Professional Documents
Culture Documents
November 2005
Troubleshooting
C7 and C9 Industrial Engines
JRA1-Up (Engine)
JSC1-Up (Engine)
MBD1-Up (Engine)
JTF1-Up (Engine)
i01658146
CID 0168 FMI 02 System Voltage intermittent/ Digital Sensor Supply Circuit - Test .................... 120
erratic .................................................................. 67 Electrical Connectors - Inspect ........................... 124
CID 0172 FMI 03 Intake Manifold Air Temp open/short Electrical Power Supply Circuit - Test ................. 129
to +batt ................................................................ 67 Engine Pressure Sensor Open or Short Circuit -
CID 0172 FMI 04 Intake Manifold Air Temp short to Test ................................................................... 133
ground ................................................................. 68 Engine Speed/Timing Sensor Circuit - Test ........ 141
CID 0190 FMI 08 Engine Speed signal abnormal .. 68 Engine Temperature Sensor Open or Short Circuit -
CID 0247 FMI 09 J1939 Data Link Test ................................................................... 147
communications .................................................. 68 Ether Injection System - Test .............................. 155
CID 0253 FMI 02 Personality Module mismatch .. 68 Injection Actuation Pressure - Test ..................... 160
CID 0261 FMI 13 Engine Timing Calibration Injection Actuation Pressure Control Valve Circuit -
required ............................................................... 69 Test ................................................................... 167
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Injection Actuation Pressure Sensor - Test ......... 172
short to +batt ....................................................... 69 Injector Solenoid Circuit - Test ............................ 177
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Maintenance Due Lamp Circuit - Test ................. 184
short to ground .................................................... 69 PTO Switch Circuit - Test .................................... 188
CID 0268 FMI 02 Check Programmable Switch Circuits - Test .......................................... 193
Parameters ......................................................... 70 Throttle Position Sensor Circuit - Test ................ 197
CID 0274 FMI 03 Atmospheric Pressure open/short Warning Lamp Circuit - Test ................................ 201
to +batt ................................................................ 70
CID 0274 FMI 04 Atmospheric Pressure short to Calibration Procedures
ground ................................................................. 70 Engine Speed/Timing Sensor - Calibrate ............ 205
CID 0342 FMI 08 Secondary Engine Speed signal Throttle Position Sensor - Calibrate .................... 207
abnormal ............................................................. 71
CID 0617 FMI 05 Air Inlet Heater Relay open/current Index Section
below normal ....................................................... 71
CID 0617 FMI 06 Air Inlet Heater Relay Index ................................................................... 210
grounded/current above norm ............................. 71
CID 1835 FMI 03 Auxiliary Pressure Sensor
open/short to +batt .............................................. 72
CID 1835 FMI 04 Auxiliary Pressure Sensor short to
ground ................................................................. 72
CID 1836 FMI 03 Auxiliary Temperature Sensor
open/short to +batt .............................................. 72
CID 1836 FMI 04 Auxiliary Temperature Sensor short
to ground ............................................................. 72
CID 2417 FMI 05 Ether Injection Control Solenoid
current low .......................................................... 73
CID 2417 FMI 06 Ether Injection Control Solenoid
current high ......................................................... 73
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 RENR2418-02
Troubleshooting Section
Certain parameters that affect the engine operation 1U-5804 Crimp Tool (12−AWG TO 18−AWG)
may be changed with electronic service tools. 175-3700 Connector Repair Kit (DEUTSCH DT)
The parameters are stored in the ECM, and the
parameters are protected from unauthorized changes
by passwords. Two short jumper wires are needed to check the
continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A
Passwords long extension wire may also be needed to check the
continuity of some wiring harness circuits.
Several system configuration parameters and
most logged events are protected by passwords.
Refer to programming parameters Troubleshooting, Optional Service Tools
“Customer Passwords” and refer to programming
parameters Troubleshooting, “Factory Passwords”. Table 2 lists the optional service tools that may be
needed during testing or repair.
i02437007
• Information access
• System diagnostics
• System calibrations
• System configurations
RENR2418-02 7
Troubleshooting Section
8T-5319 Connector Tool Group Standard Hardware for the Use of Cat ET
• Parameters
• Event codes
• Diagnostic codes
• Engine configuration
Cat ET can be used by the technician to perform the
following functions:
• Diagnostic tests
• Calibrations
• Flash programming
• ECM configuration
Table 3 lists the software that is required in order to
use Cat ET. Illustration 1
g01178796
JERD2124 Single user license for Cat ET Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
Data Subscription for All Engines and
JERD2129
Machines Use the following procedure in order to connect Cat
ET and the Communication Adapter II.
Note: Ensure that the ECM is receiving power and b. Disconnect the P1 and P2 connectors from
that the ECM is properly wired to the negative battery the ECM.
circuit before a replacement of the ECM is attempted.
Refer to Troubleshooting, “Electrical Power Supply NOTICE
Circuit - Test”. Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
A test ECM can be used to determine if the ECM
is faulty. Install a test ECM in place of the suspect
ECM. Flash program the correct flash file into the test NOTICE
ECM. Program the parameters for normal operation. Do not allow dirt to enter the fuel system. Thoroughly
The parameters must match the parameters in the clean the area around a fuel system component that
suspect ECM. Refer to the following test steps for will be disconnected. Fit a suitable cover over discon-
details. If the test ECM resolves the problem, connect nected fuel system component.
the suspect ECM. Verify that the problem returns.
If the problem returns when the suspect ECM is
c. Remove the fuel lines (if equipped) from the
connected, replace the suspect ECM.
ECM.
i02378227
Self-Diagnostics
SMCS Code: 1901
i02428849
Table 6
Connector Function
J1/P1 ECM Connector (70−Pin)
J2/P2 ECM Connector (120−Pin)
J61/P61 Customer Connector (40-Pin)(1)
J63 Engine Service Tool Connector(1)
J66 Customer Supplied Service Tool
Connector
J100/P100 Engine Coolant Temperature Sensor
J103/P103 Intake Manifold Air Temperature
Sensor
J142/P142 Auxiliary Temperature Sensor
J200/P200 Boost Pressure Sensor
J201/P201 Engine Oil Pressure Sensor
J203/P203 Atmospheric Pressure Sensor
J204/P204 Injection Actuation Pressure Sensor
J209/P209 Fuel Pressure Sensor
J220/P220 Auxiliary Pressure Sensor
J300/P300 Injector Solenoid Harness
P400 Engine Timing Calibration
J401/P401 Primary Engine Speed/Timing
Sensor
J402/P402 Secondary Engine Speed/Timing
Sensor
J403/P403 Throttle Position Sensor
J500/P500 Injection Actuation Pressure Control
Valve
J501/P501 Air Inlet Heater Relay
J800/P800 Engine Coolant Level Sensor
(1) This connector is part of the optional 194-1091 Electronic
Control Wiring Gp.
12 RENR2418-02
Troubleshooting Section
g01213751
Illustration 3
Components for the engine’s control system
RENR2418-02 13
Troubleshooting Section
Connector and the J61 Customer Cross-Reference for the P1 ECM Connector
and the J61 Customer Connector
Connector
Description Terminal
P1 J61
Auxiliary temperature sensor 16 11
Ether starting aid switch 22 38
Diagnostic lamp 28 24
Warning lamp 29 25
Maintenance due lamp 30 13
J1939 (−) 34 18
PTO interrupt switch 41 19
J1939 shield 42 16
Remote shutdown switch 44 27
Intermediate engine speed switch 45 28
+Battery 48 1
Coolant level sensor 49 36
J1939 (+) 50 17
+Battery 52 31
+Battery 53 32
Overspeed verify switch 54 40
PTO enable switch 56 29
g01120826
Illustration 4
PTO ramp up switch
Terminal locations on the P1 ECM connector and J61 customer 58 30
PTO set switch
connector
PTO ramp down switch
60 39
Table 7 provides a cross-reference between the P1 PTO resume switch
ECM connector and the J61 customer connector.
-Battery 61 N/C(1)
Table 7 -Battery 63 N/C(1)
Cross-Reference for the P1 ECM Connector -Battery 65 N/C(1)
and the J61 Customer Connector
Throttle position 66 10
Description Terminal
Air shutoff solenoid 67 5
P1 J61
Keyswitch 70 26
+5 VDC for the pressure sensors 2 14
(1) No connection
Return for the analog sensors 3 15
+8 VDC for the digital sensors 4 8
Return for the digital sensors 5 9
Maintenance clear switch 6 12
Torque limit switch 7 2
CAT Data Link + 8 7
CAT Data Link − 9 6
Ether relay 10 22
Air shutoff solenoid 11 4
Auxiliary pressure sensor 15 33
(continued)
14 RENR2418-02
Troubleshooting Section
Component Location
g01120750
Illustration 5
Component locations for C9 industrial engines
(1) Engine coolant temperature sensor (10) Service tool connector
(2) Connector for the injection actuation (11) Customer connector
pressure control valve (12) Optional 194-1091 Electronic Control
(3) Air inlet heater relay Wiring Gp
(4) Injection actuation pressure sensor (13) P400 connector for engine timing
(5) Boost pressure sensor calibration
(6) Intake manifold air temperature sensor (14) J2/P2 connector
(7) Connector for the injector solenoid (15) J1/P1 connector
harness (16) Primary engine speed/timing sensor
(8) Atmospheric pressure sensor (17) Secondary engine speed/timing sensor
(9) Ground stud (18) Engine oil pressure sensor
RENR2418-02 15
Troubleshooting Section
Table 8
Color Codes for the Harness Wire
Color Code Color Color Code Color
BK Black GN Green
BR Brown BU Blue
RD Red PU Purple
OR Orange GY Gray
YL Yellow WH White
PK Pink
Table 9
i02157279
Metric Equivalents for AWG Numbers
Engine Wiring Information
AWG Diameter AWG Diameter
SMCS Code: 1408 Number (mm) Number (mm)
20 0.8 14 1.6
The wiring schematics are revised periodically. The
wiring schematics will change with updates to the 18 1.0 12 2.0
harness wire. For the most current information, 16 1.3 4 3.2
always check the revision number of the schematic.
Use the schematic with the latest revision number.
Welding on a Machine that is Equipped 3. Connect the welding ground cable as close
with an Electronic Engine Control System as possible to the area that will be welded.
Components which may be damaged by welding
Proper welding procedures are necessary in order include bearings, hydraulic components, and
to avoid damage to the engine’s electronic control electrical/electronic components.
module, sensors, and associated components. The
component that requires welding should be removed. 4. Protect the wiring harness from welding debris
When welding on a machine that is equipped with and from spatter.
an electronic engine control system and removal
of the component is not possible, the following 5. Weld the materials by using standard welding
procedure must be followed. This procedure provides methods.
the minimum amount of risk to the electronic
components.
NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.
g01100101
Illustration 7
The welding current will not cause damage to any of the associated
components.
RENR2418-02 17
Troubleshooting Section
2. When the “Factory Password” screen appears, Since factory passwords contain alphabetic
record the information that is listed on the “Factory characters, the Caterpillar Electronic Technician (ET)
Passwords Worksheet”. Refer to programming must be used to perform these functions. In order to
parameters Troubleshooting, “Factory Passwords obtain factory passwords, proceed as if you already
Worksheet” for additional information. have the password. If factory passwords are needed,
Cat ET will request the factory passwords and
3. Obtain the factory passwords. The information Cat ET will display the information that is required
that is recorded on the “Factory Passwords to obtain the passwords. For the worksheet that
Worksheet” must be provided. When you obtain is used for acquiring factory passwords, refer to
the factory passwords, a permanent record of your Troubleshooting, “Factory Passwords Worksheet”.
access is generated at Caterpillar.
i02334692 i02419726
Note: A mistake in recording these parameters will Flash Programming – This is a method of
result in incorrect passwords. programming or updating the flash file in an engine’s
Electronic Control Module (ECM).
Some of the following information is required to
obtain factory passwords: Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine’s ECM.
Table 10
Dealer Code If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench
Customer’s Name (STW) to obtain the flash file for your engine.
Address Alternatively, use the “Service Software Files” feature
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
Telephone Number
down the name of the flash file for future reference.
Information From Engine Information Plate
Engine Serial Number Programming a Flash File
Full Load Setting
1. Establish communication between Cat ET and the
Full Torque Setting engine’s ECM.
Information From Engine Hour Meter 2. Select “WinFlash” from the “Utilities” menu on Cat
Engine Hours ET.
Information From Factory Password Entry Note: If “WinFlash” will not communicate with the
Screen on ET
ECM, refer to troubleshooting without a diagnostic
Electronic Service Tool code Troubleshooting, “Electronic Service Tool Will
Serial Number Not Communicate with ECM”.
Engine Serial Number
3. Program the flash file into the ECM.
ECM Serial Number
a. Select the engine ECM under the “Detected
Total Tattletale
ECMs”.
Reason Code
b. Press the “Browse” button in order to select the
From Interlock(1)
name of the flash file that will be programmed
To Interlock(1) into the ECM.
Factory Passwords
c. When the correct flash file is selected, press
Factory Password (No. 1) the “Open” button.
Factory Password (No. 2)
d. Verify that the “File Values” match the
(1) This parameter is required when the engine is being rerated. application. If the “File Values” do not match
This parameter is displayed only when the engine is being the application, obtain the correct flash file.
rerated.
e. When the correct flash file is selected, press
the “Begin Flash” button.
The Caterpillar Electronic Technician (ET) is used to 11. If you are prompted by Cat ET enter the injector
load the injector trim files into the Electronic Control confirmation code into the field.
Module (ECM).
12. Click on the “OK” button.
The injector trim files must be loaded into the ECM if
any of the following conditions occur: The injector trim file is loaded into the ECM.
Exchanging Injectors After verifying the correct repair has been performed
on the engine, it is critical to provide brief, detailed
Exchanging injectors can help determine if a information. This information helps Caterpillar better
combustion problem is in the injector or in the serve you and the customer.
cylinder. If two injectors that are currently installed
in the engine are exchanged between cylinders, Recommendations
the injector trim files can also be exchanged. Press
the “Exchange” button at the bottom of the “Injector
Trim Calibration” screen on Cat ET. Select the two Customer’s Complaint
injectors that will be exchanged and press the “OK”
button. The tattletale for the injectors that were Obtain as much information from the customer
exchanged will increase by one. as possible. Investigate any written information
that is available and document any information
Note: The injector serial number and the injector that is gathered from the customer. The following
confirmation code are located on the injector. information is of particular importance:
1. Record the injector serial number and the injector • Indicate if the diagnostic lamp was flashing.
confirmation code for each injector.
• Indicate if the warning lamp was flashing, or if the
2. Click on “Service Software Files” in SIS Web. lamp was on continuously.
3. Enter the serial number for the injector in the • Indicate the symptoms of engine operation that are
search field. present.
4. Download the injector trim file to the PC. Repeat Be as specific as possible.
this procedure for each injector, as required.
Cause of Failure
Comments on the cause of failure should include
the number of diagnostic codes that were logged.
Comments should also indicate if the code was an
active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
problem. Examples of the methods that were used to
discover the problem could be one of the following
methods:
Be as specific as possible.
Repair Procedure
Comments on the repair procedure should include
the following types of information:
Be as specific as possible.
RENR2418-02 21
Troubleshooting Section
System Configuration
Parameters
SMCS Code: 1901
Parameter Descriptions
“Equipment ID”
g00763900
“Equipment ID” allows the customer to enter a Illustration 8
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of “TEL” is a customer programmable parameter that
17 characters may be entered in the field. This defines the maximum allowable engine speed for
parameter is only for reference by the customer. This maximum power. “TEL” can be programmed up to
parameter is not required. the maximum rated engine speed. “TEL” is defined
along the engine’s lug curve.
“Engine Serial Number”
“Engine Accel. Rate”
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine “Engine Accel. Rate” determines the rate of change
information plate. If the ECM is replaced, the engine of the engine speed (acceleration or deceleration)
serial number from the engine information plate must during PTO operation. This rate of change is also
be programmed into the new ECM. used to achieve intermediate engine speed.
Note: When you are requesting factory passwords, “Low Idle Speed”
always use the engine serial number that is
programmed in the ECM. “Low Idle Speed” is the minimum allowable operating
speed for the engine. This parameter can be
“Rating Number” programmed between 600 and 1400 rpm.
g00763900 g00817759
Illustration 9 Illustration 10
“High Idle Speed” is the maximum no-load engine “Engine Torque Limit” can be used to limit torque
speed when the throttle or the PTO switch is in the output to the programmed value when the torque
maximum position. limit switch is activated.
Note: “High Idle Speed” cannot be programmed “FLS” (Full Load Setting)
lower than “TEL”.
“FLS” is a number that represents the adjustment to
“Intermediate Engine Speed” the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for
“Intermediate Engine Speed” defines the speed this parameter is stamped on the engine information
for the engine when the intermediate engine plate. Factory passwords are required in order to
speed switch is activated. This parameter can be change this parameter.
programmed to any engine speed between “Low Idle
Speed” and “TEL”. Engine speed will increase or “FTS” (Full Torque Setting)
engine speed will decrease at the rate that is defined
by the programmed value for “Engine Accel. Rate”. “FTS” is similar to “FLS”. Factory passwords are
required in order to change this parameter.
“Ether Control”
Program the “Ether Control” to “Enabled” if an
ether injection system is installed on the engine.
This allows the ECM to control ether injection. If
the engine is not equipped with ether, program this
parameter to “Disabled”.
“Air Shutoff”
“Air Shutoff” allows the ECM to be programmed for
operation of an air shutoff system. If this parameter
is programmed to “Installed”, the ECM will activate
the air shutoff solenoid in the event of an engine
overspeed condition.
RENR2418-02 23
Troubleshooting Section
Note: If an engine overspeed occurs and “Air Shutoff” “Aux Temp Sensor Installation Status”
is programmed to “Enabled”, the switched power to
the ECM must be cycled and the air shutoff solenoid Program “Aux Temp Enable” to “Installed” if an
must be manually reset before the engine will restart. auxiliary temperature sensor is installed. This will
allow the display for the Engine Monitoring System
“Maintenance Indicator Mode” (EMS) to monitor the temperature of another system.
Program this parameter to “Not Installed” if an
The ECM records data that is related to equipment auxiliary temperature sensor is not installed.
maintenance. The ECM will activate the maintenance
indicator lamp when scheduled maintenance is
due. The maintenance indicator lamp can be reset
by actuating the maintenance clear switch. The
maintenance interval may be based on operating
hours or on fuel consumption. The ECM provides
information that pertains to maintenance intervals
and the last maintenance that was performed.
“PM1 Interval”
“PM1 Interval” allows the customer to define the
maintenance interval if “Maintenance Indicator Mode”
is programmed to one of the manual options. Refer
to the engine’s Operation and Maintenance Manual
for more information.
Injector Codes
Warnings, derates, and shutdowns can be disabled
for any parameter or for all of the parameters.
Injector Code (1)
Monitoring System
The monitoring system determines the level of action
that is taken by the ECM in response to a condition
that can damage the engine. The monitoring of the
various sensors by the ECM can be turned “On” or
“Off”. These conditions are identified by the ECM
from the signals that are produced from the following
sensors:
Table 13
Settings for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
E057 Derate On 1 to 54 10
“Low Coolant Level” E058 Shutdown Off 1 to 54 10 None
E059 Warning On 1 to 54 10
“High Fuel Pressure” E096 Warning On None 8 Maps are not programmable. (1)
Warning
On 8
“Low Engine Oil Pressure” E360 Derate None Maps are not programmable.(1)
Shutdown Off 4
85 °C (185 °F)
110 °C
Warning None 10 to
(230 °F)
110 °C (230 °F)
On
86 °C (187 °F)
“High Engine Coolant
E361 Derate 1 to 54 10 to
Temperature”
111 °C (232 °F) 111 °C
87 °C (189 °F) (232 °F)
Shutdown Off 1 to 54 10 to
111 °C (232 °F)
C11/
C13 1800-2600 2600
Warning
C15
C18 1800-2500 2500
“Engine Overspeed” E362 On None 1
C11/
C13 1800-2800 2800
Shutdown
C15
C18 1800-2700 2700
70 °C (158 °F)
Warning 1 to 54 30 to 90 °C (194 °F)
On 90 °C (194 °F)
“High Fuel Temperature” E363
Derate 1 to 54 10 71 °C (160 °F)
to 91 °C (196 °F)
Shutdown Off 1 to 54 10 91 °C (196 °F)
Warning On 1 to 54 4
0 kPa (0 psi)
1500 kPa
“High Auxiliary Pressure”(2) E443 Derate 1 to 54 3 to
Off (218 psi)
3150 kPa (457 psi)
Shutdown 1 to 54 3
105 °C
Warning On 1 to 54 4
(221 °F)
0 °C (0 °F)
“High Auxiliary 106 °C
E445 Derate 1 to 54 4 to
Temperature”(2) (223 °F)
Off 140 °C (284 °F)
107 °C
Shutdown 1 to 54 4
(224 °F)
The connection of any electrical equipment and Refer to Special Instruction, REHS0354, “Charging
the disconnection of any electrical equipment may System Troubleshooting” for the proper testing
cause an explosion hazard which may result in in- procedures.
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an Probable Causes
explosive atmosphere.
• Worn battery
Refer to Special Instruction, REHS0354, “Charging
System Troubleshooting” for the proper testing • Switched battery circuit
procedures.
Recommended Actions
Probable Causes
Worn Battery
• Alternator drive belts
1. Verify that the battery is no longer able to hold a
• Charging circuit charge.
