The current is below 400 mA. Engine symptoms (misfire,

________________
excessive smoke, low power, runs rough)
Repair: Refer to Troubleshooting, “Injection
Actuation Pressure Control Valve Circuit - Test”. ________________ Conditions when the engine
symptom occurs, (high load, idle, cold start,
STOP. acceleration, ect.)
Test Step 15. Disconnect J500/P500 and ________________ The frequency of the engine
Check the Oil Pressure symptoms (intermittent, constant, ect.)
A. Disconnect the J500/P500 connector at the unit A. Perform a cylinder cutout procedure if the
injector hydraulic pump. test has not already been performed or if any
other repairs have been completed since the
B. Crank the engine and record the following data. most recent cylinder cutout procedure. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test”
Note: The pressure readings may vary between for troubleshooting details.
gauges.
Expected Result:
________________Observed pressure reading from
the pressure gauge The injectors are operating properly according to the
“Injector Solenoid Circuit - Test”. Also, the engine
________________ Observed engine speed from Cat symptoms are still present.
ET
Results:
________________Observed “Injection Actuation
Output Percent” from Cat ET • OK – The injectors are operating properly
according to the “Injector Solenoid Circuit - Test”.
Expected Result: Also, the engine symptoms are still present.
The oil pressure is below 8 MPa (1160 psi). Repair: Consult your local technical communicator
for assistance.
STOP.
RENR9313-04 161
• Not OK – The “Injector Solenoid Circuit - Test”

indicates faulty injectors.
Repair: Replace the faulty injectors. Verify that the

repair eliminates the problem. If the problem still
exists, consult your local technical communicator
for assistance.
STOP.
i02464947

Control Valve Circuit - Test
SMCS Code: 1714-038

problems with the Injection Actuation Pressure
Control Valve (IAPCV).
This procedure covers the 42-11 Inject Actuation

Control Valve open/short.
The IAPCV is internal to the unit injector hydraulic

pump. The IAPCV is a precision displacement control
actuator. This actuator changes the pump outlet flow
that is based on the control current that is supplied by
the Electronic Control Module (ECM). The variable
displacement unit injector hydraulic pump pressurizes
only the amount of high pressure oil that is needed.
The ECM software contains performance maps. The

performance maps have a desired actuation pressure
for every engine operating condition. The ECM sends
a control current to the IAPCV. This signal creates an
actual actuation pressure that matches the desired
actuation pressure. If the actual actuation pressure
does not match the desired actuation pressure, the
ECM will increase the control current or the ECM will
decrease the control current to the IAPCV in order to
adjust pump outlet flow.
g01229672
Illustration 81
Schematic for the injection actuation pressure control valve
162 RENR9313-04

g01223470
Illustration 82
(1) IAPCV connector
(2) J2/P2 connectors
B. Thoroughly inspect connectors (1) and (2). Refer

g01223476
Illustration 83
P2 terminations for the IAPCV
(P2-10) Return
(P2-20) Control

wires that are associated with the IAPCV.
D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
E. Check the harness and wiring for abrasion and for

pinch points from the IAPCV back to the ECM.
Note: Ensure that the seal is installed on the harness

connector for the injection actuation pressure control
valve.
Expected Result:

RENR9313-04 163
Results: B. Disconnect the connector.
• OK – The connectors and the wiring are OK. Note: Ensure that the seal on the IAPCV connector
Proceed to Test Step 2. remains on the connector when the connector is
disconnected.
and/or the wiring. C. Measure the resistance between terminals 1
(Control) and 2 (Return) on the IAPCV. Record the
Repair: Repair the connectors or wiring and/or value of the resistance measurement.
the seals are properly in place and ensure that the Expected Result:
The resistance measurement is between 6.5 and
Verify that the repair eliminates the problem. 10.5 Ohms.
STOP. Results:
Test Step 2. Check for Active Diagnostic • OK – The resistance measurement is between
Codes 6.5 and 10.5 Ohms. Connect the J500/P500
connectors. Proceed to Test Step 4.
to the service tool connector. Refer to electronic • Not OK – The resistance measurement is not
troubleshootingTroubleshooting, “Electronic between 6.5 and 10.5 Ohms. The solenoid's
Service Tools”. resistance is not within the specification.
B. Restore the electrical power to the ECM. Repair: Replace the unit injector hydraulic pump.
C. Start the engine.
STOP.
D. Observe the “Active Diagnostic” screen on Cat ET.
Wait at least 30 seconds so that any codes may Test Step 4. Check the Wiring for an Open
become active. Circuit
Expected Result: A. Remove the electrical power from the ECM.
The 42-11 code is active. B. Disconnect the J2/P2 connectors.
Results: C. Measure the resistance between terminals P2-20

(Control) and P2-10 (Return).
• Active code – The 11 code is active. Proceed to
Test Step 3. Expected Result:
• No active codes – Neither of the above codes are The resistance measurement is within two Ohms of
active. the value that was measured in the previous Test
Step.
Repair: If the 11 code is logged and the engine
is not running properly, refer to Troubleshooting, Results:
“Troubleshooting without a diagnostic code”.
• OK – The resistance measurement is within two
If the engine is running properly at this time, there Ohms of the value that was measured in the
may be an intermittent problem in a harness previous Test Step. Proceed to Test Step 5.
that is causing the codes to be logged. Refer to
the diagnostic functional test Troubleshooting, • Not OK – The resistance measurement is not
“Electrical Connectors - Inspect”. within two Ohms of the value that was measured
in the previous Test Step. There is a problem with
STOP. the wiring harness. There may be a problem with a
connector.
Test Step 3. Measure the Resistance of
the Injection Actuation Pressure Control Repair: Repair the wiring and/or the connector.
Valve's Solenoid Replace parts, if necessary. Verify that the problem
is resolved.
STOP.
164 RENR9313-04
Test Step 5. Check the Wiring for a Short A. Verify that the IAPCV harness connector is
Circuit disconnected.
A. Disconnect the IAPCV harness connector. Note: Do not insert any wire that is larger than
18 AWG into the IAPCV harness connector. Do
Note: Ensure that the seal on the IAPCV harness not insert the probe for the voltage test lamp into
connector remains on the connector when the the harness connector. These actions will spread
connector is disconnected. the sockets of the connector which will damage
the connector. Damaged connectors could cause
B. Disconnect the P1 connector. intermittent connections.
C. Measure the resistance between the points that B. Insert a Deutsch connector pin into each socket
are listed in Table 29. Be sure to wiggle the wires of the J500 harness connector.
measurement. C. Connect a voltage test lamp to the connector pins
that are inserted in the IAPCV harness connector.
Table 29 Crank the engine and observe the test lamp.
Resistance Measurements for the Wiring Harness
Expected Result:
Terminal The voltage test lamp illuminates when the engine
P2-20 (Control) All of the other terminals on is cranking.
the P2 connector
Results:
connector
• OK – The voltage test lamp illuminates when the
Engine ground engine is cranking. Remove the connector pins
from the IAPCV harness connector. Connect all
P2-10 (Return) All of the other terminals on
the P2 connector
of the electrical connectors. Clear any diagnostic
codes. Proceed to Test Step 7.
connector • Not OK – The voltage test lamp does not illuminate
Engine ground when the engine is cranking.

Expected Result: troubleshooting Troubleshooting, “Replacing the
ECM”.
All of the resistance measurements indicate an open
circuit. STOP.
Results: Test Step 7. Perform the “Injection
Actuation Pressure Test”
• OK – All of the resistance measurements indicate
an open circuit. Proceed to Test Step 6. A. Disconnect the IAPCV harness connector.
• Not OK – At least one resistance measurement NOTICE

problem with a wiring harness. There may be a
problem with a connector.
Replace parts, if necessary. Verify that the problem B. Crank the engine three times at 30 seconds
is resolved. intervals. This will purge the air from the system.
STOP. C. Connect the IAPCV harness connector.
Test Step 6. Check the ECM by Cranking D. Start the engine.

the Engine
E. Run the “Injection Actuation Pressure Test”. The
Note: This Test Step may activate additional “Injection Actuation Pressure Test” is located in
diagnostic codes. Ignore the codes and monitor the the “Diagnostics” menu on Cat ET. Step through
test lamp. Clear the codes at the end of the Test Step. all of the pressure ranges.
RENR9313-04 165
Note: This is not the “Injection Act Press Driver Test”.
F. After performing the “Injection Actuation Pressure

Test”, check for active diagnostic codes.
Expected Result:
The test is successful. There are no diagnostic codes.
Results:
• OK – The problem appears to be resolved. The

original problem was probably caused by a poor
electrical connection. STOP.
• Not OK – There is a problem with the IAPCV.

Repair: Replace the unit injector hydraulic pump.
STOP.
i02464988

Sensor - Test
SMCS Code: 1439-038; 1925-038

problems with the injection actuation pressure sensor.
This procedure covers the 164-02 Injector Actuation

Pressure signal erratic.
Note: This procedure can check the accuracy of

the injection actuation pressure sensor against a
pressure gauge.
The injection actuation pressure sensor measures

the pressure of the oil in the high pressure oil
manifold. The high pressure oil in the manifold is
used to actuate the injectors and the high pressure
oil is used to control the fuel injection pressure. The
Electronic Control Module (ECM) uses the reading
from the injection actuation pressure sensor in order
to control the operation of the injection actuation
pressure control valve.
g01230041
Illustration 84
Schematic for the injection actuation pressure sensor
166 RENR9313-04
Test Step 1. Check for Active Diagnostic Repair: Refer to troubleshooting without a
Codes diagnostic code Troubleshooting, “Engine Cranks
but Will Not Start”.
to the service tool connector. Refer to electronic STOP.
troubleshooting Troubleshooting, “Electronic
Service Tools”. Test Step 3. Inspect the Electrical
C. Observe the “Active Diagnostic” screen on Cat
ET. Wait at least 30 seconds so that any codes
may become active. Look for an active 164-02
diagnostic code.
Note: If one of the following diagnostic codes

is active, refer to the diagnostic functional test
Troubleshooting, “Engine Pressure Sensor Open or
Short Circuit - Test”.
• 164-03 Injector Actuation Pressure voltage high

• 164-04 Injector Actuation Pressure voltage low
Expected Result:
The 164-02 diagnostic code is active.
Results:
• Active code – The 02 diagnostic code is active.

