RENR9318-11

December 2013

Troubleshooting
C11 and C13 Engines for Caterpillar
Built Machines
BJ6 1-Up (Machine)
BS6 1-Up (Machine)
GTA 1-Up (Machine)
LCC 1-Up (Machine)
9SD 1-Up (Machine)
A6D 1-Up (Machine)
A7D 1-Up (Machine)
NPE 1-Up (Machine)
LFF 1-Up (Machine)
RYF 1-Up (Machine)
A6G 1-Up (Machine)
A7G 1-Up (Machine)
LFH 1-Up (Machine)
A6J 1-Up (Machine)
A7J 1-Up (Machine)
TAL 1-Up (Machine)
WTL 1-Up (Machine)
WTM 1-Up (Machine)
WTN 1-Up (Machine)
NYY 1-Up (Machine)
SEY 1-Up (Machine)
WXZ 1-Up (Machine)

SAFETY.CAT.COM
 i05296198

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9318 3
Table of Contents

Table of Contents Fuel in Cooling System.................. ................. 45

Fuel Dilution of Engine Oil ............... ............... 46
Troubleshooting Section Intermittent Engine Shutdown ............ ............ 46
Intermittent Low Power or Power Cutout .... .... 47
Electronic Troubleshooting Low Engine Oil Pressure ................ ................ 48
System Overview....................... ....................... 6 Low Power/Poor or No Response to Throttle . 49
Electronic Service Tools .................. ................. 7 Mechanical Noise (Knock) in Engine....... ....... 51
Electronic Display Module (If Equipped)..... .... 12 Noise Coming from Cylinder.............. ............. 51
Poor Acceleration or Response........... ........... 52
Replacing the ECM..................... .................... 12
Valve Rotator or Spring Lock Is Free....... ....... 53
Self-Diagnostics....................... ....................... 14
Sensors and Electrical Connectors ........ ........ 15
Engine Wiring Information ............... ............... 17
Troubleshooting with a Diagnostic Code
Diagnostic Codes ...................... ..................... 55
CID 0001 FMI 05 Cylinder #1 Injector open
Programming Parameters
circuit............................... .............................. 56
Programming Parameters ............... ............... 19
CID 0001 FMI 06 Cylinder #1 Injector short.. .. 56
Test ECM Mode ....................... ....................... 19
CID 0002 FMI 05 Cylinder #2 Injector open
Factory Passwords ..................... .................... 19
circuit............................... .............................. 56
Flash Programming .................... .................... 20
CID 0002 FMI 06 Cylinder #2 Injector short.. .. 57
Injector Trim File ....................... ...................... 20
CID 0003 FMI 05 Cylinder #3 Injector open
System Configuration Parameters circuit............................... .............................. 57
System Configuration Parameters......... ......... 22 CID 0003 FMI 06 Cylinder #3 Injector short.. .. 57
CID 0004 FMI 05 Cylinder #4 Injector open
Troubleshooting without a Diagnostic circuit............................... .............................. 57
CID 0004 FMI 06 Cylinder #4 Injector short.. .. 58
Code
CID 0005 FMI 05 Cylinder #5 Injector open
Alternator (Charging Problem and/or Noisy
circuit............................... .............................. 58
Operation)........................... .......................... 26
CID 0005 FMI 06 Cylinder #5 Injector short.. .. 58
Can Not Reach Top Engine RPM .......... ......... 26
CID 0006 FMI 05 Cylinder #6 Injector open
Coolant in Engine Oil ................... ................... 27
circuit............................... .............................. 58
Coolant Temperature Is Too High .......... ......... 29
CID 0006 FMI 06 Cylinder #6 Injector short.. .. 59
ECM Will Not Accept Factory Passwords.... ... 30
CID 0041 FMI 03 8 Volt DC Supply short to
ECM Will Not Communicate with Other Systems
+batt............................... ............................... 59
or Display Modules .................... ................... 30
CID 0041 FMI 04 8 Volt DC Supply short to
Electronic Service Tool Will Not Communicate
ground.............................. ............................. 59
with ECM............................ ........................... 31
CID 0091 FMI 08 Throttle Position signal
Elevated Idle.......................... ......................... 32
abnormal............................ ........................... 59
Engine Cranks but Will Not Start .......... .......... 32
CID 0094 FMI 03 Fuel Pressure open/short to
Engine Has Early Wear ................. ................. 33
+batt............................... ............................... 60
Engine Misfires, Runs Rough or Is Unstable. . 35
CID 0094 FMI 04 Fuel Pressure short to
Engine Oil in Cooling System ............. ............ 36
ground.............................. ............................. 60
Engine Oil Temperature Is Too High ........ ....... 36
CID 0100 FMI 03 Engine Oil Pressure open/
Engine Stalls at Low RPM ............... ............... 37
short to +batt......................... ........................ 60
Engine Vibration ....................... ...................... 39
CID 0100 FMI 04 Engine Oil Pressure short to
Engine Will Not Crank................... .................. 40
ground.............................. ............................. 60
Excessive Black Smoke ................. ................ 41
CID 0100 FMI 10 Engine Oil Pressure Sensor
Excessive Engine Oil Consumption ................ 42
abnormal rate of change................ ............... 61
Excessive Fuel Consumption............. ............ 43
CID 0110 FMI 03 Engine Coolant Temperature
Excessive Valve Lash................... .................. 43
open/short to +batt.................... .................... 61
Excessive White Smoke................. ................ 44
CID 0110 FMI 04 Engine Coolant Temperature
Exhaust Temperature Is Too High ......... ......... 45
short to ground....................... ....................... 61
4 RENR9318
Table of Contents
CID 0168 FMI 00 System Voltage High ..... ..... 62
CID 0168 FMI 01 System Voltage Low...... ..... 62
CID 0168 FMI 02 System Voltage intermittent/
erratic.............................. .............................. 62
CID 0172 FMI 03 Intake Manifold Air Temp open/
short to +batt......................... ........................ 63
CID 0172 FMI 04 Intake Manifold Air Temp short
to ground............................ ........................... 63
CID 0174 FMI 03 Fuel Temperature open/short
to +batt............................. ............................. 63
CID 0174 FMI 04 Fuel Temperature short to
ground.............................. ............................. 63
CID 0253 FMI 02 Personality Module
mismatch ........................... ........................... 64
CID 0261 FMI 11 Engine Timing Offset fault.. . 64
CID 0261 FMI 13 Engine Timing Calibration
required............................. ............................ 65
CID 0262 FMI 03 5 Volt Sensor DC Power
Supply short to +batt................... .................. 66
CID 0262 FMI 04 5 Volt Sensor DC Power
Supply short to ground................. ................. 66
CID 0267 FMI 02 Incorrect Engine Shutdown
Switch inputs......................... ........................ 66
CID 0268 FMI 02 Check Programmable
Parameters .......................... ......................... 66
CID 0274 FMI 03 Atmospheric Pressure open/
short to +batt......................... ........................ 67
CID 0274 FMI 04 Atmospheric Pressure short to
ground.............................. ............................. 67
CID 0275 FMI 03 Right Turbo Inlet Pressure
open/short to +batt.................... .................... 67
CID 0275 FMI 04 Right Turbo Inlet Pressure
short to ground....................... ....................... 68
CID 0283 FMI 05 Filter Restrict Lamp open/short
to +batt............................. ............................. 68
CID 0283 FMI 06 Filter Restrict Lamp short to
ground.............................. ............................. 68
CID 0291 FMI 05 Engine Cooling Fan Solenoid
open circuit.......................... .......................... 68
CID 0291 FMI 06 Engine Cooling Fan Solenoid
short to ground....................... ....................... 69
CID 0296 FMI 09 Unable to communicate with
Transmission ECM ................... .................... 69
CID 0296 FMI 12 See Service Manual ...... ..... 69
CID 0342 FMI 08 Secondary Engine Speed
signal abnormal ...................... ...................... 70
CID 0596 FMI 09 Unable to communicate with
Implement ECM ...................... ...................... 70
CID 0596 FMI 12 Wrong Response from
Implement ECM ...................... ...................... 70
CID 1639 FMI 02 Machine Security System
incorrect ............................ ............................ 71
CID 1639 FMI 09 Machine Security System
Module not communicating on link ................ 71
CID 1785 FMI 03 Intake Manifold Pressure
Sensor voltage high ................... ................... 71
CID 1785 FMI 04 Intake Manifold Pressure
Sensor voltage low ........................................ 71
CID 1785 FMI 10 Intake Manifold Pressure
Signal abnormal rate of change.......... .......... 72
CID 2417 FMI 05 Ether Injection Control
Solenoid current low ................... .................. 72
CID 2417 FMI 06 Ether Injection Control
Solenoid current high.................. .................. 72
Troubleshooting with an Event Code
Event Codes .......................... ......................... 73
E096 High Fuel Pressure ............... ................ 76
E172 High Air Filter Restriction............ ........... 77
E194 High Exhaust Temperature.......... .......... 77
E265 User Defined Shutdown ............ ............ 78
E360 Low Engine Oil Pressure............ ........... 78
E362 Engine Overspeed ................ ................ 79
E390 Fuel Filter Restriction .............. .............. 80
E441 Idle Elevated to Increase Battery
Voltage............................. ............................. 80
E539 High Intake Manifold Air Temperature.. . 80
E1171 Engine Idle Shutdown Occurred..... ..... 81
E1172 Engine Idle Shutdown Pending ...... ..... 82
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit -
Test ................................ ............................... 83
Cat Data Link Circuit - Test ............... .............. 88
Electrical Connectors - Inspect............ ........... 91
Electrical Power Supply Circuit - Test ....... ...... 97
Engine Fan Control Solenoid Circuit - Test.. . 101
Engine Fan Reversing Solenoid Circuit - Test 105
Engine Pressure Sensor Open or Short Circuit -
Test ............................... .............................. 109
Engine Speed/Timing Sensor Circuit - Test . ..115
Engine Temperature Sensor Open or Short
Circuit - Test ........................ .........................119
Ether Injection System - Test ............ ............ 124
Fuel Filter Differential Pressure Switch Circuit -
Test ............................... .............................. 129
Indicator Lamp Circuit - Test ............. ............ 132
Injector Solenoid Circuit - Test ........... ........... 136
Throttle Position Sensor Circuit - Test ..... ..... 144
User Defined Shutdown Input Circuit - Test. . 148
RENR9318 5
Table of Contents

Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ... .. 152

Index Section

Index............................... .............................. 156

6 RENR9318
Electronic Troubleshooting
Troubleshooting Section
Electronic Troubleshooting
i02581726
System Overview
SMCS Code: 1900
System Operation
This engine is electronically controlled. Each cylinder
has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector
solenoid in order to control the operation of the fuel
injection system.
Electronic Controls
The electronic system consists of the following
components: the ECM, the Electronically Controlled
Unit Injectors (EUI), the wiring harness, the switches
and the sensors. The ECM is the computer. The flash
file is the software for the computer. The flash file
contains the operating maps. The operating maps
define the following characteristics of the engine:
• Horsepower
• Torque curves
The ECM determines the timing and the amount of
fuel that is delivered to the cylinders. This is based on
the actual conditions and/or on the desired conditions
at any given time.
The ECM compares the desired engine speed to the
actual engine speed. The actual engine speed is
determined through a signal from the engine speed/
timing sensor. The desired engine speed is
determined with the following factors:
• Throttle signal
• Other input signals from sensors
• Certain diagnostic codes
If the desired engine speed is greater than the actual
engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
Cold Mode
The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
during cold mode operation. Cold mode operation
provides the following benefits:
• Increased cold weather starting capability
• Reduced warm-up time
• Reduced white smoke
Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
mode remains active until the engine temperature
rises above a predetermined value or until a time limit
is exceeded.
Fuel Injection
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injector will
pump fuel only if the injector solenoid is energized.
The ECM sends a high voltage signal to the solenoid.
This high voltage signal energizes the solenoid. By
controlling the timing and the duration of the high
voltage signal, the ECM can control injection timing
and the engine RPM.
The flash file inside the ECM sets certain limits on the
amount of fuel that can be injected. The “FRC Fuel
Limit” is used to control the air/fuel ratio for control of
emissions. The “FRC Fuel Limit” is a limit that is
based on the intake manifold pressure. A higher
intake manifold pressure indicates that there is more
air in the cylinder. When the ECM senses a higher
intake manifold pressure, the ECM increases the
“FRC Fuel Limit” . When the ECM increases the
“FRC Fuel Limit” , the ECM allows more fuel into the
cylinder. The “FRC Fuel Limit” is programmed into
the ECM at the factory. The “FRC Fuel Limit” cannot
be changed.
The “Rated Fuel Limit” is a limit that is based on the
power rating of the engine and on engine rpm. The
“Rated Fuel Limit” is similar to the rack stops and to
the torque spring on a mechanically governed engine.
The “Rated Fuel Limit” provides the power curves
and the torque curves for a specific engine family and
for a specific engine rating. The “Rated Fuel Limit” is
programmed into the ECM at the factory. The “Rated
Fuel Limit” cannot be changed.
Once the ECM determines the amount of fuel that is
required, the ECM must determine the timing of the
fuel injection. The ECM calculates the TOP CENTER
position of each cylinder from the engine speed/
timing sensor's signal. The ECM determines when
fuel injection should occur relative to the top center
position and the ECM provides the signal to the
injector at the desired time. The ECM adjusts timing
for optimum engine performance, for optimum fuel
economy, and for optimum control of white smoke.
Programmable Parameters
Certain parameters that affect the engine operation
may be changed with Caterpillar Electronic
Technician (ET). The parameters are stored in the
ECM, and some parameters are protected from
unauthorized changes by passwords. These
passwords are called factory passwords.
RENR9318 7
Electronic Troubleshooting

Passwords (Table 1, contd)

Several system configuration parameters and most Service Tools

logged events are protected by factory passwords. Part
Factory passwords are available only to Caterpillar Description
Number
dealers. Refer to Troubleshooting, “Factory
Passwords” for additional information. 326-4904 Adapter Cable As
3-PIN BREAKOUT

i05450113
7X-1715 Adapter Cable As
Electronic Service Tools 134-5195 40-PIN BREAKOUT

SMCS Code: 0785 Harness

40-PIN

Service Tools (For ADEM 2 ECM (two 40-pin connectors))

Most of the tools that are listed in Table 1 are 208-0059 Adapter Cable As
required to enable a service technician to perform the 70-PIN BREAKOUT
test procedures in this manual. Some of the devices
may be specific to the type of Electronic Control (For ADEM 3 ECM (two 70-pin connectors) and for
Module (ECM) that is being used. ADEM 4 ECM (one 70-pin connector and one 120-
Table 1 pin connector))

Service Tools 257-8718 The 257-8718 Adapter Cable As is not appli-

cable with Tier IV Engines.
Part Description Adapter Cable As
Number
120-PIN BREAKOUT
349-4200 Thermometer
(For ADEM 4 ECM (one 70-pin connector and one
360-0774 Refractometer 120-pin connector))
Tool Gp
N/A Torque Wrench (capable of applying 1.5 N·m
431-7087 REFRACTOMETER (DEF)
(13.3 lb in))

Repair Kits for Connectors

N/A 4 mm Allen Wrench
Wire Removal Tool 362-3555 Connector Repair Kit (AMPSEAL)
1U-5805 14-GA, GREEN
Connector Repair Kit
175-3700 Deutsch connector
Magnetic Transducer As
6V-2197 TIMING CALIBRATION
Bypass Harnesses for the ECM

Wire Removal Tool 129-2018 Power Cable

121-9588 16-GA, BLUE (Stand alone cable for ADEM 2 ECM)

217-0113 Wiring Harness

147-6456 Wedge Removal Tool ECM BYPASS

151-6320 Wire Removal Tool (The bypass harness connects to the battery. The
14-GA TO 18-GA, RED bypass harness is used with the following har-
nesses for different types of electronic control
modules.)
1U-5804 Crimp Tool
12−AWG TO 18−AWG 328-2292 Harness
ENGINE ECM BYPASS
6V-2197 Transducer
(For ADEM 3 ECM and ADEM 4 ECM)
7X-1171 Transducer Adapter
277-4734 Harness
7X-1695 Cable As ENGINE ECM BYPASS
146-4080 Digital Multimeter Gp
(For A4:E2 ECM (Two 64-pin connectors))
RS232
276-7273 Sensor Test Box(1)
7X-1710 Multimeter Probes (1) Instrument used to test Cylinder Position sensors.

(continued)
8 RENR9318
Electronic Troubleshooting

Two short jumper wires may be needed to check the Caterpillar Electronic Technician
continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A long (Cat-ET )
extension wire may also be needed to check the
continuity of some wiring harness circuits. Cat ET can be used by the technician to help
perform the following procedures:
Except for harness tests, the use of certain test
equipment is not recommended for use on modern • Diagnostic testing
Caterpillar electrical circuits. Such testers include
the following examples: the 8T-0500 Continuity • Calibrations
Tester and 5P-7277 Voltage Tester.
• Flash programming
Note: A procedure has been developed to test "In
• Configuration of the ECM
Cylinder" Position Sensors. Reference Special
Instruction REHS7338, “Procedure to Test the • Print various reports
Position Sensor of a Hydraulic Cylinder”.
Cat ET can display the following information:
Optional Service Tools
• Status parameters
Table 2 lists the optional service tools that may be
needed during testing or repair. • Event codes
Table 2
• Diagnostic codes
Optional Service Tools
• ECM settings
Part Number Description
Digital Pressure Indicator
• Engine configuration
198-4240
or or
Always use the latest revision of Cat-ET. The media is
1U-5470 Engine Pressure Group
available on CD and the media can also be
4C-4075 Crimp Tool downloaded from various Caterpillar web sites.
4−AWG TO 10−AWG Table 3
Software, JEBD3003, “CATERPILLAR ELECTRONIC
4C-4911(1) Battery Load Tester TECHNICIAN”

5P-7277 Voltage Tester

Once you have downloaded Cat-ET onto your PC,
6V-9130(2) Temperature Adapter you will need a license from your Caterpillar dealer in
MULTIMETER order to use the software. Various licenses are
available for different users with different
requirements. Consult your Caterpillar dealer.
8T-5319 Connector Tool Group

349-4199 AC/DC Current Probe

Note: For more information regarding the use of Cat-
ET and PC requirements, refer to the documentation
348-5430 Multi-Tool Gp that accompanies your Cat-ET program software.
8T-8726 Adapter Cable As
Connecting Cat-ET
156-1060 Emissions Analyzer Gp
GAS ENGINE
Connecting the Communication Adapter
163-5443 Adapter Cable As
Table 4 lists the standard hardware that is required in
3-PIN BREAKOUT
order to connect Cat-ET.

177-2330 Battery Analyzer Note: The 275-5120 Communication Adapter Gp

DIGITAL was canceled and replaced by the 317-7484
Communication Adapter Gp. However, the
190-8900 Connector Repair Kit 275-5120 Communication Adapter Gp can still be
used.
225-5985 Parallel Port Cable
COMMUNICATION ADAPTER

(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911 Bat-

tery Load Tester for 6, 8, and 12 v Lead Acid Batteries” and Spe-
cial Instructions, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
Temperature Adapter Group”.
RENR9318 9
Electronic Troubleshooting

Table 4
Standard Hardware for Connecting with Cat ET

Part Number Description

N/A Personal Computer (PC)

317-7484 Communication Adapter Gp

317-7492 Radio Kit (NACD only)

349-1206 Radio Kit (EAME only)

Components of the 317-7484 Communication Adapter Gp

Communication Adapter
317-7485 3

Cable As
370-4617 USB

Cable As
327-8981 DATA LINK

Illustration 1 g02051513
Components of the 317-7492 Radio Kit
(1) PC
317-7493 Wireless Communication Radio (2) 353-5083 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
317-7496 Computer Cable As (4) 327-8981 Cable As (DATA LINK)

317-7510 Radio Cable Assembly

2. Connect cables (2) and (4) to communication
326-9606 Antenna (2) adapter (3).
Components of the 349-1206 Radio Kit

Communication Radio Gp
Note: The communication adapter will power up
348-9250
when the adapter is connected to a PC or to an ECM
317-7496 Computer Cable As that is powered up.
3. Connect cable (2) to the USB port of the PC.
317-7510 Radio Cable Assembly

326-9606 Antenna (2) 4. Connect cable (4) to a service tool connector.

Tool Operating Manual & Software CD ROM, NETG5057, “Com-
munication Adapter 3”
Follow the instructions for the communication
adapter. Use the following procedure in order to
connect Cat-ET and the communication adapter to a
PC.
1. Remove the electrical power from the ECM.
5. Restore electrical power to the ECM. Verify that the
“POWER” indicator on the communication adapter
is illuminated. Make sure that the PC is powered
up.
6. Establish communication between Cat-ET and the
ECM. If Cat-ET indicates that there is more than
one ECM, select the engine ECM.