Probable Causes
• Diagnostic codes
• Event codes
RENR2418-02 29
Troubleshooting Section
• Programmable parameters Note: There are no event codes that are associated
with the altitude derate.
• Cold mode
Throttle Signal
• Altitude derate
Connect Cat ET to the service tool connector. View
• Throttle signal the status for the throttle position on the status
screen. Operate the throttle from the Low Idle
• Rated fuel position and/or FRC fuel position position to the High Idle position. The status should
be 0 percent at low idle and the status should be 100
• Boost pressure sensor percent at high idle. If the status can not operate
in the full range, refer to Troubleshooting, “Throttle
• Fuel supply Position Sensor - Calibrate”.
• Air inlet and exhaust system Diagnostic codes that are related to the J1939 data
link will prevent correct operation of the throttle if the
• Accessory equipment throttle position is transmitted over the data link. If
there is a problem with the data link, the engine will
Recommended Actions remain at low idle until the data link is repaired.
Diagnostic Codes and Event Codes Boost Pressure Sensor, Rated Fuel
Position and/or FRC Fuel Position
Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar 1. With the engine at full load, monitor “Fuel Position”
Electronic Technician (ET) and check for active codes and “Rated Fuel Limit” on the status screen. If
and logged codes. Troubleshoot any codes that are “Fuel Position” does not equal “Rated Fuel Limit”
present before continuing with this procedure. then check air inlet manifold pressure.
Cold Mode 2. Check the fuel tank for foreign objects which may
block the fuel supply.
Connect Cat ET to the service tool connector. Verify
that the engine has exited cold mode. A status flag 3. Check for air in the low pressure fuel supply
will appear if the engine is operating in cold mode. system if any of the following procedures have
This may limit engine speed. been performed:
The engine may be derated due to high elevation. • Service on the low pressure fuel supply circuit
Connect Cat ET to the service tool connector. Check
for an active engine derate on the status screens. • Replacement of unit injectors
30 RENR2418-02
Troubleshooting Section
4. Prime the low pressure fuel supply circuit. Refer Recommended Actions
to Operation and Maintenance Manual, “Fuel
System - Prime” for the correct procedure. Engine Oil Cooler Core
Note: A sight glass in the low pressure supply line is 1. Check for leaks in the oil cooler core. If a leak is
helpful in diagnosing air in the fuel. found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
5. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and 2. Drain the crankcase and refill the crankcase with
Maintenance Manual for information on improving clean engine oil. Install new engine oil filters.
the characteristics of the fuel during cold weather Refer to the Operation and Maintenance Manual.
operation.
6. Check the fuel pressure during engine cranking. Cylinder Head Gasket
Check the fuel pressure on the outlet side of
the fuel filter. Refer to Specifications for correct 1. Remove the cylinder head. Refer to the
pressure values. If the fuel pressure is low, Disassembly and Assembly manual.
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump, 2. Check the cylinder liner projection. Refer to the
fuel transfer pump coupling, and fuel pressure Systems Operation/Testing and Adjusting manual.
regulating valve.
3. Install a new cylinder head gasket and new water
seals in the spacer plate. Refer to the Disassembly
Air Inlet and Exhaust System and Assembly manual.
1. Clean plugged air filters or replace plugged air
filters. Refer to the Operation and Maintenance Cylinder Head
Manual.
Check for cracks in the cylinder head. If a crack
2. Check the air inlet and exhaust system for is found, repair the cylinder head and/or replace
restrictions and/or leaks. Refer to Testing and the cylinder head. Refer to the Disassembly and
Adjusting, “Air Inlet and Exhaust System”. Assembly manual.
Check all accessory equipment for problems that Check for cracked cylinder liners. Replace any
may create excessive load on the engine. Repair cracked cylinder liners. Refer to the Disassembly and
any damaged components or replace any damaged Assembly manual.
components.
Cylinder Block
i02381103 Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
Coolant in Engine Oil block.
SMCS Code: 1348-035; 1395-035
i02194394
• Cylinder block
RENR2418-02 31
Troubleshooting Section
2. Verify that Cat ET is on the “Factory Password” Electronic Service Tool Will
screen. Not Communicate with ECM
3. Use Cat ET to verify that the following information SMCS Code: 0785-035; 1901-035
has been entered correctly:
• Electrical power to the Electronic Control Module 7. Check the fuel pressure during engine cranking.
(ECM) Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, “Fuel
• Starting aids System” for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
• Engine shutdown switches pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
• Air shutoff system fuel pressure regulating valve.
• Starting motor, solenoid, or starting circuit Diagnostic Codes and Event Codes
• Engine speed/timing Certain diagnostic codes and/or event codes may
prevent the engine from starting. Connect the
• Unit injector Caterpillar Electronic Technician (ET) and check for
active codes and/or for logged codes. Troubleshoot
• Combustion any codes that are present before continuing with
this procedure.
Recommended Actions
Electrical Power Supply to the ECM
Fuel Supply
If the ECM is not receiving battery voltage, the ECM
1. Visually check the fuel level. Do not rely on the fuel will not operate. Refer to Troubleshooting, “Electrical
gauge only. If necessary, add fuel. If the engine Power Supply Circuit - Test”.
has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to Starting Aids
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure. If cold ambient conditions exist, check operation of
starting aids. Verify that the ether system is operating
2. Check the fuel lines for the following problems: correctly. Refer to Troubleshooting, “Ether Injection
restrictions, collapsed lines, and pinched lines. If System - Test”.
problems are found with the fuel lines, repair the
lines and/or replace the lines. Engine Shutdown Switches
3. Check the fuel tank for foreign objects which may The engine shutdown switches must be in the RUN
block the fuel supply. position in order to start the engine. Use Cat ET to
verify the status of the shutdown switches. When an
4. Prime the fuel system if any of the following engine shutdown switch is used to shut down the
procedures have been performed: engine, the keyswitch must be turned to the RUN
position for at least 15 seconds before restarting the
• Replacement of the fuel filters engine.
• Service on the low pressure fuel supply circuit Air Shutoff System
• Replacement of unit injectors Check the air shutoff mechanism. If an engine
Note: A sight glass in the low pressure supply line is overspeed has occurred, the keyswitch must be
helpful in diagnosing air in the fuel. Refer to Testing cycled. There may be a manual reset for the air
and Adjusting for more information. shutoff mechanism that is on the engine. Refer to
Troubleshooting, “Air Shutoff System - Test” for
5. Check the fuel filters. information.
6. Cold weather adversely affects the characteristics Starting Motor, Solenoid, or Starting
of the fuel. Refer to the Operation and Circuit
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather Remove the starter and visually inspect the pinion of
operation. the starter and the flywheel ring gear for damage.
• Diagnostic codes Monitor the throttle signal on Cat ET. Verify that the
throttle signal is stable from the low idle position to
• Programmable parameters the high idle position.
5. Check the fuel pressure during engine cranking. 3. Install a new cylinder head gasket and new water
Check the fuel pressure after the fuel filter. Refer seals in the spacer plate. Refer to Disassembly
to Systems Operation/Testing and Adjusting, “Fuel and Assembly, “Cylinder Head - Install” for the
System” for the correct pressure values. If the fuel correct procedure.
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
i02424562
transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve. Engine Oil Temperature Is Too
Air Inlet and Exhaust System High
1. Check for an air filter restriction. Clean plugged air SMCS Code: 1348-035-TA
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual for additional Probable Causes
information.
• Oil specifications
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems • Engine oil temperature reading
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”. • Engine oil cooler bypass valve
i02173692
• High coolant temperature
2. Check the fuel lines for the following problems: Probable Causes
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the • Vibration damper
lines and/or replace the lines.
• Engine supports
3. Check the fuel tank for foreign objects which may
block the fuel supply. • Driven equipment
• Engine misfiring or running rough
38 RENR2418-02
Troubleshooting Section
Inspect the mounts and the brackets while you run a. Charge the batteries. Refer to Special
the engine through the speed range. Look for mounts Instruction, SEHS7633, “Battery Test
and brackets that are loose and/or broken. Tighten Procedure”.
all of the mounting bolts. Install new components, if
necessary. b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Driven Equipment Acid Batteries”.
Check the alignment and the balance of the driven
equipment. Starting Motor Solenoid or Starting
Circuit
Engine Misfiring or Running Rough
1. Test the operation of the starting motor solenoid.
Refer to troubleshooting without a diagnostic code
Troubleshooting, “Engine Misfires, Runs Rough or 2. Check the wiring to the starting motor solenoid.
Is Unstable”.
Starting Motor or Flywheel Ring Gear
i02214238
1. Test the operation of the starting motor.
Engine Will Not Crank 2. Inspect the starter motor pinion and the flywheel
SMCS Code: 1000-035 ring gear for damage.
Hydraulic Cylinder Lock 4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any
Check for fluid in the cylinders (hydraulic cylinder damaged components that were found.
lock) by removing the individual unit injectors.
Engine Speed/Timing
Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when 1. Check the calibration of the engine speed/timing
the unit injector is removed. sensor. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Internal Engine Problem
2. Verify that the crankshaft and the camshaft drive
Disassemble the engine. Refer to the Disassembly gears are set with the proper orientation. Refer to
and Assembly manual. Inspect the internal the Disassembly and Assembly manual.
components for the following conditions:
Atmospheric Pressure Sensor
• Seizure
1. Remove the sensor.
• Broken components
2. Remove debris, moisture, or ice from the sensor.
• Bent components
3. Install the sensor.
i02432467
4. Check the Caterpillar Electronic Technician (ET)
Excessive Black Smoke for active diagnostic codes on the sensor. If no
active diagnostic code exists, the sensor may be
SMCS Code: 1088-035 used. The correct reading for the atmospheric
pressure is between 50 kPa (7.25 psi) and
100 kPa (14.5 psi).
Probable Causes
• Air inlet or exhaust system Boost Pressure Sensor, “Fuel Position”,
and/or “FRC Fuel Limit”
• Engine speed/timing sensor
1. Monitor the status of “Fuel Position” and “Rated
• Atmospheric pressure sensor Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
• Boost pressure sensor and “Fuel Position” is less than “FRC Fuel Limit”,
the Electronic Control Module (ECM) is providing
• “Fuel Position” and/or “FRC Fuel Limit” the correct control. Otherwise, proceed to the next
Step.
• Flash file
2. Verify that there are no active diagnostic codes for
• Fuel quality the boost pressure sensor.
Check the engine compartment for oil leaks. Repair • Accessory equipment
any oil leaks that are identified.
Recommended Actions
Oil Level
Engine Operation
Check the engine oil level. Too much oil in the engine
crankcase can cause the engine to consume oil. Use the Caterpillar Electronic Technician (ET) to
Remove excessive engine oil from the crankcase. check the “Current Totals” for excessive idle time
and/or for a high load factor which would be indicative
Ensure that the dipstick is properly calibrated of poor operating habits.
and/or that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick. Note: Engine operation may also be affected by
environmental conditions such as wind and snow.
Turbocharger
Fuel Leaks
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from Check the fuel pressure during engine cranking.
the turbocharger. Check the compressor wheel and Check the fuel pressure after the fuel filter. Refer
the turbine for evidence of an oil leak. If necessary, to Systems Operation/Testing and Adjusting for the
repair the turbocharger or replace the turbocharger. correct pressure values. If the fuel pressure is low,
Refer to Systems Operation/Testing and Adjusting. replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel
transfer pump coupling, and fuel pressure regulating
valve.
RENR2418-02 41
Troubleshooting Section
Accessory Equipment 3. Adjust the engine valve lash. Refer to the engine’s
Systems Operation/Testing and Adjusting manual.
Check all accessory equipment for problems that
may create excessive load on the engine. Repair i02312564
any damaged components or replace any damaged
components. Excessive White Smoke
SMCS Code: 1088-035
i02424626
Excessive Valve Lash Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
SMCS Code: 1105-035 normally. If the white smoke persists, there may be
a problem.
Probable Causes
Probable Causes
• Lubrication
• Starting aids
• Valve lash
• Water temperature regulators
• Valve train components
42 RENR2418-02
Troubleshooting Section
• Fuel supply 3. Ensure that the fuel system has been primed.
Refer to the engine’s Operation and Maintenance
• Cooling system Manual for the correct procedure.
• Component wear 4. Check for fuel supply lines that are restricted.
Ensure that the air inlet heater is functioning properly. Cooling System
For additional information, refer to Troubleshooting,
Check for an internal coolant leak. Check for coolant
“Air Inlet Heater Circuit - Test”.
in the engine oil, coolant in the cylinders, and
coolant in the exhaust system. Refer to Systems
Ether Injection System (If Equipped)
Operation/Testing and Adjusting, “Cooling System -
Ensure that the ether injection system is programmed Test”.
to “On”.
Component Wear
Ensure that the ether injection system is functioning
properly. For additional information, refer to Check the following components for excessive wear:
Troubleshooting, “Ether Injection System - Test”.
• Valves
Water Temperature Regulators
• Pistons
Check the water temperature regulators for correct
operation. Refer to Systems Operation/Testing and • Rings
Adjusting, “Cooling System” for the proper procedure.
• Cylinder liners
Unit Injectors
i02332993
Use Cat ET to perform the cylinder cutout test. Try
to simulate the conditions for the test that were Exhaust Temperature Is Too
experienced during operation. Cut out each cylinder High
individually for approximately one minute in order
to isolate any misfiring cylinders. If the misfire SMCS Code: 1088-035-TA
can be isolated to a specific cylinder, proceed to
Troubleshooting, “Injector Solenoid Circuit - Test”.
Probable Causes
Flash File • Diagnostic codes
Verify that the correct flash file is installed in the
Engine Control Module (ECM).
• Electrical connectors
• Air inlet and exhaust system
Fuel Supply
1. Monitor the exhaust for smoke while the engine
is being cranked.
Diagnostic Codes
Fuel Dilution of Engine Oil
SMCS Code: 1348-035
Connect the Caterpillar Electronic Technician (ET)
and check for active diagnostic codes. Troubleshoot
any active diagnostic codes before continuing with Probable Causes
this procedure.
• Leaking seals on the case of the unit injector or on
Electrical Connectors the barrel of the unit injector
Check for correct installation of the J2/P2 Electronic • Leaking seals on the fuel line adapter for the
Control Module (ECM) connector and of the cylinder head
J300/P300 connector that is for the injectors. Refer
to Troubleshooting, “Electrical Connectors - Inspect” • Excessive leakage from the unit injector tip or
for more information. breakage of the unit injector tip
SMCS Code: 1350-035 Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
Probable Causes lines or components.
• Internal cylinder head Excessive Leakage from the Unit Injector
Tip or Breakage of the Unit Injector Tip
Recommended Actions
Look for signs of damage to the unit injectors. If
Internal Cylinder Head necessary, repair the unit injectors or replace the unit
injectors.
1. Remove the valve mechanism covers.
Cracked Fuel Supply Manifold
2. Remove the fuel supply and the fuel return line
from the cylinder head. Look for signs of damage to the fuel supply manifold.
3. Cap the fuel return connector and apply 700 kPa
(100 psi) maximum air pressure to the fuel supply Leaking Fuel Transfer Pump Seal
connector. Check for fuel leakage around the unit
injectors. If leakage is present, remove the unit Ensure that the weep hole is not plugged. If
injector and install a new O-ring seal. necessary, repair the fuel transfer pump or replace
the fuel transfer pump.
44 RENR2418-02
Troubleshooting Section
Recommended Actions 1. Access the status screen that displays the remote
shutdown switch status. The remote shutdown
switch status on Cat ET is called “User Shutdown”.
Diagnostic Codes or Event Codes
2. Refer to Table 14. Measure the voltage between
Certain diagnostic codes and/or event codes each terminal that is listed and the engine ground.
may cause the engine to shutdown. Connect the
Caterpillar Electronic Technician (ET) and check for Table 14
active codes and/or for logged codes. Troubleshoot
any codes that are present before continuing with Measured Voltage at
“User Shutdown” Status
J1-44 or P61-27
this procedure.
ON <0.9 VDC
Operating Conditions OFF >10 VDC
A problem with the circuit for the overspeed verify 1. Inspect the battery wires from the Electronic
feature may be causing the engine to shut down. Control Module (ECM) back to the battery
There are no diagnostic codes or event codes that compartment. Refer to the Electrical System
are associated with the overspeed verify feature. Schematic. Inspect the wires and the power relay.
Refer to Troubleshooting, “Switch Circuits - Test”. Check the power and ground connections to
the ECM. Refer to the diagnostic functional test
Troubleshooting, “Electrical Power Supply Circuit
i02433196 - Test” for more information.
Intermittent Low Power or Injection Actuation Pressure
Power Cutout
Ensure that the injection actuation system is
SMCS Code: 1000-035 operating properly. Refer to Troubleshooting,
“Injection Actuation Pressure - Test”.
Note: Use this procedure only if the engine does not
shut down completely. Fuel Supply
Probable Causes 1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
• Diagnostic codes problems are found with the fuel lines, repair the
lines and/or replace the lines.
• Event codes
2. Check the fuel tank for foreign objects which may
• Throttle signal block the fuel supply.
4. Cold weather adversely affects the characteristics Engine Oil Filters and Oil Filter Bypass
of the fuel. Refer to Special Publication, Valve
SEBU6250, “Caterpillar Machine Fluids
Recommendations” for information on improving Check the service records of the engine for
the characteristics of the fuel during cold weather information that is related to the last oil change. If
operation. necessary, perform an oil change on the engine and
replace the engine oil filters.
5. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to Systems Check the operation of oil filter bypass valve. Clean
Operation/Testing and Adjusting, “Fuel System the bypass valve and the housing. If necessary,
Pressure - Test” for the correct pressure values. install new parts.
If the fuel pressure is low, replace the fuel filters.
If the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
Engine Oil Pump
coupling, and fuel pressure regulating valve. Refer
Check for blockage of the inlet screen for the engine
to Systems Operation/Testing and Adjusting, “Fuel
oil pump. Check the components of the engine oil
System” for additional information.
pump for excessive wear. If necessary, repair the oil
pump or replace the oil pump.
i02430113
Oil Cooler
Low Engine Oil Pressure
Check the engine’s oil cooler for plugging or
SMCS Code: 1348-035-LP blockage. Clean the engine oil cooler core(s) and/or
install new engine oil cooler core(s).
NOTICE
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure is
Fuel Dilution
low, discontinue engine operation until the problem is
Check for presence of fuel in lubricating oil. Refer
corrected.
to the troubleshooting without a diagnostic code
procedure Troubleshooting, “Fuel Dilution of Engine
Probable Causes Oil”.
• Engine oil filters and oil filter bypass valve Inspect the camshaft and/or camshaft bearings
for excessive wear. Inspect the crankshaft and/or
• Engine oil pump crankshaft bearings. Excessive wear to discrete
components may be an indication of a blocked oil
• Engine oil cooler passage. Use an oil pressure gauge to check the
oil pressure at the main oil gallery. This will help
• Fuel dilution determine if the excessive wear is from low system
pressure or from passages that are blocked.
• Engine wear
i02214503
Recommended Actions
Low Power/Poor or No
Engine Oil Level Response to Throttle
Inspect the engine oil level. If engine oil is low add SMCS Code: 1000-035
engine oil. Refer to the Operation and Maintenance
Manual.
Probable Causes
• Programmable parameters
• Diagnostic codes
• Event codes
RENR2418-02 47
Troubleshooting Section
Verify that the complaint is not due to a normal Note: There are no event codes that are associated
operation such as a programmed parameter. with the altitude derate.
Connect the electronic service tool and verify that the
parameters are programmed correctly. Electrical Connections to the ECM
Diagnostic Codes and Event Codes 1. Check the following connectors for proper
installation:
Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar • J1/P1 and J2/P2 ECM connectors
Electronic Technician (ET) and check for active codes
and for logged codes. Troubleshoot any codes that • J61/P61 Customer connectors
are present before continuing with this procedure.
• J300/P300 Connectors for the injector solenoid
Injector Trim Codes harness
If any of the injectors or the Electronic Control Module • J401/P401 and J402/P402 Engine
(ECM) have been replaced, ensure that the injector Speed/Timing Sensor connectors
trim codes have been programmed to the correct
values. Refer to Troubleshooting, “Injector Code - 2. Check the associated wiring for the following
Calibrate” for additional information. conditions: damage, abrasion, corrosion, and
incorrect attachment.
Verify that the “PTO Enable Switch” is “Not Engaged”. Boost Pressure Sensor, Rated Fuel
If the value of the parameter does not match the Position and/or FRC Fuel Position
position of the switch, there is a problem with
the circuit for the PTO enable switch. Refer to 1. With the engine at full load, monitor “Fuel Position”
Troubleshooting, “Switch Circuits - Test”. and “Rated Fuel Limit” on the status screen. If
“Fuel Position” does not equal “Rated Fuel Limit”,
If the value of the “PTO Enable Switch” parameter then check the boost pressure.
matches the position of the switch, continue to next
step. 2. Verify that there are no active diagnostic codes
that are associated with the boost pressure sensor
Intermediate Speed Switch or with the atmospheric pressure sensor.
Verify that the value of the “Intermediate Speed 3. Monitor the boost pressure and the atmospheric
Switch” matches the position of the switch. If the pressure for normal operation on the status
value of the parameter does not match the position screen.
of the switch, there is a problem with the circuit
for the switch for the intermediate speed. Refer to Note: Atmospheric pressure is not a default
Troubleshooting, “Switch Circuits - Test”. parameter on the status screen.