• No active code – The 02 diagnostic code is not

active. Proceed to Test Step 2.
Test Step 2. Try to Start the Engine

g01180781
Try to start the engine. Illustration 85
Expected Result: (1) Injection actuation pressure sensor
The engine starts. B. Thoroughly inspect the J2/P2 ECM connectors.

Thoroughly inspect the connector for the injection
Results: actuation pressure sensor. Refer to the diagnostic
• OK – The engine starts. There are no active codes Connectors - Inspect”.
for the injection actuation pressure sensor and the
engine starts.
Repair: There may be an intermittent problem

in a harness that is causing the code to be
logged. Refer to the diagnostic functional test
STOP.
• Not OK – The engine does not start.

RENR9313-04 167
g01123211
Illustration 87
Harness connector for the injection actuation pressure sensor
(A) Supply
(B) Return
(C) Signal
C. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the injection
actuation pressure sensor.
D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
E. Check the harness and wiring for abrasion and for

pinch points from the sensor back to the ECM.
Expected Result:
g01180788
Illustration 86 All connectors, pins, and sockets are completely
P2 terminals that are associated with the injection actuation coupled and/or inserted. The harness and wiring are
pressure sensor free of corrosion, of abrasion, and of pinch points.
(P2-17) Return
(P2-72) +5 VDC Results:
(P2-85) Injection Actuation pressure

to Test Step 4.
• Not OK – There is a problem in the wiring and/or a

connector.

STOP.
168 RENR9313-04
Test Step 4. Check the Status of the Test Step 6. Compare the Sensor's
Sensor Output to a Pressure Gauge
A. Restore the electrical power to the ECM.
B. Check the value of the “Injection Actuation

Pressure” on Cat ET. Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
Note: The following codes will cause the value of the contact the skin.
“Injection Actuation Pressure” to revert to a default
value. A. Remove the electrical power from the ECM.
• 03 Injector Actuation Pressure voltage high B. Install a 8T-0852 Pressure Gauge to an oil port
on the side of the cylinder head or to the port on
• 04 Injector Actuation Pressure voltage low the top of the fuel transfer pump.
Expected Result: C. Start the engine.
The value of the “Injection Actuation Pressure” is D. Go to the “Injection Actuation Pressure Test” on
0 kPa (0 psi). the diagnostic menu of Cat ET.
Results: E. Start the “Injection Actuation Pressure Test”.
• OK – The value of the “Injection Actuation F. Refer to Table 30. Observe the value of the
Pressure” is 0 kPa (0 psi). Proceed to Test Step 6. “Injection Actuation Pressure” on Cat ET. Vary the
engine speed in order to obtain each “Injection
• Not OK – The value of the “Injection Actuation Actuation Pressure” value that is listed in the
Pressure” is above 0 kPa (0 psi). Proceed to Test Table. For each pressure value, observe the
Step 5. reading on the pressure gauge.
Test Step 5. Check the Voltage Supply to Table 30

the Injection Actuation Pressure Sensor Comparison of Pressure Readings
A. Remove the electrical power from the ECM. “Injection Actuation Range of Acceptable
Pressure” Values on Pressure Values on the
B. Disconnect the injection actuation harness Cat ET Pressure Gauge
connector. 6000 kPa (870 psi) 4000-7800 kPa (580-1130
psi)
C. Connect a 3-terminal breakout T to the injection
actuation harness connector only. 10000 kPa (1450 psi) 8000-11800 kPa
(1160-1710 psi)
D. Restore the electrical power to the ECM. 15000 kPa (2175 psi) 13000-16800 kPa
(1885-2435 psi)
E. Measure the voltage between terminals A and B 21000-24800 kPa
23000 kPa (3336 psi)
at the breakout T. (3045-3595 psi)
Expected Result:
Expected Result:
The voltage reading is 5 ± 0.2 VDC.
Each value on the pressure gauge is within the
Results: specification.
• OK – The voltage is within the specified range. Results:

• OK – Each value on the pressure gauge is within
• Not OK – The voltage is not within the specified the specification. The injection actuation pressure
range. sensor and the ECM are working properly.
Repair: Refer to the diagnostic functional test

Troubleshooting, “Analog Sensor Supply Circuit -
Test”.
STOP.
RENR9313-04 169
Repair: The problem appears to be resolved. The These engines have Hydraulically Actuated
original diagnostic code was probably caused by Electronically Controlled Unit Injectors (HEUI). The
an intermittent problem in an electrical connector. Engine Control Module (ECM) sends a 105 volt pulse
If the code continues to be logged, refer to to each injector solenoid. The pulse is sent at the
the diagnostic functional test Troubleshooting, proper time and at the correct duration for a given
“Electrical Connectors - Inspect”. engine load and speed. The solenoid is mounted on
top of the fuel injector body.
STOP.
If an open is detected in the solenoid circuit, a
• Not OK – At least one of the values on the diagnostic code is generated. The ECM continues
pressure gauge is not within the specification. to try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
Repair: Install a new injection actuation pressure the solenoid circuit. The ECM will periodically try
sensor and repeat the test. to fire the injector. If the short circuit remains, this
sequence of events will be repeated until the problem
If the new sensor corrects the problem, leave the is corrected.
new sensor in place.
When an injector is replaced, program the new
If the new sensor does not correct the problem, the injector code into the ECM. If the ECM is replaced,
pressure gauge is faulty. Obtain a new pressure all six injector codes must be programmed into
gauge and repeat the test. the new ECM. Refer to programming parameters
Troubleshooting, “Injector Trim File” for more
STOP. information.
The Caterpillar Electronic Technician (ET) includes

i02465034
the following tests that aid in troubleshooting the
Injector Solenoid Circuit - Test injector solenoids:
SMCS Code: 1290-038 “Cylinder Cutout Test”
System Operation Description: All active diagnostic codes must be repaired before
running the “Cylinder Cutout Test”. Use the “Cylinder
Use this procedure for the following conditions: Cutout Test” to diagnose a malfunctioning injector
while the engine is running. When a good injector is
cut out, the “Fuel Position” of the remaining injectors
• An injector solenoid may have a problem. will show a consistent change. This consistent
change in the fuel position is caused by the remaining
• You have been directed to this procedure from injectors that are compensating for the cut out
Troubleshooting, “Troubleshooting without a
Diagnostic Code”. injector. If a malfunctioning injector is cut out, the
“Fuel Position” will not show a proportional change.
This unbalanced change is the result of the smaller
• There is an active diagnostic code for an injector quantity of fuel that is needed to compensate for
solenoid.
the power loss from the malfunctioning injector.
Use this procedure for the following diagnostic codes: The “Cylinder Cutout Test” is used to isolate the
malfunctioning injector in order to avoid replacement
of injectors that are in good repair.
• 1-11 Cylinder #1 Injector fault
“Injector Solenoid Test”
Use the “Injector Solenoid Test” to aid in diagnosing
• 3-11 Cylinder #3 Injector fault an open circuit or a short circuit while the engine
is not running. The “Injector Solenoid Test” briefly
• 4-11 Cylinder #4 Injector fault activates each solenoid. A good solenoid will create
an audible click when the solenoid is activated. Cat
• 5-11 Cylinder #5 Injector fault ET will indicate the status of the solenoid as “OK”,
“Open”, or “Short”.
Perform this procedure under conditions that are Note: Refer to Illustration 89. Two injector solenoids
identical to the conditions that exist when the problem share a common supply wire. For this reason, an
occurs. Typically, problems with the injector solenoid open circuit or a short circuit in a supply wire could
occur when the engine is warmed up and/or when cause diagnostic codes for two injector solenoids.
the engine is under vibration (heavy loads).
170 RENR9313-04
g01180562
Illustration 88
HEUI injector
RENR9313-04 171
g01149208
Illustration 89
Schematic for the injector solenoids


tor system uses 90-120 volts.
A. Remove the electrical power from the ECM. A

strong electrical shock hazard is present if the
electrical power is not removed.
g01180156
Illustration 90
A typical left side view
(1) J2/P2 connectors
172 RENR9313-04
B. Thoroughly inspect the connectors. Refer to

g01180583
Illustration 92
J300 terminals that are associated with the injector solenoids
(J300-1) Injector 1 supply
(J300-13) Injector 6 return

wires that are associated with injector solenoids.
D. Check the allen head screws for each ECM

E. Check the harness and the wiring for abrasion

and for pinch points from the P300 injector valve
cover connector back to the ECM.
Expected Result:

Illustration 91
g01099568 are free of corrosion, of abrasion, and of pinch points.
P2 terminals that are associated with the injector solenoids
Results:
(P2-99) Injector 5 & 6 supply
(P2-104) Injector 1 & 2 supply
(P2-105) Injector 6 return • OK – The harness and wiring are OK. Proceed
(P2-106) Injector 3 return to Test Step 2.
(P2-107) Injector 5 return
(P2-115) Injector 3 & 4 supply • Not OK – There is a problem in the connectors
(P2-116) Injector 1 return and/or wiring.
STOP.
RENR9313-04 173
Test Step 2. Check for Logged Diagnostic Expected Result:

Codes
The variation of the fuel rate for all cylinders is within
A. Connect the Caterpillar Electronic Technician (ET) specifications.
Results:
• OK – The variation of the fuel rate for all cylinders
C. Monitor the “Logged Diagnostic Codes” screen is within specifications.
on Cat ET.
Repair: If the engine is misfiring or if the
D. Check Cat ET for logged diagnostic codes related engine has low power, refer to troubleshooting
to the injector solenoids. without a diagnostic code Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”
Expected Result: and the troubleshooting without a diagnostic
code Troubleshooting, “Low Power/Poor or No
There is a diagnostic code that has been logged for Response to Throttle”.
one of the unit injectors.
If a diagnostic code results from running the
Results: “Cylinder Cutout Test”, proceed to Test Step 4.
• OK – There are logged diagnostic codes for the • Not OK – A problem was found with one of the
injectors. Proceed to Test Step 4. cylinders. Proceed to Test Step 4.
• Not OK – There are no logged diagnostic codes Test Step 4. Use the Injector Solenoid
for the injectors. Proceed to Test Step 3. Test to Test the Injector Solenoids
Test Step 3. Check the Variation of the A. Start the engine.
Injectors Between Each of the Cylinders
B. Allow the engine to warm up to normal operating
A. Connect Cat ET to the service tool connector. temperature (approximately 77 °C (171 °F)).
B. Start the engine. C. Stop the engine.
C. Allow the engine to warm up to normal operating D. Restore the electrical power to the ECM.
temperature (approximately 77 °C (171 °F)).
E. Access the “Injector Solenoid Test” by accessing
D. After the engine is warmed to operating the following display screens in order:
temperature, access the “Cylinder Cutout Test” on
Cat ET by accessing the following display screens • “Diagnostics”
in order:
• “Diagnostic Tests”
• “Diagnostics”
• “Injector Solenoid Test”
• “Diagnostic Tests”
F. Activate the test.
• “Cylinder Cutout Test”
Note: The test is in the “Interactive Diagnostic Tests”.
E. Shut off all parasitic loads. Do not confuse the injector solenoid test with the
cylinder cutout test. The cylinder cutout test is used
F. Set the engine speed to 1200 ± 20 rpm. to shut off fuel to a specific cylinder while the engine
is running. The injector solenoid test is used in order
G. Select the start button at the bottom of the screen to actuate the injector solenoids. This allows the click
for the cylinder cutout test. of the injector solenoids to be heard when the engine
is not running in order to determine that the circuit is
H. Select the “4 Cylinder Cutout Test” which is the functioning properly.
default test.
G. As each solenoid is energized by the ECM an
I. Follow the instructions that are provided in the audible click can be heard at the valve cover.
“Cylinder Cutout test”. The cylinder cutout tests Listen for a click at each valve cover. A black
are interactive so the procedure is guided to the square will appear over the cylinder number on
finish. Cat ET as each cylinder is being fired.
174 RENR9313-04
H. Perform the injector solenoid test at least two A. Remove the electrical power from the ECM.
times.
B. Disconnect the J300/P300 injector valve cover
Expected Result: entry connectors.
All cylinders indicate “OK”. C. Fabricate a jumper wire that is long enough to
jumper two terminals at the P300 connector.
Results: Crimp a connector pin to both ends of the wire.
• OK – There is not an electronic problem with the

injectors at this time.
Repair: If the cylinder cutout test returned a

“NOT OK” for any injector, refer to troubleshooting
without a diagnostic code Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable”.
STOP.
• Not OK – Note the cylinders that indicate “OPEN”

and/or “SHORT”. Proceed to Test Step 5.
Test Step 5. Use the Injector Solenoid

g01180674
Test to Check for Shorts in the Engine Illustration 93
Wiring Harness J300/P300 Injector valve cover entry connector (left side engine
view)
P300 terminals that are associated with the injector solenoids
(P300-1) Injector 1 supply
Electrical shock hazard. The electronic unit injec- (P300-3) Injector 3 supply
tor system uses 90-120 volts. (P300-4) Injector 4 supply
A. Remove the electrical power from the ECM. (P300-13) Injector 6 return
B. Disconnect the J300/P300 injector valve cover (P300-16) Injector 3 return
entry connector at the valve cover base. (P300-17) Injector 2 return
D. Insert one end of the jumper wire into the
D. Perform the injector solenoid test at least two connector socket for supply wire of the problem
times. injector. Insert the other end of the jumper wire
into the appropriate socket for the suspect injector
Expected Result: in the P300 valve cover connector. For example, if
injector 5 is the problem injector, insert the jumper
All cylinders indicate “OPEN”. into terminal 5 and into terminal 8 of the P300
injector valve cover entry connector.
Results:
E. Restore the electrical power to the ECM.
• OK – Proceed to Test Step 6.
F. Perform the injector solenoid test at least two
• Not OK – Record the cylinder numbers that times.
indicate a short circuit. Proceed to Test Step 7.
G. Remove the electrical power from the ECM.
Test Step 6. Use the Injector Solenoid
Test to Check for Opens in the Engine H. Repeat this test for each suspect Injector. Ensure
Wiring Harness that the injector solenoid test is disabled before
handling the jumper wires.
Expected Result:
Electrical shock hazard. The electronic unit injec- Cat ET displays “SHORT” for the cylinder with the
tor system uses 90-120 volts. jumper wire.
RENR9313-04 175
Results: Verify that the repair eliminates the problem.
• OK 1 - “SHORT” – The results that were recorded STOP.

from Test Step 4 indicated that only one injector
had an “OPEN” or “SHORT”, or that one injector • Not OK – At least one cylinder indicates “SHORT”.
had an “OPEN” but the other injector on the
injector's supply line had a “SHORT”. Proceed to Repair: Replace the ECM. Refer to electronic
Test Step 9. troubleshooting Troubleshooting, “Replacing the
ECM”. Verify that the repair eliminates the problem.
• OK 2 - “SHORT” – The results that were recorded
from Test Step 4 indicated that two injectors that STOP.
share an injector's supply line are open. Proceed
to Test Step 10. Test Step 8. Check the ECM for an Open
Circuit
• OK 3 - “SHORT” – The results that were recorded
from Test Step 4 indicated that two injectors that
share an injector's supply line are shorted. Proceed
to Test Step 11. Electrical shock hazard. The electronic unit injec-
• Not OK - “OPEN” – Cat ET displays “Open” for
the cylinder with the jumper wire. Proceed to Test
Step 8. A. Remove the electrical power from the ECM.
Test Step 7. Use the Injector Solenoid B. Disconnect the J2/P2 ECM connectors. Install a
Test to Check the ECM for Short Circuits breakout T to the ECM. Do not connect the P2
ECM connector to the breakout T.
C. Use a jumper wire to short between the socket

of the injector and the socket for the supply line
of the suspect injector.
E. Perform the injector solenoid test at least two
B. Disconnect the J2/P2 ECM connectors. Check times.
for evidence of moisture entry or damage to the
connector terminals. Note: When the ECM connector is disconnected
all of the diagnostic codes for supply voltage to the
C. Restore the electrical power to the ECM. sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.
D. Perform the injector solenoid test at least two
times. F. Remove the electrical power from the ECM.
All cylinders indicate “OPEN” when the P2 ECM Cat ET displays “SHORT” for the cylinder with the
connector is disconnected from the ECM. jumper wire.
Note: When the engine harness is disconnected Results:

all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of • OK – The ECM is OK.
these diagnostic codes after completing this test step.
Repair: There is a open in the harness between
Results: the P300 injector valve cover entry connector
and the P2 ECM connector. Replace the engine
• OK – All cylinders indicate “OPEN”. harness or repair the engine harness, as required.
Repair: The short circuit is in the engine harness.
Repair the engine harness or replace the engine STOP.
harness, as required. Clear all diagnostic codes
after completing this test step. • Not OK
176 RENR9313-04
Repair: Replace the ECM. Refer to electronic Repair: Replace both injectors. Verify that the
troubleshooting Troubleshooting, “Replacing the repair eliminates the problem.
ECM”. Verify that the repair eliminates the problem.
STOP.
STOP.
Test Step 10. Check the Engine Harness
Test Step 9. Check the Injector Harness Under the Valve Cover for an Open
Under the Valve Cover Circuit in the Supply Line
Electrical shock hazard. The electronic unit injec- Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts. tor system uses 90-120 volts.
A. Remove the electrical power from the ECM. A. Remove the electrical power from the ECM.
B. Remove the valve cover. B. Remove the valve cover.
C. Disconnect each of the injectors that indicate an C. Disconnect each of the injectors that indicate an
“OPEN” from the wiring harness. Ensure that each “OPEN” from the wiring harness. Ensure that each
of the connectors from the disconnected injector of the connectors from the disconnected injector
harness does not touch other components and harness does not touch other components and
short to ground. short to ground.
D. Attach a jumper wire to both terminals of the
injector harness for the two injectors that share
a supply line.
E. Restore the electrical power to the ECM.
F. Perform the injector solenoid test at least two

times.
G. Remove the electrical power from the ECM.
Expected Result:
The cylinders with the short in place indicate an

“OPEN”. Illustration 94
g01180694
Connector terminals for the solenoid connector

Results:
D. Attach a jumper wire to both terminals of the
• OK – The problem appears to be in the engine injector harness for the two injectors that share
harness under the valve cover. a supply line.
Repair: Perform the following repair: E. Restore the electrical power to the ECM.
1. Replace the engine harness under the valve F. Perform the injector solenoid test at least two
cover. times.
2. Run the injector solenoid test in order to check Expected Result:
the installation of the new harness before
installing the valve covers. Verify that the repair The cylinders with the short in place indicate an
eliminates the problem. “OPEN”.
3. Results:
STOP. • OK – The problem appears to be in the engine
harness under the valve cover.
• Not OK – Both injectors indicate “SHORT”.
Repair: Perform the following repair:
RENR9313-04 177
1. Replace the engine harness under the valve Repair: Replace the injector harness under the
cover. valve cover. Verify that the repair eliminates the
problem.
2. Run the injector solenoid test in order to check
the installation of the new harness before STOP.
installing the valve covers. Verify that the repair
eliminates the problem. Test Step 12. Check for a Short Circuit in
the Supply Line to the Engine
STOP.
• Not OK – Both injectors indicate “SHORT”.