7. If Cat-ET and the communication adapter do not

communicate with the ECM, refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
Refer to Troubleshooting, “Electronic Service Tool
Does Not Communicate” if any of the following
conditions exist:

• Cat-ET displays a message that refers to a

communication problem.

• Cat-ET displays “Error #142 The interface

hardware is not responding” .
10 RENR9318
Electronic Troubleshooting

• Cat-ET displays a message that indicates that

the firmware in the communications adapter is
old.

Dual Data Link Communications (If so

equipped)
When the connection of the communication adapter
is complete, observe the communication adapter and
Cat-ET. Certain applications require that dual data
link communications be established in order to
perform various test procedures. These tests will be
listed in the “Diagnostic Tests” menu, some tests
may not be available (grayed out). If there are
diagnostic tests that are unavailable in Cat-ET,
ensure that your service tool is communicating in dual
data link mode.
Use the following indicators to confirm that Cat-ET is
communicating on dual data links:

• “J1939” indicator is flashing

Illustration 2 g02342942
• “Cat Data Link” indicator is flashing (1) Personal computer (PC)
(5) 261-4867 Card (PCMCIA)
• Cat-ET is not displaying “Service tool support is (6) 239-9955 Communication Radio Gp
limited” (7) 259-3183 Data Link Cable As

Refer to Troubleshooting, “Electronic Service Tool
Does Not Communicate” if the “J1939” indicator and
the “Cat Data Link” indicator are not flashing. Both
indicators will be flashing during dual data link
communications with the ECM.
Communicating with the Wireless
Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed in
order to connect Cat-ET by using a wireless
connection.
Note: Some applications cannot use a wireless
connection. Also, a dual data link cannot be used with
a wireless connection.
Table 5
Optional Hardware for the Use of Cat-ET
Note: Items (5), (6), and (7) are part of the
261-3363 Wireless Communication Adapter Gp.
Note: The 261-3363 Wireless Communication
Adapter Gp was canceled and replaced by the
349-1206 Radio Kit. However, the 261-3363
Wireless Communication Adapter Gp can still be
used.
Use the following procedure in order to connect the
wireless communication adapter for use with Cat-ET.
1. Remove the electrical power from the ECM.
2. Ensure that the computer has been correctly
configured for the 261-4867 Card. Verify that the
PC card is installed in the computer PCMCIA
expansion slot.

Part Number Description 3. Connect cable (9) between communication radio

(8) and the service tool connector.
N/A Personal Computer (PC)
4. Restore the electrical power to the ECM. If Cat-ET
and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate with ECM”.

Communicating with the Wireless

Communication Adapter (If so equipped)
Table 6 lists the optional hardware that is needed in
order to connect Cat ET by using a wireless
connection.
RENR9318 11
Electronic Troubleshooting

Note: Some applications cannot use a wireless
connection. Also, a dual data link cannot be used with
a wireless connection.
Although changes can be made to the internal
settings of the W-CA3 wirelessly. Caterpillar
recommends that the radio is connected to a PC via
317-7496 Computer Cable As (USB)Cable
Assembly (8) and 317-7510 Radio Cable Assembly
(9).
Table 6
Optional Hardware for the Use of Cat-ET
Part Number Description
2. Ensure that the computer has been correctly
configured for the 802.11a or 802.11b/g enabled
wireless card. Verify that the PC wireless is
installed and working correctly.
3. Connect cable (9) between communication radio
(8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat-ET
and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate with ECM”.

N/A Personal Computer (PC)

Illustration 3 g02151132
(8) 317-7496 Computer Cable As (USB)
(9) 317-7510 Radio Cable AssemblyC

Illustration 4 g02596964
(9) 317-7510 Radio Cable Assembly
(10) W-CA3

Note: Items (8), (9), and (10) are part of the

349-1206 Radio Kit.
Use the following procedure in order to connect the
wireless communication adapter for use with Cat-ET.

1. Remove the electrical power from the ECM.

12
Electronic Troubleshooting
PL1000E Communication ECM (If so equipped)
Illustration 5
The PL1000E is an ECM that provides the customer
with the ability to integrate Caterpillar engines into
specific applications. The PL1000E enables
communication from a J1939 data link to a device
that utilizes a MODBUS communication protocol. A
PC with the latest version of Cat-ET installed can be
connected to the PL1000E through the RS232 serial
port of the PC. The PL1000E contains an embedded
communications adapter that will allow Cat ET to
communicate with the engine over the J1939 data
link.
Refer to System Operation/Troubleshooting/Test and
Adjust, RENR8091, “PL1000E Communication ECM”
for additional information.
i02139021
Electronic Display Module
(If Equipped)
SMCS Code: 7490
An electronic display module may be used to display
CID-FMI information from the electronic control
system. Refer to the service manual for your
electronic display module for more information.
RENR9318
g01163897
i02881454
Replacing the ECM
SMCS Code: 1901-510
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
The Electronic Control Module (ECM) contains no
moving parts. Replacement of the ECM can be costly.
Replacement can also be a time consuming task.
Use these procedures to ensure that the ECM is the
cause of the problem.
RENR9318
Note: Ensure that the ECM is receiving power and
that the ECM is properly wired to the negative battery
circuit before you attempt to replace the ECM. Refer
to the diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test”.
Some application software supports the use of a new
ECM as a test ECM. A new ECM can be temporarily
placed into a “Test ECM Mode” . This ECM can then
be used to replace a suspect ECM in order to
determine if the suspect ECM is faulty. Refer to
programming parameters Troubleshooting, “Test
ECM Mode”.
NOTICE
If the flash file and engine application are not
matched, engine damage may result.
Perform the following procedure in order to replace
the ECM:
1. Print the parameters from the “Configuration”
screen on Caterpillar Electronic Technician (ET).
If a printer is unavailable, record all of the
parameters. Record any logged diagnostic codes
and logged event codes for your records. Record
the injector serial numbers from the “Calibrations”
screen under the “Service” menu on Cat ET.
Note: The injector serial numbers are necessary for
obtaining the correct injector trim files. The ECM uses
the injector trim files in order to compensate for
manufacturing variations between individual injectors.
If you replace any of the unit injectors, you must
reprogram the injector trim files for the new injectors.
Also, if you replace the ECM, the injector trim files
must be installed into the new ECM. A successful
“Copy Configuration” process will accomplish this
task. For more instruction, refer to programming
parameters Troubleshooting, “Injector Trim File”.
2. Use the “Copy Configuration/ECM Replacement”
feature that is found under the “Service” menu on
Cat ET. Select “Load from ECM” in order to copy
the configuration from the suspect ECM.
Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from the
factory.
3. Remove the ECM from the engine.
a. Remove the electrical power from the ECM.
b. Disconnect the J1/P1 and J2/P2 ECM
connectors.
13
Electronic Troubleshooting
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
c. Remove the fuel lines (if equipped) from the
ECM.
d. Remove the mounting bolts from the ECM.
e. Disconnect the ECM ground strap from the
engine.
4. Install the replacement ECM.
a. If the old mounting hardware is in good repair,
you can use the old mounting hardware to
install the replacement ECM.
b. Reconnect the fuel lines (if equipped).
c. Ensure that the ECM mounting hardware is
installed correctly. The fuel lines must not put
tension on the ECM. The rubber grommets are
used to protect the ECM from excessive
vibration. The ECM must be able to drift in the
rubber grommets. If the ECM cannot be
moved slightly in the grommets, check that the
fuel lines (if equipped) are not pulling the ECM
against one side of the grommets.
d. Connect the ECM ground strap.
e. Connect the J1/P1 and J2/P2 ECM
connectors. Tighten the allen head screw on
each of the ECM connectors to the proper
torque. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque value.
5. Program the flash file into the ECM. Refer to
programming parameters Troubleshooting, “Flash
Programming”.
6. If the replacement ECM was used previously for a
different application, use Cat ET to match the
engine application and the flash file.
7. Configure the ECM.
a. If the “Load from ECM” process from Step 2
was successful, return to the “Copy
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM” .
14 RENR9318
Electronic Troubleshooting

After using the “Program ECM” feature, be • Active

sure to cycle the power to the ECM. Wait at
least 15 seconds after turning the keyswitch to
the OFF position.
Note: Some control modules have a power off
delay. The 15 seconds will be sufficient to cover
this delay.
b. If the “Program ECM” process was
successful, proceed to Step 9.
c. If the “Program ECM” process was
unsuccessful, manually program the ECM
parameters into the replacement ECM. The
parameters must match the parameters from
Step 1.
Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
d. If necessary, program the engine monitoring
system.
8. Program the injector trim files. Refer to
programming parameters Troubleshooting,
“Injector Trim File”.
9. Check for an active diagnostic code for timing
calibration.
If the diagnostic code is active, calibrate the
injection timing. Refer to calibration procedures
Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate”.
10. Check for diagnostic codes and for event codes.
• Logged
Active Code
An active diagnostic code indicates that an active
problem has been detected. Active codes require
immediate attention. Always service active codes
prior to servicing logged codes.
Logged Code
Every generated code is stored in the permanent
memory of the ECM. The codes are logged.
Logged codes may not indicate that a repair is
needed. The problem may have been temporary. The
problem may have been resolved since the logging of
the code. If the system is powered, it is possible to
generate an active diagnostic code whenever a
component is disconnected. When the component is
reconnected, the code is no longer active. Logged
codes may be useful to help troubleshoot intermittent
problems. Logged codes can also be used to review
the performance of the engine and of the electronic
system.
Event Code
An event code is generated by the detection of an
abnormal engine operating condition. For example,
an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the
symptom of a problem.

i02378227

Self-Diagnostics
SMCS Code: 1901
The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
There are two types of codes:

• Diagnostic
• Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.

Diagnostic codes can have two different states:

RENR9318 15
Electronic Troubleshooting

i02403068

Sensors and Electrical Connectors

SMCS Code: 1439; 7553-WW

Illustration 6 g01200199
Diagram of components
16
Electronic Troubleshooting
C11 and C13 Engines
Illustration 7
Left side engine view (typical example)
(1) Engine coolant temperature sensor
(2) Atmospheric pressure sensor
(3) Fuel pressure sensor
(4) Fuel temperature sensor
(5) Differential pressure switch (fuel)
(6) Intake manifold pressure sensor
(7) Injector valve cover entry connector
(8) Intake manifold air temperature sensor
(9) Secondary engine speed/timing sensor
(10) Primary engine speed/timing sensor
RENR9318
g01200152
(11) Engine oil pressure sensor
(12) Timing calibration probe connector
(13) J2/P2 ECM connector
(14) Engine Control Module (ECM)
(15) J1 ECM connector
RENR9318 17
Electronic Troubleshooting

Table 7
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

For example, a wire identification of A701-GY(Grey)

Illustration 8 g01193730 on the schematic would signify a gray wire with the
Location of the throttle position sensor (typical circuit number A701. A701-GY(Grey) identifies the
example) power circuit for the No. 1 Injector solenoid.
Another wire identification on the schematic is the
size of the wire. The size of the wire will follow the
wire color. Wire size or gauge is referred to as AWG
(American Wire Gauge). AWG is a description of the
diameter of the wire.
For example, a code of 150-OR-14(Orange) on the
schematic would indicate that the orange wire in
circuit 150 is a 14 AWG wire.
If the gauge of the wire is not listed, the wire is 16
AWG.

Conversion of AWG Numbers to Metric

Measurements
Table 8 shows the various AWG numbers that are
used for the wires. The metric equivalent for the
diameter of each AWG number are also shown.
Table 8
Metric Equivalents for AWG Numbers

Diameter Diameter
AWG Number AWG Number
Illustration 9 g01195919 (mm) (mm)

Location of the right turbocharger inlet pressure 20 0.8 14 1.6

sensor (typical example)
18 1.0 12 2.0

i02433503
16 1.3 4 3.2

Engine Wiring Information Welding on Applications that are

SMCS Code: 1408
The wiring schematics are revised periodically. The
wiring schematics will change as updates are made
to the engine's harness. For the most current
information, always check the revision number of the
schematic. Use the schematic with the latest revision
number.
Harness Wire Identification
Caterpillar identifies all wires with eleven solid
colors. The circuit number is stamped on the wire at a
25 mm (1 inch) spacing. Table 7 lists the wire colors
and the color codes.
Equipped with an Electronic Control
Module (ECM)
Proper welding procedures are necessary in order to
avoid damage to the engine's electronic control
module, sensors, and associated components.
Remove the component that requires welding. When
welding on an application that is equipped with an
ECM and removal of the component is not possible,
the following procedure must be followed. This
procedure provides the minimum amount of risk to
the electronic components.
18 RENR9318
Electronic Troubleshooting

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
components.
Clamp the ground cable from the welder to the com-
ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

1. Stop the engine. Remove the electrical power from

the ECM.
2. Disconnect the negative battery cable from the
battery. If a battery disconnect switch is installed,
open the switch.

Illustration 10 g01143634
Service welding guide (typical diagram)

3. Connect the welding ground cable as close as

possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
electrical/electronic components.

4. Protect the wiring harness from welding debris and

spatter.

5. Weld the materials by using standard welding

methods.
RENR9318
Programming Parameters
i03312021
Programming Parameters
SMCS Code: 1901
The electronic service tool can be used to view
certain parameters that can affect the operation of the
engine. The electronic service tool can also be used
to change certain parameters. The parameters are
stored in the Electronic Control Module (ECM). Some
of the parameters are protected from unauthorized
changes by passwords. Parameters that can be
changed have a tattletale number. The tattletale
number shows if a parameter has been changed.
i02405151
Test ECM Mode
SMCS Code: 1901
“Test ECM Mode” is a feature that can be used to
help troubleshoot an engine that may have a problem
with the Engine Control Module (ECM). This feature
allows a standard ECM to be used as a test ECM.
This feature eliminates the need to stock a test ECM.
1. Obtain the latest available flash file for the engine.
Note: If a newer software version is available for the
engine, install the newest software on the suspect
ECM. If the new software does not fix the problem
continue with this procedure.
2. Use the “Copy Configuration” feature on
Caterpillar Electronic Technician (ET) to copy the
parameters from the suspect ECM.
Note: If the “ECM Replacement” feature cannot be
used, record the customer parameters and
passwords. Record the trip points for the monitoring
system. Also, record the system configuration
parameters.
3. Disconnect the suspect ECM. Temporarily connect
the test ECM to the engine. Do not mount the test
ECM on the engine.
4. Flash program the test ECM with the latest
available flash file.
5. Start the “Test ECM Mode” on Cat ET. Access
the feature through the “Service” menu. Cat ET
will display the status of the test ECM and the
hours that are remaining for the “Test ECM Mode”
.
19
Programming Parameters
Note: “Test ECM Mode” can only be activated if the
engine serial number has not already been
programmed during normal operation of the ECM. If
the engine serial number is programmed and the
ECM is not in “Test ECM Mode” , the ECM can never
be used as a test ECM.
6. Use the “Copy Configuration” feature on Cat ET
to program the test ECM.
Note: If the “ECM Replacement” feature cannot be
used, program the customer parameters and
passwords. Program the trip points for the monitoring
system. Also, program the system configuration
parameters.
7. Program the engine serial number into the test
ECM.
Note: The “Test ECM Mode” must be activated
before the engine serial number is programmed into
the ECM.
8. Verify that the test ECM fixes the problem.
When the “Test ECM Mode” is activated, an internal
timer sets a 24 hour clock. This clock will count down
only while the ECM is powered and the keyswitch is
in the ON position. After the ECM has counted down
the 24 hour period, the ECM will exit the “Test ECM
Mode” . The parameters and the engine serial
number will be set.
If the test ECM fixes the problem, the engine can be
released while the “Test ECM Mode” is still active.
Once an ECM has been activated in the “Test ECM
Mode” , the ECM will stay in the “Test ECM Mode”
until the timer times out. If the ECM is used as a test
ECM for more than one engine, the “Test ECM
Mode” must be reactivated. Anytime prior to the
“Test ECM Mode” timing out, the ECM can be reset
to 24 hours by starting the “Test ECM Mode” on Cat
ET.
i02433393
Factory Passwords
SMCS Code: 0785
NOTICE
Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash
file is correct for your engine.
Note: Factory passwords are provided only to
Caterpillar dealers.
Factory passwords are required to perform each of
the following functions:
20
Programming Parameters
• Program a new Electronic Control Module (ECM).
When an ECM is replaced, the system
configuration parameters must be programmed
into the new ECM. A new ECM will allow these
parameters to be programmed once without
factory passwords. After the initial programming,
some parameters are protected by factory
passwords.
• Clear event codes.
Most event codes require the use of factory
passwords to clear the code once the code has
been logged. Clear these codes only when you are
certain that the problem has been corrected.
• Unlock parameters.
Factory passwords are required in order to unlock
certain system configuration parameters. Refer to
Troubleshooting, “System Configuration
Parameters”.
Since factory passwords contain alphabetic
characters, the Caterpillar Electronic Technician
(ET) must be used to perform these functions. In
order to obtain factory passwords, proceed as if you
already have the password. If factory passwords are
needed, Cat ET will request the factory passwords
and Cat ET will display the information that is
required to obtain the passwords. For the worksheet
that is used for acquiring factory passwords, refer to
programming parameters Troubleshooting, “Factory
Passwords Worksheet”.
i02419726
Flash Programming
SMCS Code: 1901-591
Flash Programming – This is a method of
programming or updating the flash file in an engine's
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to
flash program a file into the memory of the engine's
ECM.
If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench
(STW ) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files”
feature on SIS Web to obtain the flash file for your
engine. You must have the engine serial number in
order to search for the flash file. After locating the
correct flash file, download the flash file to your PC.
Write down the name of the flash file for future
reference.
Programming a Flash File
1. Establish communication between Cat ET and the
engine's ECM.
RENR9318
2. Select “WinFlash” from the “Utilities” menu on
Cat ET.
Note: If “WinFlash” will not communicate with the
ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM”.
3. Program the flash file into the ECM.
a. Select the engine ECM under the “Detected
ECMs” .
b. Press the “Browse” button in order to select
the name of the flash file that will be
programmed into the ECM.
c. When the correct flash file is selected, press
the “Open” button.
d. Verify that the “File Values” match the
application. If the “File Values” do not match
the application, obtain the correct flash file.
e. When the correct flash file is selected, press
the “Begin Flash” button.
f. Cat ET will indicate when flash programming
has been successfully completed.
4. Start the engine and check for proper operation.
Repair any active diagnostic or event codes.
“ WinFlash”” Error Messages
If you receive any error messages during flash
programming, click on the “Cancel” button in order to
stop the process. Access the information about the
“ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for
your engine.
i02490769
Injector Trim File
SMCS Code: 1290
The Caterpillar Electronic Technician (ET) is used to
load the injector trim files into the Electronic Control
Module (ECM).
The injector trim files must be loaded into the ECM if
any of the following conditions occur:
• An injector is replaced.
• The ECM is replaced.
• “Injector Trim” is displayed below a 268-02
diagnostic code on Cat ET.
• Injectors are exchanged between cylinders.
Exchanging Injectors
RENR9318 21
Programming Parameters

Exchanging injectors can help determine if a

combustion problem is in the injector or in the
cylinder. If two injectors that are currently installed in
the engine are exchanged between cylinders, 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
injectors that will be exchanged and press the “OK”
button. The tattletale for the injectors that were
exchanged will increase by one.

Note: The injector serial number and the injector

confirmation code are located on the injector. Cat ET
may require the entry of injector confirmation code
during this process. Cat ET will prompt you for the
code, if necessary.
1. Record the injector serial number and the injector
confirmation code for each injector.

2. Click on “Service Software Files” in SIS Web.

3. Enter the serial number for the injector in the
search field.
4. Download the injector trim file to the PC. Repeat
this procedure for each injector, as required.

5. Connect Cat ET to the service tool connector.

Refer to electronic troubleshooting
Troubleshooting, “Electronic Service Tools”.

6. Select the following menu options on Cat ET:

• Service

• Calibrations

• Injector Trim Calibration

7. Select the appropriate cylinder.

8. Click on the “Change” button.

9. Select the appropriate injector trim file from the PC.

10. Click on the “Open” button.

11. If you are prompted by Cat ET enter the injector

confirmation code into the field.
12. Click on the “OK” button.
The injector trim file is loaded into the ECM.