If the value of the “Intermediate Speed Switch” Air Inlet and Exhaust System
parameter matches the position of the switch,
continue to next step. Check the air inlet and exhaust systems for
restrictions and for leaks. Refer to Systems
Throttle Signal Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”. Replace the plugged air filters
View the status for the throttle position on the status or clean the plugged air filters according to the
screen. Operate the throttle from the low idle position guidelines in the engine’s Operation and Maintenance
to the high idle position. The status should be 0 Manual. Repair any leaks that are found in the
percent at low idle and the status should be 100 system.
percent at high idle. If the status cannot operate in
the full range, refer to Troubleshooting, “Throttle
i02281043
Position Sensor - Calibrate”.
• Fuel Position, Rated Fuel Limit, and FRC Fuel Fuel Position, Rated Fuel Limit, and FRC
Position Fuel Position
• Air inlet and exhaust system 1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
• Fuel supply load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”,
Recommended Actions the electronics are operating correctly. Otherwise,
proceed to the next Step.
Engine “Derated”
2. Verify that there are no active diagnostic codes for
the boost pressure sensor.
The engine may be derated due to dirty air filters
or other factors. Use the Caterpillar Electronic
Technician (ET) in order to check for engine derates. 3. Monitor the “Boost Pressure” and “Atmospheric
Pressure” for normal operation. When the engine
is not running, “Boost Pressure” should be 0 kPa
Cold Mode Operation (0 psi).
Monitor the status screen on Cat ET in order to verify
that the engine has exited cold mode. Observe the
Air Inlet and Exhaust System
reading for coolant temperature on the Cat ET. Refer
1. Check for an air filter restriction indicator. Clean
to Troubleshooting, “System Overview” for additional
plugged air filters or replace plugged air filters.
information.
Refer to the Operation and Maintenance Manual.
Flash File 2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Verify that the correct flash file is installed. Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
Throttle Position Sensor
Fuel Supply
Monitor “Throttle Status” on Cat ET. Verify that the
throttle position is stable and that the engine is able 1. Check the fuel lines for the following problems:
to reach high idle rpm. Refer to Troubleshooting, restrictions, collapsed lines, and pinched lines. If
“Throttle Position Sensor Circuit - Test” for the proper problems are found with the fuel lines, repair the
troubleshooting procedure. lines and/or replace the lines.
Electrical Connectors 2. Check the fuel tank for foreign objects which may
block the fuel supply.
Check for correct installation of the J1/P1 and J2/P2
connectors for the Electronic Control Module (ECM). NOTICE
Check for correct installation of the JH300/P300 Do not crank the engine continuously for more than
unit injector connectors. Refer to Troubleshooting, 30 seconds. Allow the starting motor to cool for two
“Electrical Connectors - Inspect”. minutes before cranking the engine again.
Unit Injectors
3. Prime the fuel system if any of the following
1. Use Cat ET to determine if there are any active procedures have been performed:
diagnostic codes for the unit injectors.
• Replacement of the fuel filters
2. Perform the injector solenoid test on Cat ET in
order to determine if all of the injector solenoids • Service on the low pressure fuel supply circuit
are being energized by the ECM. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test” • Replacement of unit injectors
for the proper procedure.
Note: A sight glass in the low pressure supply line is
3. Perform the cylinder cutout test on Cat ET in order helpful in diagnosing air in the fuel. Refer to Testing
to identify any injectors that might be misfiring. and Adjusting for more information.
Refer to Troubleshooting, “Injector Solenoid
Circuit - Test” for the proper procedure.
RENR2418-02 51
Troubleshooting Section
i01405939
Probable Causes
• Cracked valve rotator
• Broken spring locks
• Broken valve spring(s)
• Broken valve
Recommended Actions
1. Determine the cause of an engine overspeed that
would crack the valve rotator. Repair the condition.
• Valve rotators
• Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the
piston. If the valve has contacted the piston, check
the exhaust system for debris.
i02432846
Diagnostic Codes
SMCS Code: 1900
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to
the service technician. The Caterpillar Electronic
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that
has Cat ET software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).
Table 15
i02430358 i02430360
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting The Electronic Control Module (ECM) is attempting to
to operate the injector. The ECM detects an open operate the injector. The ECM detects a short circuit
circuit in the circuit for the injector. in the circuit for the injector.
The ECM will log the diagnostic code. The ECM will The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the continue to attempt to operate the injector after the
code has been logged. code has been logged.
Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
RENR2418-02 57
Troubleshooting Section
i02430362 Troubleshooting:
CID 0002 FMI 05 Cylinder #2 Perform the following diagnostic procedure: “Injector
Injector open circuit Solenoid Circuit - Test”
i02430368
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
CID 0004 FMI 05 Cylinder #4 code has been logged.
Injector open circuit Possible Performance Effect:
SMCS Code: 1290-038
• The engine may misfire.
Conditions Which Generate This Code:
• The engine may experience low power.
The Electronic Control Module (ECM) is attempting Troubleshooting:
to operate the injector. The ECM detects an open
circuit in the circuit for the injector. Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
System Response:
Results:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
• OK – STOP.
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
Perform the following diagnostic procedure: “Injector • The engine may misfire.
Solenoid Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02430373
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.
• The engine may misfire. The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• The engine may experience low power. code has been logged.
Perform the following diagnostic procedure: “Injector • The engine may misfire.
Solenoid Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02430375
The ECM will log the diagnostic code. The ECM will The voltage level of the 8 volt supply is above normal.
continue to attempt to operate the injector after the
code has been logged.
60 RENR2418-02
Troubleshooting Section
The Electronic Control Module (ECM) will log the CID 0042 FMI 05 Injector
diagnostic code. The ECM flags all digital sensors Actuation Valve open circuit
as invalid data and all digital sensors are set to the
respective default values. SMCS Code: 1714-038
Possible Performance Effect: Conditions Which Generate This Code:
• The engine may experience low power. The Electronic Control Module (ECM) detects an
open circuit in the circuit for the injection actuation
Troubleshooting: pressure control valve (IAPCV).
Perform the following diagnostic procedure: “Digital System Response:
Sensor Supply Circuit - Test”
The diagnostic code may be viewed on a display
Results: module or on the Caterpillar Electronic Technician
(ET).
• OK – STOP.
Possible Performance Effect:
i02419278
• Engine misfires
CID 0041 FMI 04 8 Volt DC
Supply short to ground • Low power
• The engine may experience low power. CID 0042 FMI 06 Injector
Troubleshooting:
Actuation Valve short to
ground
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test” SMCS Code: 1714-038
System Response:
• Engine misfires The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags the throttle position
• Low power as invalid data and a default value of zero percent
is used.
• Reduced engine speed (rpm)
Possible Performance Effect:
• Engine shutdown
• The engine speed is limited to low idle.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Injection
Actuation Pressure Control Valve Circuit - Test” Perform the following diagnostic procedure: “Throttle
Position Sensor - Calibrate”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02417388
Perform the following diagnostic procedure: “Throttle Perform the following diagnostic procedure: “Engine
Position Sensor Circuit - Test” Pressure Sensor Open or Short Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02426246 i02416295
Conditions Which Generate This Code: Conditions Which Generate This Code:
The duty cycle of the signal from the throttle that is The Electronic Control Module (ECM) detects a
connected to the primary throttle input is incorrect. signal voltage that is below normal.
62 RENR2418-02
Troubleshooting Section
The code is logged. The ECM flags fuel pressure as The code is logged. The ECM flags oil pressure as
invalid data and a default value is used. invalid data and a default value is used.
• None • None
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: “Engine Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” Pressure Sensor Open or Short Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02416374 i02437737
CID 0100 FMI 03 Engine Oil CID 0100 FMI 10 Engine Oil
Pressure open/short to +batt Pressure Sensor abnormal
SMCS Code: 1924-038
rate of change
SMCS Code: 1924-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a Conditions Which Generate This Code:
signal voltage that is above normal.
This code indicates that the 5 volt supply is missing
System Response: from the sensor connector.
System Response:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
A snapshot is triggered. The ECM uses a default
value for the oil pressure.
Results:
Possible Performance Effect:
• OK – STOP.
• There are no performance effects.
i02416377
Troubleshooting:
CID 0100 FMI 04 Engine Oil
Pressure short to ground Repair the Open Circuit
SMCS Code: 1924-038 A. Repair the supply wire or replace the supply wire
between the ECM and the sensor.
Conditions Which Generate This Code:
Expected Result:
The Electronic Control Module (ECM) detects a
signal voltage that is below normal. The problem is resolved.
RENR2418-02 63
Troubleshooting Section
Repair: Replace the sensor. Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
STOP.
Results:
i02411901
• OK – STOP.
CID 0102 FMI 03 Boost
Pressure Sensor short to +batt i02433370
The Electronic Control Module (ECM) will log the This code indicates that the 5 volt supply is missing
from the sensor connector.
diagnostic code. The ECM will flag the boost pressure
as invalid data and a default value is used for the
boost pressure. System Response:
The signal voltage from the boost pressure sensor is The problem is resolved.
below normal.
Results:
System Response:
• OK – The problem is resolved. STOP.
The Electronic Control Module (ECM) will log the
diagnostic code. The ECM will flag the boost pressure • Not OK – The problem is not resolved.
as invalid data and a default value is used for the
boost pressure.
64 RENR2418-02
Troubleshooting Section
None
• OK – STOP.
Troubleshooting: i02290633
Perform the following diagnostic procedure: “Engine CID 0111 FMI 02 Engine
Temperature Sensor Open or Short Circuit - Test” Coolant Level Sensor Loss of
Results: Signal
• OK – STOP. SMCS Code: 5574-038-CLT
The Electronic Control Module (ECM) will log the Perform the following diagnostic procedure: “Injection
diagnostic code. The diagnostic code may be viewed Actuation Pressure Sensor - Test”
on a display module or on the electronic service tool.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Coolant
Level Sensor Circuit - Test”
i02427705
Perform the following diagnostic procedure: The Electronic Control Module (ECM) will log the
“Electrical Power Supply Circuit - Test” diagnostic code. The ECM flags engine coolant
temperature as invalid data and a default value of
Results: 40 °C (104 °F) is used.
None
i02415969
System Response:
i02424787 Troubleshooting:
CID 0172 FMI 04 Intake Perform the following diagnostic procedure: “Engine
Manifold Air Temp short to Speed/Timing Sensor Circuit - Test”
ground Results:
Possible Performance Effect: Caterpillar Electronic Technician (ET) will not be able
to clear the code.
• The engine may not start.
Possible Performance Effect:
• The engine will run rough.
• The fuel injection system is disabled and the
engine will not start.
RENR2418-02 69
Troubleshooting Section
• OK – The correct flash file is installed in the ECM. CID 0262 FMI 03 5 Volt Sensor
Repair: The engine will not start until the 253-02 DC Power Supply short to
diagnostic code is cleared. Clearing this code
requires factory passwords.
+batt
SMCS Code: 5574-038
Acquire factory passwords. Clear the 253-02
diagnostic code. Return the engine to service.
Conditions Which Generate This Code:
STOP.
The Electronic Control Module (ECM) detects an
above normal voltage on the 5 volt supply.
• Not OK – The correct flash file is not installed in
the ECM.
System Response:
Repair: Flash program the ECM with the correct The code is logged. The check engine lamp will
flash file. Refer to programming parameters
illuminate while this diagnostic code is active. The
Troubleshooting, “Flash Programming”. Verify that
ECM sets all of the pressure sensors to the default
the problem is resolved. values.
STOP.
Possible Performance Effect:
The Electronic Control Module (ECM) detects the • The engine may experience hard starting and/or
following conditions: the engine may emit excessive white smoke.
• The pattern for the timing ring is incorrect for five Perform the following diagnostic procedure: “Air Inlet
seconds. Heater Circuit - Test”
The ECM will log the diagnostic code. The ECM flags • OK – STOP.
the secondary engine speed signal as invalid data
and a default value of zero rpm is used.
i02424832
Perform the following diagnostic procedure: “Air Inlet • There are no performance effects.
Heater Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Engine
• OK – STOP. Pressure Sensor Open or Short Circuit - Test”
Results:
i02427110
• OK – STOP. Results:
i02427111
• OK – STOP.
The Electronic Control Module (ECM) detects a Conditions Which Generate This Code:
signal voltage from the auxiliary pressure sensor that
is below normal. The Electronic Control Module (ECM) detects a
signal voltage from the auxiliary temperature sensor
System Response: that is below normal.
The ECM logs the diagnostic code. The value of the The code is logged.
auxiliary temperature is set to a default value.
Possible Performance Effect:
Possible Performance Effect:
• The engine may be difficult to start.
• There are no performance effects.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Ether
Perform the following diagnostic procedure: “Engine Injection System - Test”
Temperature Sensor Open or Short Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02418270
System Response:
Results:
• OK – STOP.
i02418652
Troubleshooting with an
Event Code
i02275527
Event Codes
SMCS Code: 1901
In this example, the number 3 indicates the severity 1. Obtain the following information about the
of the event. The ECM has three levels of response complaint from the operator:
to events:
• The event and the time of the event
Warning (1) – 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 (2) – For this condition, the ECM reduces
the engine’s power in order to help prevent possible • Determine if there are any systems that were
engine damage. installed by the dealer or by the customer that
could cause the event.
Shutdown (3) – For this condition, the ECM shuts
down the engine in order to help prevent possible • Determine whether any additional events
engine damage. occurred.
Responses to certain events may be programmed 2. Verify that the complaint is not due to normal
into the ECM. Refer to Troubleshooting, “System engine operation. Verify that the complaint is not
Configuration Parameters”. due to error of the operator.
This information can be helpful for troubleshooting Be sure to check the connectors. This is very
important for problems that are intermittent. Refer to
intermittent problems. Logged codes can also be
Troubleshooting, “Electrical Connectors - Inspect”.
used to review the performance of the engine.
If these steps do not resolve the problem, identify
Clearing Event Codes the procedures in this manual that best describe the
event. Check each probable cause according to the
A code is cleared from memory when one of the tests that are recommended.
following conditions occur:
Note: The warning will be cancelled if the fuel • Engine oil pressure is in the “DERATE/SHUTDOWN
pressure drops below 733 kPa (106 psi) for four REGION” in Illustration 13 for eight seconds.
seconds.
Note: The derate will be cancelled if the oil pressure
System Response: rises 21 kPa (3 psi) above the set point for 20
seconds.
The ECM will log the code.
360-3
Possible Performance Effect:
• The engine has been running for at least ten
Engine operation is not affected. seconds.
Check the pressure of the fuel system. Refer to • Engine oil pressure is in the “DERATE/SHUTDOWN
Systems Operation/Testing and Adjusting, “Fuel REGION” in Illustration 13 for four seconds.
System Pressure - Test” for more information.
Results:
• OK – STOP.
i02116608
360-1
Note: The warning will be cancelled if the oil pressure The warning lamp will flash while the warning is
rises 21 kPa (3 psi) above the set point for 20 active.
seconds.
The Electronic Control Module (ECM) will generate a
360-2 46 flash code that will be displayed via the diagnostic
lamp.
• The engine has been running for at least ten
seconds. The ECM will generate a E360-1 event code.
• There are no active diagnostic codes for the oil The ECM will generate a SPN 100-FMI 17 event
pressure sensor or for the atmospheric pressure code on the J1939 data link. The event code may be
sensor. displayed on a receiving device on the J1939 data
link.
RENR2418-02 77
Troubleshooting Section
360-2 i02433558
The warning lamp will flash while the derate is active. E361 High Engine Coolant
Temperature
The ECM will generate a 46 flash code that will be
displayed via the diagnostic lamp. SMCS Code: 1395-038-TA
The ECM will generate a E360-2 event code. Conditions Which Generate This Code:
Caterpillar Electronic Technician (ET) will display The following conditions occur:
“Engine Derate” in the first “Engine Status” box on
any Cat ET status screen. 361-1
The ECM will generate a SPN 100-FMI 18 event • The engine has been running for three minutes.
code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data • There are no active diagnostic codes for the
link. coolant temperature sensor.
360-3 • The coolant temperature has exceeded the set
point for ten seconds.
The warning lamp will flash.
Note: The warning will be cancelled if the coolant
The ECM will generate a 46 flash code that will be temperature rises 2 °C (36 °F) above the set point
displayed via the diagnostic lamp. for 20 seconds.
The ECM will generate a E360-3 event code. 361-2
The ECM will generate a SPN 100-FMI 01 event • The engine has been running for three minutes.
code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data • There are no active diagnostic codes for the
link. coolant temperature sensor.
Possible Performance Effect: • The coolant temperature has exceeded the set
point for ten seconds.
360-1
Note: The derate will be cancelled if the coolant
Engine operation is not affected. temperature rises 2 °C (36 °F) above the set point
for 45 seconds.
360-2
361-3
The ECM will derate power by 17.5 percent per
second up to a maximum of 35 percent while the • The engine has been running for three minutes.
derate is active.
• There are no active diagnostic codes for the
360-3 coolant temperature sensor.
The engine will shut down. • The coolant temperature has exceeded the set
point for ten seconds.
Troubleshooting:
System Response:
Refer to Troubleshooting, “Low Engine Oil Pressure”.
361-1
Results:
The warning lamp will flash while the warning is
• OK – STOP. active.
443-2
i02172516
E443 High Auxiliary Pressure The warning lamp will flash while the derate is active.
SMCS Code: 5095-038-AX The ECM will generate a E443-2 event code.
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) will display
“Engine Derate” in the first “Engine Status” box on
The following conditions occur: any Cat ET status screen.
Note: The warning will be cancelled if the pressure The ECM will generate a SPN 1835-FMI 00 event
falls 40 kPa (6 psi) below the set point for two code on the J1939 data link. The event code may be
seconds. displayed on a receiving device on the J1939 data
link.
443-2
Possible Performance Effect:
• The engine has been running for three minutes. 443-1
• There are no active diagnostic codes for the Engine operation is not affected.
auxiliary pressure sensor.
443-2
• The pressure that is sensed by the auxiliary
pressure sensor has exceeded the set point for
three seconds. The ECM will derate power by 25 percent. The power
will be derated at one percent per second.
Note: The derate will be cancelled if the pressure falls
40 kPa (6 psi) below the set point for two seconds. 443-3
80 RENR2418-02
Troubleshooting Section
The engine will shut down. • The temperature that is sensed by the auxiliary
temperature sensor has exceeded the set point for
Troubleshooting: four seconds.
Verify that the set points are valid for the application. System Response:
Temperature 445-2
SMCS Code: 5095-038-AX The warning lamp will flash while the derate is active.
Conditions Which Generate This Code: The ECM will generate a E445-2 event code.
The following conditions occur: Caterpillar Electronic Technician (ET) will display
“Engine Derate” in the first “Engine Status” box on
445-1 any Cat ET status screen.
• The engine has been running for three minutes. The ECM will generate a SPN 1836-FMI 16 event
code on the J1939 data link. The event code may be
• There are no active diagnostic codes for the displayed on a receiving device on the J1939 data
auxiliary temperature sensor. link.
Note: The warning will be cancelled if the temperature The ECM will generate a E445-3 event code.
falls 2 °C (4 °F) below the set point for two seconds.
The ECM will generate a SPN 1836-FMI 00 event
445-2 code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data
• The engine has been running for three minutes. link.
• There are no active diagnostic codes for the Possible Performance Effect:
auxiliary temperature sensor.
445-1
• The temperature that is sensed by the auxiliary
temperature sensor has exceeded the set point for Engine operation is not affected.
four seconds.
445-2
Note: The derate will be cancelled if the temperature
falls 2 °C (4 °F) below the set point for two seconds. The ECM will derate power by 25 percent. The power
will be derated at one percent per second.
445-3
445-3
• The engine has been running for three minutes.
The engine will shut down.
• There are no active diagnostic codes for the
auxiliary temperature sensor.
RENR2418-02 81
Troubleshooting Section
Verify that the set points are valid for the application. The ECM will generate a SPN 1636-FMI 15 event
code on the J1939 data link. The event code may be
Determine the events that caused the high displayed on a receiving device on the J1939 data
temperature condition. Make corrections in order to link.
prevent the high temperature from recurring.
539-2
Results:
The warning lamp will flash while the derate is active.
• OK – STOP.
The ECM will generate a 64 flash code that will be
displayed via the diagnostic lamp.
i02433579
E539 High Intake Manifold Air The ECM will generate a E539-2 event code.
Conditions Which Generate This Code: The ECM will generate a SPN 1636-FMI 16 event
code on the J1939 data link. The event code may be
The following conditions occur: displayed on a receiving device on the J1939 data
link.
539-1
Possible Performance Effect:
• The engine has been running for three minutes.
539-1
• There are no active diagnostic codes for the intake
manifold air temperature sensor. Engine operation is not affected.
539-2 Troubleshooting:
• The engine has been running for three minutes. Check the air inlet system. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
• There are no active diagnostic codes for the intake Exhaust System” for more information.
manifold air temperature sensor.
Results:
• The intake manifold air temperature is at least
79 °C (174 °F) for eight seconds. • OK – STOP.
Note: The derate will be cancelled if the intake
manifold air temperature drops below 77 °C (171 °F) i02221421
for 25 seconds.
E2143 Low Engine Coolant
System Response: Level
539-1 SMCS Code: 1395-038-LO
The warning lamp will flash while the warning is Conditions Which Generate This Code:
active.
The following conditions occur:
The Electronic Control Module (ECM) will generate a
64 flash code that will be displayed via the diagnostic 2143-1
lamp.
• The engine has been running for one minute.