Repair: Replace both injectors. Verify that the Electrical shock hazard. The electronic unit injec-
repair eliminates the problem. tor system uses 90-120 volts.
STOP. A. Remove the electrical power from the ECM.

Test Step 11. Check the Engine Harness B. Disconnect the J2/P2 ECM connector.
Under the Valve Cover for Short Circuits
in the Injector Wires C. Locate the supply line for the problem injector in
the P2 connector. Measure the resistance from
the terminal to the engine ground stud connection.
Expected Result:
The multimeter indicates that the resistance is
greater than five Ohms.
Results:
B. Remove the valve cover.
• OK – The harness is not shorted to ground.
C. Disconnect each of the injectors that indicate a
“SHORT” from the wiring harness. Ensure that Repair: Reconnect the engine harness to the ECM.
each of the connectors from the disconnected
injector harness does not touch other components Proceed to Test Step 13.
and short to ground.
• Not OK
Repair: Replace the injector harness under the
E. Perform the injector solenoid test at least two valve cover. Verify that the repair eliminates the
times. problem.
F. Remove the electrical power from the ECM. STOP.
Expected Result: Test Step 13. Check for a Short Circuit in

the Injector
Both cylinders indicate an “OPEN”.
Results:
• OK – Neither of the injector wires are shorted to tor system uses 90-120 volts.
the engine.
Repair: Leave the injector wires disconnected. A. Remove the electrical power from the ECM.
Proceed to Test Step 12. B. Reconnect one of the two disconnected injectors.
• Not OK – There is a short in the injector harness C. Restore the electrical power to the ECM.
under the valve cover.
times.

178 RENR9313-04
Expected Result: i02466132
The reconnected injector indicates a “SHORT”. Switch Circuits - Test

Results: SMCS Code: 1435-038
• OK – The injector has an internal short. System Operation Description:
Repair: Replace the Injector. Verify that the repair Switch circuits may have problems such as faulty
eliminates the problem. wiring, faulty switches, or faulty connectors. Use the
following diagnostic procedures in order to diagnose
STOP. problems with these switch circuits and repair these
switch circuits:
• Not OK – The injector is OK. There may be a
problem with the other injector. Proceed to Test • “Trolling mode switch”
Step 14.
• “Slow vessel mode switch”
Test Step 14. Check for a Short Circuit
in the Other Injector • “Maintenance clear switch”
• “Trip clear switch”
• “Remote shutdown switch”
tor system uses 90-120 volts. • “Synchronize switch 1”
A. Remove the electrical power from the ECM. • “Synchronize switch 2”
B. Reconnect the other disconnected injector.

times.
Expected Result:
The reconnected injector indicates a “SHORT”.
Results:
• OK – The injector has an internal short.

Repair: Replace the faulty injector. Restore the
wiring to the proper injectors.
STOP.
• Not OK – This injector is OK.

Repair: There may be an intermittent problem. If
the problem is intermittent, refer to the diagnostic
STOP.
RENR9313-04 179
g01230589
Illustration 95
Schematic for the switch inputs
Test Step 1. Check the Electrical B. Thoroughly inspect connectors (1), and (2).
Connectors and the Wiring Thoroughly inspect the connections for the
suspect switch. Refer to the diagnostic functional
A. Remove the electrical power from the ECM. test Troubleshooting, “Electrical Connectors -
Inspect”.
g01230043
Illustration 96
Engine components for the switch inputs
(2) J61/P61 customer connector
180 RENR9313-04
g01180881
Illustration 98
J61/P61 terminals that are associated with the switch inputs
(3) −Battery
(19) “Trip clear switch”
(36) “Remote shutdown switch”
(37) “Trolling mode switch”
(38) “Slow vessel mode switch”
(39) “Maintenance clear switch”
(34) “Synchronize switch 1”
(35) “Synchronize switch 2”

wires in the circuit for the suspect switch.
g01149211
Illustration 97 D. Check the allen head screw on the connector
P1 terminals for the various switches for the Electronic Control Module (ECM) for the
(P1-22) “Remote shutdown switch”
proper torque. Refer to the diagnostic functional
(P1-23) “Maintenance clear switch” test Troubleshooting, “Electrical Connectors -
(P1-40) “Trip clear switch” Inspect” for the correct torque values.
(P1-41) “Trolling mode switch”
(P1-59) “Slow vessel mode switch” E. Check the allen head screw on the customer
(P1-63) −Battery
(P1-35) “Synchronize switch 1” connector for the proper torque. Refer to the
(P1-44) “Synchronize switch 2” diagnostic functional test Troubleshooting,
F. Check the harness and wiring for abrasions and

for pinch points from the battery to the ECM.
Expected Result:

are free of corrosion, of abrasion or of pinch points.
Results:
• OK – The wiring and connectors are OK. Proceed

to Test Step 2.
• Not OK – There is a problem with the wiring and/or

a connector.
RENR9313-04 181
Repair: Repair the wiring and/or the connector. Results:

seals are properly connected. Verify that the repair • OK – When the switch is not activated, the
eliminates the problem. resistance measurement indicates an open circuit.
When the switch is activated, the resistance
STOP. measurement indicates a short circuit. The switch
is operating correctly. The wiring does not have a
Test Step 2. Test the Switch for Proper short circuit or an open circuit.
Operation
Repair: Operate the engine and check the switch
A. Disconnect the P1 connector. for proper operation.
B. Refer to Table 31. Determine the P1 terminal for If the switch does not operate correctly, there may
the suspect switch. be a short circuit between the circuit for the suspect
switch and another circuit. Carefully reinspect the
Table 31 components. Refer to the diagnostic functional test
Terminals for the Switch Inputs Troubleshooting, “Electrical Inspectors - Inspect”.
Locate the short circuit and make repairs.
Name of the J61/P61
P1 Terminals
Switch Terminals STOP.
“Trolling mode
41 37
switch” • Not OK – Both resistance measurements indicate
an open circuit or both resistance measurements
“Slow vessel
59 38 indicate a short circuit. There is a problem with the
mode switch”
circuit for the switch.
“Maintenance
23 39
clear switch” Repair: The problem could be in the switch, in the
“Trip clear
wiring, or in a connector.
40 19
switch”
Carefully reinspect the components. Refer to
“Remote the diagnostic functional test Troubleshooting,
22 36
shutdown switch” “Electrical Inspectors - Inspect”.
“Synchronize
35 34 If the inspection does not identify the faulty
switch 1”
component, replace the switch and test the switch
“Synchronize again.
44 35
switch 2”
If the problem is not resolved, repair the wiring or
C. Connect a meter lead to the P1 terminal for the the connector. Replace parts, if necessary. Verify
suspect switch. Connect the other meter lead to that the problem is resolved.
engine ground.
STOP.
Note: Wiggle the harnesses during the following
i02379340
conditions.
D. Measure the resistance between the P1 terminal

Throttle Position Sensor
for the suspect switch and engine ground. Circuit - Test
E. Activate the switch and measure the resistance SMCS Code: 1439-038; 1913-038
again.
Expected Result:
Note: If the vessel is equipped with a Multi-Station
When the switch is not activated, the resistance Control System (MSCS), refer to Service Manual,
measurement indicates an open circuit. When the RENR7651, “Marine Multi-Station Control System”
switch is activated, the resistance measurement for the proper troubleshooting procedure.
indicates a short circuit.
182 RENR9313-04
The use of a Throttle Position Sensor (TPS) If one of the above diagnostic codes is active,
eliminates the need for a mechanical throttle and troubleshoot that code before you continue with
governor linkages. The TPS converts a lever this procedure. If you suspect a problem with the
movement by the operator into an electrical signal. synchronization switch, refer to diagnostic functional
The electrical signal is sent to the engine's Electronic tests Troubleshooting, “Engine Synchronization
Control Module (ECM). The ECM processes the Switch Circuit - Test”.
signal in order to control the engine speed.
This troubleshooting procedure verifies that the
A Pulse Width Modulated signal (PWM) is created signal from a TPS is valid at the ECM.
by the TPS. The duty cycle varies with the throttle
position. The signal has a low duty cycle when the When you make repairs to the circuit for the
throttle is at low idle. The signal has a high duty cycle TPS, follow the guidelines in Special Instruction,
when the throttle is at high idle. REHS1187, “Electronic Installation Guide”. This
document provides information that will ensure that
the TPS is protected from transient voltages and from
problems that are caused by improper grounding.
Two throttle position sensors are shown in Illustration

100. A vessel may contain more than one TPS. Each
TPS may be connected to more than one ECM. Refer
to the vessel's schematic diagram for the actual
configuration. Use this procedure to troubleshoot all
possible configurations.
g01122143
Illustration 99
Duty cycle versus throttle position
The signal that is produced by the TPS has a

variable frequency. The frequency of the signal must
be between 150 Hz and 1050 Hz or the ECM will
activate an -08 diagnostic code. Use this procedure
to troubleshoot these diagnostic codes:
• 91-08 Throttle Position signal abnormal

• 1249-08 Secondary Throttle Position signal
abnormal
A problem with the circuit for the synchronization

switch may prevent the ECM from responding to
a valid signal from the TPS. The following active
diagnostic codes will also prevent the ECM from
responding to the throttle input:
• 91-13 Throttle Position Calibration required

• 268-02 Check Programmable Parameters
• 1249-13 Secondary Throttle Position Calibration
required
RENR9313-04 183
g01136782
Illustration 100
Typical schematic for the throttle position sensor
Test Step 1. Verify that the “Secondary Verify that the repair eliminates the problem.
Throttle Enable” Parameter is
Programmed Correctly STOP.
A. Connect the Caterpillar Electronic Technician (ET) Test Step 2. Inspect the Electrical
to the service tool connector. Connectors and the Wiring
B. Establish communication with the ECM that A. Remove the electrical power from the ECM.
activated the 08 diagnostic code.
C. Verify that the “Secondary Throttle Enable” status

is programmed correctly.
a. If the engine is equipped with a single TPS,

verify that the “Secondary Throttle Enable”
parameter is programmed to “Disabled”.
b. If the engine is equipped with multiple throttle

position sensors, verify that the “Secondary
Throttle Enable” parameter is programmed to
“Enabled”.
Expected Result:
The “Secondary Throttle Enable” parameter is

programmed correctly.
Results:
• OK – The “Secondary Throttle Enable” parameter Illustration 101

g01146374
is programmed correctly. Proceed to Test Step 2.
Engine view (typical example)
• Not OK – The “Secondary Throttle Enable” (1) J1/P1 ECM connector

parameter is not programmed correctly.
Repair: Program the “Secondary Throttle Enable”

parameter to the correct value.
184 RENR9313-04
g01146383
Illustration 102
Engine view (typical example)
(2) P61 Customer connector
B. Thoroughly inspect connectors (1) and (2).