13. Repeat the procedure for each cylinder, as

required.
22
System Configuration Parameters
System Configuration
Parameters
i04112617
System Configuration
Parameters
SMCS Code: 1901
System configuration parameters are parameters that
affect emissions, power of the engine, and machine
applications. Default values for the parameters are
programmed at the factory. Some parameters may be
changed by the customer in order to suit the needs of
the specific application. Reprogram the system
configuration parameters if the Electronic Control
Module (ECM) is replaced and/or if you reprogram
the engine rating. Proper values for these parameters
are available on Caterpillar Electronic Technician
(ET). Certain configuration parameters are also
stamped on the engine information plate.
Parameter Descriptions
“ Product ID””
The “Product ID” parameter allows the customer to
enter a description into the ECM in order to identify
the machine. A maximum of eight characters can be
entered in the field.
“ Equipment ID””
The “Equipment ID” parameter allows the customer
to enter a description into the ECM in order to identify
the machine. A maximum of 17 characters can be
entered in the field.
“ Engine Serial Number””
Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine
information plate. The engine serial number is not
preprogrammed on a replacement ECM.
“ FLS”” (Full Load Setting)
“FLS” is the adjustment to the fuel system that was
made at the factory in order to fine-tune the fuel
system. The correct value for this parameter is
stamped on the engine information plate. Only
change this value if the engine is rerated or if a new
ECM is installed. Factory passwords are required.
“ FTS”” (Full Torque Setting)
“FTS” is similar to “FLS” . Only change this value if
the engine is rerated or if a new ECM is installed.
Factory passwords are required.
RENR9318
“ Engine Fan Control””
The “Engine Fan Control” parameter allows the
operation of this feature to be enabled or disabled.
“ Engine Fan Reversing Feature””
The “Engine Fan Reversing Feature” parameter
allows the operation of this feature to be enabled or
disabled. The feature changes the direction of the fan
momentarily in order to purge debris from the radiator
cores and grill. Reversing the airflow can be activated
by a manual control or by setting an automatic purge
cycle.
“ Engine Fan Purge Cycle Interval””
The automatic setting for the engine fan purge cycle
interval can be adjusted from every 3 minutes to
every 60 minutes. The setting has an incremental
adjustment of one minute.
“ Security System Immobilizer Installation
Status””
The security system immobilizer shuts off fuel
injection to the engine. This feature requires Machine
Security System (MSS) installation to be set to
“Installed” . If the machine is equipped with the MSS,
set the security system immobilizer installation status
to “Installed” . A factory password is required to
enable this feature.
“ Ether Solenoid Configuration””
The ether attachment is available as a cold start aid.
Set the parameter to “Continuous Flow Solenoid ” if
the machine is equipped with ether.
“ Low System Battery Voltage Elevated
Idle””
The “Low System Battery Voltage Elevated Idle”
enables monitoring of the battery voltage while the
machine is idling. If the battery voltage drops below
24.5 V, the engine speed is increased to 1100 rpm.
The feature helps to reduce the risk of the battery
becoming fully discharged. The feature becomes
active when the following conditions are met:
• The transmission is in neutral.
• The parking brake is engaged.
• The throttle pedal is not depressed for greater than
five percent.
• Five minute have elapsed.
The “Machine Working Engine Low Idle Speed
Configuration” rpm will return if one of the following
conditions are met:
RENR9318 23
System Configuration Parameters

• The parking brake is released. • The transmission is in neutral.

• A directional shift occurs. • The parking brake is engaged.

• The governor pedal is pushed.
“ Engine Warm-up Elevated Idle Feature
Enable Status””
The engine warm-up elevated idle feature is designed
to keep the engine and the machine warmer in cold-
weather operations. The warm-up mode is engaged
after ten minutes and the following conditions are
met:
• The transmission is in neutral.
• The parking brake is engaged
• The throttle pedal is not depressed for greater than
five percent.
The software will monitor coolant and inlet manifold
temperature. When the coolant temperature drops
below 70° C (158° F) and the inlet manifold
temperature drops below 5° C (41° F), the engine
idle speed will increase to 1100 rpm. The warm-up
mode is discontinued when the coolant temperature
reaches 80° C (176° F). The “Machine Working
Engine Low Idle Speed Configuration” rpm will return
if one of the following conditions is met:
• The parking brake is released.
• A directional shift occurs.
• The governor pedal is pushed.
After the first time warm-up mode has been engaged,
the following conditions will reactivate warm-up
mode:
• One minute has elapsed.
• The implement hydraulic levers are in neutral
positions.
• The throttle pedal is not depressed for greater than
five percent.
• The fan current is greater than 0.8 amp and the
engine temperature is greater than 50° C (122° F)
The “Machine Working Engine Low Idle Speed
Configuration” rpm will return if one of the following
conditions are met:
• The parking brake is released.
• A directional shift occurs.
• A hydraulic lever is moved.
• The governor pedal is pushed.
The machine hibernating engine low idle speed
configuration can be set in the range of 600 to 825
rpm.
“ Engine Idle Shutdown Enable Status””
This feature enables the ECM to shut down the
engine after the Engine Idle Shutdown Delay Time
has expired.
“ Engine Idle Shutdown Delay Time””
The delay time is the amount of time that the engine
is allowed to idle prior to shutdown if the machine is
not being operated.

• The coolant temperature is below 70° C (158° F).

“ Machine Working Engine Low Idle

Speed Configuration””
The “Machine Working Engine Low Idle Speed
Configuration” is the engine rpm for the machine
during normal operation. The engine idle rpm may be
set for work mode in order to meet the application
requirements.

“ Machine Hibernating Engine Low Idle

Speed Configuration””
The machine hibernate engine low idle speed
provides lower fuel consumption and reduced sound
and emissions levels in applications with
considerable idle time. The hibernate mode is
engaged after ten seconds and the following
conditions are met:
24 RENR9318
System Configuration Parameters

Parameter Table
Table 9
Customer Specified Parameters

Parameter Available Range or Options Default Required Password

“Product ID” eight characters blank none

“Equipment ID” 17 characters blank none

“Engine Serial Number” eight characters blank none

“FLS” -128 to +127 0 Factory

“FTS” -128 to +127 0 Factory

“Engine Fan Control” “Enabled” or “Disabled” “Enabled” none

“Engine Fan Reversing Feature” “Enabled” or “Disabled” “Enabled” none

“Engine Fan Purge Cycle Interval” 3 to 60 minutes none

“Security System Immobilizer Installation Status” “Installed” or “Not installed” “Not installed” Factory

“Ether Solenoid Configuration” “Enabled” or “Disabled” “Disabled” none

“Low System Battery Voltage Elevated Idle” “Enabled” or “Disabled” “Enabled” none

“Engine Warm-up Elevated Idle Feature Enable Status” “Enabled” or “Disabled” Enabled none

800 rpm (980H)

“Machine Working Engine Low Idle Speed Configuration” 650 to 1000 rpm 825 rpm (other none
machines)

“Machine Hibernating Engine Low Idle Speed

600 to 825 rpm 600 rpm none
Configuration”

Enabled
“Engine Idle Shutdown Enable Status” Enabled none
Disabled
“Engine Idle Shutdown Delay Time” 3 to 60 minutes 5 minutes none

Parameter Worksheet (Table 10, contd)

Record the following information before you change Settings for the Configuration Parameters
any programmable parameter. “Engine Fan Reversing
Table 10 Feature”
Settings for the Configuration Parameters “Engine Fan Purge Cycle
Interval”
“Product ID”
“Security System Immobil-
“Equipment ID” izer Installation Status”
“Engine Serial Number” “Ether Solenoid
Configuration”
“ECM Serial Number”
“Personality Module Part “Low System Battery Volt-
Number” age Elevated Idle”

“Personality Module Re- “Engine Warm-up Elevated

lease Date” Idle Feature Enable Status”

“Personality Module “Machine Working Engine

Description” Low Idle Speed
Configuration”
“FLS”
“Machine Hibernating En-
“FTS” gine Low Idle Speed
“Engine Fan Control” Configuration”

(continued) (continued)
RENR9318 25
System Configuration Parameters

(Table 10, contd)

Settings for the Configuration Parameters
“Engine Idle Shutdown Ena-
ble Status”
“Engine Idle Shutdown De-
lay Time”

“Total Tattletale”
Engine Serial Number

Full Load Setting

(for new ECM)

Full Torque Setting

(for new ECM)

Injector Code (1)

Injector Code (2)

Injector Code (3)

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from the ECM
with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could damage the
engine.
26 RENR9318
Troubleshooting without a Diagnostic Code

Troubleshooting without a Charging Circuit

Diagnostic Code Inspect the battery cables, wiring, and connections in

the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts.

Alternator or Regulator
i02476459
Verify that the alternator or the regulator is operating
Alternator correctly. Refer to Special Instruction, REHS0354,
“Charging System Troubleshooting” for the proper
(Charging Problem and/or Noisy testing procedures. Repair the alternator or replace
the alternator, as needed.
Operation)
SMCS Code: 1405-035 i02407601

Probable Causes Can Not Reach Top Engine

• Alternator drive belts RPM
SMCS Code: 1915-035
• Alternator drive pulley
Note: If this problem occurs only under load, refer to
• Alternator bearings
Troubleshooting, “Low Power/Poor or No Response
• Charging circuit to Throttle”.

• Regulator Probable Causes

• Alternator • Active engine derate

Recommended Actions • Cold mode

• Throttle signal
Alternator Drive Belts
• Intake manifold pressure sensor
1. Inspect the condition of the alternator drive belts. If
the alternator drive belts are worn or damaged, • Atmospheric pressure sensor
replace the belts. Refer to Disassembly and • Fuel supply
Assembly.
• Air inlet and exhaust system
2. Check the belt tension. Refer to the engine's
Specifications manual. • Accessory equipment

3. If the engine is equipped with an automatic belt Recommended Actions

tensioner, check the automatic belt tensioner. If
necessary, replace the automatic belt tensioner.
Note: Excessive belt tension can result in damage to
the alternator.
Alternator Drive Pulley
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the
pulley by the belt. If there is excessive wear, replace
the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
Note: Make sure that the alignment is correct.
Alternator Bearings
Check the alternator bearings for signs of wear.
Repair the alternator or replace the alternator, as
needed.
Active Engine Derate
If this application supports engine derates, use
Caterpillar Electronic Technician (ET) to check for
logged derates. Refer to Troubleshooting,
“Troubleshooting with an Event Code” for the specific
events that are applicable to this application. A status
flag will appear on Cat ET if a derate is active. The
engine speed might be limited due to one of the
following conditions: high altitude, dirty air filters and
other factors.
Cold Mode
Use Cat ET to verify that the engine has exited cold
mode. A status flag will appear if the engine is
operating in cold mode. This may limit engine speed.
RENR9318
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed. If
a problem is suspected with the throttle, refer to the
appropriate troubleshooting procedure for
troubleshooting the throttle signal.
Intake Manifold Pressure Sensor or
Atmospheric Pressure Sensor
1. Monitor the status of “Fuel Position” , “Rated Fuel
Limit” , and “FRC Fuel Limit” on Cat ET while the
engine is operating under full load. These
parameters should reflect the information below.
Table 11
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit” , the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Monitor the status of “Intake Manifold Pressure”
and “Atmospheric Pressure” for normal operation
on Cat ET. When the engine is not running, the
correct “Intake Manifold Pressure” is 0 kPa
(0 psi).
3. Verify that the intake manifold pressure sensor is
operating properly.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting for more information.
27
Troubleshooting without a Diagnostic Code
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer to
Systems Operation/Testing and Adjusting for the
correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump,
fuel transfer pump coupling and fuel pressure
regulating valve.
Air Inlet and Exhaust System
1. Observe the check engine lamp. Check for an air
filter restriction indicator. Clean plugged air filters
or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
Accessory Equipment
Check all accessory equipment for problems that may
create excessive load on the engine. Repair any
damaged components or replace any damaged
components.
i05451030
Coolant in Engine Oil
SMCS Code: 1348-035; 1395-035
Probable Causes
• Engine oil cooler core
• Water-cooled turbocharger
• Cylinder head gasket
• Cylinder head
• Cylinder liner
• Cylinder block
28 RENR9318
Troubleshooting without a Diagnostic Code

Recommended Actions
Table 12
Troubleshooting Test Steps Values Results

Result: No leak is found in the oil cooler core.

1. Check for leaks in the oil cooler core. Oil cooler core
Proceed to Test Step 2.

Result: There is a leak found in the oil cooler

core.

Replace the oil cooler core.

2. If the engine is equipped with a water- Turbocharger Result: The turbocharger is not cracked.
cooled turbocharger, inspect the turbo-
charger for cracks. Proceed to Test Step 3.

Result: The turbocharger is cracked.

Replace the turbocharger. Refer to the Disas-

sembly and Assembly Manual for more
information.

3. Check the cylinder liner projection. Liner projection Result: Cylinder liner projection is OK.

Proceed to Test Step 4.

Result: Cylinder liner projection is NOT OK.

Install a new cylinder head gasket and new

water seals in the spacer plate. Refer to the
Disassembly and Assembly manual.

4. Check for cracks in the cylinder head. Cracks in cylinder head Result: There are no cracks in the cylinder
head.

Proceed to Test Step 5.

Result: There are cracks in the cylinder head.

Repair the cylinder head and/or replace the cyl-

inder head. Refer to the Disassembly and As-
sembly manual.

(continued)
RENR9318 29
Troubleshooting without a Diagnostic Code

(Table 12, contd)

5. Check for cracked cylinder liners. Cracks in cylinder liners Result: There are no cracks in the cylinder
liners.

Proceed to Test Step 6.

Result: There are cracks in the cylinder liners.

Replace any cracked cylinder liners. Refer to

the Disassembly and Assembly manual.

7. Inspect the cylinder block for cracks. Cracks in cylinder block. Result: The cylinder block is not cracked.

STOP

Result: The cylinder block is cracked.

Repair the cylinder block or replace the cylinder

block.

STOP

i02433524 2. Check the radiator for internal blockage. Check the

temperature difference between the top and the
Coolant Temperature Is Too bottom of the radiator.
High
Low Coolant Level
SMCS Code: 1395-035
1. Verify that the cooling system is filled to the proper
Probable Causes level. If the coolant level is too low, air will get into
the cooling system. Air in the cooling system will
• Faulty temperature regulator
cause a reduction in coolant flow and bubbles in
• Radiator the coolant. Air bubbles will keep coolant away
from the engine parts, which will prevent the
• Low coolant level transfer of heat to the coolant. Low coolant level is
caused by leaks or incorrectly filling the radiator.
• Faulty jacket water coolant pump
• Faulty engine cooling fan (if equipped) 2. Check the mixture of antifreeze and water. The
mixture should be approximately 50 percent water
• Faulty pressure relief valve and 50 percent antifreeze with 3 to 6 percent
coolant conditioner. Refer to Operation and
Recommended Actions Maintenance Manual. If the coolant mixture is
incorrect, drain the system. Put the correct mixture
Faulty Temperature Regulator of water, antifreeze and coolant conditioner in the
cooling system.
Check the water temperature regulator. A water
temperature regulator that does not open, or a water 3. Check for air in the cooling system. Air can enter
temperature regulator that only opens part of the way the cooling system in different ways. The most
can cause overheating.
common causes of air in the cooling system are
the incorrect filling of the cooling system and
Radiator combustion gas leakage into the cooling system.
Combustion gas can get into the system through
1. Check the cooling fins on the radiator for dirt and/or inside cracks, a damaged cylinder head, or a
for debris. Remove the dirt and/or debris. damaged cylinder head gasket.
Inspect the cooling fins on the radiator for damage.
Refer to the Systems Operation/Testing and
Adjusting manual.
30 RENR9318
Troubleshooting without a Diagnostic Code

4. Check the cooling system hoses and clamps. Recommended Actions

Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during
operation. The soft areas of the hose can become
kinked or crushed during operation. These areas of
the hose can restrict the coolant flow. Hoses
become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
flow.
Faulty Jacket Water Coolant Pump
Inspect the impeller vanes at the jacket water pump
for damage and/or for erosion. Repair impeller vanes
and/or replace the impeller vanes.
Faulty Engine Cooling Fan (if equipped)
1. Verify that the correct passwords were entered.
Check every character in each password. Remove
the electrical power from the engine for 30
seconds and then retry.
2. Verify that Cat ET is displaying the “Enter Factory
Passwords” dialog box.
3. Use Cat ET to verify that the following information
has been entered correctly:
• Engine serial number
• Serial number for the electronic control module
• Serial number for Cat ET
• Total tattletale

1. If the fan is belt driven, check for loose drive belts. • Reason code
A loose fan drive belt will cause a reduction in the
For additional information, refer to Troubleshooting,
air flow across the radiator. Check the fan drive “Factory Passwords”.
belt for proper belt tension. Adjust the tension of
the fan drive belt, if necessary. Refer to Operation
i02471377
and Maintenance Manual.
2. Check the fan clutch, if equipped. A fan clutch or a ECM Will Not Communicate
hydraulic driven fan that is not turning at the with Other Systems or Display
correct speed can cause improper air speed
across the radiator core. The lack of proper air flow Modules
across the radiator core can cause the coolant not SMCS Code: 1901-035
to cool to the proper temperature differential.
Probable Causes
Faulty Pressure Relief Valve
• Electronic Control Module (ECM)
Check operation of the pressure relief valve and the
radiator cap. If necessary, clean the pressure relief • Electrical connectors
valve and/or the radiator cap. Check that the seating
surface of the valve is clean and undamaged. If • Cat Data Link
necessary, install new parts.
Recommended Actions
i02826488 1. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. If the ECM does not
ECM Will Not Accept Factory communicate with Cat ET, refer to
Passwords troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will Not
SMCS Code: 1901-035
Communicate with ECM”.

Probable Causes 2. Ensure that the following items are correctly

installed and undamaged. Refer to the diagnostic
One of the following items may not be recorded functional test Troubleshooting, “Electrical
correctly on the Caterpillar Electronic Technician
(ET): Connectors - Inspect”.

• Passwords • ECM connector J1/P1

• Serial numbers • Machine connector

• Total tattletale • Wiring to display modules

• Reason code • Wiring to other control modules

RENR9318
3. Troubleshoot the Cat Data Link for possible
problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
i02429900
Electronic Service Tool Will
Not Communicate with ECM
SMCS Code: 0785-035; 1901-035
Probable Causes
• Configuration for the communications adapter
• Electrical connectors
• Communication adapter and/or cables
• Electrical power supply to the service tool
connector
• Caterpillar Electronic Technician (ET) and related
hardware
• Electrical power supply to the Electronic Control
Module (ECM)
• Flash file
• Cat Data Link
Recommended Actions
Start the engine. If the engine starts, but the ECM will
not communicate with Cat ET, continue with this
procedure. If the engine will not start, refer to the
troubleshooting without a diagnostic code procedure
Troubleshooting, “Engine Cranks but Will Not Start”. If
the engine will not crank, refer to the troubleshooting
without a diagnostic code procedure Troubleshooting,
“Engine Will Not Crank”.
Configuration for the Communications
Adapter
1. Access “Preferences” under the “Utilities” menu
on Cat ET.
2. Verify that the correct “Communications Interface
Device” is selected.
3. Verify that the correct port is selected for use by the
communication adapter.
Note: The most commonly used port is “COM 1” .
4. Check for any hardware that is utilizing the same
port as the communications adapter. If any devices
are configured to use the same port, exit or close
the software programs for that device.
31
Troubleshooting without a Diagnostic Code
Electrical Connectors
Check for correct installation of the J1/P1 and J2/
P2ECM connectors and of the service tool connector.
Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
Communication Adapter and/or Cables
1. If you are using a “Communication Adapter II” ,
ensure that the firmware and driver files for the
communication adapter are the most current files
that are available. If the firmware and driver files do
not match, the communication adapter will not
communicate with Cat ET.
2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect
the communication adapter to the service tool
connector.
3. Verify that the correct cable is being used between
the communication adapter and the service tool
connector. Refer to electronic troubleshooting
Troubleshooting, “Electronic Service Tools”.
Electrical Power Supply to the Service
Tool Connector
Verify that battery voltage is present between
terminals A and B of the service tool connector. If the
communication adapter is not receiving power, the
display on the communication adapter will be blank.
Cat ET and Related Hardware
In order to eliminate Cat ET and the related
hardware as the problem, connect Cat ET to a
different engine. If the same problem occurs on a
different engine, check Cat ET and the related
hardware in order to determine the cause of the
problem.
Electrical Power Supply to the Electronic
Control Module (ECM)
Check power to the ECM. Refer to the diagnostic
functional test Troubleshooting, “Electrical Power
Supply Circuit - Test”.
Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
Flash File
Ensure that the correct flash file is properly installed
in the ECM.
32 RENR9318
Troubleshooting without a Diagnostic Code

Note: A new ECM is not programmed to any specific i02349327

engine until a flash file has been installed. The engine
will not start and the engine will not communicate with Engine Cranks but Will Not
Cat ET until the flash file has been downloaded.
Refer to programming parameters Troubleshooting, Start
“Flash Programming”. SMCS Code: 1000-035

Cat Data Link Probable Causes

Troubleshoot the Cat Data Link for possible • Diagnostic codes and event codes
problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”. • Electronic Control Module (ECM)

i01941237
• Engine shutdown switches

• Starting motor, solenoid, or starting circuit

Elevated Idle
SMCS Code: 1915-035 • Engine speed/timing

• Unit injector
Probable Causes
• Fuel supply
The low idle speed may be elevated due to one of the
following conditions: • Combustion
• Low battery Recommended Actions
• Cold mode
Diagnostic Codes and Event Codes
Note: The “Elevated Idle” status flag will be
activated if one of the above conditions is met. Certain diagnostic codes and/or event codes may
prevent the engine from starting. Connect the
Conditions Caterpillar Electronic Technician (ET) and check for
active codes and/or for logged codes. Troubleshoot
any codes that are present before continuing with this
Low Battery procedure.
The engine idle speed will be elevated to 1000 rpm
when all of the following conditions occur: Electronic Control Module
• System battery voltage is less than 24.5 VDC for If the ECM is not receiving battery voltage, the ECM
five minutes. will not operate. Refer to Troubleshooting, “Electrical
Power Supply Circuit - Test”.
• The throttle pedal position is below 25 percent for
five minutes. Starting Aids
• The machine is not in gear. If cold ambient conditions exist, check operation of
starting aids. Verify that the ether system is operating
• The parking brake is set. correctly. Refer to Troubleshooting, “Ether Injection
System - Test”.
Cold Mode
Engine Shutdown Switches
The engine idle speed will be elevated to 1000 rpm
when all of the following conditions occur: The engine shutdown switches must be in the RUN
position in order to start the engine. Use Cat ET to
• Cold mode is active. verify the status of the shutdown switches. When an
• The throttle pedal position has not exceeded 25 engine shutdown switch is used to shut down the
engine, the keyswitch must be turned to the RUN
percent for ten minutes. position for at least 15 seconds before restarting the
engine.
• The machine is not in gear.