82 RENR2418-02
Troubleshooting Section
• There are no active diagnostic codes for the The ECM will generate a 62 flash code that will be
coolant level sensor. displayed via the diagnostic lamp.
• The signal from the coolant level sensor indicates The ECM will generate a E2143-2 event code.
that the coolant level is low.
Caterpillar Electronic Technician (ET) will display
• The low coolant level persists for the programmed “Engine Derate” in the first “Engine Status” box on
period of time. any Cat ET status screen.
• The signal from the coolant level sensor indicates The warning lamp will flash.
that the coolant level is low.
The ECM will generate a 62 flash code that will be
• The low coolant level persists for the programmed displayed via the diagnostic lamp.
period of time.
The ECM will generate a E2143-3 event code.
Note: The derate will be cancelled if the coolant level
rises above the low level for at least five seconds. The ECM will generate a SPN 111-FMI 01 event
code on the J1939 data link. The event code may be
2143-3 displayed on a receiving device on the J1939 data
link.
• The engine has been running for one minute.
Possible Performance Effect:
• There are no active diagnostic codes for the
coolant level sensor. 2143-1
• The signal from the coolant level sensor indicates Engine operation is not affected.
that the coolant level is low.
2143-2
• The low coolant level persists for the programmed
period of time. The ECM will derate power by one percent per
second up to a maximum of 35 percent while the
System Response: derate is active.
2143-1 2143-3
The warning lamp will flash while the warning is The engine will shut down.
active.
Troubleshooting:
The Electronic Control Module (ECM) will generate a
62 flash code that will be displayed via the diagnostic Check the cooling system. Refer to Systems
lamp. Operation/Testing and Adjusting, “Cooling System”.
2143-2
Diagnostic Functional
Tests
i02289813
g01119880
Illustration 14
Schematic for the 5 volt supply
g01121143
Illustration 15
Left side view
(1) Boost pressure sensor
(2) Atmospheric pressure sensor
(3) J2/P2 connectors
(4) J1/P1 connectors
(5) Engine oil pressure sensor
86 RENR2418-02
Troubleshooting Section
g01121144
Illustration 16
The location of the fuel pressure sensor depends on the engine’s
configuration.
(6) Fuel pressure sensor
g01123205
Illustration 17
P2 terminals that are associated with the 5 volt supply for the
pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC
RENR2418-02 87
Troubleshooting Section
g01123208
Illustration 19
J61/P61 terminals that are associated with the 5 volt supply for the
pressure sensors
(14) +5 VDC
(15) Return
g01123207
Illustration 18
P1 terminals that are associated with the 5 volt supply for the
pressure sensors
(P1-2) +5 VDC
(P1-3) Return
g01123211
Illustration 20
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
E. Check the allen head screw on the customer • Active 04 code – An 04 diagnostic code is active.
connector for the proper torque. Refer to Proceed to Test Step 5.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. • Active 10 code – A 10 diagnostic code is active.
Proceed to Test Step 4.
F. Check the harness and the wiring for abrasion
and for pinch points from each sensor back to the • No active codes – None of the above codes are
ECM. active.
Verify that the problem is resolved. C. Verify that all of the pressure sensors are
disconnected.
STOP.
Note: Wiggle the harness during the following
• No – The voltage measurement is not 5.0 ± 0.2 measurements in order to reveal an intermittent
VDC. The 5 volt supply is not present at the condition.
harness connector. There is a problem with the
wiring or with the ECM. Proceed to Test Step 6. D. Measure the resistance between terminal P2-72
(+5 V Supply) and all of the other terminals on the
Test Step 5. Disconnect the +5 V Pressure P2 connector.
Sensors and Check for Active Diagnostic
Codes E. Measure the resistance between terminal P2-72
and the engine ground.
A. Disconnect the following sensors one at a time:
F. Measure the resistance between terminal P2-80
• Injection actuation pressure sensor J500/P500 (+5 V Supply) and all of the other terminals on the
P2 connector.
90 RENR2418-02
Troubleshooting Section
G. Measure the resistance between terminal P2-80 Repair: Repair the wire and/or the connector,
and the engine ground. when possible. Replace parts, if necessary. Verify
that the problem is resolved.
H. Measure the resistance between terminal P1-2
(+5 V Supply) and all of the remaining terminals STOP.
on the P1 connector.
Test Step 8. Check the +5 V Supply at the
a. Measure the resistance between terminal P1-2 ECM
and the engine ground.
A. Remove terminal 72 (+5 V Supply) from the
Expected Result: P2 connector. Install a wire jumper with socket
terminals on both ends into P2-72.
Each resistance measurement indicates an open
circuit. B. Connect ECM connectors J2/P2.
Test Step 7. Check the +5 V Supply and I. Restore both wires to the original configuration.
the Sensor Common for an Open Circuit
Expected Result:
A. Install a wire jumper between terminals P2-72 (+5
V Supply) and P2-3 (Sensor Common). Both voltage measurements are 5.0 ± 0.2 VDC.
• Power up cycle
• Preheat cycle
• Crank cycle
• Running cycle
• Postheat cycle
Power Up Cycle – The ECM activates the air inlet
heater for two seconds after the ECM is first powered
up regardless of temperature or engine speed.
g01118538
Illustration 21
Schematic for the air inlet heater
g01121147
Illustration 22
Typical component locations for the air inlet heater
(1) Air inlet heater
(2) Air inlet heater relay
(3) Ground connection for the air inlet heater
(4) J2/P2 connectors
(5) Circuit breaker
94 RENR2418-02
Troubleshooting Section
B. Thoroughly inspect the J501/P501 air inlet heater D. Check the allen head screw on the ECM connector
relay connectors and connector (4). Inspect the for the proper torque of 6 ± 1 N·m (55 ± 9 lb in).
connections on air inlet heater relay (2) and
air inlet heater (1). Refer to Troubleshooting, E. Check the harness and wiring for abrasion and
“Electrical Connectors - Inspect”. for pinch points from the air inlet heater back to
the ECM and from the air inlet heater back to the
battery.
Expected Result:
Results:
STOP.
• 617-05
• 617-06
Expected Result:
Results:
g01123219
Illustration 23
• Active 617-05 code – A 617-05 diagnostic code is
P2 terminals that are associated with the air inlet heater active. Proceed to Test Step 3.
(P2-5) Air inlet heater
(P2-79) Air inlet heater • Active 617-06 – A 617-06 diagnostic code is
active. Proceed to Test Step 5.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the connectors that are associated with
the circuit.
RENR2418-02 95
Troubleshooting Section
• No active codes – None of the above codes are Note: Be sure to wiggle the harness during the
active. There may be a problem with the high following measurements in order to reveal an
power circuit. Proceed to Test Step 6. intermittent condition.
Test Step 3. Check for an Open Circuit B. Measure the resistance between terminals P2-5
to the Relay and P501-1.
Expected Result:
Results:
Note: Do not leave the “Air Inlet Heater Override” Repair: Repair the wire and/or the connector,
ON. This prevents unnecessary cycling of the air inlet when possible. Replace parts, if necessary. Verify
heater and the battery from discharging. The “Air 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 turn the Test Step 5. Check for a Short Circuit in
keyswitch to the OFF position. the Wiring to the Relay
Expected Result:
Results:
STOP.
g01118589
Illustration 25
• Not OK – The test lamp did not turn on while the Small terminals for the typical air inlet heater relay
override was active. Proceed to Test Step 4.
A. Disconnect the wires from the small terminals for
Test Step 4. Check the Wiring Between the air inlet heater relay.
the ECM and the Relay
B. Turn the keyswitch to the ON position.
A. Disconnect the J2/P2 connectors.
96 RENR2418-02
Troubleshooting Section
C. Observe the “Active Diagnostic” screen on Cat Repair the wire and/or the connection, when
ET. Wait at least 15 seconds so that any codes possible. Replace parts, if necessary. Verify that
may become active. the problem is resolved.
Results: Note: Observe the test lamp. The test lamp should
be off, since the relay is not energized. If the test
• OK – The short circuit diagnostic code (617-06) lamp is on, ensure that the test lamp is connected to
changed to an open circuit diagnostic code the output side of the relay.
(617-05) when the wires to the relay were
disconnected. The short circuit is in the relay. B. Turn the keyswitch to the ON position.
Repair: Replace the relay. Clear the diagnostic C. Run the “Air Inlet Heater Override” on Cat ET and
codes. observe the test lamp.
Verify that the problem is resolved. Note: Do not leave the “Air Inlet Heater Override”
ON. This prevents unnecessary cycling of the air inlet
STOP. heater and the battery from discharging. The “Air
Inlet Heater Override” has a one minute timer that
• Not OK – The short circuit diagnostic code disables the test when the time expires.
(617-06) remained when the wires to the relay
were disconnected. There is a problem in the D. Stop the “Air Inlet Heater Override” and turn the
wiring between the ECM and the relay. There may keyswitch to the OFF position.
be a problem with a connector.
Expected Result:
Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify The test lamp turned on when the “Air Inlet Heater
that the problem is resolved. Override” was enabled.
STOP. Results:
Test Step 6. Check for Battery Voltage at • OK – The test lamp turned on when the “Air Inlet
the Relay Heater Override” was enabled. The air inlet heater
relay and the +Battery connection to the air inlet
A. Connect a test lamp between the +Battery side of heater relay are operating correctly. Proceed to
the air inlet heater relay and the engine ground. Test Step 8.
Expected Result: • Not OK – The test lamp did not turn on when the
“Air Inlet Heater Override” was enabled.
The test lamp turns ON.
Repair: Replace the relay.
Results:
Verify that the problem is resolved.
• OK – The test lamp turns ON. Battery voltage is
reaching the relay. Proceed to Test Step 7. STOP.
Test Step 8. Check the Wiring Between Test Step 9. Measure the Current through
the Relay and the Heater and Between the Heater
the Heater and the Engine Block
g01118617
Illustration 27
g01118615 Left side view
Illustration 26
Left side view (1) Wire
(2) Terminal
(1) Wire
(3) Terminal
(2) Bar
A. Measure the resistance of wire (1) that connects A. Connect a 155-5176 AC/DC Current Probe or an
the relay to the air inlet heater. equivalent inductive pickup clamp around wire (1)
between the relay and the air inlet heater.
B. Measure the resistance of bar (2) that connects
the air inlet heater to the engine block. B. Connect the current probe to a multimeter.
Both of the resistance measurements are less than D. Run the “Air Inlet Heater Override” on Cat ET and
ten Ohms. observe the current reading on the multimeter.
• Not OK – The voltage reading and/or the current For some air shutoff systems, after the air shutoff
reading is not within the specified ranges. mechanism has been tripped, a manual reset of the
mechanism may be necessary.
Repair: Replace the air inlet heater.
STOP.
i02433599
g01165526
Illustration 28
Schematic for the air shutoff system
g01146383
Illustration 30
Customer connector (typical example)
(2) J61 customer connector
g01167488
Illustration 29
ECM connectors (typical example)
(1) J1/P1 ECM connectors
100 RENR2418-02
Troubleshooting Section
g01210157
Illustration 31
Air shutoff mechanism
(3) Terminals for the air shutoff solenoid
g01212804
Illustration 32
P1 terminals for the air shutoff system
(P1-11) Air shutoff relay
(P1-54) Overspeed verify switch
(P1-67) Return
g01212805
Illustration 33
Terminal locations at the P61 customer connector that are
associated with the air shutoff system
(4) Air shutoff relay
(5) Return
(40) Overspeed verify switch
RENR2418-02 101
Troubleshooting Section
D. Perform a 45 N (10 lb) pull test on each of the C. Connect a test lamp between the output of the
wires that are associated with the circuit for the solenoid for the air shutoff relay and engine
air shutoff system. ground.
E. Check the allen head screw on each ECM D. Start the engine.
connector for the proper torque. Also, check the
allen head screw on the customer connector E. Activate the overspeed verify switch.
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct F. Monitor the test lamp while you increase the
torque values. engine speed past 75 percent of the programmed
overspeed setpoint.
F. Check the harness and the wiring for abrasion
and for pinch points from the air shutoff solenoid G. Stop the engine.
to the ECM.
H. Remove the test lamp from the circuit. Restore the
Expected Result: wiring to the original configuration.
g01212806
Illustration 35
Location of the test lamp
F. Monitor the test lamp while you increase the The test lamp illuminated when the engine speed
engine speed past 75 percent of the programmed increased past 75 percent of the programmed
overspeed setpoint. overspeed setpoint.
F. Monitor the test lamp while you increase the K. Monitor the test lamp while you increase the
engine speed past 75 percent of the programmed engine speed past 75 percent of the programmed
overspeed setpoint. overspeed setpoint.
Expected Result: B. Remove the diode from the air shutoff relay.
The test lamp illuminated when the engine speed C. Select the “Diode Check” function on a digital
increased past 75 percent of the programmed voltmeter.
overspeed setpoint.
D. Refer to Illustration 36. Place the red lead of the
Results: digital voltmeter on the diode at location (A). Place
the black lead of the digital voltmeter on the diode
• OK – The test lamp illuminated. at location (B).
Repair: The ECM is operating correctly. Perform E. Measure the voltage drop across the diode.
the following procedure:
Expected Result:
1. Verify the continuity of the ground circuit for the
overspeed verify switch. The voltage drop across the diode is less than one
volt.
2. Isolate the overspeed verify switch from the
circuit. Close the switch and measure the Results:
continuity across the switch. Open the switch
and measure the continuity across the switch. • OK – The voltage drop across the diode is less
than one volt. The voltage drop across the diode is
3. Verify the continuity of the circuit between OK. Proceed to Test Step 7.
the overspeed verify switch and the P1 ECM
connector. • Not OK – The voltage drop across the diode is
greater than one volt.
4. Restore the wiring to the original configuration.
Repair: The diode is damaged. Replace the diode.
If the overspeed verify switch is OK and the Verify that the problem is resolved.
circuit has continuity from the P1 and the
engine ground stud, there is a problem in the STOP.
wiring between the P1 ECM connector and the
air shutoff relay. Test Step 7. Test the Diode for Current
Flow
Repair the circuit connectors or wiring and/or
replace the circuit connectors or wiring. Verify that A. Reverse the position of the leads for the digital
the problem is resolved. voltmeter.
Repair: Restore the wiring to the original For a diode that is operating properly, the digital
configuration. There is a problem with the ECM. voltmeter will indicate an OL across the diode.
Replace the ECM. Refer to Troubleshooting,
“Replacing the ECM”. Results:
STOP.
Illustration 36
g00761537 Test Step 8. Check the Voltage from the
Diode leads Keyswitch to the Voltage Input of the Air
Shutoff Relay
A. Disconnect the air shutoff relay’s control wires at
the relay. A. Ensure that the keyswitch is in the OFF position.
104 RENR2418-02
Troubleshooting Section
Expected Result:
i02433602
• Faulty connectors
• Missing termination resistors
• Short circuits
• Open circuits
• Faulty J1939 display
g01119843
Illustration 38
Schematic for the CAN data link
g01167488
Illustration 39
Engine view (typical example)
(1) J1/P1 ECM conntctors
g01215698
Illustration 41
P1 terminals that are associated with the CAN data link
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
g01149983
Illustration 40
Engine view (typical example)
(2) J61 customer connector
(3) J63 service tool connector
STOP.
Expected Result:
Results:
g01123351
Illustration 42 • OK – No codes are active.
J61/P61 terminals that are associated with the CAN data link
(16) CAN shield Repair: The problem may be intermittent. If the
(17) CAN data link + problem is intermittent, refer to Troubleshooting,
(18) CAN data link − “Electrical Connectors - Inspect”.
C. Perform a 45 N (10 lb) pull test on each of the STOP.
wires that are associated with the CAN data link.
• Not OK – A 247-09 diagnostic code is active.
D. Check the allen head screw on each ECM Proceed to Test Step 3.
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” Test Step 3. Verify the Proper Installation
for the correct torque values. of the CAN Data Link
E. Check the allen head screw on the customer A. Disconnect the J1939 display.
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” B. Disconnect the P1 connector and measure the
for the correct torque value. resistance between terminals P1-50 (CAN data
link +) and P1-34 (CAN data link -).
F. Check the wiring harnesses for abrasion, for
corrosion and for pinch points. Expected Result:
Expected Result: The resistance is between 57 and 63 Ohms.
All connectors, pins and sockets are completely Results:
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion and of pinch points. • OK – The resistance is between 57 and 63 Ohms.
Proceed to Test Step 6.
Results:
• Not OK – The resistance is between 114 Ohms
• OK – The harness and the wiring appear to be and 126 Ohms. A terminating resistor is missing.
OK. Proceed to Test Step 2.
Repair: Verify that two terminating resistors exist • Not OK – At least one check of the resistance
on the data link. One resistor must be located on does not indicate an open circuit. There is a short
each end of the data link. The engine is shipped circuit in a harness. There may be a problem with
with one terminating resistor that is installed a connector.
between the ECM and the customer connector.
Repair: Repair the wiring and/or the connector.
Refer to the appropriate electrical schematic in Replace part, if necessary. Verify that the problem
order to determine the missing resistor. Replace is resolved.
the missing resistor. Verify that the problem is
resolved. STOP.
Test Step 4. Check for a Short Circuit C. Measure the resistance between terminals P1-50
(CAN data link +) and P1-34 (CAN data link -).
A. Disconnect the J1/P1 ECM connector.
D. Remove the jumper wire from the service tool
B. Remove the terminating resistors from the CAN connector.
data link.
Expected Result:
C. If a J1939 display is installed, disconnect the
display. The resistance is less than ten Ohms.
Expected Result: B. Operate the engine and monitor the J1939 display.
STOP. g01167527
Illustration 43
• Not OK – The J1939 display does not operate Schematic for the Cat Data Link
properly on another engine.
Test Step 1. Inspect the Electrical
Repair: Replace the J1939 display. Verify that the Connectors and the Wiring
problem is resolved.
A. Remove the electrical power from the (engine)
STOP. ECM.
i02403866
g01149983
Illustration 45
Engine view (typical example)
(2) P61 customer connector
(3) P63 service tool connector
g01202018
Illustration 46
P1 terminals that are associated with the Cat Data Link
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −
RENR2418-02 111
Troubleshooting Section
STOP.
Table 17
Resistance Measurements for the Cat Data Link
Connector and Terminal
Terminal
P1-8 (Cat Data Link +) All of the other terminals on
the P1 connector
Ground stud
g01119122
Illustration 47 P1-9 (Cat Data Link -) All of the other terminals on
J61 and P61 terminals that are associated with the Cat Data Link the P1 connector
(6) Cat Data Link − Ground stud
(7) Cat Data Link +
STOP.
STOP.
i02433613
g01119821
Illustration 48
Schematic of the engine coolant level sensor
Expected Result:
Results:
STOP.
g01119186
Illustration 50
Rear view of a typical radiator with a engine coolant level sensor
g01215707
Illustration 51
P1 terminals that are associated with the engine coolant level
sensor
(P1-3) Return
(P1-4) +8 VDC (digital sensor supply)
(P1-49) Engine coolant level
RENR2418-02 115
Troubleshooting Section
STOP.
Expected Result:
• OK – The status of the switch is “OK” when the Test Step 1. Check the Operation of the
jumper wire is connected. The status of the switch Diagnostic Lamp
is “Low” when the jumper wire is not connected.
The ECM is properly reading the switch input. A. Turn the keyswitch to the ON position.
However, the ECM did not detect the jumper wire at
the sensor connector. There is a problem with the B. Monitor the diagnostic lamp.
wiring. There may be a problem with a connector.
Expected Result:
Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the original The diagnostic lamp turns on for five seconds. Then,
problem is resolved. the diagnostic lamp turns off. If a diagnostic code is
active, the diagnostic lamp will flash.
STOP.
Results:
g01215717
Illustration 55
P1 terminals that are associated with the diagnostic lamp
(P1-28) Diagnostic lamp
(P1-65) −Battery
g01119456
Illustration 54
Left side view
(1) P61 customer connector
(2) J1/P1 ECM connectors
STOP.
Expected Result:
g01102219
The diagnostic lamp turned on while the jumper wire
Illustration 56 was connected. The diagnostic lamp turned off when
J61 and P61 terminals that are associated with the diagnostic lamp the jumper wire was removed.
(24) Diagnostic lamp
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the diagnostic lamp. • OK – The diagnostic lamp turned on while the
jumper wire was connected. The diagnostic lamp
D. Check the allen head screw on each ECM turned off when the jumper wire was removed.
connector for the proper torque. Refer to The circuit for the diagnostic lamp is functioning
Troubleshooting, “Electrical Connectors - Inspect” properly. Proceed to Test Step 6.
for the correct torque values.
• Not OK – The diagnostic lamp did not turn on.
E. Check the allen head screw on the customer There is a problem with the circuit for the diagnostic
connector for the proper torque. Refer to lamp. Proceed to Test Step 4.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. Test Step 4. Test the Diagnostic Lamp
Circuit at the Diagnostic Lamp
F. Check the harness and wiring for abrasions and
for pinch points from the diagnostic lamp to the A. Disconnect wire F404-RD from the diagnostic
ECM. lamp.
STOP. STOP.
120 RENR2418-02
Troubleshooting Section
STOP.
i02433728
g01146754
Illustration 57
Schematic for the digital sensor supply
RENR2418-02 121
Troubleshooting Section
g01215738
Illustration 59
P1 ECM connector
(P1-4) +8 VDC (digital sensor supply)
(P1-5) Return
g01121173
Illustration 58
Left side view
(1) P61 customer connector
(2) J1/P1 ECM connectors
STOP.
g01119753
One of the above diagnostic codes is active.