Inspect the connections on each throttle position
sensor. Refer to diagnostic functional tests
g01127049
Illustration 103
P1 terminals that are associated with the throttle position sensor
(P1-66) Primary throttle position
(P1-68) Secondary throttle position
RENR9313-04 185

seals are properly connected. Verify that the repair
eliminates the problem.
STOP.
Test Step 3. Check for Supply Voltage at

the Throttle Position Sensor
A. Disconnect the harness connector from the
suspect throttle position sensor.
C. Measure the voltage between terminals A and B

on the harness connector for the throttle position
sensor.
Expected Result:
The supply voltage is at least 11 VDC for a 12 volt

system. The supply voltage is at least 22 VDC for a
24 volt system.
Results:
g01188002
• OK – The supply voltage is at least 11 VDC for a
Illustration 104 12 volt system. The supply voltage is at least 22
J61/P61 terminals that are associated with the throttle position VDC for a 24 volt system. The supply voltage is
sensor reaching the sensor. Proceed to Test Step 4.
(10) Primary throttle position
(4) Secondary throttle position • Not OK – The supply voltage is incorrect.
C. Perform a 45 N (10 lb) pull test on each of the Repair: The configuration of the wiring between
wires that are associated with the throttle position the battery and the throttle position sensor depends
sensor. on the vessel's configuration. The problem could
be in the wiring or in a connector. There may be a
D. Check the allen head screw on the customer problem with the battery.
connector and on each ECM connector for the
proper torque. Refer to diagnostic functional tests Perform the necessary repairs. When you make
Troubleshooting, “Electrical Connectors - Inspect” repairs to the wiring for the TPS, follow the
for the correct torque values. guidelines in Special Instruction, REHS1187,
“Electronic Installation Guide”. Verify that the
E. Check the harness and wiring for abrasions and problem is resolved.
for pinch points from each throttle position sensor
to the ECM and from the throttle position sensor STOP.
to the electrical power source.
Test Step 4. Check the Signal Wire for a
Expected Result: Short Circuit
All connectors, pins, and sockets are completely A. Remove the electrical power from the ECM.
are free of corrosion, of abrasion or of pinch points. B. Disconnect the P1 connector from every ECM on
the vessel. Verify that the electrical connector
Results: for the suspect throttle position sensor is
disconnected.
• OK – The wiring and the connectors appear to be
OK. Proceed to Test Step 3. Note: Be sure to wiggle the harnesses during the
following measurements. Be sure to wiggle each
• Not OK – There is a problem with the wiring and/or harness near each connector.
the connectors.
186 RENR9313-04
C. Measure the resistance between terminal P1-66 Test Step 6. Check the Frequency of the
and all of the other terminals in the P1 connector Throttle Position Signal at the Sensor
for the ECM that activated the -08 diagnostic code.
A. Connect the Cat (ET) to the service tool
Expected Result: connector. Refer to electronic troubleshooting
Troubleshooting, “Electronic Service Tools”.
Each resistance measurement indicates an open
circuit. B. Connect a breakout T between the harness
connectors (3 pin) for the throttle position sensor.
Results:
C. Connect a multimeter between terminals B and C
• OK – Each resistance measurement indicates an on the breakout T.
open circuit. Connect the P1 connectors. Proceed
to Test Step 6. D. Restore the electrical power to the ECM.
• Not OK – At least one resistance measurement E. Measure the frequency of the throttle position
does not indicate an open circuit. signal. Slowly move the throttle from low idle to
high idle and back to low idle while you measure
Repair: There is a problem with the signal wire for the frequency of the signal.
the throttle position sensor. The problem could be
in the wiring or in a connector. Repair the wiring F. Use Cat ET to check for active diagnostic codes.
and/or the connector, when possible. Replace Slowly move the throttle from the low idle position
parts, if necessary. Verify that the problem is to the high idle position. Look for an 08 diagnostic
resolved. code while you move the throttle.
STOP. Expected Result:
Test Step 5. Check the Signal Wire for an The frequency of the signal remains between 150
Open Circuit Hz and 1050 Hz as you move the throttle. An -08
diagnostic code is not activated.
Note: Be sure to wiggle the harnesses during the
following measurement. Be sure to wiggle each Results:
harness near each connector.
• OK – The frequency of the signal remains between
Measure the resistance between terminal P1-66 for 150 Hz and 1050 Hz as you move the throttle. An
the ECM that activated the 08 diagnostic code and 08 diagnostic code is not activated.
terminal C of the harness connector for the suspect
TPS. Repair: Perform the following procedure:
Expected Result: 1. Remove the electrical power from the ECM.
The resistance measurement is less than ten Ohms. 2. Remove the breakout T.
Results: 3. Connect the harness connectors for the throttle

position sensor.
• OK – The resistance measurement is less than
ten Ohms. Connect all of the electrical connectors. 4. Restore the electrical power to the ECM.
5. Operate the throttle throughout the entire range.
• Not OK – The resistance measurement is greater
than ten Ohms. There is a problem with the signal If the problem does not recur, the problem is
wire. resolved. The original problem was probably
caused by a poor electrical connection. Return
Repair: The problem could be in the wiring or in a the engine to service.
connector. Repair the wiring and/or the connector,
when possible. Replace parts, if necessary. Verify STOP.
• Not OK – The frequency of the signal is incorrect.
STOP. A 91-08 diagnostic code is activated.

RENR9313-04 187
2. Replace the throttle position sensor. Check for

an 08 diagnostic code again.
If the diagnostic code does not recur, the

problem is resolved. Return the engine to
service.
If the diagnostic code recurs, replace the

ECM. Refer to electronic troubleshooting
Troubleshooting, “Replacing the ECM”. Verify
STOP.
i02466138
Transmission Oil Temperature

Sensor Open or Short Circuit
- Test
SMCS Code: 1439-038-T3; 3194-038

problems with the marine transmission oil
temperature sensor.
• 177-03 Transmission Oil Temperature open/short

to +batt
• 177-04 Transmission Oil Temperature short to

ground
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect a problem in the
signal circuit. When the ECM detects the presence
of a voltage that is above a threshold on the signal
circuit, the ECM will generate a 03 diagnostic code
for the sensor.

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
disconnected at the sensor connector, the absence
of pull-up voltage at the sensor connector indicates
a problem in the signal wire. If the sensor is
disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
voltage, the signal wire may be shorted to another
wire in the harness.
188 RENR9313-04
g01230070
Illustration 105
Schematic for the marine transmission oil temperature sensor

g01130316
Illustration 106
Engine components that are associated with the marine
transmission oil temperature sensor
(1) J137/P137 connector for the marine transmission oil
temperature sensor
B. Thoroughly inspect connectors (2). Inspect

the connectors for the sensor (1). Refer to
the diagnostic functional test Troubleshooting, g01230077
Illustration 107
“Electrical Connectors - Inspect”. P2 terminals that are associated with the marine transmission oil
temperature sensor
(P2-93) Return
(P2-27) Marine transmission oil temperature
(P2-81) +5 VDC
RENR9313-04 189
C. Monitor the active diagnostic code screen on Cat

ET. Check and record any active diagnostic codes.

D. Look for an 03 diagnostic code or an 04 diagnostic

code for the marine transmission oil temperature
sensor.
Expected Result:
g01134372
Illustration 108
J137 harness connector for the marine transmission oil Results:
temperature sensor
(A) Supply • OK – No diagnostic codes are active.
(B) Return
(C) Signal
Repair: The problem may have been related
to a faulty connection in the harness. Carefully
C. Perform a 45 N (10 lb) pull test on each of
reinspect the connectors and wiring. Refer to
the wires that are associated with the marine
transmission oil temperature sensor.
STOP.
“Electrical Connectors - Inspect”. • Not OK – An 04 diagnostic code is active. Proceed
to Test Step 3.
for pinch points from the marine transmission oil • Not OK – An 03 diagnostic code is active. Proceed
to Test Step 5.
temperature sensor to the ECM.
Expected Result:
the Harness Connector for the Sensor
B. Disconnect the harness connector for the sensor.
Results:
• OK – The connectors and wiring are OK. Proceed D. Measure the voltage between terminals A (5
to Test Step 2.
V analog supply) and B (sensor return) at the
harness connector for the sensor.
and/or wiring.
F. Connect the sensor's harness connectors.
Expected Result:
Results:
STOP.
Test Step 2. Check for Active Diagnostic • OK – The voltage is 5.0 ± 0.2 VDC. The voltage is
correct. Proceed to Test Step 4.
Codes
A. Connect the Caterpillar Electronic Technician (ET) • Not OK – The voltage is not 5.0 ± 0.2 VDC. The
voltage is incorrect.
190 RENR9313-04
Repair: Perform the diagnostic functional test Note: Monitor the “Active Diagnostic Codes” screen
Troubleshooting, “Analog Sensor Supply Circuit - on Cat ET before installing the jumper wire and after
Test”. installing the jumper wire.
STOP. E. Remove the jumper wire. Check for an 04