• The parking brake is set. Starting Motor, Solenoid, or Starting

Circuit
Remove the starter and visually inspect the pinion of
the starter and the flywheel ring gear for damage.
RENR9318
Test the operation of the starting motor solenoid.
Check the condition of the engine wiring for the
starting motor solenoid. Test the operation of the
starting motor.
If necessary, repair the starter or the starter circuit.
Engine Speed/Timing
1. Crank the engine and observe the engine speed on
the Cat ET status screen. If Cat ET indicates
zero rpm, refer to Troubleshooting, “Engine Speed/
Timing Sensor Circuit - Test”.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an
engine speed once the ECM is able to calculate a
speed from the signal.
2. If an engine speed is present, check the sensor
installation. If the sensor is not properly installed,
the ECM may read engine speed, but the ECM
cannot determine the tooth pattern. The ability for
the ECM to read the tooth pattern is necessary to
determine the cylinder position. Engine speed is
present when engine speed is greater than 50 rpm.
Refer to Troubleshooting, “Engine Speed/Timing
Sensor Circuit - Test”.
Unit Injector
1. Ensure that the J300/P300injector valve cover
entry connector is fully connected and free of
corrosion.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test”
for additional information.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary to
purge the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may
block the fuel supply.
33
Troubleshooting without a Diagnostic Code
4. Check for air in the low pressure fuel supply
system if any of the following procedures have
been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Testing
and Adjusting for more information.
5. Purge air from the low pressure fuel supply circuit.
Refer to Operation and Maintenance Manual, “Fuel
System - Prime” for the correct procedure.
6. Check the fuel filters.
7. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
8. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer to
Systems Operation/Testing and Adjusting, “Fuel
System” for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling and fuel
pressure regulating valve.
Combustion
Check the engine for combustion problems.
i05451574
Engine Has Early Wear
SMCS Code: 1000-035
Probable Causes
• Incorrect maintenance intervals and/or incorrect oil
• Contaminated engine oil
• Low oil pressure
• Leaks in the air system
• Inspect the fuel filters for contamination.
Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
34 RENR9318
Troubleshooting without a Diagnostic Code

Table 13
Troubleshooting Test Steps Values Results

1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
intervals recommended by the engines Operation and Maintenance
A. Use engine oil that is recommended and change the engine oil Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.

Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.

Use at least the minimum grade of Cat oil.

Change the engine oil at the interval that is recommended.

Repair or replace any damaged parts.

2. Contaminated Engine Oil Contamination Result: The oil is contaminated.

A. Obtain an S-O-S oil analysis. The analysis will contribute to a
better understanding of oil contamination.
B. Check the oil filter bypass valve.
If the oil filter bypass valve is open, the oil will not be filtered. Check
the oil filter bypass valve for a weak spring or for a broken spring. If
the spring is broken, replace the spring. Verify that the oil bypass
valve is operating correctly. Refer to the Disassembly and Assem-
bly manual.
Determine the reason for any contamination of the engine
oil and make the necessary repairs. Drain the crankcase
and refill the crankcase with clean engine oil. Install new
engine oil filters. Refer to the engines Operation and Main-
tenance Manual.
Result: The oil is not contaminated.
Proceed to Test Step 3.

Refer to the Caterpillar guidelines for “Reusability and Salvage/

Repair” for determining if the replacement of parts is necessary in
order to perform a quality repair.

3. Low Oil Pressure Restriction Result: The inlet tube has a restriction.

A. Engine oil that is contaminated with another liquid can cause Clear the obstruction. Verify the repair.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil. Result: The inlet tube does not have a restriction.

B. The inlet screen of the suction tube for the engine oil pump can Proceed to Test Step 4.
have a restriction. This restriction will cause cavitation and a loss
of engine oil pressure. Check the inlet screen on the suction tube
and remove any material that may be restricting engine oil flow.

When some components of the engine show wear in a short time,

the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.

(continued)
RENR9318 35
Troubleshooting without a Diagnostic Code

(Table 13, contd)

Troubleshooting Test Steps Values Results

4. Leaks in Air System Air leak Result: There are no air leaks.

A. A leak in the air intake system may allow unfiltered air into the Proceed to Test Step 5.
engine. Inspect the air intake system for streaks which may indi-
cate a leakage of unfiltered air. Inspect all of the gaskets and the Result: There are air leaks.
connections.
Repair any leaks.

5. Inspect the Fuel Filters for Contamination Fuel filters Result: The fuel has contamination.

A. Remove the fuel filters. Inspect the fuel filters for contamination. Determine the cause of any contamination and make the
Contaminants in the fuel such as hydrogen sulfide and sulfur can necessary repairs.
lead to the formation of acids in the crankcase. Obtain a fuel
analysis. Install new fuel filters. Refer to the Operation and Mainte-
nance Manual.

Complete the procedure in the order in which the Recommended Actions

steps are listed.
Note: If the symptom only occurs under certain
The procedure corrected the issue. Return the engine operating conditions (high idle, full load, engine
to service. operating temperature, etc), test the engine under
The procedure did not correct the issue. those conditions. Troubleshooting the symptom under
other conditions can give misleading results.
Contact your Cat dealer Technical Communicator
(TC). For further assistance, your TC can confer with Diagnostic Codes
the Dealer Solutions Network (DSN).
Check for active diagnostic codes on Caterpillar
i02526054 Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
Engine Misfires, Runs Rough
Electrical Connectors
or Is Unstable
SMCS Code: 1000-035 Check for correct installation of the J1/P1 and J2/
P2Electronic Control Module (ECM) connectors and
the unit injector connectors. Refer to Troubleshooting,
Note: If the symptom is intermittent and the symptom “Inspecting Electrical Connectors”.
cannot be repeated, refer to Troubleshooting,
“Intermittent Low Power or Power Cutout”. If the
symptom is consistent and the symptom can be Fuel Supply
repeated, continue with this procedure.
Check the fuel level in the fuel tank. Ensure that
adequate fuel is available for the application.
Probable Causes
Check fuel lines for the following problems:
• Diagnostic codes restrictions, collapse and pinched line. Repair the
lines and/or replace the lines.
• Electrical connectors
1. Check the fuel tank for foreign objects which may
• Fuel supply
block the fuel supply. Check for air leaks in the
• Cold mode operation and cold cylinder cutout suction line of the fuel pump. Prime the fuel system
after you perform the following procedures:
• Throttle signal
• Replacing the fuel filters
• Unit injectors
• Working on the low pressure fuel supply circuit
• Air inlet and exhaust system
• Replacing fuel injectors
36 RENR9318
Troubleshooting without a Diagnostic Code

2. Cold weather adversely affects the characteristics i02549498

of the fuel. Refer to the Operation and
Maintenance Manual for information on improving Engine Oil in Cooling System
the characteristics of the fuel during cold weather SMCS Code: 1348-035; 1350-035
operation.

3. Check the fuel pressure during engine operation. Probable Causes

Check the fuel pressure after the fuel filter. Refer to
• Engine oil cooler core
the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the fuel • Cylinder head gasket
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel • Water pump
transfer pump, fuel transfer pump coupling and fuel
pressure regulating valve. Recommended Actions

Cold Mode Operation and Cold Cylinder
Cutout
Use Cat ET in order to verify that the engine has
exited cold mode. During cold mode, fuel injection
timing is modified. When the engine is in cold mode,
the cold cylinder cutout strategy may be active. Cold
mode cylinder cutouts may cause variations in
vibration and available power. This is normal
operation.
Throttle Signal
Monitor the throttle signal on Cat ET. Verify that the
throttle signal is smooth from the low idle position to
the high idle position.
Unit Injectors
Engine Oil Cooler Core
1. Inspect the engine oil cooler core for leaks. If a leak
is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Refer
to Operation and Maintenance Manual.
Cylinder Head Gasket
1. Remove the cylinder head. Refer to Disassembly
and Assembly.
2. Check the cylinder liner projection. Refer to
Systems Operation/Testing and Adjusting.

3. Install a new cylinder head gasket and new water

1. Use Cat ET to determine if there are any active seals in the spacer plate. Refer to Disassembly
diagnostic codes for the unit injectors. and Assembly.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids Water Pump
are being energized by the ECM.
Check the weep hole in the water pump for blockage.
Check the water pump seals.
3. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer to
Troubleshooting, “Injector Solenoids” for more i02421677

information.
Engine Oil Temperature Is Too
Air Inlet and Exhaust System High
SMCS Code: 1348-035-TA
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the Probable Causes
Operation and Maintenance Manual.
• Engine oil level
2. If air shutoff valves are installed, verify that the air
shutoff valves are fully opened. • Engine oil cooler bypass valve

3. Check the air inlet and exhaust system for • Engine oil cooler core
restrictions and/or leaks. Refer to the Systems
• Engine coolant temperature
Operation/Testing and Adjusting for information on
the air inlet and exhaust system.
RENR9318 37
Troubleshooting without a Diagnostic Code

Recommended Actions
Engine Oil Level
Use the engine oil dipstick to check for the correct oil
level. If necessary, add engine oil to the crankcase.

Engine Oil Cooler Bypass Valve

Inspect the components of the engine oil cooler
bypass valve for damage. Clean the engine oil cooler
bypass valve and clean the bore for the valve. Ensure
that the bypass valve is not stuck in the open
position. Replace the components of the bypass
valve, if necessary. Refer to Systems Operation/
Testing and Adjusting for information that is related to
troubleshooting an increased engine oil temperature.

Engine Oil Cooler Core

Check the engine oil cooler core for damage and for
plugging. Clean the engine oil cooler core or replace
the engine oil cooler core, if necessary.

Engine Coolant Temperature

If a high coolant temperature condition is also
occurring, refer to troubleshooting without a
diagnostic code Troubleshooting, “Coolant
Temperature Is Too High”.

i05451609

Engine Stalls at Low RPM

SMCS Code: 1915-035

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Probable Causes
• Unit injectors
• Fuel supply

• Air supply
• Engine idle

• Accessory equipment

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
38 RENR9318
Troubleshooting without a Diagnostic Code

Table 14
Troubleshooting Test Steps Values Results

1. Unit Injectors Unit Injectors Result: The J1/P1 and J2/P2 connectors have been in-
stalled correctly.
A. Check for correct installation of the J1/P1 and J2/P2 connectors
for the Electronic Control Module (ECM). Result: The J300/P300 connectors have been installed
correctly.
B. Check for correct installation of the J300/P300 connectors for the
unit injectors. Refer to the diagnostic functional test Troubleshooting, Proceed to Test Step 2.
“Electrical Connectors - Inspect” .
Result: The connectors have not been installed properly.

Repair the connectors.

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

A. Check the fuel pressure. Refer to Systems Operation/Testing and Result: The fuel lines are NOT OK.
Adjusting.
Replace or repair the fuel lines.
B. Check the fuel lines for the following problems: restrictions, col-
lapsed lines and pinched lines. Result: The fuel tank does not have a blockage of the
fuel supply.
C. Check the fuel tank for foreign objects which may block the fuel
supply. Result: The fuel tank has a blockage of the fuel tank.

Note: A sight glass in the low-pressure supply line is helpful in diag- Repair the blockage in the fuel tank.
nosing air in the fuel. Refer to Systems Operation/Testing and
Adjusting. Result: The fuel pressure is OK.

D. Cold weather adversely affects the characteristics of the fuel. Re- Proceed to Test Step 3.
fer to the Operation and Maintenance Manual.
Result: The fuel pressure is NOT OK.
E. Check the fuel pressure after the fuel filter while the engine is
being cranked. For the correct pressure values, refer to the Systems Make the necessary repairs.
Operation/Testing and Adjusting manual.

3. Air Supply Air inlet system Result: The are no restrictions in the air inlet system.

A. Check for restrictions in the air inlet system. Refer to Systems Op- Proceed to Test Step 4.
eration/Testing and Adjusting.
Result: There are restrictions in the air inlet system.

Repair the restrictions in the air inlet system.

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

A. Check the parameter for the low engine idle (if applicable). Refer Proceed to Test Step 5.
to Troubleshooting, “System Configuration Parameters” .
Result: The low engine idle parameters are NOT OK.

Repair the low engine idle parameters.

5. Engine Accessories Engine Result: An engine accessory is creating an excessive

accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair the engine accessory.

Complete the procedure in the order in which the The procedure corrected the issue. Return the engine
steps are listed. to service.
RENR9318 39
Troubleshooting without a Diagnostic Code

The procedure did not correct the issue.

Contact your Cat dealer Technical Communicator
(TC). For further assistance, your TC can confer with
the Dealer Solutions Network (DSN).

i05451717

Engine Vibration
SMCS Code: 1000-035

Probable Causes
• Vibration damper
• Engine supports

• Driven equipment
• Engine misfiring or running rough
40 RENR9318
Troubleshooting without a Diagnostic Code

Recommended Actions
Table 15

1. Vibration Damper
A. Check the vibration damper for damage.
B. Inspect the mounting bolts for damage and/
or for wear.
Damage to vibration damper
Result: The vibration damper has not been
damaged.
Proceed to Test Step 2.
Result: The vibration damper has been
damaged.

Replace the vibration damper. Replace any

damaged bolts. Refer to the Disassembly and
Assembly manual.

2. Engine Supports Loose or broken mounts Results: Mounts and brackets are not
damaged.
A. Inspect the mounts and the brackets while
you run the engine through the speed range. Proceed to Test Step 3.
Look for mounts and brackets that are loose
and/or broken. Results: Mounts and brackets are damaged.

Tighten all of the mounting bolts. Install new

components, if necessary.

3. Driven Equipment Alignment and balance of driven equipment Result: Driven equipment is OK.

Check the alignment and the balance of the STOP

driven equipment.
Result: Driven equipment is NOT OK.

Repair or replace the faulty driven equipment.

i02445247 Recommended Actions

Engine Will Not Crank Engine Shutdown Switches (If
SMCS Code: 1000-035 Applicable)

Probable Causes The engine shutdown switches should be in the OFF

position. Use Caterpillar Electronic Technician (ET)
• Engine shutdown switches (if applicable) to verify the status of the shutdown switches. When a
shutdown occurs, the engine control must be in the
• Circuit breakers OFF/RESET mode for at least 15 seconds before
restarting the engine.
• Battery cables
Note: If Cat ET will not communicate with the
• Batteries Electronic Control Module (ECM), the problem is
most likely with the electrical power supply to the
• Starting circuit ECM. Refer to the diagnostic functional test
Troubleshooting, “Electrical Power Supply Circuit -
• Flywheel ring gear Test”.
• Driven equipment
Circuit Breakers
• Engine accessories
Check the state of each of the circuit breakers. Reset
• Hydraulic cylinder lock the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine the
• Internal engine problem condition that caused the circuit breaker to trip. Make
the necessary repairs.
RENR9318 41
Troubleshooting without a Diagnostic Code

Battery Cables and/or Batteries • Broken components

• Bent components
1. Inspect the battery disconnect switch, bus bars,
battery posts, and battery cables for loose
i02407674
connections and corrosion. If the battery cables
are corroded, remove the battery cables and clean
the battery cables. Tighten any loose connections. Excessive Black Smoke
SMCS Code: 1088-035
2. Inspect the batteries.

a. Charge the batteries. Refer to Special Probable Causes

Instruction, SEHS7633, “Battery Test • Air inlet or exhaust system
Procedure”.
• Engine speed/timing sensor
b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911 • Atmospheric pressure sensor
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”. • Intake manifold pressure sensor
• “Fuel Position” and/or “FRC Fuel Limit”
Starting Circuit
• Flash file
Test the operation of the starting motor and
associated circuit components. Refer to the Systems • Fuel quality
Operation/Testing and Adjusting manual.
• Valve adjustment
Driven Equipment and/or Engine
Recommended Actions
Accessories
Air Inlet or Exhaust System
1. Ensure free movement of the driveline.
2. Ensure that the timing pin was not left in the 1. Check the air inlet system for restrictions and/or for
flywheel housing. leaks.

3. Remove any engine accessories that may lock up
the engine. Inspect the condition of the
accessories.
The following list illustrates examples of engine
accessories that may lock up the engine:
• Fuel transfer pump
• Air compressor
• Engine oil pump
Hydraulic Cylinder Lock
Check for fluid in the cylinders (hydraulic cylinder
lock) by removing the individual unit injectors.
Note: Be sure to drain the fuel from the cylinder head
prior to removing the injectors. Fuel will flow from the
cylinder head into the cylinders when the unit injector
is removed.
Internal Engine Problem
a. Check for an air filter restriction.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet
piping .
2. Ensure that the turbocharger is in good repair.
3. Check the exhaust system for restrictions.
4. Repair any leaks that were found. Remove any
restrictions that were found. Replace any damaged
components that were found.
Engine Speed/Timing
1. Check the calibration of the engine speed/timing
sensor. Refer to Troubleshooting, “Engine Speed/
Timing Sensor - Calibrate”.
2. Verify that the crankshaft and the camshaft drive
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.

1. Inspect the internal components for the following

conditions:

• Seizure
42 RENR9318
Troubleshooting without a Diagnostic Code

Atmospheric Pressure Sensor i02410997

Check the atmospheric pressure sensor for dirt and/ Excessive Engine Oil
or for debris. Remove any dirt and/or debris that is
present. The correct reading for the atmospheric Consumption
pressure is between 50 kPa (7.25 psi) and 100 kPa SMCS Code: 1348-035
(14.5 psi).

Intake Manifold Pressure Sensor, “ Fuel Probable Causes

Position”” , and/or “ FRC Fuel Limit”” • Oil leaks

1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit” ,
the Electronic Control Module (ECM) is providing
the correct control. Otherwise, proceed to the next
Step.
2. Verify that there are no active diagnostic codes for
the intake manifold pressure sensor.
3. Monitor the status of “Intake Manifold Pressure”
and “Atmospheric Pressure” on the Caterpillar
Electronic Technician (ET). When the engine is not
running, “Intake Manifold Pressure” should be
0 kPa (0 psi).
Note: A problem with the “FRC Fuel Limit” will only
cause black smoke during acceleration. A problem
with the “FRC Fuel Limit” will not cause black smoke
during steady state operation.
Flash File
Verify that the correct flash file is installed. Refer to
Troubleshooting, “Flash Programming” for
information.
Fuel Quality
• Oil level
• Turbocharger seal
• Internal engine wear
Recommended Actions
Oil Leaks
Check the engine compartment for oil leaks. Repair
any oil leaks that are identified.
Oil Level
Check the engine oil level. Too much oil in the engine
crankcase can cause the engine to consume oil.
Remove excessive engine oil from the crankcase.
Ensure that the dipstick is properly calibrated and/or
that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick.
Turbocharger
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from
the turbocharger. Check the compressor wheel and
the turbine for evidence of an oil leak. If necessary,
repair the turbocharger or replace the turbocharger.
Refer to Systems Operation/Testing and Adjusting.