Illustration 60
J61 and P61 customer connectors Results:
(8) +8 VDC (digital sensor supply)
(9) Return • Active 041-03 code – A 041-03 diagnostic code is
active. Proceed to Test Step 3.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the digital sensor • Active 041-04 code – A 041-04 diagnostic code is
supply. active. Proceed to Test Step 4.
D. Check the allen head screw on each ECM • No active codes – None of the above codes are
connector for the proper torque. Refer to active.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. Repair: If any of the above codes are logged
and the engine is not running properly, refer to
E. Check the harness and wiring for abrasions and Troubleshooting, “Troubleshooting Without a
for pinch points from the battery to the ECM. Diagnostic Code”.
• Not OK – There is a problem with a connector B. Disconnect the harness connectors for the engine
and/or the wiring. coolant level sensor J800/P800.
D. Measure the voltage between terminals A and B Note: Wiggle the harness during the following
at the harness connector for the sensor. measurements in order to reveal an intermittent
condition.
Expected Result:
D. Measure the resistance between P1-4 (+8 V
The voltage measurement is 8.0 ± 0.4 VDC. supply) and the remaining terminals on the P1
and P2 connectors.
Results:
E. Measure the resistance between P1-4 (+8 VDC
• OK – The voltage measurement is 8.0 ± 0.4 VDC. supply) and the engine ground.
STOP. Results:
• Not OK – The voltage measurement is not 8.0 ± • OK – Each check of the resistance indicates an
0.4 VDC. There is a problem with the wiring or with open circuit. Proceed to Test Step 6.
the ECM. Proceed to Test Step 5.
• Not OK – At least one check of the resistance
Test Step 4. Disconnect the +8 V Digital does not indicate an open circuit. A +8 V supply
Sensor and Check for Active Diagnostic wire has a problem. There may be a problem with
Codes a connector.
A. Disconnect the Engine coolant level sensor. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
B. Wait for 15 seconds after you disconnect each that the problem is resolved.
sensor. Look for the active 041-04 diagnostic code
to deactivate. STOP.
Repair: Connect the suspect sensor. If the B. Measure the resistance between terminals A and
diagnostic code returns, replace the sensor. B at the harness connector for each digital sensor.
Connect all of the connectors. Verify that the C. Remove the jumper wire.
problem is resolved.
Expected Result:
STOP.
Each resistance measurement is less than ten Ohms.
• Not OK – The 041-04 diagnostic code remains
after all of the sensors are disconnected. Leave Results:
the sensors disconnected. Proceed to Test Step 5.
• OK – Each resistance measurement is less than
Test Step 5. Check the +8 V Supply Wire ten Ohms. Proceed to Test Step 7.
for a Short Circuit
• Not OK – At least one resistance measurement
A. Turn the keyswitch to the OFF position. is more than ten Ohms. A +8 V supply wire or a
return wire has excessive resistance. There may
B. Disconnect the J1/P1 and J2/P2 connectors. be a problem with a connector.
Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If any
Moisture and Corrosion of the plugs are missing, replace the plug. Ensure
that the plugs are inserted correctly into the
connector. Refer to Illustration 62.
g01131019
Illustration 63
Seal for a three-pin connector (typical example)
g01131211
Illustration 61
Leaky seal at the connector (typical example)
g01131165
Illustration 64
Seal for ECM connector (typical example)
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.
STOP.
g01131604
Illustration 66
Diagram for testing pin retention (typical example)
A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.
Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.
Results:
STOP.
• OK – The connectors are in good repair. Proceed
to Test Step 7.
128 RENR2418-02
Troubleshooting Section
STOP.
g01132827
Illustration 67
Allen head screw for the 120 pin ECM connector (typical example)
g01133047
a. Torque the allen head bolt for the 120 pin ECM Illustration 70
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
Expected Result:
Results:
Illustration 68
g01132849
• OK – The ECM connectors and the customer
Allen head screw for the 70 pin ECM connector (typical example) connector is properly connected. Proceed to Test
Step 8.
b. Torque the allen head screw for the 70
pin ECM connector to 6.0 + 1.5 - 0.5 N·m • Not OK – The allen head screws for the ECM
(55 + 13 - 4 lb in). connector or the customer connector is damaged.
RENR2418-02 129
Troubleshooting Section
Repair: Repair the connector or replace the This procedure tests whether proper voltage is being
connector, as required. Verify that the repair supplied to the Electronic Control Module (ECM).
eliminates the problem.
Unswitched battery voltage is supplied through the
STOP. customer connector to the ECM at P1-48, P1-52, and
P1-53. The negative battery is supplied to the ECM
Test Step 8. Perform the “Wiggle Test” on at P1-61, P1-63, and P1-65. The ECM receives the
the Caterpillar Electronic Technician (ET) input from the keyswitch at P1-70 when the keyswitch
is in the ON position or the START position. When
A. Select the “Wiggle Test” from the diagnostic tests the ECM detects battery voltage at this input, the
on Cat ET. ECM will power up. When battery voltage is removed
from this input, the ECM will power down.
B. Choose the appropriate group of parameters to
monitor. The cause of an intermittent power supply to the ECM
can occur on either the positive side or the negative
C. Press the “Start” button. Wiggle the wiring harness side of the battery circuit. Both sides are routed from
in order to reproduce intermittent problems. the ECM to the battery. The three connections for
the unswitched +Battery should be routed through a
If an intermittent problem exists, the status will be dedicated protective device (circuit breaker).
highlighted and an audible beep will be heard.
The engine ECM requires the keyswitch to be in the
Expected Result: ON position in order to maintain communications with
the electronic service tool.
No intermittent problems were indicated during the
“Wiggle Test”.
Results:
STOP.
i02289857
g01102414
Illustration 71
Schematic diagram for the electrical power supply
g01120079 g01104383
Illustration 72 Illustration 73
Left side view P1 terminals that are associated with the electrical power supply
(1) P61 customer connector (P1-44) Shutdown
(2) J1/P1 ECM connectors (P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
B. Thoroughly inspect connectors (1) and (2). (P1-61) −Battery
Inspect the connections for the battery and (P1-63) −Battery
the connections to the keyswitch. Refer to (P1-65) −Battery
Troubleshooting, “Electrical Connectors - Inspect” (P1-70) Keyswitch
for details.
132 RENR2418-02
Troubleshooting Section
Results:
STOP.
Verify that the repairs eliminate the problem. • Atmospheric pressure sensor
STOP. • Fuel pressure sensor
Test Step 3. Check the Batteries • Engine oil pressure sensor
A. Measure the no-load battery voltage at the battery • Auxiliary pressure sensor (if equipped)
posts.
This procedure covers the following diagnostic codes:
B. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to Special Instruction, • 094-03 Fuel Pressure open/short to +batt
SEHS9249, “Use of 4C-4911 Battery Load Tester
for 6, 8 and 12 Volt Lead Acid Batteries” and • 094-04 Fuel Pressure short to ground
Special Instruction, SEHS7633, “Battery Test
Procedure”. • 100-03 Engine Oil Pressure open/short to +batt
Expected Result: • 100-04 Engine Oil Pressure short to ground
The batteries pass the load test. The measured • 102-03 Boost Pressure Sensor short to +batt
voltage is the minimum specification for a 12V or 24V
system. • 102-04 Boost Pressure Sensor short to ground
Results: • 274-03 Atmospheric Pressure open/short to +batt
• OK – The batteries are OK. • 274-04 Atmospheric Pressure short to ground
Repair: Check the wiring between the batteries The troubleshooting procedures for the diagnostic
and the ECM for shorts. codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 volt supply
Check the connectors between the batteries and to terminal A of each sensor. The sensor common
the ECM for moisture and/or corrosion. connection is connected to terminal B of each sensor.
The signal voltage from terminal C of each sensor is
Repair the wiring and/or the connectors. sent to the appropriate ECM connector.
Engine Pressure Sensor Open If the sensor is disconnected at the sensor connector,
the absence of pull-up voltage at the sensor
or Short Circuit - Test connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.
SMCS Code: 5574-038-PX
If the sensor is disconnected at the sensor connector
System Operation Description: and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
Use this procedure to troubleshoot any suspect wire is shorted to another wire in the harness.
problems with the following sensors:
g01119880
Illustration 75
Schematic for the engine pressure sensors
g01121143
Illustration 76
Left side view
(1) Boost pressure sensor
(2) Atmospheric pressure sensor
(3) J2/P2 connectors
(4) J1/P1 connectors
(5) Engine oil pressure sensor
136 RENR2418-02
Troubleshooting Section
g01121144
Illustration 77
The location of the fuel pressure sensor depends on the engine’s
configuration.
(6) Fuel pressure sensor
g01123383
Illustration 78
P2 terminals that are associated with the engine pressure sensors
(P2-15) Boost pressure
(P2-17) Return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-54) Return
(P2-57) Atmospheric pressure
(P2-72) +5 VDC
(P2-80) +5 VDC
(P2-85) Injection actuation pressure
RENR2418-02 137
Troubleshooting Section
g01123211
Illustration 80
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal
g01123384
Illustration 79
P1 terminals that are associated with the engine pressure sensors
(P1-2) +5 VDC
(P1-3) Return
(P1-15) Auxiliary pressure
g01120120
Illustration 81
J61 and P61 terminals that are associated with the engine
pressure sensors
(14) +5 VDC
(15) Return
(33) Auxiliary pressure
138 RENR2418-02
Troubleshooting Section
C. Perform a 45 N (10 lb) pull test on each of the E. Turn the keyswitch to the OFF position.
wires that are associated with the engine pressure
sensors. F. Connect all of the sensors.
Test Step 2. Check the Voltage on the +5 D. Determine if the problem is related to a -03
V Supply Wire diagnostic code or a -04 diagnostic code.
B. Disconnect the harness connectors for the No diagnostic codes are active.
following sensors:
Results:
• Injection actuation pressure sensor J500/P500
• OK – No diagnostic codes are active for the engine
• Boost pressure sensor J200/P200 pressure sensors.
• Atmospheric pressure sensor J203/P203 Repair: If any of the above codes are logged
and the engine is not running properly, refer to
• Fuel pressure sensor J209/P209 Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
• Engine oil pressure sensor J201/P201
If the engine is running properly at this time, there
• Auxiliary pressure sensor J220/P220 (if may be an intermittent problem in a harness
equipped) that is causing the codes to be logged. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
C. Turn the keyswitch to the ON position.
STOP.
D. Measure the voltage between terminals A (+5
VDC) and B (Return) at each sensor connector • Active -04 code – An 04 diagnostic code is active.
on the engine harness. Proceed to Test Step 4.
RENR2418-02 139
Troubleshooting Section
A. Turn the keyswitch to the OFF position. • OK – The voltage is 11 ± 2 VDC. The signal wire
to the ECM from the sensor connector is OK.
B. Disconnect the sensor connector of the sensor
with the -04 diagnostic code. Repair: The open circuit is in the sensor or the
wire between the sensor and the sensor connector.
C. Turn the keyswitch to the ON position. Wait at Temporarily connect a new sensor to the engine
least 15 seconds for activation of the diagnostic harness. Do not install the sensor in the engine.
codes. Verify that no diagnostic codes are active for the
new sensor before you permanently install the
D. Access the “Active Diagnostic Code” screen on sensor.
Cat ET. Check for an active 03 diagnostic code for
the disconnected sensor. STOP.
E. Turn the keyswitch to the OFF position. • Not OK – The voltage is not 11 ± 2 VDC. Proceed
to Test Step 6.
Expected Result:
Test Step 6. Check the Signal Wire for a
A -03 diagnostic code is now active for the Short Circuit
disconnected sensor.
A. Turn the keyswitch to the OFF position.
Results:
B. Disconnect the J1/P1 and J2/P2 connectors.
• OK – A -04 diagnostic code was active before you
disconnected the sensor. A -03 diagnostic code C. Disconnect the harness connector for the suspect
became active after the sensor was disconnected. sensor.
Repair: Temporarily connect a new sensor to the D. Identify the terminal for the signal wire on the
harness, but do not install the new sensor in the ECM connector that is appropriate for the suspect
engine. Verify that there are no active diagnostic sensor. Measure the resistance between the
codes for the sensor. If there are no active appropriate terminal and the remaining terminals
diagnostic codes for the sensor, permanently on both ECM connectors.
install the new sensor. Clear any logged diagnostic
codes. E. Measure the resistance between the appropriate
terminal and the engine ground.
STOP.
F. Connect J1/P1 and J2/P2 connectors. Connect
• Not OK – A -04 diagnostic code was active before the connectors for the suspect sensor.
you disconnected the sensor. The -04 diagnostic
code remained after the sensor was disconnected. Expected Result:
Leave the sensor disconnected. Proceed to Test
Step 8. Each resistance measurement indicates an open
circuit.
Test Step 5. Check the Pull-up Voltage at
the Sensor Connector Results:
D. Turn the keyswitch to the OFF position. Repair: Repair the wiring and/or the connector.
Replace parts, if necessary.
140 RENR2418-02
Troubleshooting Section
Verify that the problem is resolved. Test Step 8. Check the Operation of the
ECM
STOP.
A. Turn the keyswitch to the OFF position.
Test Step 7. Create a Short at the Suspect
Sensor Connector B. Check the operation of the ECM by creating an
open at the ECM:
A. Turn the keyswitch to the OFF position.
a. Disconnect the appropriate ECM connector.
B. Install a jumper wire with Deutsch sockets on
each end between terminals B (sensor return) b. Remove the signal wire for the suspect sensor
and C (signal) on the harness connector for the from the ECM connector.
suspect sensor.
c. Remove the return wire for the suspect sensor
C. Turn the keyswitch to the ON position. from the ECM connector.
Note: Monitor the “Active Diagnostic Codes” screen Note: Disconnecting the return wire from the ECM
on the electronic service tool before installing the will generate an open circuit diagnostic code for
jumper wire and after installing the jumper wire. all sensors that are connected to the return wire.
Ignore the additional codes. Troubleshoot the original
D. Observe the “Active Diagnostic Codes” screen diagnostic code and clear the codes when you are
on Cat ET. Wait at least 15 seconds so that finished.
any codes may become active. Look for a -04
diagnostic code. d. Connect the ECM connector.
F. Turn the keyswitch to the OFF position. D. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 15 seconds so that any
Expected Result: codes may become active.
A -04 diagnostic code was active when the jumper A -03 diagnostic code should be active for the
wire was installed. A -03 diagnostic code became suspect sensor.
active when the jumper wire was removed.
E. Turn the keyswitch to the OFF position.
Results:
F. Check the operation of the ECM by creating a
• OK – A -04 diagnostic code was active when the short circuit at the ECM:
jumper wire was installed. A -03 diagnostic code
became active when the jumper wire was removed. a. Disconnect the appropriate ECM connector.
The engine harness and the ECM are OK.
b. Install a jumper wire between the two terminals
Repair: Temporarily connect a new sensor to the for the sensor’s signal wire and the sensor’s
harness, but do not install the new sensor in the return wire.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active c. Connect the ECM connector.
diagnostic codes for the new sensor, permanently
install the new sensor. Clear any logged diagnostic G. Turn the keyswitch to the ON position.
codes.
H. Monitor the “Active Diagnostic Code” screen on
Verify that the problem is resolved. Cat ET. Wait at least 15 seconds so that any
codes may become active.
STOP.
A short circuit diagnostic code (04) should be
• Not OK – A -04 diagnostic code was active when active when the wire jumper is installed.
the jumper wire was installed. The -04 code
remained when the jumper wire was removed. I. Turn the keyswitch to the OFF position.
Proceed to Test Step 8.
J. Remove the jumper wire. Return the wiring to the
original configuration.
RENR2418-02 141
Troubleshooting Section
• OK – The ECM is operating properly. There is a Under normal operation, the secondary engine
problem in the wiring between the ECM and the speed/timing sensor is used to determine timing
sensor connector. for starting purposes. The secondary engine
speed/timing sensor is used to determine when
Repair: If the code is active for more than one the piston in the No. 1 cylinder is at the top of the
sensor, the problem is most likely in the return wire compression stroke. When the timing has been
for the sensor. The problem may be in a connector. established, the primary engine speed/timing sensor
Repair the return wire and/or the connector. is then used to determine engine speed.
Replace parts, if necessary.
When the timing has been established, the ECM
If the code is only active for one sensor, the triggers each injector in the correct firing order at the
problem is most likely in the signal wire for the correct time. The actual timing and duration of each
sensor. Repair the signal wire and/or the connector. injection is based on engine rpm and on load.
Replace parts, if necessary.
If the engine is running and the signal from one
Verify that the problem is resolved. sensor is lost, no noticeable change in engine
performance will be noticed. If the engine is running
STOP. and the signals from both sensors are lost, fuel
injection will be terminated and the engine will be
• Not OK – One of the following conditions exists: shut down by the ECM.
The -03 diagnostic code is not active when the
signal wire is disconnected. The -04 diagnostic The engine will start when only one sensor signal is
code is not active when the wire jumper is installed. present. The engine will not start if the signals from
both sensors are lost.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Both sensors are magnetic sensors. The two sensors
Verify that the problem is resolved. are not interchangeable. Do not switch the positions
of the sensors. Replace the sensors as a set. If the
STOP. sensors are replaced, a timing calibration is not
necessary.
i02428908
If a replacement of the ECM is required, the ECM
Engine Speed/Timing Sensor parameters and the timing calibration can be
transferred from the suspect ECM to the replacement
Circuit - Test ECM. Timing calibration will not be necessary. This
feature requires the Caterpillar Electronic Technician
SMCS Code: 1912-038 (ET) and this feature is only possible if the existing
ECM can communicate with Cat ET. Use the “Copy
System Operation Description: Configuration - ECM Replacement” feature on Cat
ET.
Use this procedure to troubleshoot any suspect
problems with the following sensors: Complete all of the following tasks when you
install the speed/timing sensors:
• Primary engine speed/timing sensor
• Ensure that an O-ring is installed on each sensor.
• Secondary engine speed/timing sensor If an O-ring is damaged or missing, replace the
O-ring.
This procedure covers the following diagnostic codes:
• Lubricate the O-rings with oil.
• 190-08 Engine Speed abnormal
• Ensure that the sensor assembly is fully seated
• 342-08 Secondary Engine Speed signal abnormal into the engine before tightening the bracket bolt.
142 RENR2418-02
Troubleshooting Section
g01120211
Illustration 82
Schematic for the engine speed/timing sensors
Test Step 1. Check for Diagnostic Codes • 190-08 or 342-08 code – There is an active
diagnostic code or a logged diagnostic code for
A. Connect the Caterpillar Electronic Technician the engine speed/timing sensor. Proceed to Test
(ET) to the service tool connector. Refer to Step 4.
Troubleshooting, “Electronic Service Tools”.
• No codes – Neither code is active or logged.
B. Turn the keyswitch to the ON position.
Repair: Refer to the appropriate symptoms in
C. Start the engine and run the engine until the Troubleshooting, “Troubleshooting Without a
engine is at normal operating temperature. Diagnostic Code”.
Note: If the engine will not start, monitor the engine STOP.
rpm on Cat ET while the engine is being cranked. Cat
ET may need to be powered from another battery Test Step 2. Check the Installation of the
while the engine is being cranked. Sensor Assembly
D. Look for these codes on Cat ET: A. Turn the keyswitch to the OFF position.
• 190-08
• 342-08
Expected Result:
Results:
g01120250 g01142633
Illustration 83 Illustration 84
Left side view Sensor assembly
(1) Engine (4) O-ring
(2) Flanges
(3) Bracket
D. Ensure that one O-ring (4) is installed on each
sensor. Check the O-rings for damage. Replace
B. Visually inspect the sensor assembly without the O-rings, if necessary.
removing the sensor assembly from the engine.
Flanges (2) must be flush against engine (1) in Results:
order to ensure proper operation.
STOP.
RENR2418-02 145
Troubleshooting Section
g01120293
Illustration 85
Left side view
(1) P400 connector for engine timing (3) J401/P401 connectors for the primary (4) J402/P402 connectors for the secondary
calibration engine speed/timing sensor engine speed/timing sensor
(2) J2/P2 connectors
Expected Result:
Results:
STOP.
1. Temporarily install a new ECM. Refer to 1. Before you install the new sensor assembly,
Troubleshooting, “Replacing the ECM”. measure the resistance of the new sensors.
2. Start the engine. Run the engine until the engine If the resistance measurements of the new
is at normal operating temperature. sensors are within the specifications, install the
new sensor assembly in the engine according
3. If the problem is resolved with the test ECM, to the following procedure:
connect the original ECM and verify that the
problem recurs. a. Loosen the bolt and remove the bolt that
holds the sensor assembly to the engine.
4. If the problem returns with the original ECM,
replace the ECM. b. Ensure that O-rings are installed on the new
sensor assembly. Verify that the O-rings are
Verify that the problem is resolved. free of damage.
Test Step 5. Measure the Resistance of 2. Verify that the repair eliminates the problem.
the Sensor
STOP.
A. Disconnect the harness connector for the suspect
sensor.
i02433750
Pull-up Voltage
g01121181
Illustration 87
Schematic for the engine temperature sensors
g01121203
Illustration 88
Left side view
(1) Engine coolant temperature sensor (3) J61/P61 Customer connector (5) J1/P1 connectors
(2) Intake manifold air temperature sensor (4) J2/P2 connectors
g01121228
Illustration 90
J1/P1 terminals that are associated with the engine temperature
sensors
(3) Return
(16) Auxiliary temperature
g01120360
Illustration 89
P2 terminations for the engine temperature sensors
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature
152 RENR2418-02
Troubleshooting Section
Expected Result:
Results:
STOP.