diagnostic code again.
Test Step 4. Disconnect the Sensor in
Order to Create an Open Circuit F. Remove the electrical power from the ECM.
A. Remove the electrical power from the ECM. Expected Result:
B. Disconnect the harness connector for the sensor. An 04 diagnostic code is active when the jumper wire
is installed. An 03 diagnostic code is active when the
C. Restore the electrical power to the ECM. Wait at jumper wire is removed.
least 30 seconds for activation of the diagnostic
codes. Results:
D. Access the “Active Diagnostic Codes” screen on • OK – The engine harness and the ECM are OK.
Cat ET and check for an active 03 diagnostic code
for the sensor. Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor in
E. Remove the electrical power from the ECM. the transmission. Verify that there are no active
diagnostic codes for the sensor. If there are no
Expected Result: active diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic
An 03 diagnostic code is now active for the sensor. codes.
Results: STOP.
• OK – An 04 diagnostic code was active before • Not OK – The 03 diagnostic code remains active
disconnecting the sensor. An 03 diagnostic code with the jumper in place. Proceed to Test Step 6.
became active after the sensor was disconnected.
Test Step 6. Check the Operation of the
Repair: Temporarily connect a new sensor to ECM
the harness, but do not install the new sensor in
the transmission. Verify that there are no active A. Remove the electrical power from the ECM.
diagnostic codes for the sensor. If there are no
active diagnostic codes for the sensor, permanently B. Check the operation of the ECM by creating an
install the new sensor. Clear any logged diagnostic open circuit at the ECM:
codes.
a. Remove terminal P2-27 (signal).
b. Remove terminal P2-93 (return).
STOP.
c. Restore the electrical power to the ECM.
• Not OK – The 04 diagnostic code is still present. Monitor the “Active Diagnostic Code” screen on
Leave the sensor disconnected. Proceed to Test Cat ET. Wait at least 30 seconds for activation
Step 6. of the code.
Test Step 5. Create a Short at the Harness An 03 diagnostic code should be active for the
Connector sensor.
A. Remove the electrical power from the ECM. C. Check the operation of the ECM by creating a
short at the ECM:
B. Install a jumper wire between terminals B and C
on the harness connector for the sensor. a. Install a wire jumper between terminals P2-27
(signal) and P2-93 (return).
b. Monitor the “Active Diagnostic Code” screen on
D. Wait at least 30 seconds for activation of the 04 Cat ET. Wait at least 30 seconds for activation
diagnostic code. of the code.
RENR9313-04 191
An 04 diagnostic code should be active when

the wire jumper is installed.
c. Remove the wire jumper. Return all wiring to

the original configuration.
Expected Result:
An 03 diagnostic code is active when the signal

wire is removed from the ECM connector. An 04
diagnostic code is active when the signal wire is
connected to the return wire.
Results:
• OK – The ECM is working properly. The problem

is in the wiring between the ECM and the harness
connector. There may be a problem in a connector.
Repair: Repair the wire and/or the connector.

Replace parts, if necessary.
STOP.
• Not OK – One of the following conditions exists:

The 03 diagnostic code is not active when the
sensor signal wire is disconnected. The 04
is installed.

ECM”. Verify that the original problem is resolved.
STOP.
192 RENR9313-04
Calibration Procedures
i03447401
Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1439-524; 1912-524
Use this procedure if the diagnostic code in Table

32 is active.
Table 32
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
22-13 “Engine Timing Calibration A timing calibration is required for a The code is logged.
Not Performed” new engine. A timing calibration is also
required after a repair to the front gear
261-13 Engine Timing Calibration train, the camshaft, or the crankshaft
calibration required has been completed. The code may
also become active after replacing
an Electronic Control Module (ECM)
that fails to communicate.
261-11 Engine Timing Offset fault The wiring to the sensors may The code is logged.
have the wrong polarity. There
may be a mechanical problem with
the front gear train.
The ECM has the ability to compensate for Table 33

mechanical differences between the Top Center (TC) Required Special Tools
of the flywheel and the TC of the timing gear on the
camshaft. Part Number Description
7X-1171 Transducer Adapter
An “Engine Timing Calibration Not Performed” code
is activated if a timing calibration is required. 6V-2197 Transducer
7X-1695 Cable As
TC of the Flywheel – The ECM determines the
TC of the flywheel via a signal from a magnetic 170-3519 Harness (1)
transducer. The transducer is installed into the side (1) This item is not required if the engine harness has a connector
of the engine block. The transducer creates a signal for timing calibration.
as a notch on a crankshaft counterweight rotates
past the transducer. Test Step 1. Install the Transducer
Adapter
TC of the Timing Gear – The ECM determines the
TC of the timing gear by signals from the engine A. Remove the electrical power from the ECM.
speed/timing sensors.
B. Use the appropriate engine turning tool to put
Any offset between the TC of the flywheel and the either the No. 1 piston or the No. 6 piston at top
TC of the timing gear is stored into the memory of center. Refer to the Systems Operation/Testing
the ECM. and Adjusting.
Note: A timing calibration will not increase the C. Refer to Table 34. After the top center position has
available engine power. been located, rotate the crankshaft for the number
of degrees that is applicable to your engine model.
Table 33 lists the special tools that are required in Be sure to rotate the crankshaft in the direction of
order to perform this procedure. rotation that is specified in the Table.
RENR9313-04 193
Table 34 A. Apply clean engine oil to a 2D-6392 O-Ring Seal.

Crankshaft Rotation
Install the O-ring seal on the end of the 6V-2197
Transducer.
Engine Number of Direction of Rotation
Model Degrees B. Push the transducer through the transducer
C7 100 Normal Rotation adapter until the transducer contacts the
crankshaft counterweight.
C-9 85 Normal Rotation
C-10 60 Opposite Normal Rotation C. Withdraw the transducer 1.0 mm (0.04 inch) and
hand tighten the nut on the adapter sleeve in
C11 75 Normal Rotation order to secure the transducer. Move the O-ring
C-12 60 Opposite Normal Rotation seal against the adapter.
C13 75 Normal Rotation Continue to the next test step.

C-15 60 Opposite Normal Rotation
Test Step 3. Connect the 7X-1695 Cable
C15 60 Opposite Normal Rotation As
C-16 60 Opposite Normal Rotation
A. If the engine harness is equipped with a connector
C18 30 Opposite Normal Rotation for timing calibration, connect the 7X-1695 Cable
As to the connector for timing calibration and to
D. Refer to Table 35. Locate the engine's timing the transducer.
calibration port.
Note: In certain applications, the engine uses the port

as a return for the crankcase breather fumes. Detach
the hose fitting in order to install the timing probe.
Table 35
Location of the Timing Calibration Port
Engine Crankshaft Engine Location
Model Counterweight
C7 3 Left Side
C-9 3 Left Side
C-10 8 Right Side
C11 8 Left Side
C-12 8 Right Side
C13 8 Left Side
C-15 2 Left Side
C15 2 Left Side
C-16 2 Left Side
C18 2 Left Side
E. Remove the plug from the timing calibration port. Illustration 109
g01345358
Connecting the 7X-1695 Cable As to an ADEM III ECM

F. Thread the transducer adapter into the port.
Test Step 2. Install the Transducer
NOTICE
If the crankshaft is not in the correct position when the
transducer is installed, the transducer will be damaged
when the engine is started.
194 RENR9313-04
d. Install the yellow wire of the 170-3519

Harness into the appropriate location.
Note: Ensure that each wire is installed into the

correct location. The timing calibration will not be
successful if the wires are installed incorrectly.
e. Connect the 7X-1695 Cable As to the

connector for timing calibration and to the
transducer.
Test Step 4. Start the Engine and Check

for Diagnostic Codes
A. Connect Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.
B. Start the engine and run the engine until the

engine is at the normal operating temperature.
C. Check for active diagnostic codes. Wait at least 30

seconds in order for the codes to become active.
The engine must not have any active diagnostic

g01345359
codes during the timing calibration except for a
Illustration 110 261-13 Engine Timing Calibration required.
Connecting the 7X-1695 Cable As to an ADEM IV ECM
Expected Result:
B. If the engine harness is not equipped with a
connector for timing calibration, perform the There are no active diagnostic codes or there is only
following procedure: a code for timing calibration that is active at this time.
Note: Refer to Illustration 109 or 110. The 170-3519 Results:

Harness can be connected to the P1 connector or
to the P2 connector. Select the connector with the • OK – There are no active diagnostic codes or there
easiest access. is only a code that is active for timing calibration at
this time. Proceed to Test Step 5.
a.
• Not OK – There is at least one active code that is
Table 36 not a code for timing calibration.
Locations for Connection of the 170-3519 Harness
Repair: Troubleshoot and repair any active
Locations Locations Locations diagnostic codes before you continue with this
on the on the on the P1 procedure.
Wire Color 70−pin P2 120−pin Connector
Connector P2
Connector STOP.
White 22 26 24 Test Step 5. Calibrate the Engine

Yellow 23 36 25 Speed/Timing Sensor
A. Set the engine speed to 1100 ± 50 rpm. The
b. Refer to Table 36. Remove the sealing plugs engine speed must be steady within this rpm
from the appropriate terminals. Do not discard range in order for the calibration to be successful.
the sealing plugs. The sealing plugs may
be reinstalled when the timing calibration is B. After the engine has warmed up, access the
complete. “Timing Calibration” screen on the Cat ET. Access
the following display screens in order:
c. Disregard the pin-outs on the label of the
harness. Install the white wire of the 170-3519 • Service
Harness into the appropriate location.
RENR9313-04 195
• Calibrations • Verify that the timing calibration probe is installed

correctly.
• Timing Calibration
• Verify that the engine speed is correct and that
C. To calibrate the timing, select “Continue” on Cat the engine speed is stable. If the engine speed
ET. Wait until Cat ET indicates that the timing is is unstable, refer to troubleshooting without
calibrated. a diagnostic code Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable”.
Expected Result:
• There may be a problem with the transducer or
Cat ET indicates that the timing is calibrated. with the cables. Obtain a new transducer and/or
a new cable and repeat the timing calibration.
Results:
STOP.
• OK – Cat ET indicates that the timing is calibrated.
i02466264
1. Set the engine speed to low idle.