Cold weather adversely affects the characteristics of Internal Engine Wear

the fuel. Refer to Operation and Maintenance Manual
for information on improving the characteristics of the
fuel during cold weather operation.
Valve Adjustment
Check the valve adjustment. Refer to Systems
Operation/Testing and Adjusting for information on
valve adjustments.
Internal engine wear can cause excessive oil leakage
into the combustion area of the cylinders. Excessive
wear on the following components may cause oil
consumption:
• Piston rings
• Valve guides
Check for excessive crankcase blowby at the engine
crankcase breather. Refer to Systems Operation/
Testing and Adjusting.
RENR9318 43
Troubleshooting without a Diagnostic Code

i02430014 1. Check for correct installation of the J1/P1 and J2/

P2Electronic Control Module (ECM) connectors
Excessive Fuel Consumption and the unit injector connectors. Refer to the
SMCS Code: 1250-035 diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
Probable Causes 2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
• Engine operation
are being energized by the ECM.
• Fuel leaks
3. Perform the “Cylinder Cutout Test” on Cat ET in
• Fuel quality order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test
• Engine speed/timing Troubleshooting, “Injector Solenoid Circuit - Test”.
• Unit injectors
Air Inlet and Exhaust System
• Air inlet and exhaust system
• Accessory equipment 1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter or
Recommended Actions replace the air filter.

2. Check the air inlet and exhaust system for

Engine Operation restrictions and/or for leaks. Refer to Systems
Use the Caterpillar Electronic Technician (ET) to Operation/Testing and Adjusting.
check the “Current Totals” for excessive idle time
and/or for a high load factor which would be indicative Accessory Equipment
of poor operating habits.
Check all accessory equipment for problems that may
Note: Engine operation may also be affected by create excessive load on the engine. Repair any
environmental conditions such as wind and snow. damaged components or replace any damaged
components.
Fuel Leaks
i02424626
Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer to
Systems Operation/Testing and Adjusting for the Excessive Valve Lash
correct pressure values. If the fuel pressure is low, SMCS Code: 1105-035
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 Probable Causes
valve.
• Lubrication
Fuel Quality • Valve lash
Cold weather adversely affects the characteristics of • Valve train components
the fuel. Refer to the Operation and Maintenance
Manual for information on improving the Recommended Actions
characteristics of the fuel during cold weather
operation.
Lubrication
Engine Speed/Timing
1. Remove the valve mechanism covers. Refer to the
Perform a speed/timing sensor calibration. Refer to engine's Disassembly and Assembly manual.
the calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”. 2. Check the lubrication in the valve compartment.
Ensure that there is adequate engine oil flow in the
Unit Injectors valve compartment. The passages for the engine
oil must be clean.
44 RENR9318
Troubleshooting without a Diagnostic Code

Valve Lash 1. Check for proper operation of the jacket water

heater. Repair the jacket water heater or replace
Adjust the engine valve lash. Refer to the engine's the jacket water heater.
Systems Operation/Testing and Adjusting manual.
2. Ensure that the ether canister is not empty or low.
Valve Train Components Replace the ether canister if the ether canister is
empty or low. Refer to Troubleshooting, “Ether
1. Inspect the following components of the valve train: Injection System - Test”.

• Rocker arms Coolant Temperature Sensor

• Pushrods
1. Use the Caterpillar Electronic Technician (ET) to
• Valve lifters verify that the engine has exited cold mode.

• Camshaft 2. Compare the coolant temperature from Cat ET to

the coolant temperature that is obtained from the
• Valve stems 6V-9130 Temperature Adapter (MULTIMETER).
Ensure that the temperature readings are
• Rocker shafts
reasonable for the conditions that are present.
2. Check the components for the following conditions:
abnormal wear, excessive wear, straightness and Engine Speed/Timing
cleanliness. Replace parts, if necessary.
1. Check the calibration of the engine speed/timing
Note: If you replace the camshaft, you must also
replace the valve lifters. sensor. Refer to Troubleshooting, “Engine Speed/
Timing Sensor - Calibrate”.
3. Adjust the engine valve lash. Refer to the engine's
Systems Operation/Testing and Adjusting manual. 2. Verify that the timing of the crankshaft and
camshaft drive gears are set with the proper
orientation. Refer to Disassembly and Assembly
i02711029
for information that is related to the correct gear
installation.
Excessive White Smoke
SMCS Code: 1088-035 Unit Injectors
Note: Some white smoke may be present during cold
start-up conditions when the engine is operating 1. Perform the “Cylinder Cutout Test” on Cat ET in
normally. If the white smoke persists, there may be a order to try to isolate any cylinders that may be
problem. misfiring. A misfiring cylinder could be related to an
injector that is worn or in poor repair. Refer to
Probable Causes Troubleshooting, “Injector Solenoid Circuit - Test”.
• Starting aids (if applicable) 2. Cut out each individual cylinder for 30 to 60
seconds. Verify that the smoke decreases.
• Coolant temperature sensor
• Engine speed/timing Flash File
• Unit injectors Verify that the correct flash file is installed. Refer to
Troubleshooting, “Flash Programing”.
• Flash file

• Fuel supply
Fuel Supply

• Component wear 1. Inspect the fuel system components.

• Cooling system

Recommended Actions
Starting Aids
RENR9318
2. Check the fuel pressure during engine cranking.
Check the filtered fuel pressure. Refer to Systems
Operation/Testing and Adjusting for the correct
pressure values. If the fuel pressure is low, replace
the fuel filters. If the fuel pressure is still low, check
the following items: fuel transfer pump, fuel transfer
pump coupling and fuel pressure regulating valve.
3. Check the fuel quality. Low cetane fuel can create
white smoke. If necessary, replace the fuel with a
higher cetane fuel.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
Component Wear
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner
wear and reduced compression pressure.
Cooling System
Check for an internal coolant leak into the cylinder
and/or the exhaust. Refer to Systems Operation/
Testing and Adjusting for information on inspecting
the cooling system.
i02405574
Exhaust Temperature Is Too
High
SMCS Code: 1088-035-TA
Probable Causes
• Diagnostic codes
• Air inlet and exhaust system
• Air leak
Recommended Actions
Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) in
order to determine if any diagnostic codes for the
injector solenoids are present. Check that the injector
trim codes have been entered. Perform the “Injector
Solenoid Test” . Observe that the injector solenoids
are being energized on Cat ET. Perform the
“Cylinder Cutout Test” . Locate the misfiring cylinder.
Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoids”.
Air Inlet and Exhaust System
45
Troubleshooting without a Diagnostic Code
1. Check the air inlet manifold pressure. Check for air
inlet restrictions and/or leaks. Refer to the Systems
Operation/Testing and Adjusting manual for more
information.
2. Check for leaks between the exhaust manifold and
the turbocharger. Check for exhaust restrictions.
Refer to the Systems Operation/Testing and
Adjusting manual for more information.
i02769235
Fuel in Cooling System
SMCS Code: 1350-035
Probable Causes
• Injector sleeve or injector sleeve seal
Recommended Actions
Injector Sleeve or Injector Sleeve Seals
1. Remove the valve mechanism covers.
2. Remove the fuel injectors from the cylinder head.
Refer to the Disassembly and Assembly manual
for details.
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.
3. Pressurize the cooling system in order to identify
the injector sleeve that is leaking. Closely inspect
the sealing joint around the top of the injector
sleeve. Small amounts of coolant will be dripping
from the injector sleeve that is leaking.
Note: Do not allow the pressure on the cooling
system to exceed 103 kPa (15 psi) during the test.
Damage to the cooling system may result from
applying excessive pressure.
Refer to the Systems Operation/Testing and
Adjusting manual for details.
46 RENR9318
Troubleshooting without a Diagnostic Code

4. Remove the injector sleeve that is leaking. Cracked Fuel Supply Manifold
Carefully inspect the sleeve for damage. If there
are visible signs of damage to the injector sleeve, Look for signs of damage to the fuel supply manifold.
replace the sleeve. Replace the O-ring seals for
the injector sleeve and reinstall the sleeve. Leaking Fuel Transfer Pump Seal
Replace any damaged components.
Ensure that the weep hole is not plugged. If
Note: Coolant may also be contaminating the fuel necessary, repair the fuel transfer pump or replace
system. After the engine is shutdown, the retention of the fuel transfer pump.
pressure in the cooling system may cause the
transfer of coolant into the fuel system. Visually i02881460
inspect the fuel tank for coolant. The contamination of
coolant in the fuel system may cause damage to Intermittent Engine Shutdown
injectors and other fuel system components. Ensure
that all of the fuel system components are in good SMCS Code: 1000-035
repair prior to returning the engine to service.
Note: Use this procedure only if the engine shuts
down completely during operation.
i02119587

Probable Causes
Fuel Dilution of Engine Oil
• Diagnostic codes
SMCS Code: 1348-035
• Event codes
Probable Causes
• Electrical connectors
• Leaking seals on the case of the unit injector or on
the barrel of the unit injector • Air inlet and exhaust restrictions

• Leaking seals on the fuel line adapter for the
cylinder head
• Excessive leakage from the unit injector tip or
breakage of the unit injector tip
• Cracked fuel supply manifold
• Leaking seal on the fuel transfer pump
Recommended Actions
Leaking Seals on the Case of the Unit
Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit
injectors. Replace any seals that are leaking.
Leaking Seals on the Fuel Line Adapter
for the Cylinder Head
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
lines or components.
• Circuit breakers
• Fuel supply
Recommended Actions
Diagnostic Codes and/or Event Codes
Certain diagnostic codes and/or event codes may
cause an engine shutdown. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Electrical Connectors
1. Check for correct installation of the J1/P1 and J2/
P2 connectors for the Electronic Control Module
(ECM). Also, thoroughly inspect the connectors for
the engine speed/timing sensors. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.

Excessive Leakage from the Unit Injector

Tip or Breakage of the Unit Injector Tip
Look for signs of damage to the unit injectors. If
necessary, repair the unit injectors or replace the unit
injectors.
RENR9318
2. Inspect the battery wires from the ECM to the
battery compartment. Refer to the Schematic for
specific wiring information. Check the unit injector
connectors and associated wiring for damage, or
for intermittent problems. Inspect the wires and
connectors to all circuit protection for the engine.
Check the power and ground connections to the
ECM. Check any engine shutdown switches and
associated wiring. Refer to the diagnostic
functional test Troubleshooting, “Electrical Power
Supply Circuit - Test”.
Air Inlet and Exhaust Restrictions
Check the air inlet system for the following problems:
restrictions, collapse and pinched line. Repair the
lines and/or replace the lines.
Check for an air filter restriction. Replace plugged air
filters and/or clean filters. Repair any leaks.
Circuit Breakers
Check the state of each of the circuit breakers. Reset
the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine the
condition that caused the circuit breaker to trip. Make
the necessary repairs.
Fuel Supply
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system.
Refer to the Operation and Maintenance Manual.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for debris or foreign objects
which may block the fuel supply.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
47
Troubleshooting without a Diagnostic Code
Note: Check the fuel system for air. Refer to the
Systems Operation/Testing and Adjusting manual.
5. Check fuel quality. Cold weather adversely affects
the characteristics of the fuel. Refer to the
Operation and Maintenance Manual.
6. Check the filtered fuel pressure while the engine is
being cranked. Refer to Systems Operation/
Testing and Adjusting.
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual.
If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting.
i02520545
Intermittent Low Power or
Power Cutout
SMCS Code: 1000-035
Note: Use this procedure only if the engine does not
shut down completely.
Probable Causes
• Diagnostic codes
• Event codes
• Turbocharger
• Air inlet and exhaust restrictions
• Throttle signal
• Power supply for the Electronic Control Module
(ECM)
• Fuel supply
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
48
Troubleshooting without a Diagnostic Code
Turbocharger
Ensure that the turbocharger is operating correctly.
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side).
Air Inlet and Exhaust Restrictions
Check the air inlet system for the following problems:
restrictions, collapse and pinched line. Repair the
lines and/or replace the lines.
Check for an air filter restriction. Replace plugged air
filters and/or clean filters. Repair any leaks.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic test for your
application:
• Troubleshooting, “Throttle Position Sensor Circuit -
Test”
• Troubleshooting, “Throttle Switch Circuit - Test”
• Troubleshooting, “Speed Control - Test”
ECM Power Supply
1. Inspect the circuit between the ECM and the
batteries. Refer to the Electrical System
Schematic. Inspect the wires, the connectors, and
the components in the circuit. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information.
2. Inspect the circuit between the ECM and the
keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors, and
the components in the circuit. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
RENR9318
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. For more
information, refer to Systems Operation/Testing and
Adjusting, “Air in Fuel - Test”.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
5. Check the fuel pressure after the fuel filter while the
engine is being cranked. Refer to Systems
Operation/Testing and Adjusting, “Fuel System” for
the correct pressure values. If the fuel pressure is
low, replace the fuel filters. If the fuel pressure is
still low, check the following items: fuel transfer
pump, fuel transfer pump coupling and fuel
pressure regulating valve. Refer to Systems
Operation/Testing and Adjusting for more
information.
i02430113
Low Engine Oil Pressure
SMCS Code: 1348-035-LP
NOTICE
Do not operate engine with low oil pressure. Engine
damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is
corrected.
Probable Causes
• Engine oil level
• Engine oil filters and oil filter bypass valve
• Engine oil pump
• Engine oil cooler
• Fuel dilution
• Engine wear
RENR9318
Recommended Actions
Engine Oil Level
Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance
Manual.
Engine Oil Filters and Oil Filter Bypass
Valve
Check the service records of the engine for
information that is related to the last oil change. If
necessary, perform an oil change on the engine and
replace the engine oil filters.
Check the operation of oil filter bypass valve. Clean
the bypass valve and the housing. If necessary, install
new parts.
Engine Oil Pump
Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil
pump for excessive wear. If necessary, repair the oil
pump or replace the oil pump.
Oil Cooler
Check the engine's oil cooler for plugging or
blockage. Clean the engine oil cooler core(s) and/or
install new engine oil cooler core(s).
Fuel Dilution
Check for presence of fuel in lubricating oil. Refer to
the troubleshooting without a diagnostic code
procedure Troubleshooting, “Fuel Dilution of Engine
Oil”.
Engine Wear
Inspect the camshaft and/or camshaft bearings for
excessive wear. Inspect the crankshaft and/or
crankshaft bearings. Excessive wear to discrete
components may be an indication of a blocked oil
passage. Use an oil pressure gauge to check the oil
pressure at the main oil gallery. This will help
determine if the excessive wear is from low system
pressure or from passages that are blocked.
49
Troubleshooting without a Diagnostic Code
i02407690
Low Power/Poor or No
Response to Throttle
SMCS Code: 1000-035
Probable Causes
• Diagnostic codes
• Event codes
• Cold mode
• Throttle signal
• Electrical connectors
• Unit injectors
• Intake manifold pressure sensor
• Air inlet and exhaust system
• Parameters
• Fuel supply
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may
cause poor performance. Connect Caterpillar
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Cold Mode
1. Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may cause the
engine to run rough and engine power may be
limited.
2. Observe the coolant temperature on the Cat ET
status screen. Verify that the reading is valid.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed. If
a problem is suspected with the throttle, refer to the
appropriate troubleshooting procedure for
troubleshooting the throttle signal.
50
Troubleshooting without a Diagnostic Code
Electrical Connectors
Check for correct installation of the J1/P1 and J2/
P2Electronic Control Module (ECM) connectors and
the unit injector connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
Unit Injectors
1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
2. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer to
Troubleshooting, “Injector Solenoids Circuit - Test”
for more information.
Intake Manifold Pressure Sensor
1. Monitor the status of “Fuel Position” , “Rated Fuel
Limit” , and “FRC Fuel Limit” on Cat ET while the
engine is operating under full load. These
parameters should reflect the information below.
Table 16
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit” , the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Monitor the status of “Intake Manifold Pressure”
and “Atmospheric Pressure” for normal operation
on Cat ET. When the engine is not running, the
correct value for “Intake Manifold Pressure” is
0 kPa (0 psi).
Air Inlet and Exhaust System
1. Observe the indicator lamps. Check for an air filter
restriction indicator. Clean plugged air filters or
replace plugged air filters. Refer to the Operation
and Maintenance Manual for additional
information.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.
Parameters
If the ECM has been replaced, compare the values
on the Engine Information Plate to following
parameters from Cat ET:
RENR9318
• FRC offset
• Full Load Setting (FLS)
• Full Torque Setting (FTS)
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting for more information.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure after the fuel filter while the
engine is being cranked. Refer to Systems
Operation/Testing and Adjusting for the correct
pressure values. If the fuel pressure is low, replace
the fuel filters. If the fuel pressure is still low, check
the following items: fuel transfer pump, fuel transfer
pump coupling and fuel pressure regulating valve.
Refer to Systems Operation/Testing and Adjusting
for more information.
RENR9318
i02514294
Mechanical Noise (Knock) in
Engine
SMCS Code: 1000-035
Probable Causes
• Faulty accessory
• Cylinder head and related components
• Gear train
• Crankshaft and related components
• Piston
Recommended Repairs
Faulty Accessory
Isolate the source of the noise. Remove the suspect
engine accessories. Inspect the suspect engine
accessories. Repair the engine accessories and/or
replace the engine accessories.
Cylinder Head and Related Components
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear to
the valves, cylinder head gasket, springs, lifters,
pushrods, etc. Inspect the condition of the camshafts.
If a camshaft is replaced, new valve lifters must be
installed. Replace any damaged parts.
Gear Train
Inspect the condition of the gear train. Replace any
damaged parts.
Inspect the flywheel and the flywheel bolts.
Inspect the engine oil filters for nonferrous material.
Flaking of nonferrous material could indicate worn
gear train bearings.
Crankshaft
Inspect the crankshaft and the related components.
Inspect the connecting rod bearings and the bearing
surfaces on the crankshaft. Make sure that the
bearings are in the correct position. Look for worn
thrust plates and wear on the crankshaft. Check the
counterweight bolts. Replace any damaged parts.
Piston
Inspect the condition of the pistons. Make sure that
the piston pins are correctly installed. Replace any
damaged parts.
51
Troubleshooting without a Diagnostic Code
i02477338
Noise Coming from Cylinder
SMCS Code: 1000-035
Probable Causes
• Diagnostic codes
• Fuel quality
• Unit injectors
• Valve lash
• Cylinder head and related components
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
Fuel Quality
Refer to Operation and Maintenance Manual for
information on the characteristics of the fuel.
Unit Injectors
1. Check the connectors at the Electronic Control
Module (ECM). Check for correct installation of the
J1/P1 and J2/P2 ECM connectors. Also,
thoroughly inspect the unit injector wiring harness
from the ECM to the J300/P300valve cover entry
connector. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
3. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any injectors that may be misfiring.
Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Valve Lash
Check the engine valve lash settings. Inspect the
valve train for sufficient lubrication. Check damage to
valve train components which may cause excessive
valve lash. Repair any problems that are found. Refer
to troubleshooting without a diagnostic code
Troubleshooting, “Excessive Valve Lash”.
52
Troubleshooting without a Diagnostic Code
Cylinder Head and Related Components
Check for signs of damage and/or wear to the valves,
cylinder head gasket, etc. Inspect the condition of the
camshafts.
i02407700
Poor Acceleration or Response
SMCS Code: 1000-035
Probable Causes
• Engine derate or active codes
• Cold mode
• Flash file
• Throttle signal
• Electrical connectors
• Unit injectors
• Intake manifold pressure sensor
• Air inlet and exhaust system
• Fuel supply
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Engine Derate or Active Codes
Some engine monitoring parameters that are capable
of triggering an engine derate do not produce an
event code. Connect Caterpillar Electronic
Technician (ET) in order to check for a derate of the
engine.
Certain diagnostic codes and/or event codes may
cause poor performance. Use Cat ET to check for
active codes and for logged codes. Troubleshoot any
codes that are present before continuing with this
procedure.
Note: Although a sensor's signal may be in the
operational range of the sensor, the signal may not
represent the actual reading. Use Cat ET to check
that the pressures and the temperatures are
fluctuating. Also check that the values are reasonable
for the conditions that are present.
RENR9318
Cold Mode
Use Cat ET to verify that the engine has exited cold
mode. Cold mode operation may slow throttle
response.
Flash File
Verify that the latest flash file is installed in the
Electronic Control Module (ECM).
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed. If
a problem is suspected with the throttle, refer to the
appropriate troubleshooting procedure for
troubleshooting the throttle signal.
Electrical Connectors
Check for correct installation of the J1/P1 and J2/
P2Electronic Control Module (ECM) connectors and
the J300/P300 connectors for the unit injectors. Refer
to Troubleshooting, “Electrical Connectors - Inspect”.
Unit Injectors
1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
2. Perform the “Cylinder Cutout Test” on Cat ET in
order to determine the performance of each
cylinder. Refer to Troubleshooting, “Injector
Solenoid Circuit - Test” for the proper procedure.
Intake Manifold Pressure Sensor
1. Monitor the status of “Fuel Position” , “Rated Fuel
Limit” , and “FRC Fuel Limit” on Cat ET while the
engine is operating under full load. These
parameters should reflect the information below.
Table 17
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit” , the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Monitor the status of “Intake Manifold Pressure”
and of “Atmospheric Pressure” for normal
operation on Cat ET. When the engine is not
running, the correct value for “Intake Manifold
Pressure” is 0 kPa (0 psi).
RENR9318 53
Troubleshooting without a Diagnostic Code

Air Inlet and Exhaust System
1. Observe the check engine lamp. Check for an air
filter restriction indicator. Clean plugged air filters
or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting for information on
inspecting the air inlet and exhaust system.
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual
for details.
If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
i04563324

Fuel Supply
Valve Rotator or Spring Lock Is
Free
1. Visually check the fuel level in the fuel tank. Do not SMCS Code: 1109-035
rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of Use this procedure in order to troubleshoot a problem
with the valve rotators or spring locks.
fuel, it will be necessary to purge the air from the
fuel system. Refer to Operation and Maintenance Probable Cause
Manual for the correct procedure.
• Valve Components
2. Check the fuel lines for the following problems:
restrictions, collapsed lines and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.