Expected Result:
g01120369
Illustration 92
Harness connector for the temperature sensors No diagnostic codes are active.
(1) Signal
(2) Return Results:
C. Perform a 45 N (10 lb) pull test on each of the • OK – No diagnostic codes are active.
wires that are associated with the temperature
sensors. Repair: The problem may have been related
to a faulty connection in the harness. Carefully
D. Check the allen head screw on the ECM reinspect the connectors and wiring. Refer to
connectors for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect”
Troubleshooting, “Electrical Connectors - Inspect”. for additional information.
• OK – An 04 diagnostic code was active before C. Measure the resistance between the terminal
disconnecting the sensor. An 03 diagnostic code for the suspect sensor’s signal wire at the ECM
became active after the sensor was disconnected. connector and all of the remaining terminals on
the P2 connector.
Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the D. Measure the resistance between the terminal
engine. Verify that there are no active diagnostic for the suspect sensor’s signal wire at the ECM
codes for the sensor. If there are no active connector and all of the remaining terminals on
diagnostic codes for the sensor, permanently the P1 connector.
install the new sensor. Clear any logged diagnostic
codes. E. Measure the resistance between the terminal
for the suspect sensor’s signal wire at the ECM
Verify that the repair eliminates the problem. connector and the engine ground.
A. Disconnect the suspect sensor at the sensor • OK – Each check of the resistance indicates an
connector. open circuit. Proceed to Test Step 6.
B. Turn the keyswitch to the ON position. • Not OK – At least one check of the resistance does
not indicate an open circuit. There is a problem
C. Measure the voltage between terminal 1 (signal) with the wiring. There may be a problem with a
and terminal 2 (return) at the harness connector. connector.
D. Turn the keyswitch to the OFF position. Repair: Repair the wiring and/or the connectors.
Replace parts, if necessary.
Expected Result:
Verify that the original problem is resolved.
The voltage is 5.5 ± 0.5 VDC.
STOP.
154 RENR2418-02
Troubleshooting Section
Test Step 6. Create a Short at the Suspect Note: Disconnecting the return wire from the ECM
Sensor Connector will generate an 03 diagnostic code for all sensors
that are connected to the return wire. Troubleshoot
A. Turn the keyswitch to the OFF position. the original diagnostic code. Clear the logged
diagnostic codes when you are finished.
B. Install a jumper wire between terminals 1 and 2 on
the harness connector for the suspect sensor. c. Turn the keyswitch to the ON position. Monitor
the “Active Diagnostic Code” screen on Cat
C. Turn the keyswitch to the ON position. ET. Wait at least 15 seconds for activation of
the code.
D. Wait at least 15 seconds for activation of the 04
diagnostic code. An 03 diagnostic code should be active for the
suspect sensor.
Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET before installing the jumper wire and after C. Check the operation of the ECM by creating a
installing the jumper wire. short at the ECM:
E. Remove the jumper wire. Check for an 04 a. Install a wire jumper between the terminals for
diagnostic code again. the sensor signal wire and the return wire.
F. Turn the keyswitch to the OFF position. b. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 15 seconds for activation
Expected Result: of the code.
An 04 diagnostic code is active when the jumper wire An 04 diagnostic code should be active when
is installed. An 03 diagnostic code is active when the the wire jumper is installed.
jumper wire is removed.
c. Remove the wire jumper. Return all wiring to
Results: the original configuration.
• OK – The engine harness and the ECM are OK. Expected Result:
Repair: Temporarily connect a new sensor to the An 03 diagnostic code is active when the sensor
harness, but do not install the new sensor in the signal wire is removed from the ECM connector. An
engine. Verify that there are no active diagnostic 04 diagnostic code is active when the signal wire is
codes for the sensor. If there are no active connected to the return wire.
diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic Results:
codes.
• OK – The ECM is working properly. The problem
STOP. is in the wiring between the ECM and the sensor
connector.
• Not OK – The 03 diagnostic code remains active
with the jumper in place. Proceed to Test Step 7. Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire
Test Step 7. Check the Operation of the for the sensor. Repair the return wire for the sensor
ECM or replace the harness.
A. Turn the keyswitch to the OFF position. If the code is only active for one sensor, the
problem is most likely in the signal wire for the
B. Check the operation of the ECM by creating an sensor. Repair the signal wire for the sensor.
open circuit at the ECM:
STOP.
a. Remove the signal wire for the suspect sensor
from the appropriate ECM connector. • Not OK – One of the following conditions exists:
The 03 diagnostic code is not active when the
b. Remove terminal P2-30 (return). sensor signal wire is disconnected. The 04
diagnostic code is not active when the wire jumper
is installed.
RENR2418-02 155
Troubleshooting Section
Repair: Replace the ECM. Refer to If a problem is suspected with the ether starting aid
Troubleshooting, “Replacing the ECM”. switch, refer to Troubleshooting, “Switch Circuits -
Verify that the original problem is resolved. Test”.
g01213005
Illustration 93
Schematic of the ether injection system
g01146383
Illustration 95
Engine view (typical example)
(2) P61 customer connector
g01167488
Illustration 94
Engine view (typical example)
(1) J1/P1 ECM connectors
g01170983
Illustration 96
Ether starting aid group (typical example)
(3) Ether injection solenoid
RENR2418-02 157
Troubleshooting Section
g01155187
Illustration 99
Terminal locations at the harness connector for the ether solenoid
(1) Ether injection solenoid
(2) Chassis ground
Expected Result:
Results:
STOP.
Expected Result:
g01212957
Illustration 98
The ether canister is not empty.
P61 terminals for the ether injection system
(22) Ether injection solenoid
(38) Override switch
158 RENR2418-02
Troubleshooting Section
B. Restore electrical power to the engine ECM. E. Monitor the active diagnostic code screen on Cat
ET. Look for an active 05 code.
C. Proceed to the “Diagnostic Overrides” screen on
Cat ET. Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
D. Activate the ether injection system. The system
will activate for ten seconds. F. Remove electrical power from the engine ECM.
F. Look for a 05 diagnostic code or a 06 diagnostic • OK – A 06 code was active before the connector
code. was disconnected. A 05 code became active after
the connector was disconnected.
G. Remove electrical power from the engine ECM.
Repair: The circuit for the ether solenoid is OK.
Expected Result: Temporarily connect a new solenoid to the harness,
but do not install the new solenoid. After connecting
No diagnostic codes are active. the new solenoid to the harness, verify that there
are no active codes for the ether injection system.
Results:
If there are no active codes for the ether injection
• No active codes – Neither diagnostic code is system, permanently install the new solenoid.
active. Clear any logged diagnostic codes.
Test Step 5. Create a Short at the Test Step 6. Check the Operation of the
Connector for the Ether Injection ECM
Solenoid
A. Disconnect the J1/P1 ECM connectors.
A. Disconnect the harness connector for the ether
solenoid. B. Fabricate a jumper wire that is long enough to
create a test circuit from the ECM connector to the
B. Fabricate a jumper wire that is long enough to engine ground stud. Crimp a connector socket to
create a short circuit between terminal 1 and one end of the jumper wire.
terminal 2 at the harness connector for the ether
solenoid. Crimp connector pins to each end of the C. Remove the wire from terminal location J1-10
jumper wire. (ether injection solenoid) at the ECM connector.
Install the jumper wire into this terminal location.
C. Install the jumper wire between terminals 1 and 2
of the harness connector. D. Connect the J1/P1 ECM connectors.
D. Restore electrical power to the engine ECM. E. Check the operation of the ECM by creating
an open at the ECM:
E. Proceed to the “Diagnostic Overrides” screen on
Cat ET. a. Hold the loose end of the jumper wire away
from any ground source in order to create an
F. Activate the ether injection system. The system open circuit condition.
will activate for ten seconds.
b. Restore electrical power to the ECM.
G. Monitor the active diagnostic code screen on Cat
ET. Look for an active 06 code. c. Proceed to the “Diagnostic Overrides” screen
on Cat ET.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. d. Activate the ether injection system. The system
will activate for ten seconds.
H. Remove electrical power from the engine ECM.
e. Monitor the active diagnostic code screen on
I. Remove the jumper wire from the harness Cat ET. Look for an active 05 code. Record
connector. the result.
Expected Result:
Results:
STOP.
B. Restore the electrical power to the ECM. DO NOT A. Crank the engine. Observe the status for “Injection
START THE ENGINE. Actuation Pressure” and “Engine Speed” on Cat
ET while the engine is cranking. Record the
C. Print the “Lifetime Totals” and the “Configuration” following data:
screen.
________________ Desired injection actuation
D. Check for active diagnostic codes. pressure
Expected Result: Note: If the multimeter is not set to the correct scale,
the following measurement may provide misleading
The test lamp illuminates while the engine is cranking. results.
• OK – The test lamp illuminates while the engine ________________Observed pressure reading from
is cranking. The ECM is operating correctly and the pressure gauge
the wiring harness to the pump is probably OK.
Proceed to Test Step 5. ________________ Observed engine speed from
Cat ET
• Not OK – The test lamp does not illuminate while
the engine is cranking. ________________Observed “Injection Actuation
Output Percent” from Cat ET
Repair: Refer to diagnostic functional tests
Troubleshooting, “Injection Actuation Pressure ________________ Current reading from the
Control Valve Circuit - Test”. ammeter
Test Step 5. Check the Oil Pressure at the The oil pressure is above 26.5 MPa (3840 psi) and
Pump (Deadhead Test) the current is above 400 mA.
Results:
Note: There must be a continuous electrical • Not OK, Result 2 – The current is below 400 mA.
connection between the ECM and the unit injector
hydraulic pump. The improper connection or the Repair: Refer to diagnostic functional tests
incomplete connection of the adapter cable may Troubleshooting, “Injection Actuation Pressure
provide incorrect results. Control Valve Circuit - Test”.
• ________________ 164-02
Hot oil and components can cause personal in- • ________________ 164-11
jury.
Results:
Do not allow hot oil or components to contact
skin. • 164-00 or 164-11 is active or logged – 164-00 or
164-11 is active or logged. 164-02 or 42-11 may
A. Remove the valve cover and inspect the high also be active or logged. Proceed to Test Step 8.
pressure oil system for oil leaks.
• 164-02 is active or logged – 164-02 is active or
B. While the engine is being cranked, look around the logged, but 164-00 and 164-11 are not active or
injector bores for any signs of oil leakage. Inspect logged.
the spill ports on the injectors for an excessive
discharge of oil. All six injectors should spill the Repair: Refer to diagnostic functional tests
same amount of oil. Troubleshooting, “Injection Actuation Pressure
Sensor - Test” for information on troubleshooting
C. While the engine is being cranked, perform the the active 164-02 code.
“Injection Actuation Pressure Test”. Run the test at
the highest step in order to maximize any possible STOP.
leaks.
Test Step 8. Evaluate the Quality of the
Expected Result: Oil
No leaks are apparent. Extended oil drain intervals may cause elevated
levels of soot in the engine oil. The elevated levels
Results: of soot may also deplete the additive package of the
oil. This can affect the operation of the high pressure
• OK – There are no apparent leaks. Contact oil system.
your Engine Technical Communicator (TC) for
assistance. STOP. Record the current drain interval.
Repair: Replace the O-ring on the injector or ________________ Engine serial number
replace the damaged injector.
________________ Drain interval
STOP.
________________ Hours since last oil change
Test Step 7. Engine Starts
Expected Result:
A. Start the engine.
The customer has not exceeded the suggested oil
B. Check for the following codes on Cat ET: change interval and an oil change does not need to
be performed.
• 42-11 Inject Actuation Control Valve open/short
Results:
• 164-00 High Injector Actuation Pressure
• OK – The customer has not exceeded the
• 164-02 Injector Actuation Pressure signal erratic suggested oil change interval. Proceed to Test
Step 9.
• 164-11 Injector Actuation Pressure system fault
• Not OK – The customer has exceeded the
Expected Result: suggested oil change interval.
Repair: Before you proceed, ask the customer F. Remove the gauge from the unit injector hydraulic
to authorize an oil change with a new oil filter. pump. Install the plug into the secondary outlet
Oil changes are not covered by the warranty. port. Tighten the plug to a torque of 34 ± 3 N·m
After the engine oil and the oil filter have been (25 ± 2 lb ft).
changed, operate the engine until normal operating
temperature has been reached. Run the engine up Expected Result:
and down through the operating rpm range for 10
to 15 minutes. This will purge any trapped air or The pressure that was measured with the pressure
debris that is in the system. gauge for each step and the pressure that was
displayed on Cat ET for each step are within
If the problem persists, or if the problem recurs in a 1379 kPa (200 psi).
short period or time, proceed to Test Step 9.
Note: Under some situations, the injection actuation
Test Step 9. Check the System with the pressure may not change. Use this step to compare
“Injection Actuation Pressure Test” the pressure reading from the pressure gauge to the
pressure reading that is displayed on Cat ET.
Results:
Escaping fluid under pressure, even a pinhole size • OK – The pressures are within 1379 kPa
leak, can penetrate body tissue, causing serious (200 psi). The injection actuation pressure sensor
injury, and possible death. If fluid is injected into is operating properly. Do not replace the sensor.
your skin, it must be treated immediately by a doc- Proceed to Test Step 10.
tor familiar with this type of injury.
• Not OK – The pressures are not within 1379 kPa
Always use a board or cardboard when checking (200 psi). The injection actuation pressure sensor
for a leak. may be faulty. Replace the sensor and repeat
this test step. If the problem persists, verify the
A. Remove the plug from the secondary outlet port accuracy of the pressure gauge. Install the original
on the unit injector hydraulic pump. sensor onto the engine and proceed to Test Step
10.
B. Install a 8T-0852 Pressure Gauge in the
secondary outlet port. Test Step 10. Use a Test Lamp to Check
for the Presence of Current
C. Start the engine.
A. Disconnect J500/P500 IAPCV connector from the
D. Access the “Injection Actuation Pressure Test” in unit injector hydraulic pump.
the “Diagnostics Menu” of Cat ET and begin the
test. Note: Do not insert any wire that is larger than
18 AWG into the P500 harness connector. Do not
Note: The “Injection Actuation Pressure Test” can insert the probe for the voltage test lamp into the
increase the injection actuation pressure or the P500 harness connector. These actions will spread
“Injection Actuation Pressure Test” can decrease the the sockets of the connector which will damage
injection actuation pressure. The test adjusts the oil the connector. Damaged connectors could cause
pressure in steps. intermittent connections.
E. Record the pressure readings from the pressure B. Insert a 186-3735 Connector Pin into each of the
gauge and from Cat ET. P500 harness connector sockets.
• Not OK – The test lamp does not illuminate while • OK – The actual injection actuation pressure and
the engine is cranking. the desired injection actuation pressure are within
1379 kPa (200 psi).
Repair: Refer to diagnostic functional tests
Troubleshooting, “Injection Actuation Pressure Repair: Contact your Engine Technical
Control Valve Circuit - Test”. Communicator (TC) for assistance.
STOP. STOP.
Test Step 11. Perform the “Injection • Not OK – The actual injection actuation pressure
Actuation Pressure Test” at Low Idle and and the desired injection actuation pressure are not
at High Idle within 1379 kPa (200 psi). Proceed to Test Step 12.
Start the engine. Run the “Injection Actuation Test Step 12. Check the Oil Pressure at
Pressure Test” at low idle and at high idle. the Pump (Deadhead Test)
Note: There should not be any noticeable lag in
the reaction to the injection pressure. The pressure
changes should be instantaneous.
Escaping fluid under pressure, even a pinhole size
Record the data in the following tables: leak, can penetrate body tissue, causing serious
injury, and possible death. If fluid is injected into
Table 19 your skin, it must be treated immediately by a doc-
tor familiar with this type of injury.
Low Idle
Actual injection Always use a board or cardboard when checking
Desired injection
actuation for a leak.
Step actuation pressure
pressure from
from Cat ET
Cat ET
A. Disconnect the high pressure oil line from the
1 unit injector hydraulic pump. Install a 8T-0852
2 Pressure Gauge onto the outlet port of the pump.
3 Note: Ensure that the pump is supplying oil only to
4 the gauge.
Note: If the multimeter is not set to the correct scale, Test Step 13. Disconnect J500/P500
the following measurement may provide misleading Connector and Check the Oil Pressure
results.
A. Disconnect the J500/P500 connector at the unit
D. Crank the engine and record the following data: injector hydraulic pump.
________________Observed pressure reading from B. Crank the engine and record the oil pressure.
the pressure gauge
Note: The pressure readings may vary between
________________ Observed engine speed from gauges.
Cat ET
________________ Observed pressure reading from the
________________Observed “Injection Actuation pressure gauge
Output Percent” from Cat ET
________________ Observed engine speed from Cat ET
________________ Current reading from the
ammeter ________________ Observed “Injection Actuation
Output Percent” from Cat ET
Expected Result:
Expected Result:
The oil pressure is above 26.5 MPa (3843 psi) and
the current is above 400 mA. The oil pressure is below 8 MPa (1160 psi).
Results: Results:
• OK – The oil pressure is above 26.5 MPa • OK – The pressure reading is below 8 MPa
(3840 psi) and the current is above 400 mA. (1160 psi). The unit injector hydraulic pump is
Remove the adapter cable from the circuit. Leave working properly. Proceed to Test Step 14.
the pressure gauge installed on the pump. Proceed
to Test Step 13. • No – The unit injector hydraulic pump is faulty.
• Not OK - Result 1 – The oil pressure is below Repair: The unit injector hydraulic pump is faulty.
26.5 MPa (3840 psi) and the current is above 400 Replace the unit injector hydraulic pump. Verify that
mA. the repair eliminates the problem. If the problem
remains after the repair, contact your Engine
Repair: Replace the unit injector hydraulic pump. Technical Communicator (TC) for assistance.
If the drive gear on the pump is loose, do not
attempt to tighten the drive gear and reuse the After the unit injector hydraulic pump has been
pump. Verify that the repair eliminates the problem. replaced, the engine may need to be cranked for
If the problem remains after the repair, contact a significant length of time in order to fill the pump
your Engine Technical Communicator (TC) for with oil. Clear any diagnostic codes or event codes
assistance. that activated during the initial start-up. Retest the
system.
After the unit injector hydraulic pump has been
replaced, the engine may need to be cranked for STOP.
a significant length of time in order to fill the pump
with oil. Clear any diagnostic codes or event codes Test Step 14. Check the High Pressure
that activated during the initial start-up. Retest the Oil System for Leaks
system.
STOP.
• Not OK - Result 2 – The current is below 400 mA. Hot oil and components can cause personal in-
jury.
Repair: Refer to diagnostic functional tests
Troubleshooting, “Injection Actuation Pressure Do not allow hot oil or components to contact
Control Valve Circuit - Test”. skin.
B. While the engine is being cranked, look around the The ECM software contains performance maps. The
injector bores for any signs of oil leakage. Inspect performance maps have a desired actuation pressure
the spill ports on the injectors for an excessive for every engine operating condition. The ECM sends
discharge of oil. All six injectors should spill the a control current to the IAPCV. This signal creates an
same amount of oil. actual actuation pressure that matches the desired
actuation pressure. If the actual actuation pressure
C. While the engine is being cranked, perform the does not match the desired actuation pressure, the
“Injection Actuation Pressure Test”. Run the test at ECM will increase the control current or the ECM will
the highest step in order to maximize any possible decrease the control current to the IAPCV in order to
leaks. adjust pump outlet flow.
Repair: Replace the O-ring on the injector or • The control wire has a short to the +Battery.
replace the damaged injector. Verify that the repair
eliminates the original problem. • The return wire has a short to the +Battery.
STOP. • A short circuit in the IAPCV
i02433756
• A short to ground on the control wire
g01121315
Illustration 101
Schematic for the injection actuation pressure control valve
g01121264
Illustration 102
Left side view
(1) Connector for the IAPCV (2) J2/P2 connectors
RENR2418-02 169
Troubleshooting Section
g01121316
Illustration 103
P2 terminations for the IAPCV
(P2-10) Control (P2-20) Return
C. Perform a 45 N (10 lb) pull test on each of the Repair: Repair the connectors or wiring and/or
wires that are associated with the IAPCV. replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
D. Check the allen head screw on the ECM connector connectors are completely coupled.
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect”. Verify that the repair eliminates the problem.
E. Check the harness and wiring for abrasion and for STOP.
pinch points from the IAPCV back to the ECM.
Test Step 2. Check for Active Diagnostic
Note: Ensure that the seal is installed on the harness Codes
connector for the injection actuation pressure control
valve. A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to
Expected Result: Troubleshooting, “Electronic Service Tools”.
All connectors, pins, and sockets are completely B. Turn the keyswitch to the ON position.
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points. C. Start the engine.
Repair: If any of the above codes are logged The resistance measurement is within two Ohms of
and the engine is not running properly, refer to the value that was measured in the previous Test
Troubleshooting, “Troubleshooting Without a Step.
Diagnostic Code”.
Results:
If the engine is running properly at this time, there
may be an intermittent problem in a harness • OK – The resistance measurement is within two
that is causing the codes to be logged. Refer to Ohms of the value that was measured in the
Troubleshooting, “Electrical Connectors - Inspect”. previous Test Step. Proceed to Test Step 5.
A. Turn the keyswitch to the OFF position. Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the problem
B. Disconnect the J204/P204 connectors. is resolved.
STOP.