Throttle Position Sensor -
Calibrate
Note: Disconnect the 7X-1695 Cable As before
you exit the “Timing Calibration” screen. Otherwise, SMCS Code: 1439-524; 1913-524
diagnostic codes may be activated.
2. Disconnect the 7X-1695 Cable As.
Note: If the vessel is equipped with a Multi-Station
3. Exit the “Timing Calibration” screen on Cat ET. Control System (MSCS), refer to Service Manual,
RENR7651, “Marine Multi-Station Control System”
4. Remove the electrical power from the ECM. for the proper troubleshooting procedure.
5. Remove the transducer and remove the adapter. Test Step 1. Check the Throttle for Proper
Operation
6. Install the plug into the timing calibration port.
7. If you installed a 170-3519 Harness, you may
remove the harness or you may permanently B. Inspect the throttle linkage for components with
install the harness for future use. If you remove the following conditions:
the harness, install the sealing plugs into
the unused cavities of the ECM connector. • Loose
Otherwise, moisture and debris will enter the
connector. • Bent
If you choose to permanently install the harness, • Broken
fasten the harness to the existing engine wiring
harness with cable ties. Also, install a 3E-3364 • Missing
Receptacle and two 8T-8737 Seal Plugs on
the 2-pin connector in order to prevent moisture • Worn
and debris from entering the connector.
Note: The sensor stops are not intended to be the
8. Return the engine to service. primary means of limiting the travel of the throttle. If
you apply excessive force to the sensor stops you
STOP. will damage the sensor assembly.
• Not OK – The timing calibration was unsuccessful. C. Move the throttle throughout the entire range. The
throttle should move without binding and without
Repair: The following conditions can cause the excessive drag.
timing calibration to fail:
Expected Result:
• If the crankshaft and camshaft gears have been
reassembled incorrectly, the timing will not The throttle linkage is in good condition. The throttle
calibrate. moves without binding and without excessive drag.
196 RENR9313-04
Results: B. Observe the duty cycle for the throttle position

sensor on Cat ET.
• OK – The throttle linkage is in good condition. The
throttle operates properly. Proceed to Test Step 2. Note: Adjustment of the sensor stops is not
necessary.
• Not OK – One of the following conditions exist:
The throttle linkage is not in good condition. The C. Adjust the throttle linkage in order to achieve a 90
throttle binds or the throttle has excessive drag. to 95 percent duty cycle when the throttle lever is
in the high idle position.
Repair: Identify the source of the mechanical
problem and make repairs. Replace parts, if Expected Result:
necessary.
The duty cycle is between 90 to 95 percent when the
Proceed to Test Step 2 when the throttle operates throttle is in the high idle position.
properly.
Results:
Test Step 2. Adjust the Throttle Linkage
for the Low Idle Position • OK – The duty cycle is between 90 to 95 percent
when the throttle is in the high idle position.
to the service tool connector. Repair: Perform the following procedure:
B. Restore the electrical power to the ECM. Do not 1. Verify that the duty cycle is between five and
start the engine. ten percent when the throttle is in the low idle
position.
C. Place the throttle in the low idle position.
2. Verify that the duty cycle is between 90 and
D. Observe the duty cycle for the throttle position 95 percent when the throttle is in the high idle
sensor on Cat ET. position.
Note: Adjustment of the sensor stops is not If the duty cycle is not correct at either throttle
necessary. position, repeat this procedure.
E. Adjust the throttle linkage in order to achieve a If the throttle linkage cannot be adjusted in order
five to ten percent duty cycle while the throttle is to meet the specifications, replace the throttle
in the low idle position. lever assembly.
Expected Result: Verify that the problem is resolved.
The duty cycle is between five and ten percent when STOP.
the throttle is in the low idle position.
• Not OK – The throttle linkage can not be adjusted
Results: in order to obtain a 90 to 95 percent duty cycle
when the throttle is in the high idle position. There
• OK – The duty cycle is between five and ten is a problem with the throttle linkage.
percent when the throttle is in the low idle position.
Proceed to Test Step 3. Repair: Repair the throttle linkage. Replace parts,
if necessary.
• Not OK – The throttle linkage can not be adjusted
in order to obtain a five to ten percent duty cycle Verify that the problem is resolved.
when the throttle is in the low idle position. There is
a problem with the throttle linkage. STOP.
Repair: Repair the throttle linkage. Replace parts,

if necessary. Verify that the problem is resolved.
STOP.
Test Step 3. Adjust the Throttle Linkage

for the High Idle Position
A. Place the throttle in the high idle position.
RENR9313-04 197
Index Section
Index
A CID 0127 FMI 03 Transmission Oil Pressure
open/short to +batt............................................... 59
Air Inlet Heater Circuit - Test.................................. 83 CID 0127 FMI 04 Transmission Oil Pressure short to
Alternator (Charging Problem and/or Noisy ground.................................................................. 59
Operation)............................................................ 24 CID 0164 FMI 00 High Injector Actuation
Probable Causes ............................................... 24 Pressure .............................................................. 59
Recommended Actions...................................... 24 CID 0164 FMI 02 Injector Actuation Pressure signal
Analog Sensor Supply Circuit - Test ...................... 90 erratic................................................................... 60
high ...................................................................... 60
B CID 0164 FMI 04 Injector Actuation Pressure voltage
low ....................................................................... 61
Battery ................................................................... 24 CID 0164 FMI 11 Injector Actuation Pressure system
Probable Causes ............................................... 24 fault ...................................................................... 61
Recommended Actions...................................... 24 CID 0168 FMI 00 System Voltage High................. 61
CID 0168 FMI 01 System Voltage Low.................. 62
CID 0168 FMI 02 System Voltage intermittent/
C erratic................................................................... 62
CID 0174 FMI 03 Fuel Temperature open/short to
Calibration Procedures ........................................ 192 +batt..................................................................... 62
CAN Data Link Circuit - Test.................................. 95 CID 0174 FMI 04 Fuel Temperature short to
Can Not Reach Top Engine RPM .......................... 24 ground.................................................................. 63
Probable Causes ............................................... 25 CID 0177 FMI 03 Transmission Oil Temperature
Recommended Actions...................................... 25 open/short to +batt............................................... 63
Cat Data Link Circuit - Test.................................. 100 CID 0177 FMI 04 Transmission Oil Temperature short
CID 0001 FMI 11 Cylinder #1 Injector fault............ 53 to ground.............................................................. 63
CID 0002 FMI 11 Cylinder #2 Injector fault............ 53 CID 0190 FMI 11 Engine Speed Sensor mechanical
CID 0003 FMI 11 Cylinder #3 Injector fault............ 53 failure ................................................................... 64
CID 0004 FMI 11 Cylinder #4 Injector fault............ 54 CID 0253 FMI 02 Personality Module mismatch ... 64
CID 0005 FMI 11 Cylinder #5 Injector fault............ 54 CID 0254 FMI 12 Electronic Control Module
CID 0006 FMI 11 Cylinder #6 Injector fault............ 54 Error..................................................................... 64
CID 0042 FMI 11 Inject Actuation Control Valve CID 0261 FMI 13 Engine Timing Calibration
open/short............................................................ 55 required................................................................ 65
CID 0091 FMI 08 Throttle Position signal CID 0262 FMI 03 5 Volt Sensor DC Power Supply
abnormal.............................................................. 55 short to +batt........................................................ 65
CID 0091 FMI 13 Throttle Position calibration CID 0262 FMI 04 5 Volt Sensor DC Power Supply
required................................................................ 55 short to ground..................................................... 65
CID 0094 FMI 03 Fuel Pressure open/short to CID 0263 FMI 03 Digital Sensor Supply short to
+batt..................................................................... 56 +batt..................................................................... 66
CID 0094 FMI 04 Fuel Pressure short to ground... 56 CID 0263 FMI 04 Digital Sensor Supply short to
CID 0096 FMI 03 Fuel Level Sensor open/short to ground.................................................................. 66
+batt..................................................................... 56 CID 0268 FMI 02 Check Programmable
CID 0096 FMI 04 Fuel Level Sensor short to Parameters .......................................................... 66
ground.................................................................. 56 CID 0342 FMI 11 Secondary Engine Speed Sensor
CID 0100 FMI 03 Engine Oil Pressure open/short to mechanical failure................................................ 66
+batt..................................................................... 57 CID 0535 FMI 08 Exhaust Temperature Sensor noisy
CID 0100 FMI 04 Engine Oil Pressure short to signal ................................................................... 67
ground.................................................................. 57 CID 0617 FMI 05 Air Inlet Heater Relay open/current
CID 0102 FMI 03 Boost Pressure Sensor short to below normal ....................................................... 67
+batt..................................................................... 57 CID 0617 FMI 06 Air Inlet Heater Relay
CID 0102 FMI 04 Boost Pressure Sensor short to grounded/current above norm ............................. 67
ground.................................................................. 57 CID 1249 FMI 08 Secondary Throttle Position signal
CID 0105 FMI 03 Inlet Manifold Temp Sensor abnormal.............................................................. 68
open/short to +batt............................................... 58 CID 1249 FMI 13 Secondary Throttle Position
CID 0105 FMI 04 Inlet Manifold Temp Sensor short to calibration required .............................................. 68
ground.................................................................. 58 Coolant in Engine Oil............................................. 26
CID 0110 FMI 03 Engine Coolant Temperature Probable Causes ............................................... 26
open/short to +batt............................................... 58 Recommended Actions...................................... 26
CID 0110 FMI 04 Engine Coolant Temperature short Coolant Level Sensor Circuit - Test ..................... 103
to ground.............................................................. 59
198 RENR9313-04
Index Section
Coolant Temperature Is Too High .......................... 26 Engine Misfires, Runs Rough or Is Unstable......... 31
Probable Causes ............................................... 26 Probable Causes ............................................... 31
Recommended Actions...................................... 26 Recommended Actions...................................... 32
Customer Passwords ............................................ 16 Engine Oil in Cooling System ................................ 32
Probable Causes ............................................... 32
Recommended Actions...................................... 33
D Engine Oil in Exhaust System ............................... 33
Probable Causes ............................................... 33
Diagnostic Code Cross Reference ........................ 50 Recommended Actions...................................... 33
Cross-Reference for Flash Code to SPN-FMI Code Engine Oil Temperature Is Too High...................... 33
to CID-FMI (Diagnostics) or EID (Events) ........ 51 Probable Causes ............................................... 33
Diagnostic Codes .................................................. 49 Recommended Actions...................................... 33
Active Diagnostic Codes .................................... 50 Engine Pressure Sensor Open or Short Circuit -
Diagnostic Codes............................................... 49 Test .................................................................... 120
Logged Diagnostic Codes.................................. 50 Engine Speed/Timing Sensor - Calibrate ............ 192
Diagnostic Functional Tests................................... 83 Engine Speed/Timing Sensor Circuit - Test......... 125
Digital Sensor Supply Circuit - Test ..................... 107 Engine Stalls at Low RPM ..................................... 34
Probable Causes ............................................... 34
E Engine Synchronize Switch Circuit - Test ............ 130
Engine Temperature Sensor Open or Short Circuit -
E015 High Engine Coolant Temperature Derate ... 73 Test .................................................................... 139
E017 High Engine Coolant Temperature Warning.. 74 Engine Vibration .................................................... 35
E025 High Inlet Air Temperature Derate................ 75 Probable Causes ............................................... 35
E027 High Inlet Air Temperature Warning ............. 76 Recommended Actions...................................... 35
E030 High Transmission Oil Temperature Engine Will Not Crank ........................................... 35
Warning ............................................................... 76 Probable Causes ............................................... 35
E039 Low Engine Oil Pressure Derate.................. 77 Recommended Actions...................................... 35
E053 Low Fuel Pressure Warning......................... 78 Engine Wiring Information ..................................... 14
E056 High Fuel Temperature Warning .................. 78 Harness Wire Identification ................................ 14
E057 Low Engine Coolant Level Derate................ 79 Event Codes .......................................................... 69
E059 Low Engine Coolant Level Warning ............. 79 Active of Event Codes........................................ 69
E096 High Fuel Pressure ...................................... 80 Clearing Event Codes ........................................ 70
E100 Low Engine Oil Pressure Warning ............... 80 Logged Event Codes ......................................... 70
E113 High Transmission Oil Pressure ................... 81 Trip Points for the Monitoring System................ 70
E119 Low Fuel Level ............................................. 82 Troubleshooting ................................................. 70
E173 High Exhaust Temperature Warning ............ 82 Excessive Black Smoke ........................................ 36
E190 Engine Overspeed Warning ......................... 82 Probable Causes ............................................... 36
ECM Will Not Accept Factory Passwords.............. 27 Recommended Actions...................................... 36
Probable Causes ............................................... 27 Excessive Engine Oil Consumption....................... 37
Recommended Actions...................................... 28 Probable Causes ............................................... 37
ECM Will Not Communicate with Other Systems or Recommended Actions...................................... 37
Display Modules .................................................. 28 Excessive Fuel Consumption ................................ 37
Electrical Connectors - Inspect............................. 111 Excessive Valve Lash............................................ 38
Electrical Power Supply Circuit - Test................... 116 Probable Causes ............................................... 38
Electronic Service Tool Will Not Communicate with Recommended Actions...................................... 38
ECM..................................................................... 28 Excessive White Smoke ........................................ 39
Electronic Service Tools .......................................... 6 Exhaust Temperature Is Too High ......................... 40
Caterpillar Electronic Technician (ET).................. 7 Probable Causes ............................................... 40
Optional Service Tools ......................................... 6 Recommended Actions...................................... 40
Required Service Tools ........................................ 6
Electronic Troubleshooting ...................................... 5
Engine Cranks but Will Not Start ........................... 29 F
Probable Causes ............................................... 29
Recommended Actions...................................... 29 Factory Passwords ................................................ 16
Engine Has Early Wear ......................................... 31 Flash Codes .......................................................... 49
Probable Causes ............................................... 31 Flash Programming ............................................... 17
Recommended Actions...................................... 31 Programming a Flash File.................................. 17
RENR9313-04 199
Index Section
Fuel Dilution of Engine Oil ..................................... 40 R