3. Check the fuel tank for debris or foreign objects

which may block the fuel supply.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

4. Prime the fuel system if any of the following

procedures have been performed:

• Replacement of the fuel filters

• Service on the low pressure fuel supply circuit

• Replacement of unit injectors

Note: Check the fuel system for air. Refer to Systems

Operation/Testing and Adjusting for information that is
related to checking the fuel system for air.

5. Check fuel quality. Cold weather adversely affects

the characteristics of the fuel. Refer to the engine's
Operation and Maintenance Manual for information
on improving the characteristics of the fuel during
cold weather operation.

6. Check the filtered fuel pressure while the engine is

being cranked. Refer to Systems Operation/
Testing and Adjusting for the test procedure and
for the correct pressure values.
54 RENR9318
Troubleshooting without a Diagnostic Code

Recommended Actions
Table 18
Troubleshooting Test Steps Values Results

1. Valve Components Damaged Result: The valve components are damaged.

components
A. Inspect the following components for damage: Replace the damaged components.

1. Valve rotators A valve rotator that is cracked or a valve rotator that is

2. Spring locks broken is an indication of an engine overspeed. Deter-
3. Valve springs mine the cause of the engine overspeed. Repair the
4. Valves condition.

B. Ensure that the valve has not contacted the piston. If the valve
has contacted the piston, check the exhaust system for debris.

Complete the procedure in the order in which the

steps are listed.
If the procedure did not correct the issue, contact your
Cat dealer Technical Communicator (TC). For further
assistance, your TC can confer with the Dealer
Solutions Network (DSN).
RENR9318 55
Troubleshooting with a Diagnostic Code

Troubleshooting with a
Diagnostic Code

i02281051

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).
Component Identifier (CID) – The CID is a number
with three or four digits. The CID indicates the
component that generated the code. For example, the
CID number 0001 identifies the fuel injector for the
number one cylinder.
Failure Mode Identifier (FMI) – The FMI is a two digit
code that indicates the type of failure.

Do not confuse diagnostic codes with event codes.

Event codes alert the operator that an abnormal
operating condition such as low oil pressure or high
coolant temperature has been detected. Refer to
Troubleshooting, “Troubleshooting with an Event
Code” for additional information on event codes.
Illustration 11 g01117578
Output voltage from a typical analog temperature
sensor
Illustration 11 indicates the signal range for a typical
analog sensor. Diagnostic codes will be generated if
the sensor's output signal is below 0.2 VDC or above
4.8 VDC.

Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the “Active
Alarm” indicator ( “Engine Control Alarm Status” on
Cat ET) is activated in order to alert the operator. If
the condition that generated the code is momentary,
the message disappears from the list of active
diagnostic codes. The diagnostic code becomes
logged.
56 RENR9318
Troubleshooting with a Diagnostic Code

Logged Diagnostic Codes Troubleshooting:

When the ECM generates a diagnostic code, the Test Step 1. ...................................................
ECM logs the code in permanent memory. The ECM
has an internal diagnostic clock. Each ECM will Results:
record the following information when a code is
generated:
• OK – STOP. OK
• The hour of the first occurrence of the code i02504233

• The hour of the last occurrence of the code

CID 0001 FMI 06 Cylinder #1
• The number of occurrences of the code Injector short
This information is a valuable indicator for SMCS Code: 1290-038
troubleshooting intermittent problems.
Conditions Which Generate This Code:
A code is cleared from memory when one of the
following conditions occur:
The Electronic Control Module (ECM) is attempting to
• The service technician manually clears the code. operate the injector. The ECM detects a short circuit
in the circuit for the injector.
• The code does not recur for 100 hours.
System Response:
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is The ECM will log the diagnostic code. The ECM will
cleared. continue to attempt to operate the injector after the
code has been logged.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that did Possible Performance Effect:
not result in complaints. The most likely cause of an
intermittent problem is a faulty connection or • Engine misfires
damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure • Low power
of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs Troubleshooting:
special investigation.
Note: Always clear logged diagnostic codes after Test Step 1. ...................................................
investigating and correcting the problem which
generated the code. Results:
i02504219
• OK – STOP. OK
CID 0001 FMI 05 Cylinder #1 i02504240
Injector open circuit
SMCS Code: 1290-038
CID 0002 FMI 05 Cylinder #2
Injector open circuit
Conditions Which Generate This Code:
SMCS Code: 1290-038
The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects an open circuit Conditions Which Generate This Code:
in the circuit for the injector.
The Electronic Control Module (ECM) is attempting to
System Response: operate the injector. The ECM detects an open circuit
in the circuit for the injector.
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the System Response:
code has been logged.
The ECM will log the diagnostic code. The ECM will
Possible Performance Effect: continue to attempt to operate the injector after the
code has been logged.
• Engine misfires
Possible Performance Effect:
• Low power
• Engine misfires

• Low power
RENR9318 57
Troubleshooting with a Diagnostic Code

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. OK • OK – STOP. OK
i02504248 i02504254

CID 0002 FMI 06 Cylinder #2 CID 0003 FMI 06 Cylinder #3

Injector short Injector short
SMCS Code: 1290-038 SMCS Code: 1290-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit operate the injector. The ECM detects a short circuit
in the circuit for the injector. in the circuit for the injector.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• Engine misfires • Engine misfires
• Low power • Low power

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. OK • OK – STOP. OK
i02504251 i02504275

CID 0003 FMI 05 Cylinder #3 CID 0004 FMI 05 Cylinder #4

Injector open circuit Injector open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects an open circuit operate the injector. The ECM detects an open circuit
in the circuit for the injector. in the circuit for the injector.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• Engine misfires • Engine misfires

• Low power • Low power

58 RENR9318
Troubleshooting with a Diagnostic Code

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. OK • OK – STOP. OK
i02504282 i02504292

CID 0004 FMI 06 Cylinder #4 CID 0005 FMI 06 Cylinder #5

Injector short Injector short
SMCS Code: 1290-038 SMCS Code: 1290-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit operate the injector. The ECM detects a short circuit
in the circuit for the injector. in the circuit for the injector.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• Engine misfires • Engine misfires
• Low power • Low power

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. OK • OK – STOP. OK
i02504291 i02504299

CID 0005 FMI 05 Cylinder #5 CID 0006 FMI 05 Cylinder #6

Injector open circuit Injector open circuit
SMCS Code: 1290-038 SMCS Code: 1290-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) is attempting to The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects an open circuit operate the injector. The ECM detects an open circuit
in the circuit for the injector. in the circuit for the injector.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• Engine misfires • Engine misfires

• Low power • Low power

RENR9318 59
Troubleshooting with a Diagnostic Code

Troubleshooting: Results:

Test Step 1. ................................................... • OK – STOP.

i02405543
Results:

• OK – STOP. OK CID 0041 FMI 04 8 Volt DC

i02504302
Supply short to ground
SMCS Code: 1439-038
CID 0006 FMI 06 Cylinder #6
Conditions Which Generate This Code:
Injector short
SMCS Code: 1290-038 The Electronic Control Module (ECM) detects a
below normal voltage on the 8 volt supply.
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit The code is logged. The check engine lamp will
in the circuit for the injector. illuminate while this diagnostic code is active.

System Response: Possible Performance Effect:

The ECM will log the diagnostic code. The ECM will • None
continue to attempt to operate the injector after the
code has been logged. Troubleshooting:

Possible Performance Effect: Test Step 1. ...................................................

• Engine misfires Results:

• Low power • OK – STOP.

Troubleshooting: i02417388

Test Step 1. ................................................... CID 0091 FMI 08 Throttle

Results:
Position signal abnormal
SMCS Code: 1439-038; 1913-038
• OK – STOP. OK
Conditions Which Generate This Code:
i02405538
The Electronic Control Module (ECM) detects an
CID 0041 FMI 03 8 Volt DC incorrect frequency on the throttle signal.
Supply short to +batt System Response:
SMCS Code: 1439-038
The code is logged. The ECM flags the throttle
Conditions Which Generate This Code: position as invalid data and a default value of zero
percent is used.
The Electronic Control Module (ECM) detects an
above normal voltage on the 8 volt supply. Possible Performance Effect:

System Response: • The engine speed is limited to low idle.

The code is logged. The check engine lamp will Troubleshooting:

illuminate while this diagnostic code is active.
Test Step 1. ...................................................
Possible Performance Effect:
Results:
• None
• OK – STOP.
Troubleshooting:

Test Step 1. ...................................................

60 RENR9318
Troubleshooting with a Diagnostic Code

i02520759 i02520773

CID 0094 FMI 03 Fuel Pressure CID 0100 FMI 03 Engine Oil
open/short to +batt Pressure open/short to +batt
SMCS Code: 1439-038; 1718-038 SMCS Code: 1439-038-OC; 1924-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
signal voltage from the sensor that is above normal. signal voltage that is above normal.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• There are no performance effects. • There are no performance effects.

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. • OK – STOP.
i02520760 i02520774

CID 0094 FMI 04 Fuel Pressure CID 0100 FMI 04 Engine Oil
short to ground Pressure short to ground
SMCS Code: 1439-038; 1718-038 SMCS Code: 1439-038-OC; 1924-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
signal voltage that is below normal. signal voltage that is below normal.

System Response: System Response:

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.

Possible Performance Effect: Possible Performance Effect:

• There are no performance effects. • There are no performance effects.

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. ...................................................

Results: Results:

• OK – STOP. • OK – STOP.
RENR9318
i02581776
CID 0100 FMI 10 Engine Oil
Pressure Sensor abnormal rate
of change
SMCS Code: 1439-038-OC; 1924-038
Conditions Which Generate This Code:
This code indicates that the 5 volt supply is missing
from the sensor connector.
During normal engine operation, the oil pressure
fluctuates slightly. When the 5 volt supply is missing
from the oil pressure sensor, the signal from the oil
pressure sensor goes to a midrange value. The signal
does not fluctuate. If the signal from the oil pressure
sensor remains abnormally steady for more than 30
seconds, the Engine Control Module (ECM) activates
this code.
System Response:
A snapshot is triggered. The ECM uses a default
value for the oil pressure.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Test Step 1. Repair the Open Circuit
A. Repair the supply wire or replace the supply wire
between the ECM and the sensor.
Expected Result:
The problem is resolved.
Results:
• OK – The problem is resolved.
STOP. SOP
• Not OK – The problem is not resolved.
Repair: Refer to the diagnostic functional test
Troubleshooting, “5 Volt Engine Pressure
Sensor Supply Circuit - Test”.
STOP.
61
Troubleshooting with a Diagnostic Code
i02520775
CID 0110 FMI 03 Engine
Coolant Temperature open/
short to +batt
SMCS Code: 1439-038-CLT; 1906-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
signal voltage that is above normal.
System Response:
The code is logged if the engine has been running for
more than seven minutes. The check engine lamp will
illuminate while this diagnostic code is active. The
ECM uses the last valid engine coolant temperature.
If the diagnostic code is active at start-up the ECM
will use intake manifold temperature. If intake
manifold air temperature is not valid, the ECM will
default to 90 °C (194 °F) for engine coolant
temperature. The engine will not go into cold mode
while the diagnostic code is active. The ECM will
activate the cooling fan after this code has been
active for more than eight seconds.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Test Step 1. ...................................................
Results:
• OK – STOP.
i02520780
CID 0110 FMI 04 Engine
Coolant Temperature short to
ground
SMCS Code: 1439-038-CLT; 1906-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
signal voltage that is below normal.
62 RENR9318
Troubleshooting with a Diagnostic Code

System Response: i02415961

The code is logged. The ECM uses the last valid CID 0168 FMI 01 System
engine coolant temperature. The check engine lamp
will illuminate while this diagnostic code is active. If Voltage Low
the diagnostic code is active at start-up the ECM will SMCS Code: 1401-038
use intake manifold temperature. If intake manifold air
temperature is not valid, the ECM will default to 90 °C Conditions Which Generate This Code:
(194 °F) for engine coolant temperature. The engine
will not go into cold mode while the diagnostic code is The Electronic Control Module (ECM) detects battery
active. The ECM will activate the cooling fan after this voltage that is below 9 VDC on 12 volt systems or
code has been active for more than eight seconds. below 18 VDC on 24 volt systems.

Possible Performance Effect: System Response:

• There are no performance effects. The ECM will log the diagnostic code. The check
engine lamp will illuminate while this diagnostic code
Troubleshooting: is active. The engine will be derated 100 percent.
Test Step 1. ................................................... Possible Performance Effect:
Results: • The engine will be shutdown.

• OK – STOP. Troubleshooting:
i02424772
Test Step 1. ...................................................
CID 0168 FMI 00 System Results:
Voltage High
• OK – STOP.
SMCS Code: 1401-038
i02508878
Conditions Which Generate This Code:
CID 0168 FMI 02 System
The Electronic Control Module (ECM) detects the
following condition:
Voltage intermittent/erratic
SMCS Code: 1401-038
• For 12 volt systems, the ECM reads battery
voltage that is above 16 VDC. Conditions Which Generate This Code:
• For 24 Volt systems, the ECM reads battery While the engine is running the Electronic Control
voltage that is above 32 VDC. Module (ECM) detects battery voltage that drops
below 6 VDC and returns above 9 VDC.
Note: Excessive voltage to the ECM may damage
the ECM.
System Response:
System Response:
The ECM will log the diagnostic code.
The ECM will log the diagnostic code.
Possible Performance Effect:
Possible Performance Effect: • An engine misfire may occur.
• There are no performance effects. • An engine shutdown condition may occur.
Troubleshooting: Troubleshooting:
Test Step 1. ................................................... Test Step 1. ...................................................
Results: Results:
• OK – STOP. • OK – STOP.
RENR9318 63
Troubleshooting with a Diagnostic Code

i02440612 Results:

CID 0172 FMI 03 Intake • OK – STOP.

Manifold Air Temp open/short i02538325

to +batt CID 0174 FMI 03 Fuel

SMCS Code: 1439-038-AI; 1921-038
Temperature open/short to
Conditions Which Generate This Code: +batt
The Electronic Control Module (ECM) detects a SMCS Code: 1439-038; 1922-038
signal voltage that is above normal or the intake
manifold air temperature is below −35 °C (−31 °F) . Conditions Which Generate This Code:

System Response: The Electronic Control Module (ECM) detects a

signal voltage that is above normal or the ECM
The code is logged. The ECM will flag the intake detects fuel temperature that is below −30 °C
manifold air temperature as invalid data and the (−22 °F).
intake manifold air temperature is set to a default
value. System Response:

Possible Performance Effect: The code is logged. The ECM flags fuel temperature
as invalid data and a default value is used.
• There are no performance effects.
Possible Performance Effect:
Troubleshooting:
• There are no performance effects.
Test Step 1. ...................................................
Troubleshooting:
Results:
Test Step 1. ...................................................
• OK – STOP.
Results:
i02424787
• OK – STOP.
CID 0172 FMI 04 Intake i02538315
Manifold Air Temp short to
ground CID 0174 FMI 04 Fuel
SMCS Code: 1439-038-AI; 1921-038
Temperature short to ground
SMCS Code: 1439-038; 1922-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
signal voltage that is below normal. The Electronic Control Module (ECM) detects a
signal voltage that is below normal or the ECM
System Response: detects engine temperature that is above 140 °C
(284 °F).
The code is logged. The ECM will flag the intake
manifold air temperature as invalid data and the System Response:
intake manifold air temperature is set to a default
value. The code is logged. The ECM flags fuel temperature
as invalid data and a default value is used.
Possible Performance Effect:
Possible Performance Effect:
• The engine may experience hard starting and/or
rough running. • There are no performance effects.
• The engine may smoke. Troubleshooting:
Troubleshooting: Test Step 1. ...................................................
Test Step 1. ................................................... Results:
64
Troubleshooting with a Diagnostic Code
• OK – STOP.
i02428636
CID 0253 FMI 02 Personality
Module mismatch
SMCS Code: 1902-038
Conditions Which Generate This Code:
The flash file that is used for replacement is for a
different engine family or for a different engine
application.
System Response:
Caterpillar Electronic Technician (ET) will not be
able to clear the code.
Possible Performance Effect:
• The fuel injection system is disabled and the
engine will not start.
Troubleshooting:
Test Step 1. Check the Part Number of the
Flash File
A. Restore the electrical power to the Electronic
Control Module (ECM).
B. Verify that the part number for the flash file agrees
with the latest update that is available on Service
Technician Workbench (STW ), or on SIS Web .
Expected Result:
The correct flash file is installed in the ECM.
Results:
• OK – The correct flash file is installed in the ECM.
Repair: The engine will not start until the 253-02
diagnostic code is cleared. Clearing this code
requires factory passwords.
Acquire factory passwords. Clear the 253-02
diagnostic code. Return the engine to service.
STOP.
• Not OK – The correct flash file is not installed in the
ECM.
Repair: Flash program the ECM with the correct
flash file. Refer to programming parameters
Troubleshooting, “Flash Programming”. Verify
that the problem is resolved.
STOP.
RENR9318
i03640774
CID 0261 FMI 11 Engine Timing
Offset fault
SMCS Code: 1439-038; 1912-038
Conditions Which Generate This Code:
The engine speed/timing sensors are reporting that
the expected position of the camshaft is incorrect or
the polarity of the wiring to a speed/timing sensor is
reversed.
System Response:
The Electronic Control Module (ECM) will log the
diagnostic code.
The ECM sets engine timing calibration to zero
degrees.
Possible Performance Effect:
• The engine may misfire.
• The engine may experience low power and/or
reduced speed.
• The engine may experience increased exhaust
emissions and/or white exhaust smoke.
Troubleshooting:
Test Step 1. Check the Installation of the
Speed/Timing Sensors
A. Visually inspect the sensors for correct installation:
a. Ensure that the sensor's mounting flanges are
fully seated onto the surface of the engine.
b. Ensure that the locating notch on the flange of
each sensor is oriented correctly.
c. Ensure that the sensor's brackets are not bent
or broken. Ensure that the brackets are
securely holding the sensor in place.
d. Ensure that the sensors are tight in the
housing bore. If a sensor is loose in the bore,
check the condition of the sensor's O-ring
seals. Ensure that the seals are not missing.
Also, inspect the seals for damage.
B. Check for the correct installation of the sensor's
connectors. Ensure that the electrical connector is
securely latched. Check for the correct polarity in
the wiring at each sensor connector and at the
ECM connector.
RENR9318
C. Ensure that the harness is properly secured, and
ensure that each tie-wrap is placed in the correct
location.
Expected Result:
The sensors, the connectors, and the wiring are
correctly installed.
Results:
• OK – The sensors and the harness are OK.
Proceed to Test Step 2.
• Not OK – A problem has been identified with the
installation of the sensors and/or the harness.
Repair: Correct the problem that has been
identified. Replace parts, if necessary. Ensure
that the diagnostic code is no longer active.
A timing calibration is necessary after this
diagnostic code has become active. Refer to the
diagnostic functional test Troubleshooting,
“Engine Speed/Timing Sensor - Calibrate”.
STOP.
Test Step 2. Check the Condition of the
Engine's Front Gear Train
The problem may be due to the incorrect
orientation of the camshaft gear with respect to
the orientation of the crankshaft gear during
engine operation. Check the front gear train for
damage and excessive wear:
Refer to Disassembly and Assembly.
A. Remove the cover from the front gear housing.
B. Check for correct timing between the crankshaft
gear and the camshaft gear.
C. Check the gear train for gear tooth failure.
D. Check the gear train for excessive gear tooth wear.
Perform a timing gear backlash check.
E. Check each idler gear assembly for excessive
wear to the bearing and/or the idler stub shaft.
Check for correct bearing clearance.
Expected Result:
The mechanical condition of the gear train is within
specifications.
Results:
• OK – The condition of the gear train is OK.
65
Troubleshooting with a Diagnostic Code
Repair: The problem is not in the gear train.
Clear the diagnostic code. Refer to the
diagnostic functional test Troubleshooting,
“Engine Speed/Timing Sensor Circuit - Test”.
.
STOP.
• Not OK – The mechanical condition of the gear
train is not within specifications.
Repair: A problem with the gear train has been
identified. Make the necessary repairs to the
gear train. Clear the diagnostic code. A timing
calibration is necessary after this diagnostic
code has become active. Refer to the calibration
procedure Troubleshooting, “Engine Speed/
Timing Sensor - Calibrate”.
Verify that the original problem has been
resolved.
STOP.
i02445663
CID 0261 FMI 13 Engine Timing
Calibration required
SMCS Code: 1439-038; 1912-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an
incorrect engine timing.
Note: A timing calibration is required for a new
engine, replacing an ECM that fails to communicate
or following work on the front gear train, the camshaft,
or the crankshaft.
System Response:
The check engine lamp will illuminate while this
diagnostic code is active. The ECM uses default
timing. Timing may be off as much as three degrees.
Possible Performance Effect:
• The engine may run rough and/or the engine may
emit white smoke in the exhaust.
Troubleshooting:
Test Step 1. ...................................................
Results:
• OK – STOP.
66 RENR9318
Troubleshooting with a Diagnostic Code

i02416460 i02440601

CID 0262 FMI 03 5 Volt Sensor CID 0267 FMI 02 Incorrect

DC Power Supply short to Engine Shutdown Switch
+batt inputs
SMCS Code: 1439-038 SMCS Code: 7332-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects one of
above normal voltage on the 5 volt supply. the following conditions:

System Response: • Both of the switch inputs from the engine

shutdown switch are in the open state.
The code is logged. The check engine lamp will
illuminate while this diagnostic code is active. The • Both of the switch inputs from the engine
ECM sets all of the pressure sensors to the default shutdown switch are in the closed state.
values.
System Response:
Possible Performance Effect:
The diagnostic code may be viewed on Caterpillar
• The engine power is derated. Electronic Technician (ET). If both of the switch inputs
from the engine shutdown switch change to the same
Troubleshooting: state and the engine is running, the engine will
continue to run. If both of the switch inputs from the
Test Step 1. ................................................... engine shutdown switch change to the same state
and the engine is not running, the engine control will
Results: not allow the engine to start.

• OK – STOP. Possible Performance Effect:

i02416463 • The engine will not start.

CID 0262 FMI 04 5 Volt Sensor Troubleshooting:

DC Power Supply short to Test Step 1. ...................................................
ground
Results:
SMCS Code: 1439-038
• OK – STOP. OK
Conditions Which Generate This Code:
i02713570
The Electronic Control Module (ECM) detects a
below normal voltage on the 5 volt supply. CID 0268 FMI 02 Check
System Response: Programmable Parameters
SMCS Code: 1901-038
The code is logged. The check engine lamp will
illuminate while this diagnostic code is active. The Conditions Which Generate This Code:
ECM sets all of the pressure sensors to the default
value. The Electronic Control Module (ECM) detects that
one or more of the programmable parameters have
Possible Performance Effect: not been programmed.
• The engine power is derated. System Response:
Troubleshooting:
The diagnostic code is not logged. Any
unprogrammed parameters are set to the default
Test Step 1. ................................................... value. Engine performance may be affected. This is
dependent on the unprogrammed parameters.
Results:

• OK – STOP.
RENR9318 67
Troubleshooting with a Diagnostic Code

Possible Performance Effect: i02416783

• Low power CID 0274 FMI 04 Atmospheric

Troubleshooting: Pressure short to ground
SMCS Code: 1439-038-AI; 1923-038
Test Step 1.
Conditions Which Generate This Code:
Use Caterpillar Electronic Technician (ET) to
reprogram the system configuration parameters. The Electronic Control Module (ECM) detects a
Refer to Troubleshooting, “System Configuration signal that is below normal.
Parameters” for additional information.
System Response:
Results:
The code is logged. The ECM will use the default
• A 0268-2 code is active value for atmospheric pressure.
Repair: Identify the condition that is displayed Possible Performance Effect:
beneath the code:
• The engine power is derated.
If a programmable parameter is displayed,
program that parameter with the correct value. Troubleshooting:

If “Injector Code” is displayed, load the missing Test Step 1. ...................................................

injector trim file into the ECM.
Results:
STOP. OK
• OK – STOP.
i02417898
i02407441
CID 0274 FMI 03 Atmospheric
Pressure open/short to +batt CID 0275 FMI 03 Right Turbo
SMCS Code: 1439-038-AI; 1923-038
Inlet Pressure open/short to
+batt
Conditions Which Generate This Code:
SMCS Code: 1439-038; 1917-038
The Electronic Control Module (ECM) detects a
Conditions Which Generate This Code:
signal voltage that is above normal.
The Electronic Control Module (ECM) detects a
System Response:
signal voltage that is above normal.
The code is logged. The ECM will use the default
System Response:
value for atmospheric pressure.
The code is logged. The ECM flags turbocharger inlet
Possible Performance Effect:
pressure as invalid data and a default value is used.
• The engine power is derated.
Possible Performance Effect:
Troubleshooting:
• The engine power will be derated.
Test Step 1. ................................................... Troubleshooting:
Results:
Test Step 1. ...................................................
• OK – STOP.
Results:

• OK – STOP.
68 RENR9318
Troubleshooting with a Diagnostic Code

i02407801 i02412639

CID 0275 FMI 04 Right Turbo CID 0283 FMI 06 Filter Restrict
Inlet Pressure short to ground Lamp short to ground
SMCS Code: 1439-038; 1917-038 SMCS Code: 7431-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a The engine's Electronic Control Module (ECM)
signal voltage that is below normal. detects high current in the circuit.

System Response: System Response:

The code is logged. The ECM flags turbocharger inlet The code is logged. Since the lamp circuit is
pressure as invalid data and a default value is used. malfunctioning, the air filter restriction lamp may not
illuminate.
Possible Performance Effect:
Possible Performance Effect:
• The engine power will be derated.
• None
Troubleshooting:
Troubleshooting:
Test Step 1. ...................................................
Test Step 1. ...................................................
Results:
Results:
• OK – STOP.
• OK – STOP. STOP
i02412636
i02390257
CID 0283 FMI 05 Filter Restrict
Lamp open/short to +batt CID 0291 FMI 05 Engine
SMCS Code: 7431-038
Cooling Fan Solenoid open
circuit
Conditions Which Generate This Code:
SMCS Code: 5479-038
The engine's Electronic Control Module (ECM)
Conditions Which Generate This Code:
detects low current in the circuit.

System Response: The Electronic Control Module (ECM) detects an

The code is logged. Since the lamp circuit is
malfunctioning, the air filter restriction lamp may not
illuminate.
open circuit or a short to +Battery condition in the
circuit for the engine cooling fan solenoid.
System Response:

Possible Performance Effect: The ECM logs the diagnostic code. While the
condition is present, the ECM loses the ability to
• None control the engine cooling fan.

Troubleshooting: Possible Performance Effect:

Test Step 1. ................................................... • Overheating of the engine

• Overcooling of the engine

Results:
Troubleshooting:
• OK – STOP. STOP
Test Step 1. ...................................................
Results:

• OK – STOP.
RENR9318 69
Troubleshooting with a Diagnostic Code

i02390261 i02433154

CID 0291 FMI 06 Engine CID 0296 FMI 12 See Service

Cooling Fan Solenoid short to Manual
ground SMCS Code: 4800-038
SMCS Code: 5479-038 Conditions Which Generate This Code:
Conditions Which Generate This Code: The Electronic Control Module (ECM) for the engine
is not receiving complete information from the
The Electronic Control Module (ECM) detects a short
transmission ECM.
to ground condition in the circuit for the engine
cooling fan solenoid. System Response:
System Response:
The code is logged.
The ECM logs the diagnostic code. While the Possible Performance Effect:
condition is present, the ECM loses the ability to
control the engine cooling fan. • All features that depend on the Cat Data Link will
be disabled.
Possible Performance Effect:
Troubleshooting:
• Overheating of the engine
• Overcooling of the engine Test Step 1. Update the ECM Flash Files

Troubleshooting: A. Check that the most current version of the flash

files have been installed in both the engine ECM
Test Step 1. ................................................... and the transmission ECM.

Results: Expected Result:

• OK – STOP. The flash files that are installed in the engine ECM
and the transmission ECM are the latest version.
i02445693
Results:
CID 0296 FMI 09 Unable to
• OK – The flash files are the latest version.
communicate with
Transmission ECM Repair: There may be an electrical problem
with the data link circuit or in a connector.
SMCS Code: 4800-038
Refer to the diagnostic functional test
Conditions Which Generate This Code: Troubleshooting, “Cat Data Link Circuit - Test”.
The Electronic Control Module (ECM) detects erratic STOP.
communication with the transmission.
• Not OK – The flash files are not the latest version.
System Response:
Repair: Perform the following procedure:
The ECM will log the diagnostic code.
A. Connect Caterpillar Electronic Technician
Possible Performance Effect:
(ET) to the service tool connector.
• Transmission features that rely on the data link are
disabled. B. Obtain the latest version of the flash files for
both the engine ECM and the transmission
Troubleshooting: ECM.

Test Step 1. ................................................... Note: The “ Flash File Search”” tool on the
Service Technician Workbench (STW ) can
Results: be used to obtain flash files. SIS Web can
also be used to obtain the flash files by
• OK – STOP. clicking the “ Service Software Files”” feature
that is on the SIS Web web site.
70 RENR9318
Troubleshooting with a Diagnostic Code

C. Use Cat ET to install the flash files. Verify Troubleshooting:

that the original problem has been resolved.
Test Step 1. ...................................................
STOP.
Results:
i02407807

• OK – STOP.
CID 0342 FMI 08 Secondary
i02412290
Engine Speed signal abnormal
SMCS Code: 1439-038-VF; 1907-038 CID 0596 FMI 12 Wrong
Conditions Which Generate This Code: Response from Implement
ECM
The signal from the secondary engine speed/timing
sensor is intermittent or the signal has been lost. SMCS Code: 7610-038-II

System Response: Conditions Which Generate This Code:

The code is logged. If a valid signal is not received The Electronic Control Module (ECM) for the engine
from the secondary engine speed/timing sensor, the is not receiving complete information from the
Electronic Control Module (ECM) will default to the implement ECM.
primary engine speed/timing sensor.
System Response:
Possible Performance Effect:
The code is logged.
• None
Possible Performance Effect:
Note: The engine will shut down only if the signals
from the primary engine speed/timing sensor and the • All features that depend on the Cat Data Link will
secondary engine speed/timing sensor are abnormal. be disabled.

Troubleshooting: Troubleshooting:

Test Step 1. ................................................... Test Step 1. Update the ECM Flash Files

Results: A. Check that the most current version of the flash

files have been installed in both the engine ECM
• OK – STOP. and the implement ECM.

i02407814 Expected Result:

CID 0596 FMI 09 Unable to The flash files that are installed in the engine ECM
and the implement ECM are the latest version.
communicate with Implement
ECM Results:
SMCS Code: 7610-038-II • OK – The flash files are the latest version.
Conditions Which Generate This Code:
Repair: There may be an electrical problem
with the data link circuit or in a connector.
The Electronic Control Module (ECM) loses
communication with the implement ECM.
Refer to Troubleshooting, “Cat Data Link Circuit
System Response: - Test”.

The code is logged. All features that depend on input STOP.

from the implement ECM will be disabled.
• Not OK – The flash files are not the latest version.
Possible Performance Effect:
Repair: Perform the following procedure:
• None
A. Connect Caterpillar Electronic Technician
(ET) to the service tool connector.
RENR9318 71
Troubleshooting with a Diagnostic Code

B. Obtain the latest version of the flash files for Possible Performance Effect:
both the engine ECM and the implement
ECM. • The engine will not start.

Note: The “ Flash File Search”” tool on the Troubleshooting:

Service Technician Workbench (STW ) can
be used to obtain flash files. SIS Web can Test Step 1. ...................................................
also be used to obtain the flash files by
clicking the “ Service Software Files”” feature Results:
that is on the SIS Web web site.
• OK – STOP.
C. Use Cat ET to install the flash files. Verify
i02407892
that the original problem has been resolved.

STOP. CID 1785 FMI 03 Intake

i02418079
Manifold Pressure Sensor
voltage high
CID 1639 FMI 02 Machine SMCS Code: 1439-038-IL
Security System incorrect
Conditions Which Generate This Code:
SMCS Code: 7631-038
The Electronic Control Module (ECM) detects a
Conditions Which Generate This Code:
signal voltage above normal.
The serial number of the Machine Security System System Response:
(MSS) that is stored in the Electronic Control Module
(ECM) does not match the serial number of the MSS. The code is logged. The ECM flags intake manifold
pressure as invalid data and a default value is used.
System Response:
Possible Performance Effect:
The code is logged.
• The engine power will be derated.
Possible Performance Effect:
Troubleshooting:
• The engine will not start.

Troubleshooting:
Test Step 1. ...................................................
Results:
Test Step 1.
• OK – STOP.
Enter the correct serial number of the MSS.
i02407894
Results:
CID 1785 FMI 04 Intake
• OK – STOP.
Manifold Pressure Sensor
i02418084
voltage low
CID 1639 FMI 09 Machine SMCS Code: 1439-038-IL
Security System Module not Conditions Which Generate This Code:
communicating on link
The Electronic Control Module (ECM) detects a
SMCS Code: 7631-038 signal voltage below the normal.
Conditions Which Generate This Code: System Response:
The Electronic Control Module (ECM) detects a loss The code is logged. The ECM flags intake manifold
of communication with the Machine Security System pressure as invalid data and a default value is used.
(MSS).
Possible Performance Effect:
System Response:
• The engine power will be derated.
The code is logged.
72 RENR9318
Troubleshooting with a Diagnostic Code

Troubleshooting: i02418270

Test Step 1. ................................................... CID 2417 FMI 05 Ether Injection

Results: Control Solenoid current low
SMCS Code: 5479-038
• OK – STOP.
Conditions Which Generate This Code:
i02487751

The Electronic Control Module (ECM) detects low

CID 1785 FMI 10 Intake current in the circuit.
Manifold Pressure Signal System Response:
abnormal rate of change
SMCS Code: 1439-038-IL The code is logged.

Conditions Which Generate This Code: Possible Performance Effect:

• The engine may be difficult to start.

This code indicates that the 5 volt supply is missing
from the sensor connector. Troubleshooting:
During normal engine operation, the intake manifold Test Step 1. ...................................................
pressure fluctuates slightly. When the 5 volt supply is
missing from the intake manifold pressure sensor, the Results:
signal from the pressure sensor floats to a midrange
value. The signal does not fluctuate. If the signal from • OK – STOP. OK
the intake manifold pressure sensor remains
abnormally steady for more than 30 seconds, the i02418652
Engine Control Module (ECM) activates this code.
CID 2417 FMI 06 Ether Injection
System Response:
Control Solenoid current high
The ECM uses a default value for the intake manifold SMCS Code: 5479-038
pressure.
Conditions Which Generate This Code:
Possible Performance Effect:
The Electronic Control Module (ECM) detects
• Low power
excessive current flow in the circuit.
Troubleshooting:
System Response:
Test Step 1. Repair the Sensor Supply The code is logged.
Circuit
Possible Performance Effect:
A. Repair the circuit for the supply wire between the
ECM and the sensor. • The engine may be difficult to start.

Expected Result: Troubleshooting:

The problem is resolved. Test Step 1. ...................................................

Results: Results:

• OK – The problem is resolved. • OK – STOP. OK

STOP.

• Not OK – The problem is not resolved.

Repair: Replace the sensor.

STOP.
RENR9318 73
Troubleshooting with an Event Code

Troubleshooting with an
Event Code

i02404843

Event Codes
SMCS Code: 1901
Event codes alert the operator that an abnormal
engine operating condition such as low oil pressure or
high coolant temperature has been detected. When
the event code is generated, the event is active.

Active Event Codes

An active event code represents a problem with
engine operation. Correct the problem as soon as
possible.
Active event codes are listed in ascending numerical
order. The code with the lowest number is listed first.
Illustration 12 is an example of the operating range of
a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.

Illustration 12 g01138880
Example of the typical operating range of a
temperature sensor
(1) This area represents the normal operating range of the
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
(2) In this area, the temperature above 107 °C (225 °F) is higher
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
(3) In these areas, the output voltage of the sensor is too high or too
low. The voltage is outside of the normal range. The electronic
problem will generate a diagnostic code. Refer to
Troubleshooting, “Troubleshooting with a Diagnostic Code” for
additional information on diagnostic codes.

Events are represented in two formats. In the first

format, the “E” identifies the code as an event code.
The “XXX” represents a numeric identifier for the
event code. This is followed by a description of the
code. If a warning, a derate, or a shutdown is
applicable, the numeric identifiers are different. Refer
to the following example:
• E004Engine Overspeed Shutdown
In the second format, the “E” identifies the code as
an event code. The “XXX-X” represents a numeric
identifier for the event code. The fourth “X” identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
74
Troubleshooting with an Event Code
• E360-1Low Oil Pressure Warning
• E360-2Low Oil Pressure Derate
• E360-3Low Oil Pressure Shutdown
The definition for a warning, a derate, and a shutdown
are defined below:
Warning – This condition represents a serious
problem with engine operation. However, this
condition does not require a derate or a shutdown.
Derate – For this condition, the Electronic Control
Module (ECM) reduces the engine's power in order to
help prevent possible engine damage.
Shutdown – For this condition, the ECM shuts down
the engine in order to help prevent possible engine
damage.
Logged Event Codes
When the ECM generates an event code the ECM
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record the
following information when an event code is
generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code
• The number of occurrences of the code
Logged events are listed in chronological order. The
most recent event code is listed first.
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be
used to review the performance of the engine.
Clearing Event Codes
A code is cleared from memory when one of the
following conditions occur:
• The code does not recur for 100 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
• The service technician manually clears the code.
Always clear logged event codes after investigating
and correcting the problem which generated the
code.
Troubleshooting
For basic troubleshooting of the engine, perform the
following steps in order to diagnose a malfunction:
1. Obtain the following information about the
complaint:
• Determine the time that the event occurred.
RENR9318
• Determine the conditions for the event. The
conditions will include the engine rpm and the
load.
• Determine if there are any systems that were
installed by the dealer or by the customer that
could cause the event.
• Determine whether any additional events
occurred.
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
due to error of the operator.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
history of the engine.
4. Perform a visual inspection. Inspect the following
items:
• Fuel supply
• Oil level
• Oil supply
• Wiring
• Connectors
Be sure to check the connectors. This is very
important for problems that are intermittent. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
If these steps do not resolve the problem, identify the
procedures in this manual that best describe the
event. Check each probable cause according to the
tests that are recommended.
Trip Points for the Monitoring
System
The monitoring system determines the level of action
that is taken by the ECM in response to a condition
that can damage the engine. When any of these
conditions occur, the appropriate event code will trip.
Table 19 contains the conditions that are monitored
and the default trip points for each condition. Each
condition has an associated parameter. The settings
for each parameter can be viewed with the Caterpillar
Electronic Technician (ET). The trip points for some of
the parameters may be adjustable with Cat ET.
RENR9318 75
Troubleshooting with an Event Code

Table 19
Monitoring System Parameters

Delay Time in Seconds Trip Point

Parameter Action Default
Min Max Default Min Max Default State
758 kPa
E096-1 High Fuel Pressure Warning N/A N/A 8 N/A N/A On
(110 psi)

E172-1 High Air Filter software

Warning N/A N/A N/A N/A 8 kPa (1 psi) On
Restriction dependent

E172-2 High Air Filter software

Derate (1) N/A N/A N/A N/A 8 kPa (1 psi) On
Restriction dependent

E194 High Exhaust Software

Derate N/A N/A N/A N/A N/A On
Temperature dependent

E265 User Defined Shutdown Shutdown N/A N/A N/A N/A N/A On/Off

E360-1 Low Engine Oil Map dependent

Warning N/A N/A 8 N/A N/A On
Pressure value(2) .