RENR2418-02 171
Troubleshooting Section
B. Insert a Deutsch connector pin into each socket • OK – The problem appears to be resolved. The
of the J204 harness connector. original problem was probably caused by a poor
electrical connection. STOP.
STOP.
i02433789
g01121384
Illustration 104
Schematic for the injection actuation pressure sensor
Expected Result:
Results:
Expected Result:
Results:
STOP.
STOP.
g01121360
Illustration 105
Left side view
(1) J500/P500 connectors for the injection
actuation pressure sensor
(2) J2/P2 connectors
g01123211
Illustration 107
Connectors for the injection actuation pressure sensor
(A) Supply
(B) Return
(C) Signal
Expected Result:
Results:
STOP.
176 RENR2418-02
Troubleshooting Section
Test Step 4. Check the Status of the Test Step 6. Compare the Sensor’s
Sensor Output to a Pressure Gauge
A. Turn the keyswitch to the ON position.
• 164-03 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
• 164-04 Injector Actuation Pressure voltage low the top of the fuel transfer pump.
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.
• OK – The value of the “Injection Actuation F. Refer to Table 22. 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.
Expected Result:
Results:
STOP.
RENR2418-02 177
Troubleshooting Section
Repair: Install a new injection actuation pressure These engines have Electronic Unit Injectors (EUI)
sensor and repeat the test. that are hydraulically actuated and electronically
controlled. The Engine Control Module (ECM) sends
If the new sensor corrects the problem, leave the a high voltage signal to each injector solenoid. The
new sensor in place. signal is sent with the proper injection duration and
injection timing for the current engine load and
If the new sensor does not correct the problem, the speed. The injector solenoid is mounted on top of
pressure gauge is faulty. Obtain a new pressure the fuel injector body.
gauge and repeat the test.
If an open circuit condition is detected in the solenoid
STOP. circuit, a diagnostic code is generated. The ECM will
continue to try to fire the injector. If a short circuit
condition is detected, a diagnostic code is generated.
i02429285
The ECM will disable the solenoid circuit. The ECM
Injector Solenoid Circuit - Test will periodically try to fire the injector. If the short
circuit condition remains, this sequence of events will
SMCS Code: 1290-038 be repeated until the problem is corrected.
System Operation Description: Note: Refer to Illustration 108. Two injector solenoids
share a supply wire. For this reason, an open
Use this procedure for the following conditions: circuit or a short circuit in a supply wire could cause
diagnostic codes for two injector solenoids.
• A suspected problem with an injector solenoid
178 RENR2418-02
Troubleshooting Section
g01123451
Illustration 108
Schematic for the injector solenoids
g01121683
Illustration 109
Left side view
(1) J300/P300 connectors
(2) J2/P2 connectors
STOP.
Expected Result:
Illustration 111
g01121687 There are no logged diagnostic codes for the injector
P300 terminals that are associated with the injector solenoids
solenoids .
(P300-1) Injector 1 supply
(P300-2) Injector 2 supply
Results:
(P300-3) Injector 3 supply
(P300-4) Injector 4 supply • OK – No diagnostic codes for the injector solenoids
(P300-5) Injector 5 supply are logged. The injector solenoids are operating
(P300-6) Injector 6 supply correctly. There may be a mechanical problem with
(P300-13) Injector 6 return
(P300-14) Injector 5 return the injector’s fuel delivery. Proceed to Test Step 3.
(P300-15) Injector 4 return
(P300-16) Injector 3 return • Not OK – A diagnostic code is logged for one
(P300-17) Injector 2 return or more injector solenoid. There is an electrical
(P300-18) Injector 1 return
problem with an injector solenoid or with the circuit.
Proceed to Test Step 4.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with injector solenoids. Test Step 3. Perform the “Cylinder Cutout
Test”
D. Check the allen head screw on the ECM
connectors for the proper torque. Refer to A. Start the engine.
Troubleshooting, “Electrical Connectors - Inspect”
for the proper torque value. B. Allow the engine to warm up to normal operating
temperature 77 °C (171 °F).
E. Check the harness and the wiring for abrasion
and for pinch points from the P300 connector to C. Access the “Cylinder Cutout Test” by accessing
the ECM. the following display screens:
Expected Result:
• “Diagnostics”
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness and wiring
• “Diagnostic Tests”
are free of corrosion, of abrasion, or of pinch points.
• “Cylinder Cutout Test”
Results: D. Shut off all parasitic loads such as air compressors
which could affect the results of the test.
• OK – The harness and wiring are OK. Proceed
to Test Step 2. E. Follow the instructions that are given on the
screen.
• Not OK – There is a problem in the connectors
and/or wiring. F. To start the test, select the start button at the
bottom of the screen.
182 RENR2418-02
Troubleshooting Section
• OK – The cylinder cutout test indicates that all of If the engine is misfiring or if the engine has low
the injectors are operating correctly. power, refer to Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable” or Troubleshooting,
Repair: If a problem with the fuel system is “Low Power/Poor or No Response to Throttle”.
suspected and diagnostic codes are not active or
logged, refer to Systems Operation/Testing and STOP.
Adjusting for information that is related to the low
pressure fuel system. • Not OK - “Open” – Note the cylinder that indicates
“Open”. Proceed to Test Step 5.
STOP.
• Not OK - “Short” – Note the cylinder that indicates
• Not OK – The cylinder cutout test indicates that at “Short”. Proceed to Test Step 6.
least one of the injectors is not operating correctly.
Proceed to Test Step 4. Test Step 5. Check the Harness between
the ECM and the Valve Cover Base for an
Test Step 4. Perform the “Injector Open Circuit
Solenoid Test”
A. Start the engine.
B. Allow the engine to warm up to normal operating Electrical shock hazard. The electronic unit injec-
temperature 77 °C (171 °F). tor system uses 90-120 volts.
C. Stop the engine. A. Remove the electrical power from the ECM.
D. Restore the electrical power to the ECM. B. Disconnect the P300 connector at the valve cover
base.
E. Access the “Injector Solenoid Test” by accessing
the following display screens: C. Restore the electrical power to the ECM.
G. Repeat this test for each suspect circuit. Stop Test Step 7. Check the Injector Harness
the “Injector Solenoid Test” before handling the Under the Valve Cover for an Open
jumper wire. Circuit or a Short Circuit
Restore the wiring to the original configuration.
Expected Result:
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
Cat ET displays “Short” for each circuit that was
jumpered.
A. Remove the electrical power from the ECM.
Results:
B. Remove the valve cover in order to gain access
• OK – Cat ET displays “Short” for each circuit that to the suspect injector.
was jumpered. The harness between the ECM and
the P300 connector does not have an open circuit. C. Disconnect the harness connector from the
Proceed to Test Step 7. suspect injector.
• Not OK – Cat ET displays “Open” for the cylinder D. Thoroughly clean the terminals on the injector
with the jumper wire. There is a problem in the solenoid and on the harness connector.
wiring between the ECM and the P300 connector.
There may be a problem with the ECM. Proceed E. Use a jumper wire to short circuit the connector
to Test Step 8. terminals for the suspect injector. This will replace
the injector solenoid with a short circuit.
Test Step 6. Check the Harness between
the ECM and the Valve Cover Base for a F. Restore the electrical power to the ECM.
Short Circuit
G. Perform the “Injector Solenoid Test” at least two
times.
Electrical shock hazard. The electronic unit injec- Note: The injector solenoid that shares the supply
tor system uses 90-120 volts. wire of the injector that is short circuited may indicate
a false test result. Disregard this test result.
A. Remove the electrical power from the ECM. H. Remove the electrical power from the ECM.
B. Disconnect the P300 connector. I. Remove the jumper wire from the injector
connector. This will replace the injector solenoid
C. Restore the electrical power to the ECM. with an open circuit.
D. Perform the “Injector Solenoid Test” at least two J. Restore the electrical power to the ECM.
times.
K. Perform the “Injector Solenoid Test” at least two
Expected Result: times.
All of the cylinders in the appropriate bank indicate L. Remove the electrical power from the ECM.
“Open” on Cat ET.
Expected Result:
Results:
Cat ET displays “Short” for the cylinder with the
• OK – All cylinders indicate “Open” on Cat ET. The jumper wire and “Open” when the jumper wire is
ECM and the engine harness are OK. Proceed to removed.
Test Step 7.
Results:
• Not OK – One or more cylinders indicate “Short”
on Cat ET. Note the cylinders that indicate “Short”. • OK – Cat ET displays the correct status during
Proceed to Test Step 8. the test.
STOP.
184 RENR2418-02
Troubleshooting Section
• Not OK – Cat ET did not display the correct status b. Restore the electrical power to the ECM.
during the test.
c. Perform the “Injector Solenoid Test” at least
Repair: There is a problem with the injector two times.
harness under the valve cover. There may be a
problem with a connector. Repair the wiring and/or d. Remove the electrical power from the ECM.
the connector, when possible. Replace parts, if
necessary. Cat ET displays “Short” for the two injectors
that share the supply wire.
STOP.
Expected Result:
Test Step 8. Check the ECM for Proper
Operation Cat ET displays the correct status for each test circuit.
Results:
F. Verify that the ECM will detect an open circuit for STOP.
the suspect injector:
i02433826
a. Ensure that the jumper wire is not in contact
with a ground source or another circuit. Do not Maintenance Due Lamp Circuit
touch the jumper wire during the test. A strong
electrical shock hazard is present at the jumper - Test
wire while the test is running.
SMCS Code: 7431-038
b. Restore the electrical power to the ECM.
System Operation Description:
c. Perform the “Injector Solenoid Test” at least
two times. The maintenance due lamp is a maintenance
indicator that is based on the PM levels that are
d. Remove the electrical power from the ECM. programmed into the Electronic Control Module
(ECM). The lamp will turn ON when the programmed
Cat ET displays “Open” for the two injectors interval is met.
that share the supply wire.
Use this procedure in order to troubleshoot any
G. Verify that the ECM detects a short circuit for the suspect problems with the circuit for the maintenance
suspect injector: due lamp.
g01121831
Illustration 112
Schematic for the maintenance due lamp
Results:
g01121848
Illustration 115
J61 and P61 terminals that are associated with the maintenance
due lamp
(13) Maintenance due lamp
Expected Result:
Results:
C. Turn the keyswitch to the ON position. Observe • Not OK – The maintenance due lamp did not turn
the maintenance due lamp. on when the jumper wire was connected. There is
a problem with the +Battery side of the circuit for
D. Remove the jumper wire and observe the the maintenance due lamp. Proceed to Test Step 5.
maintenance due lamp.
Test Step 5. Check the Voltage from the
Expected Result: Keyswitch to the Maintenance Due Lamp
The maintenance due lamp turned on while the A. Turn the keyswitch to the OFF position.
jumper was connected. The maintenance due lamp
turned off when the jumper was removed. B. Remove the wire from the terminal R of the
keyswitch.
Results:
C. Turn the keyswitch to the ON position.
• OK – The maintenance due lamp turned on while
the jumper was connected. The maintenance due D. Measure the voltage on terminal B of the
lamp turned off when the jumper was removed. keyswitch to engine ground.
The maintenance due lamp circuit is functioning
properly. Proceed to Test Step 6. E. Measure the voltage on terminal R of the
keyswitch to engine ground.
• Not OK – The maintenance due lamp did not
turn on. There is a problem with the circuit for the F. Turn the keyswitch to the OFF position.
maintenance due lamp. Proceed to Test Step 4.
Expected Result:
Test Step 4. Test the Circuit at the
Maintenance Due Lamp Voltage is present on terminal B and terminal R at
the keyswitch.
A. Disconnect wire F424-YL from the maintenance
due lamp. Results:
B. Connect a jumper wire between the lamp’s open • OK – Voltage is present on terminal B and terminal
terminal and engine ground. R at the keyswitch.
C. Turn the keyswitch to the ON position. Observe Repair: If voltage is present on terminal R,
the maintenance due lamp. repair the wire between the keyswitch and the
maintenance due lamp. Verify that the breaker
D. Disconnect the jumper wire and observe the is not tripped. Return all wiring to the original
maintenance due lamp. configuration. Verify that the problem is resolved.
The maintenance due lamp turns on while the jumper • Not OK – Voltage is not present on terminal B at
is connected. The maintenance due lamp turns off the keyswitch.
when the jumper is disconnected.
188 RENR2418-02
Troubleshooting Section
Repair: If voltage is not present on terminal B, Repair: Temporarily connect a test ECM. Refer
repair the wire between the +Battery and the to Troubleshooting, “Replacing the ECM”. Check
keyswitch. Check the battery’s no-load voltage. the operation of the maintenance due lamp when
Return all wiring to the original configuration. Verify the test ECM is installed.
that the problem is resolved.
If the problem is resolved with the test ECM,
STOP. connect the suspect ECM. If the problem returns
with the suspect ECM, replace the ECM. Verify that
• Not OK – Voltage is not present on terminal R at the problem is resolved.
the keyswitch.
STOP.
Repair: If voltage is present on terminal B of the
keyswitch but not present on terminal R, replace
i02433829
the keyswitch. Return all wiring to the original
configuration. Verify that the problem is resolved. PTO Switch Circuit - Test
STOP. SMCS Code: 7332-038
Test Step 6. Check the Operation of the System Operation Description:
ECM
Use this procedure to troubleshoot any suspect
A. Remove terminal P1-30. problems with the circuits for the power take-off
controls (PTO). The PTO controls provide an
B. Fabricate a jumper wire 100 mm (4 inch) long. alternative method of controlling the desired engine
Crimp a Deutsch pin to both ends of the wire. speed.
C. Insert the jumper into P1-30. The Electronic Control Module (ECM) provides the
PTO speed control function. The PTO speed control
D. Connect the J1/P1 connectors. function requires the following inputs:
E. Connect one probe of a voltage test lamp to the
• PTO switches
jumper wire in P1-30.
• The “PTO Mode” parameter
F. Connect the other probe of the voltage test lamp
to +Battery. The PTO switches enable the PTO speed control
function and the PTO switches control the desired
G. Turn the keyswitch to the ON position. Wait for engine speed.
ten seconds.
The “PTO Mode” parameter determines the mode
H. Turn the keyswitch to the OFF position. of operation. There are two modes of operation:
“Ramp Up/Ramp Down” and “Set/Resume”. Use
Expected Result: the Caterpillar Electronic Technician (ET) in order to
change the value of the parameter.
The test lamp turned ON for five seconds. Then, the
test lamp turned OFF. “Ramp Up/Ramp Down” Mode
Results: This mode uses three inputs. The inputs are provided
by two switches. Refer to Illustration 116.
• OK – The test lamp turned ON for five seconds.
Then, the test lamp turned OFF. The ECM is
operating correctly. The problem appears to be
resolved.
STOP.
g01121879
Illustration 116
Schematic for the PTO inputs for the “Ramp Up/Ramp Down” mode of operation
“Set/Resume” Mode
g01105373
Illustration 117
Schematic for the PTO inputs for the “Set/Resume” mode of operation
Placing the PTO Enable switch to the “Enable” Test Step 1. Inspect the Electrical
position transfers the control of the desired engine Connectors and the Wiring
speed from the throttle position sensor to the PTO
speed control function. The PTO Interrupt switch A. Turn the keyswitch to the OFF position.
momentarily transfers control back to the throttle
position sensor. The PTO Set/Resume switch
controls the desired engine speed.
g01120532 g01102468
Illustration 118 Illustration 119
Left side view P1 terminals that are associated with the PTO
(1) P61 customer connector (P1-41) Input from the PTO interrupt switch
(1) J1/P1 ECM connectors (P1-56) Input from the PTO enable switch
(P1-58) Input from the PTO ramp up switch or set switch
(P1-60) Input for PTO ramp down switch or resume switch
B. Thoroughly inspect connectors (1) and (2). Refer
to Troubleshooting, “Electrical Connectors -
Inspect”.
192 RENR2418-02
Troubleshooting Section
Results:
STOP.
Table 23
g01123458 J61 Terminals for the Inputs from the PTO Switches
Illustration 120
J61/P61 terminals that are associated with the PTO Switch J61 Terminals
(19) Input from the PTO interrupt switch PTO enable switch 29
(29) Input from the PTO enable switch
(30) Input from the PTO ramp up switch or set switch PTO ramp up switch or set
58
(39) Input for PTO ramp down switch or resume switch switch
PTO ramp down switch or
C. Perform a 45 N (10 lb) pull test on each of the 60
resume switch
wires that are associated with the circuits for the
PTO switches. PTO interrupt switch 41
Repair: Repair the connectors or wiring and/or • Not OK – The voltage test lamp does not turn on
replace the connectors or wiring. Ensure that all of when the switch is closed. Alternatively, the voltage
the seals are properly in place and ensure that the test lamp does not turn off when the switch is
connectors are completely coupled. opened. There is a problem in the wiring between
the J1 connector and the switch. There may be a
Verify that the repair eliminates the problem. problem in a connector.
STOP.
194 RENR2418-02
Troubleshooting Section
g01121934
Illustration 121
Typical switch inputs
g01120532
Illustration 122
Left side view
(1) P61 customer connector
(2) J1/P1 Electronic Control Module (ECM) connectors
g01121946
Illustration 124
P61/J61 terminals for the various switches
(2) Torque limit switch
(12) Maintenance clear switch
(19) PTO interrupt switch
(27) Remote shutdown switch
(28) Intermediate engine speed switch
g01121943 (29) PTO enable switch
Illustration 123
(30) PTO ramp up switch or set switch
P1 terminals for the various switches (38) Ether starting aid switch
(P1-6) Maintenance clear switch (39) PTO ramp down switch or resume switch
(P1-7) Torque limit switch (40) Overspeed verify switch
(P1-22) Ether starting aid switch
(P1-41) PTO interrupt switch C. Perform a 45 N (10 lb) pull test on each of the
(P1-44) Remote shutdown switch
(P1-45) Intermediate engine speed switch wires in the circuit for the suspect switch.
(P1-54) Overspeed verify switch
(P1-56) PTO enable switch D. Check the allen head screw on each ECM
(P1-58) PTO ramp up switch or set switch connector for the proper torque. Refer to
(P1-60) PTO ramp down switch or resume switch
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
Expected Result:
Terminals for the Switch Inputs Repair: Operate the engine and check the switch
for proper operation.
Name of the J61/P61
P1 Terminals
Switch Terminals If the switch does not operate correctly, there may
Maintenance be a short circuit between the circuit for the suspect
6 12 switch and another circuit. Carefully reinspect the
clear switch
components. Refer to Troubleshooting, “Electrical
Torque limit Inspectors - Inspect”. Locate the short circuit and
7 2
switch
make repairs.
Ether starting aid
22 38
switch STOP.
PTO interrupt
switch
41 19 • Not OK – Both resistance measurements indicate
an open circuit or both resistance measurements
Remote are less than ten Ohms. There is a problem with
44 27
shutdown switch the circuit for the switch.
Intermediate
engine speed 45 28 Repair: The problem could be in the switch, in the
switch wiring, or in a connector.
Overspeed verify Carefully reinspect the components. Refer to
54 40
switch
Troubleshooting, “Electrical Inspectors - Inspect”.
PTO enable
56 29
switch If the inspection does not identify the faulty
PTO ramp up
component, replace the switch and test the switch
switch or set 58 30 again.
switch
If the problem is not resolved, repair the wiring or
PTO ramp down the connector. Replace parts, if necessary. Verify
switch or resume 60 39 that the problem is resolved.
switch
STOP.
C. Connect a meter lead to the P1 terminal for the
suspect switch. Connect the other meter lead to
engine ground.
RENR2418-02 197
Troubleshooting Section
i02433840
g01122050
Illustration 127
Throttle position sensor with a knob
g01123466
Illustration 125
Electronic throttle position sensor
g01122049
Illustration 126
Throttle position sensor with a lever
g01122143
Illustration 128
Duty cycle versus throttle position
g01122222
Illustration 129
Schematic for the throttle position sensor
Test Step 1. Inspect the Electrical B. Thoroughly inspect connectors (1) and (2). Inspect
Connectors and the Wiring the connections on the throttle position sensor.
Refer to Troubleshooting, “Electrical Connectors
A. Turn the keyswitch to the OFF position. - Inspect”.
g01120532 g01122213
Illustration 130 Illustration 131
Left side view P1 terminal that is associated with the throttle position sensor
(1) P61 customer connector (P1-66) Throttle position
(2) J1/P1 connectors
RENR2418-02 199
Troubleshooting Section
STOP.
Expected Result:
g01122217
Results:
Illustration 132
J61 and P61 terminal that is associated with the throttle position • OK – The supply voltage is at least 11 VDC for a
(10) Throttle position 12 volt system. The supply voltage is at least 22
VDC for a 24 volt system. The supply voltage is
C. Perform a 45 N (10 lb) pull test on each of the reaching the sensor. Proceed to Test Step 3.
wires that are associated with the throttle position
sensor. • Not OK – The supply voltage is incorrect.
D. Check the allen head screw on each ECM Repair: The configuration of the wiring between the
connector for the proper torque. Refer to +Battery and the throttle position sensor depends
Troubleshooting, “Electrical Connectors - Inspect” on the engine’s configuration. The problem could
for the correct torque values. be in the wiring or in a connector. There may be a
problem with the battery.
E. Check the allen head screw on the customer
connector for the proper torque. Refer to Perform the necessary repairs. Verify that the
Troubleshooting, “Electrical Connectors - Inspect” problem is resolved.
for the correct torque value.
STOP.