Probable Causes ............................................... 40
Recommended Actions...................................... 40 Replacing the ECM.................................................. 9
Fuel Level Sensor Circuit - Test........................... 143
S
I
Self-Diagnostics..................................................... 10
Important Safety Information ................................... 2 Sensors and Electrical Connectors ....................... 10
Indicator Lamp Circuit - Test................................ 146 C7 Marine Engine .............................................. 13
Injection Actuation Pressure - Test ...................... 150 C9 Marine Engines ............................................ 12
Injection Actuation Pressure Control Valve Circuit - Service Information Report.................................... 18
Test .................................................................... 161 Recommendations ............................................. 18
Injection Actuation Pressure Sensor - Test.......... 165 Switch Circuits - Test ........................................... 178
Injector Solenoid Circuit - Test............................. 169 System Configuration Parameters......................... 19
Injector Trim File .................................................... 17 Parameter Descriptions ..................................... 20
Intermittent Engine Shutdown ............................... 41 Parameter Worksheet ........................................ 23
Probable Causes ............................................... 41 System Overview..................................................... 5
Recommended Actions...................................... 41 Passwords ........................................................... 6
Intermittent Low Power or Power Cutout............... 42 Programmable Parameters.................................. 6
Probable Causes ............................................... 42 System Operation ................................................ 5
T
L
Table of Contents..................................................... 3
Low Engine Oil Pressure ....................................... 43 Throttle Position Sensor - Calibrate..................... 195
Probable Causes ............................................... 43 Throttle Position Sensor Circuit - Test ................. 181
Recommended Actions...................................... 43 Transmission Oil Temperature Sensor Open or Short
Low Power/Poor or No Response to Throttle ........ 43 Circuit - Test....................................................... 187
Probable Causes ............................................... 43 Troubleshooting Section.......................................... 5
Recommended Actions...................................... 44 Troubleshooting with a Diagnostic Code ............... 49
Troubleshooting with an Event Code..................... 69
Troubleshooting without a Diagnostic Code .......... 24
M
Marine Transmission Oil Pressure Is Too High ..... 45

Probable Causes ............................................... 45
Marine Transmission Oil Temperature Is Too
High ..................................................................... 45
Probable Causes ............................................... 45
Mechanical Noise (Knock) in Engine..................... 46
Probable Causes ............................................... 46
Recommended Repairs ..................................... 46
Noise Coming from Cylinder.................................. 46

Probable Causes ............................................... 46
Poor Acceleration or Response............................. 47

Probable Causes ............................................... 47
Programming Parameters ..................................... 16
©2009 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Renr9313 04 00 - Manuals Service Modules - Troubleshooting

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RENR9313-04

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Troubleshooting with a Diagnostic Code

Troubleshooting with an Event Code

Diagnostic Functional Tests

Troubleshooting Section Fuel Injection

Injection Actuation Pressure Control Required Service Tools

Electronic Service Tools

Caterpillar electronic service tools are designed to

Table 2 Note: For more information regarding the use of

155-5176 AC/DC Current Probe Part Number Description

285-0910 Multi-Tool Gp N/A Personal Computer (PC)

Table 3 lists the software that is required in order to

Use the following procedure in order to connect Cat

1. Remove the electrical power from the ECM.

2. Connect communications adapter (5) to a

a. Connect cable (4) between the “COMPUTER”

b. Connect cable (3) between the “COMPUTER”

c. Connect cables (2) and (3) between the

(1) Personal computer (PC)

Part Number Description

N/A Personal Computer (PC)

i02488890 b. Print the parameters from the “Configuration”

c. Connect the ECM ground strap.

d. Connect the P1 and P2 connectors. Tighten • Active

The Electronic Control Module (ECM) has the ability

Diagnostic codes can have two different states:

Engine Wiring Information Metric Equivalents for AWG Numbers

The wiring schematics are revised periodically. 20 0.8 14 1.6

If the gauge of the wire is not listed, the wire is 16

Conversion of AWG Numbers to Metric

3. Connect the welding ground cable as close

4. Protect the wiring harness from welding debris

5. Weld the materials by using standard welding

Programming Parameters 4. From the “Factory Password” screen, enter the

i03312021 5. When the “Read Customer Passwords” screen

The electronic service tool can be used to view i02433393

SMCS Code: 0785 Factory passwords are required to perform each of

i02419726 “WinFlash” Error Messages

Caterpillar Electronic Technician (ET) is used to flash i02431150

6. Restore the electrical power to the ECM. Cause of Failure

• Indicate if the diagnostic lamp was flashing.

• Indicate the symptoms of engine operation that are

System configuration parameters are parameters

Some values may be changed by the customer in

If the parameters that are protected with the factory

Note: The “Electronic Control Module (ECM)

The system configuration parameters are arranged in

Fuel Correction Error -63.5 to +63.5 0 Customer

Off, Man Hour, Auto Hour,

Parameter Descriptions ECM Identification Parameters

Selected Engine Rating Equipment ID

Rating Number The “Equipment ID” parameter allows the customer

Engine Serial Number FTS (Full Torque Setting)

Note: The “Number of Synchronized Engines

• Number of synchronized engines configuration

• Engine location Maintenance Parameters

Fuel Level Sensor Installation Status Maintenance Indicator Mode

Exhaust Temperature Sensor Installation Status • Auto Hour

This parameter can be programmed to “Installed” or • Man Fuel