F. Check the harness and wiring for abrasions and
for pinch points from the throttle position sensor Test Step 3. Check the Signal Wire for a
to the ECM and from the throttle position sensor Short Circuit
to the battery.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect the P1 connector.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Note: Be sure to wiggle the harnesses during the
are free of corrosion, of abrasion or of pinch points. following measurements. Be sure to wiggle each
harness near each connector.
Results:
C. Measure the resistance between terminal P1-66
• OK – The wiring and the connectors are OK. and all of the other terminals in the P1 connector.
Proceed to Test Step 2.
200 RENR2418-02
Troubleshooting Section
• Not OK – The resistance measurement is greater 5. Operate the throttle throughout the entire range.
than ten Ohms. There is a problem with the signal
wire. If the problem does not recur, the problem is
resolved. The original problem was probably
Repair: The problem could be in the wiring or in a caused by a poor electrical connection. Return
connector. Repair the wiring and/or the connector, the engine to service.
when possible. Replace parts, if necessary. Verify
that the problem is resolved. STOP.
A. Connect the Caterpillar Electronic Technician 1. Turn the keyswitch to the off position.
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. 2. Replace the throttle position sensor. Check for
a 091-08 diagnostic code again.
RENR2418-02 201
Troubleshooting Section
If the diagnostic code does not recur, the Note: The lamp will only turn off only if a “Warning”, a
problem is resolved. Return the engine to “Derate”, or a “Shutdown” condition does not exist.
service.
Expected Result:
If the diagnostic code recurs, replace the ECM.
Refer to Troubleshooting, “Replacing the ECM”. The warning lamp turns on and the warning lamp
Verify that the problem is resolved. turns off per the above description.
STOP. Results:
i02433855
• OK – The warning lamp appears to be operating
correctly at this time. STOP.
Warning Lamp Circuit - Test
• Not OK – The warning lamp is not functioning
SMCS Code: 7431-038 correctly. Check the bulb. Replace the bulb if the
bulb is not OK. If the bulb is OK, proceed to Test
System Operation Description: Step 2.
The warning lamp is a maintenance indicator that is Test Step 2. Inspect the Electrical
based on the PM levels that are programmed into the Connectors and the Wiring
Electronic Control Module (ECM). The warning lamp
will turn on when a warning, a derate, or a shutdown A. Turn the keyswitch to the OFF position.
condition exists.
g01122447
Illustration 133
Schematic for the warning lamp
g01121848
Illustration 136
J61 and P61 terminals that are associated with the warning lamp
(13) Warning lamp
Expected Result:
Results:
B. Connect a jumper wire between terminal P1-30 • Not OK – The warning lamp did not turn on when
and engine ground. the jumper wire was connected. There is a problem
with the +Battery side of the circuit for the warning
C. Turn the keyswitch to the ON position. Observe lamp. Proceed to Test Step 5.
the warning lamp.
Test Step 5. Check the Voltage from the
D. Remove the jumper wire and observe the warning Keyswitch to the Warning Lamp
lamp.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Remove the wire from the terminal R of the
The warning lamp turned on while the jumper was keyswitch.
connected. The warning lamp turned off when the
jumper was removed. C. Turn the keyswitch to the ON position.
Repair: If voltage is not present on terminal B, • Not OK – The test lamp did not turn on for five
repair the wire between the +Battery and the seconds. There is a problem with the ECM.
keyswitch. Check the battery’s no-load voltage.
Return all wiring to the original configuration. Verify Repair: Temporarily connect a test ECM. Refer to
that the problem is resolved. Troubleshooting, “Replacing the ECM”. Check the
operation of the warning lamp when the test ECM
STOP. is installed.
• Not OK – Voltage is not present on terminal R at If the problem is resolved with the test ECM,
the keyswitch. reconnect the original ECM. If the problem returns
with the original ECM, replace the original ECM.
Repair: If voltage is present on terminal B of the Verify that the problem is resolved.
keyswitch but not present on terminal R, replace
the keyswitch. Return all wiring to the original STOP.
configuration. Verify that the problem is resolved.
STOP.
Expected Result:
Results:
STOP.
RENR2418-02 205
Troubleshooting Section
C. Refer to Table 27. After the top center position has Test Step 2. Install the Transducer
been located, rotate the crankshaft for the number
of degrees that is applicable to your engine model. NOTICE
Be sure to rotate the crankshaft in the direction of If the crankshaft is not in the correct position when the
rotation that is specified in the Table. transducer is installed, the transducer will be damaged
when the engine is started.
B. Push the transducer through the transducer f. Connect the J2/P2 connectors. Tighten the
adapter until the transducer contacts the allen head screw on the P2 connector to the
crankshaft counterweight. appropriate torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical
C. Withdraw the transducer 1.0 mm (0.04 inch) and Connectors - Inspect” for the correct torque
hand tighten the nut on the adapter sleeve in value.
order to secure the transducer. Move the O-ring
seal against the adapter. g. Connect the 7X-1695 Cable As to the
connector for timing calibration and to the
Continue to the next test step. transducer.
Test Step 3. Connect the 7X-1695 Cable Continue to the next test step.
As
Test Step 4. Start the Engine and Check
A. If the engine harness is equipped with a connector for Diagnostic Codes
for timing calibration, connect the 7X-1695 Cable
As to the connector for timing calibration and to A. Connect Caterpillar Electronic Technician
the transducer. (ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.
B. If the engine harness is not equipped with a
connector for timing calibration, perform the B. Start the engine and run the engine until the
following procedure: engine is at the normal operating temperature.
a. Disconnect the P2 connector from the ECM. C. Check for active diagnostic codes. Wait at least 30
seconds in order for the codes to become active.
b. Determine the number of terminals on the P2
connector. The engine must not have any active diagnostic
codes during the timing calibration except for a
Table 29 261-13 Engine Timing Calibration required.
P2 Locations for Connection of the 7X-1695 Cable As
Expected Result:
Locations on Locations on
Wire Color the 70−pin P2 the 120−pin P2 There are no active diagnostic codes or there is only
Connector Connector
an active 261-13 diagnostic code.
White 22 26
Results:
Yellow 23 36
• OK – There are no active diagnostic codes or
c. Refer to Table 29. Remove the sealing plugs there is only an active 261-13 diagnostic code.
from the appropriate terminals. Do not discard Proceed to Test Step 5.
the sealing plugs. The sealing plugs may
be reinstalled when the timing calibration is • Not OK – There is at least one active code that
complete. is not 261-13.
d. Install the white wire of the 170-3519 Harness Repair: Troubleshoot and repair any active
into the appropriate location. diagnostic codes before you continue with this
procedure.
e. Install the yellow wire of the 170-3519
Harness into the appropriate location. STOP.
Disregard the pin-outs on the label of the
harness. Test Step 5. Calibrate the Engine
Speed/Timing Sensor
Note: Ensure that each wire is installed into the
correct location. The timing calibration will not be A. Set the engine speed to 1100 ± 50 rpm. The
successful if the wires are installed incorrectly. engine speed must be steady within this rpm
range in order for the calibration to be successful.
5. Remove the transducer and remove the Mechanical Calibration – During a manual
adapter. calibration, two set screws on the throttle position
sensor are adjusted. The set screws are for low idle
6. Install the plug into the timing calibration port. stop and high idle stop.
7. If you installed a 170-3519 Harness, you may Electronic Calibration – During an electronic
remove the harness or you may permanently calibration, the Caterpillar Electronic Technician (ET)
install the harness for future use. If you remove is used to set the PWM that is equal to low idle and
the harness, install the sealing plugs into the the PWM that is equal to high idle.
unused cavities of the P2 connector. Otherwise,
moisture and debris will enter the connector. Test Step 1. Inspect the Throttle’s
Components
If you choose to permanently install the harness,
fasten the harness to the existing engine wiring A. Turn the keyswitch to the OFF position.
harness with cable ties. Also, install a 3E-3364
Receptacle and two 8T-8737 Seal Plugs on B. Inspect the throttle linkage and related
the P400 timing calibration probe connector components for the following conditions:
in order to prevent moisture and debris from
entering the connector. • Loose
8. Return the engine to service. • Bent
STOP. • Broken
• Not OK – The timing calibration was unsuccessful. • Missing
Repair: The following conditions can cause the • Worn
timing calibration to fail:
208 RENR2418-02
Troubleshooting Section
The throttle linkage and related components are in • OK – When the throttle is at low idle, the “Throttle
good condition. Position” is zero percent. As you increase the
throttle, the value of the “Throttle Position”
Results: increases. The low idle adjustment is correct.
Proceed to Test Step 4.
• OK – The throttle linkage and related components
are in good condition. Proceed to Test Step 2. • Not OK – When the throttle is at low idle, the
“Throttle Position” is zero percent. Alternatively, as
• Not OK – The throttle linkage and related you increase the throttle, the value of the “Throttle
components are not in good condition. Position” does not increase. There is a problem
with the throttle position sensor.
Repair: Repair the throttle linkage. Replace parts,
if necessary. Continue with this procedure when Repair: Refer to Troubleshooting, “Throttle Postion
the components for the throttle linkage are in good Sensor Circuit - Test”.
condition.
STOP.
STOP.
Test Step 4. Adjust the Throttle at High
Test Step 2. Determine the Type of Idle
Calibration
A. Move the throttle to high idle. Adjust the throttle
Determine the type of calibration to be performed. linkage and/or adjust the high idle set screw until
the “Throttle Position” is 100 percent.
Results:
Note: When you adjust the high idle on some types
• Mechanical – Proceed to Test Step 3. of linkage, the low idle adjustment may change.
• Electronic – Proceed to Test Step 5. B. Verify that low idle is correctly adjusted. Make
adjustments, if necessary.
Test Step 3. Adjust the Throttle at Low
Idle Expected Result:
A. Connect Cat ET to the service tool connector. When the throttle is at high idle, the “Throttle Position”
Refer to Troubleshooting, “Electronic Service is 100 percent. When the throttle is at low idle, the
Tools”. “Throttle Position” is zero percent.
Expected Result:
Results:
Expected Result:
Results:
STOP.
210 RENR2418-02
Index Section
Index
Numerics CID 0091 FMI 13 Throttle Position calibration
required................................................................ 61
5 Volt Engine Pressure Sensor Supply Circuit - CID 0094 FMI 03 Fuel Pressure open/short to
Test ...................................................................... 83 +batt..................................................................... 61
CID 0094 FMI 04 Fuel Pressure short to ground... 61
CID 0100 FMI 03 Engine Oil Pressure open/short to
A +batt..................................................................... 62
CID 0100 FMI 04 Engine Oil Pressure short to
Air Inlet Heater Circuit - Test.................................. 91 ground.................................................................. 62
Air Shutoff System - Test ....................................... 98 CID 0100 FMI 10 Engine Oil Pressure Sensor
Alternator (Charging Problem)............................... 28 abnormal rate of change...................................... 62
Probable Causes ............................................... 28 CID 0102 FMI 03 Boost Pressure Sensor short to
Recommended Actions...................................... 28 +batt..................................................................... 63
CID 0102 FMI 04 Boost Pressure Sensor short to
ground.................................................................. 63
B CID 0102 FMI 10 Boost Pressure Sensor abnormal
rate of change...................................................... 63
Battery ................................................................... 28 CID 0110 FMI 03 Engine Coolant Temperature
Probable Causes ............................................... 28 open/short to +batt............................................... 64
Recommended Actions...................................... 28 CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 64
CID 0111 FMI 02 Engine Coolant Level Sensor Loss
C of Signal............................................................... 64
CID 0164 FMI 02 Injector Actuation Pressure signal
Calibration Procedures ........................................ 205 erratic................................................................... 65
CAN Data Link Circuit - Test................................ 105 CID 0164 FMI 03 Injector Actuation Pressure voltage
Can Not Reach Top Engine RPM .......................... 28 high ...................................................................... 65
Probable Causes ............................................... 28 CID 0164 FMI 04 Injector Actuation Pressure voltage
Recommended Actions...................................... 29 low ....................................................................... 65
Cat Data Link Circuit - Test.................................. 109 CID 0164 FMI 11 Injector Actuation Pressure system
CID 0001 FMI 05 Cylinder #1 Injector open fault ...................................................................... 66
circuit ................................................................... 56 CID 0168 FMI 00 System Voltage High................. 66
CID 0001 FMI 06 Cylinder #1 Injector short .......... 56 CID 0168 FMI 01 System Voltage Low.................. 67
CID 0002 FMI 05 Cylinder #2 Injector open CID 0168 FMI 02 System Voltage intermittent/
circuit ................................................................... 57 erratic................................................................... 67
CID 0002 FMI 06 Cylinder #2 Injector short .......... 57 CID 0172 FMI 03 Intake Manifold Air Temp open/short
CID 0003 FMI 05 Cylinder #3 Injector open to +batt................................................................. 67
circuit ................................................................... 57 CID 0172 FMI 04 Intake Manifold Air Temp short to
CID 0003 FMI 06 Cylinder #3 Injector short .......... 57 ground.................................................................. 68
CID 0004 FMI 05 Cylinder #4 Injector open CID 0190 FMI 08 Engine Speed signal abnormal.. 68
circuit ................................................................... 58 CID 0247 FMI 09 J1939 Data Link
CID 0004 FMI 06 Cylinder #4 Injector short .......... 58 communications................................................... 68
CID 0005 FMI 05 Cylinder #5 Injector open CID 0253 FMI 02 Personality Module mismatch ... 68
circuit ................................................................... 58 CID 0261 FMI 13 Engine Timing Calibration
CID 0005 FMI 06 Cylinder #5 Injector short .......... 59 required................................................................ 69
CID 0006 FMI 05 Cylinder #6 Injector open CID 0262 FMI 03 5 Volt Sensor DC Power Supply
circuit ................................................................... 59 short to +batt........................................................ 69
CID 0006 FMI 06 Cylinder #6 Injector short .......... 59 CID 0262 FMI 04 5 Volt Sensor DC Power Supply
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 59 short to ground..................................................... 69
CID 0041 FMI 04 8 Volt DC Supply short to CID 0268 FMI 02 Check Programmable
ground.................................................................. 60 Parameters .......................................................... 70
CID 0042 FMI 05 Injector Actuation Valve open CID 0274 FMI 03 Atmospheric Pressure open/short
circuit ................................................................... 60 to +batt................................................................. 70
CID 0042 FMI 06 Injector Actuation Valve short to CID 0274 FMI 04 Atmospheric Pressure short to
ground.................................................................. 60 ground.................................................................. 70
CID 0091 FMI 08 Throttle Position signal CID 0342 FMI 08 Secondary Engine Speed signal
abnormal.............................................................. 61 abnormal.............................................................. 71
RENR2418-02 211
Index Section
CID 0617 FMI 05 Air Inlet Heater Relay open/current Electronic Troubleshooting ...................................... 5
below normal ....................................................... 71 Engine Cranks but Will Not Start ........................... 32
CID 0617 FMI 06 Air Inlet Heater Relay Probable Causes ............................................... 32
grounded/current above norm ............................. 71 Recommended Actions...................................... 33
CID 1835 FMI 03 Auxiliary Pressure Sensor Engine Has Early Wear ......................................... 34
open/short to +batt............................................... 72 Probable Causes ............................................... 34
CID 1835 FMI 04 Auxiliary Pressure Sensor short to Recommended Actions...................................... 34
ground.................................................................. 72 Engine Misfires, Runs Rough or Is Unstable......... 35
CID 1836 FMI 03 Auxiliary Temperature Sensor Probable Causes ............................................... 35
open/short to +batt............................................... 72 Recommended Actions...................................... 35
CID 1836 FMI 04 Auxiliary Temperature Sensor short Engine Oil in Cooling System ................................ 36
to ground.............................................................. 72 Probable Causes ............................................... 36
CID 2417 FMI 05 Ether Injection Control Solenoid Recommended Actions...................................... 36
current low ........................................................... 73 Engine Oil Temperature Is Too High...................... 36
CID 2417 FMI 06 Ether Injection Control Solenoid Probable Causes ............................................... 36
current high.......................................................... 73 Recommended Actions...................................... 36
Coolant in Engine Oil............................................. 30 Engine Pressure Sensor Open or Short Circuit -
Probable Causes ............................................... 30 Test .................................................................... 133
Recommended Actions...................................... 30 Engine Speed/Timing Sensor - Calibrate ............ 205
Coolant Level Sensor Circuit - Test ...................... 112 Engine Speed/Timing Sensor Circuit - Test......... 141
Coolant Temperature Is Too High .......................... 30 Engine Stalls at Low RPM ..................................... 37
Customer Passwords ............................................ 17 Probable Causes ............................................... 37
Recommended Actions...................................... 37
Engine Temperature Sensor Open or Short Circuit -
D Test .................................................................... 147
Engine Vibration .................................................... 37
Diagnostic Code Cross Reference ........................ 53 Probable Causes ............................................... 37
Diagnostic Codes .................................................. 52 Recommended Actions...................................... 38
Active Diagnostic Codes .................................... 53 Engine Will Not Crank ........................................... 38
Diagnostic Codes............................................... 52 Probable Causes ............................................... 38
Logged Diagnostic Codes.................................. 53 Recommended Actions...................................... 38
Diagnostic Functional Tests................................... 83 Engine Wiring Information ..................................... 15
Diagnostic Lamp Circuit - Test.............................. 116 Harness Wire Identification ................................ 15
Digital Sensor Supply Circuit - Test ..................... 120 Ether Injection System - Test............................... 155
Event Codes .......................................................... 74
Active Event Codes............................................ 74
E Clearing Event Codes ........................................ 75
Logged Event Codes ......................................... 75
E096 High Fuel Pressure ...................................... 75 Troubleshooting ................................................. 75
E2143 Low Engine Coolant Level ......................... 81 Excessive Black Smoke ........................................ 39
E360 Low Engine Oil Pressure.............................. 76 Probable Causes ............................................... 39
E361 High Engine Coolant Temperature ............... 77 Recommended Actions...................................... 39
E362 Engine Overspeed ....................................... 78 Excessive Engine Oil Consumption....................... 40
E443 High Auxiliary Pressure................................ 79 Probable Causes ............................................... 40
E445 High Auxiliary Temperature .......................... 80 Recommended Actions...................................... 40
E539 High Intake Manifold Air Temperature.......... 81 Excessive Fuel Consumption ................................ 40
ECM Will Not Accept Factory Passwords.............. 31 Probable Causes ............................................... 40
Probable Causes ............................................... 31 Recommended Actions...................................... 40
Recommended Actions...................................... 31 Excessive Valve Lash............................................ 41
ECM Will Not Communicate with Other Systems or Probable Causes ............................................... 41
Display Modules .................................................. 31 Recommended Actions...................................... 41
Probable Causes ............................................... 31 Excessive White Smoke ........................................ 41
Recommended Actions...................................... 31 Probable Causes ............................................... 41
Electrical Connectors - Inspect............................ 124 Recommended Actions...................................... 42
Electrical Power Supply Circuit - Test.................. 129 Exhaust Temperature Is Too High ......................... 42
Electronic Service Tool Will Not Communicate with Probable Causes ............................................... 42
ECM..................................................................... 31 Recommended Actions...................................... 43
Probable Causes ............................................... 31
Recommended Actions...................................... 32
Electronic Service Tools .......................................... 6 F
Caterpillar Electronic Technician (ET).................. 7
Optional Service Tools ......................................... 6 Factory Passwords ................................................ 17
Required Service Tools ........................................ 6 Factory Passwords Worksheet.............................. 18
Flash Codes .......................................................... 52 R
Flash Programming ............................................... 18
Programming a Flash File.................................. 18 Replacing the ECM.................................................. 9
Fuel Dilution of Engine Oil ..................................... 43
Probable Causes ............................................... 43
Recommended Actions...................................... 43 S
Fuel in Cooling System.......................................... 43
Probable Causes ............................................... 43 Self-Diagnostics..................................................... 10
Recommended Actions...................................... 43 Sensors and Electrical Connectors ........................ 11
Component Location.......................................... 14
Cross-Reference for the P1 ECM Connector and
I the J61 Customer Connector ........................... 13
Service Information Report.................................... 19
Important Safety Information ................................... 2 Recommendations ............................................. 19
Injection Actuation Pressure - Test ...................... 160 Switch Circuits - Test ........................................... 193
Injection Actuation Pressure Control Valve Circuit - System Configuration Parameters......................... 21
Test .................................................................... 167 Monitoring System ............................................. 26
Injection Actuation Pressure Sensor - Test.......... 172 Parameter Descriptions ..................................... 21
Injector Solenoid Circuit - Test............................. 177 System Configuration Parameters ..................... 24
Injector Trim File .................................................... 19 System Overview..................................................... 5
Intermittent Engine Shutdown ............................... 44 Passwords ........................................................... 6
Probable Causes ............................................... 44 Programmable Parameters.................................. 6
Recommended Actions...................................... 44 System Operation ................................................ 5
Intermittent Low Power or Power Cutout............... 45
Probable Causes ............................................... 45
Recommended Actions...................................... 45 T
Table of Contents..................................................... 3
L Throttle Position Sensor - Calibrate..................... 207
Throttle Position Sensor Circuit - Test ................. 197
Low Engine Oil Pressure ....................................... 46 Troubleshooting Section.......................................... 5
Probable Causes ............................................... 46 Troubleshooting with a Diagnostic Code ............... 52
Recommended Actions...................................... 46 Troubleshooting with an Event Code..................... 74
Low Power/Poor or No Response to Throttle ........ 46 Troubleshooting without a Diagnostic Code .......... 28
Probable Causes ............................................... 46
Recommended Actions...................................... 47
V
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