E360-3 Low Engine Oil Map dependent

Shutdown N/A N/A 4 N/A N/A On
Pressure value(3) .

E361-1 High Engine Coolant 85 °C 110 °C

Warning N/A N/A 10 110 °C (230 °F) On
Temperature (185 °F) (230 °F)

E361-2 High Engine Coolant 86 °C 111 °C

Derate(4) 1 120 10 111 °C (232 °F) On
Temperature (187 °F) (232 °F)

E361-3 High Engine Coolant 87 °C 111 °C

Shutdown 1 120 10 111 °C (232 °F) Off
Temperature (189 °F) (232 °F)

E362-1 Engine Overspeed

Warning N/A N/A .6 N/A N/A 2600 On
(rpm)

E362-2 Engine Overspeed

Derate N/A N/A .6 N/A N/A 2800 On
(rpm)

E363-1 High Fuel Supply 105 °C 105 °C

Warning 1 120 30 90 °C (194 °F) On
Temperature (221 °F) (221 °F)

E363-2 High Fuel Supply 105 °C 105 °C

Derate(5) 1 120 10 91 °C (196 °F) On
Temperature (221 °F) (221 °F)

E390-1 Fuel Filter Restriction Warning N/A N/A 3600 N/A N/A open On

E390-2 Fuel Filter Restriction Derate(6) N/A N/A 14400 N/A N/A open On

E441 Idle Elevated to Increase Software

Warning N/A N/A N/A N/A N/A On
Battery Voltage dependent

E539-1 High Intake Manifold

Warning N/A N/A 8 N/A N/A 82 °C (180 °F) On
Air Temperature

E539-2 High Intake Manifold

Derate(7) N/A N/A 8 N/A N/A 86 °C (187 °F) On
Air Temperature
(1) The derate is 20 percent.
(2) Refer to Illustration 13 .
(3) Refer to Illustration 14 .
(4) The derate is 25 percent for every degree over the trip point. The maximum derate is 100 percent.
(5) The derate is 12.5 percent for every degree over the trip point. The maximum derate is 25 percent.
(6) The derate is 35 percent.
(7) The derate is 3 percent for every degree over the trip point. The maximum derate is 20 percent.
76
Troubleshooting with an Event Code
Illustration 13
Map of low oil pressure (Warning)
Illustration 14
Map of low oil pressure (Shutdown)
E096 High Fuel Pressure
SMCS Code: 1250-038-HQ
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a high
fuel pressure. Information on default settings and
ranges for this event can be found in
Troubleshooting, “Event Codes”.
RENR9318
System Response:
The ECM will log the event.
Possible Performance Effect:
E096(1)
• There are no performance effects.
Troubleshooting:
Test Step 1. Check the Fuel System's
Components
A. Inspect the pressure relief valve that is in the body
of fuel transfer pump. Check for damage to the
spring or to the valve assembly.
B. Verify that the pressure regulating valve in the fuel
manifold is operating correctly. Check for damage
g01207594
or for dirt in the valve assembly.
C. Check the return line from the fuel filter base to the
fuel tank for damage or collapse.
Expected Result:
There is a problem in the pressure relief valve, in the
pressure regulating valve, or in the return line to the
fuel tank.
Results:
• OK – A problem was found in the pressure relief
valve, in the pressure regulating valve, or in the
return line to the fuel tank.
Repair: Make the necessary repairs. Verify that
the repair eliminates the problem.
Refer to Systems Operation/Testing and
Adjusting.
STOP.
g01207595 • Not OK – A mechanical problem has not been
found with the fuel system.
i02495388 Repair: If an electrical problem with the sensor
circuit is suspected, refer to the diagnostic
functional test Troubleshooting, “Engine
Pressure Sensor Open or Short Circuit - Test”.
STOP.
RENR9318 77
Troubleshooting with an Event Code

i02281114 • Intake manifold air temperature

E172 High Air Filter Restriction • Barometric pressure

SMCS Code: 1054-038 • Engine speed

Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects
excessive pressure drop across the air cleaner
element. Information on default settings and ranges
for this event code can be found in Troubleshooting,
“Event Codes”.
System Response:
The event code is logged.
Possible Performance Effect:
E172-1(Warning)
High intake manifold air temperature, high altitude
operation, and high engine loads can cause the
exhaust temperature to increase to a level that may
damage the components of the exhaust system.
When this occurs, the ECM derates the engine in
order to reduce the exhaust temperature. This
protects the components of the exhaust system from
damage.
System Response:
The code is logged. Passwords are not required in
order to clear the logged code.
Possible Performance Effect:

None Engine power is reduced.

E172-2(Derate) Test Step 1. Determine the Operating

Conditions
The engine power is derated.
Interview the operator, when possible. Determine
Troubleshooting:
if the engine was under heavy load or the engine
is operating at a high altitude.
The air cleaner element may be plugged.
Expected Result:
Test Step 1. Check for Restrictions in the
Air Cleaner The event occurred because of normal engine
operation.
A. Inspect the air cleaner element.
Results:
Expected Result:
• OK – The event occurred because of normal
An inspection of the air cleaner element indicated a engine operation. Clear the logged event and
problem. return the engine to service.
Results: STOP.

• OK – There was a problem with the air cleaner • Not OK – The event should not have occurred.
element. Proceed to Test Step 2.

Repair: Clean the air cleaner element or

replace the air cleaner element.
Test Step 2. Check the Air-to-Air
Aftercooler (ATAAC)
STOP.
The intake manifold air temperature can increase
i03251205 if the ATAAC is obstructed. Check the fins of the
ATAAC for obstructions.
E194 High Exhaust
Expected Result:
Temperature
SMCS Code: 1088-038-TA The fins of the ATAAC are obstructed.

Conditions Which Generate This Code: Results:

The Electronic Control Module (ECM) monitors the • OK – The fins of the ATAAC are obstructed.
following parameters in order to calculate the exhaust
temperature:
78
Troubleshooting with an Event Code
Repair: Clean the fins of the ATAAC. Clear the
event. Return the engine to service.
STOP. STOP
• Not OK – The fins of the ATAAC are clear of
obstructions. Proceed to Test Step 3.
Test Step 3. Check the 5 Volt Supply to
the Atmospheric Pressure Sensor
If the atmospheric pressure sensor is not being
powered by the 5 volt supply, the output of the
sensor may float to a value that is interpreted by
the ECM as a high altitude condition. The ECM
receives the erroneous value of altitude and the
ECM derates the engine.
A. Verify that the keyswitch is in the ON position.
B. Measure the value of the 5 volt supply at the
harness connector for the atmospheric pressure
sensor.
Expected Result:
The voltage is approximately five volts.
Results:
• OK – The supply voltage at the atmospheric
pressure sensor is approximately five volts. There
are no further troubleshooting procedures for this
event. Clear the event and return the engine to
service.
STOP. STOP
• Not OK – The supply voltage at the atmospheric
pressure sensor is not approximately five volts.
There is a problem with the wiring for the 5 volt
supply between the atmospheric pressure sensor
and the ECM.
Repair: Identify the wiring problem and make
the necessary repairs.
When the 5 volt supply is present at the
atmospheric pressure sensor, clear the event
and return the engine to service.
STOP. STOP
i02432507
E265 User Defined Shutdown
SMCS Code: 1400-038
Conditions Which Generate This Code:
The user defined shutdown switch has been
activated.
RENR9318
Note: Certain conditions must be met on some
applications prior to the activation of the user defined
shutdown switch. These conditions may include
setting the parking brake and/or placing the
transmission in neutral.
System Response:
The Electronic Control Module (ECM) will log the
event.
Possible Performance Effect:
• The engine will be shutdown.
Test Step 1. Talk to the Operator
Determine the reason for the activation of the
user defined shutdown.
Results:
• OK – The operator activated the user defined
shutdown switch.
STOP.
• Not OK – The operator did not activate the user
defined shutdown.
Repair: If you suspect that there is a problem
with the user defined shutdown circuit, refer to
the diagnostic functional test Troubleshooting,
“User Defined Shutdown Input Circuit - Test”.
STOP.
i02486798
E360 Low Engine Oil Pressure
SMCS Code: 1348-038-LP
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
problem with the engine's oil pressure. Information on
default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”.
System Response:
The event code will be logged.
Possible Performance Effect:
E360(1)
• There are no performance effects.
E360(3)
• The engine will be shut down.
RENR9318
Troubleshooting:
There may be a problem with the engine's lubrication
system.
Test Step 1. Check the Engine's
Lubrication System
A. Check the engine oil level. If the oil level is below
the oil pump's supply tube, the oil pump will not
have the ability to supply enough lubrication to the
engine components. If the engine oil level is low,
add engine oil in order to obtain the correct engine
oil level.
B. Check the following problems that may occur to
the engine oil pump:
a. Air leakage in the supply side of the oil pump
will also cause cavitation and loss of oil
pressure. Check the supply side of the oil
pump and make necessary repairs.
b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the
engine oil pump.
c. If the engine is equipped with a scavenge
pump, the scavenge pump may not be
supplying oil to the main engine oil pump.
C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on the
oil pickup tube and remove any material that may
be restricting engine oil flow. Low engine oil
pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
oil pickup tube for cracks or a damaged O-ring
seal.
D. If the engine oil bypass valves are held in the open
position, a reduction in the oil pressure can be the
result. This may be due to debris in the engine oil.
If the engine oil bypass valves are stuck in the
open position, remove each engine oil bypass
valve and clean each bypass valve in order to
correct this problem. You must also clean each
bypass valve bore.
E. Engine oil that is contaminated with fuel or coolant
will cause low engine oil pressure. High engine oil
level in the crankcase can be an indication of
contamination.
F. Excessive clearance at engine bearings will cause
low engine oil pressure. Check the engine
components for excessive bearing clearance.
G. An oil line that is open, broken, or disconnected
will cause low engine oil pressure.
79
Troubleshooting with an Event Code
Expected Result:
An inspection of the engine's lubrication system
indicated a problem.
Results:
• OK – There is a problem in the engine's lubrication
system.
Repair: Repair the problem. Ensure that the
repair eliminates the problem.
STOP.
i03706980
E362 Engine Overspeed
SMCS Code: 7410-038; 7427-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an
overspeed condition. Information on default settings
and ranges for this event can be found in
troubleshooting with an event code Troubleshooting,
“Event Codes”.
System Response:
The event code will be logged.
Possible Performance Effect:
E362(1)
• There are no performance effects.
E362(2)
• The engine power is derated.
E362(3)
• The engine power is derated and/or the engine is
shut down.
Note: If the engine is not shutdown immediately
perform a safe shutdown.
Troubleshooting:
• The operator may be operating the machine
incorrectly. Determine the events that caused the
overspeed of the engine. Avoid sudden drops in
load from the engine.
• There may be a combustible atmosphere. Check
for hydrocarbons in the surrounding atmosphere.
Do not operate the engine in an environment with
hydrocarbons in the surrounding atmosphere.
Test Step 1.
80 RENR9318
Troubleshooting with an Event Code

Results: i02281912

• OK – STOP. E441 Idle Elevated to Increase

i02507630 Battery Voltage
SMCS Code: 1915-038
E390 Fuel Filter Restriction
SMCS Code: 1261-038 Conditions Which Generate This Code:

Conditions Which Generate This Code: • The parking brake is engaged.

• The transmission is in neutral.

The Electronic Control Module (ECM) detects an
abnormal fuel filter differential pressure. Information • The throttle remains below 25 percent for at least
on default settings and ranges for this event can be five minutes.
found in troubleshooting with an event code
Troubleshooting, “Event Codes”. • The battery voltage remains below 24.5 VDC for at
least five minutes.
System Response:
System Response:
The event code will be logged.
The event code will be logged.
Possible Performance Effect:
Possible Performance Effect:
E390(1)
Engine speed will increase to 1000 rpm.
• There are no performance effects.
Troubleshooting:
E390(2)
This event indicates low battery voltage.
• The ECM will derate power.

Troubleshooting: Test Step 1.

The fuel filter element may need to be replaced. This feature is used to compensate for electrical
accessories that may have been added by the
customer.
Test Step 1. Replace the Fuel Filter
Element If a problem with the charging system is
suspected, refer to Troubleshooting, “Alternator
A. Replace the fuel filter element. Refer to the (Charging Problem)”.
Operation and Maintenance Manual.
Results:
B. Restart the engine and check for an active event
code. • OK – STOP. STOP
Expected Result: i02498485

The event code is no longer active.
Results:
• OK – The event code is no longer active.
STOP.
• Not OK – The event code is active.
Repair: Perform the diagnostic functional test
Troubleshooting, “Fuel Filter Differential
Pressure Switch Circuit - Test”.
STOP.
E539 High Intake Manifold Air
Temperature
SMCS Code: 1050-038-TA
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
problem with the engine's intake manifold air
temperature. Information on default settings and
ranges for this event can be found in troubleshooting
with an event code Troubleshooting, “Event Codes”.
System Response:
The event code will be logged.
RENR9318
Possible Performance Effect:
E539(1)
• There are no performance effects.
E539(2)
• The engine power will be derated.
Troubleshooting:
Intake manifold air temperature can be high for the
following reasons:
• High ambient air temperature
• High inlet air restriction and/or high altitude
• Restriction in the exhaust system
• Faulty inlet air temperature sensor and/or circuit
Test Step 1. Perform the following
Inspections
A. Check for High Ambient Air Temperature
a. Determine if the ambient air temperature is
within the design specifications for the inlet air
system. When ambient temperatures are too
high for the rating of the inlet air system, there
is not enough of a temperature difference
between the ambient air and inlet air
temperatures.
b. Determine the cause of the high inlet air
temperature. Correct the situation, when
possible.
B. Check for High Inlet Air Restriction and/or High
Altitude Operation
When inlet air pressure is low, the turbocharger
works harder in order to achieve the desired inlet
manifold pressure. This increases inlet air
temperature.
a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer
to the Technical Marketing Information for the
engine.
b. Check for plugged air filters. Check for
obstructions to the air inlet. A restriction of the
air that enters the engine can cause high
cylinder temperatures. High cylinder
temperatures cause higher than normal
temperatures in the cooling system.
c. Replace the air filters and/or remove the
obstruction from the air inlet.
81
Troubleshooting with an Event Code
d. Consider high altitude operation. The cooling
capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system
that has been designed for the higher altitudes
must be used. Ensure that the engine is
configured for high altitude operation.
C. Check for Exhaust System Restriction
Check for a restriction in the exhaust system. A
restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
Expected Result:
A problem has been found in the inlet air system and/
or the related engine systems.
Results:
• OK – A thorough inspection revealed a problem.
Repair: Repair the problem.
STOP.
• Not OK – A thorough inspection did not reveal a
problem.
Repair: Connect Caterpillar Electronic
Technician (ET) to the service tool connector.
Check Cat ET for active/logged diagnostic
codes related for the inlet air system. If an
active/logged code is found, refer to the
appropriate troubleshooting procedure.
STOP.
i04112721
E1171 Engine Idle Shutdown
Occurred
SMCS Code: 1901-038
Conditions Which Generate This Code:
The “Engine Idle Shutdown Enable Status” is
enabled and the “Engine Idle Shutdown Delay Time”
has expired. The Electronic Control Module (ECM)
shut down the engine according to the programmable
parameters.
Test Step 1. Check the Programmable
Parameters
Note: If the “ Engine Idle Shutdown Delay Time”” is
set according to required regulations, do not
adjust the “ Engine Idle Shutdown Delay Time”” .
82 RENR9318
Troubleshooting with an Event Code

The shutdown was due to normal operation. The

“ Engine Idle Shutdown Enable Status”” can be
disabled and the “ Engine Idle Shutdown Delay
Time”” can be changed in order to add more
minutes.

Results:

• OK – STOP.
i04112843

E1172 Engine Idle Shutdown

Pending
SMCS Code: 1901-038

Conditions Which Generate This Code:

The “Engine Idle Shutdown Enable Status” is

enabled and the “Engine Idle Shutdown Delay Time”
has expired. The Electronic Control Module (ECM)
will shut down the engine according to the
programmable parameters.

Test Step 1. Check the Programmable

Parameters
Note: If the “ Engine Idle Shutdown Delay Time”” is
set according to required regulations, do not
adjust the “ Engine Idle Shutdown Delay Time”” .

The pending shutdown is due to normal

operation. The “ Engine Idle Shutdown Enable
Status”” can be disabled and the “ Engine Idle
Shutdown Delay Time”” can be changed in order
to add more minutes.

Results:

• OK – STOP.
RENR9318 83
Diagnostic Functional Tests

Diagnostic Functional
Tests

i02401701

5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1439-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the +5 V sensor supply.

Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:
• 262-035 Volt Sensor DC Power Supply short to
+batt
• 262-045 Volt Sensor DC Power Supply short to
ground

The Electronic Control Module (ECM) supplies a

regulated voltage of 5.0 ± 0.2 VDC to the following
sensors:
• Atmospheric pressure sensor

• Intake manifold pressure sensor

• Engine oil pressure sensor

• Fuel pressure sensor

• Turbocharger inlet pressure sensor

The supply for the +5 V engine pressure sensor is

routed from the ECM to terminal A of each pressure
sensor connector. The sensor return from the ECM
connector goes to terminal B of each sensor
connector. The 5 V sensor supply is output short
circuit protected. A short circuit to the battery will not
damage the circuit inside the ECM.

Note: The sensors are not protected from

overvoltage. A short from the supply line to the
+Battery may damage the sensors. If the CID-FMI
262-03 is logged, it is possible that all of the sensors
have been damaged. Repair the 5 V sensor supply
and check for any active diagnostic codes for the
sensor in order to determine if a sensor has failed.

A +5 V diagnostic code is probably caused by a short

circuit to ground or a short circuit to another voltage
source in the harness. The next likely cause is a
problem with a sensor. The least likely cause is a
problem with the ECM.
84 RENR9318
Diagnostic Functional Tests

Illustration 15 g01203122
Schematic for the pressure sensor supply

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the engine ECM.
RENR9318 85
Diagnostic Functional Tests

B. Thoroughly inspect connector (5) and (6). Also,

thoroughly inspect the connectors for sensors (1),
(2), (3), (4) and (7). Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.

Illustration 16 g01200216
Locations of the pressure sensors (typical left
side engine view)
(1) Atmospheric pressure sensor
(2) Fuel pressure sensor
(3) Intake manifold pressure sensor
(4) Engine oil pressure sensor
(5) J2/P2ECM connectors
(6) J1/P1ECM connectors

Illustration 18 g01195563
P2 ECM connector
(P2-17) Sensor return
(P2-72) 5 V sensor supply

Illustration 17 g01142856
Air filter assembly
(7) Turbocharger inlet pressure sensor
86
Diagnostic Functional Tests
Illustration 19
P1ECM connector
(P1-2) 5 V sensor supply
(P1-3) Sensor return
Illustration 20
Sensor connector
(A) 5 V sensor supply
(B) Sensor return
(C) Signal
RENR9318
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and on each of the
wires in the pressure sensor connectors.
D. Check the allen head screw for each of the ECM
connectors and the machine connectors for the
proper torque. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for the correct torque values.
E. Check the harness and wiring for abrasions and for
pinch points from each of the pressure sensors
back to the ECM.
Expected Result:
All connectors, pins and sockets are completely
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion or of pinch points.
Results:
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 2.
• Not OK – There is a problem with the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals for each of the connectors are
properly in place and ensure that the connectors
are completely coupled. Verify that the repair
eliminates the problem.
STOP.
g01195564
Test Step 2. Check for Active Diagnostic
Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Restore electrical power to the engine ECM.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
C. Monitor the active diagnostic code screen on Cat
ET. Check for an active 262-03 code or an active
262-04 code.
D. Remove electrical power from the engine ECM.
Expected Result:
No diagnostic codes are active.
g01159881
Results:
• OK – No diagnostic codes are active.
Repair: If any of the above codes are logged
and the engine is not running properly, refer to
RENR9318
Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
If the engine is running properly at this time,
there may be an intermittent problem in a
harness that is causing the codes to be logged.
Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
STOP.
• Not OK – Either the 262-03 or 262-04 diagnostic
code is active at this time. Proceed to Test Step 3.
Test Step 3. Disconnect the Pressure
Sensors and Check for Active Diagnostic
Codes
A. Restore electrical power to the engine ECM.
B. Monitor the active diagnostic code screen on Cat
ET while you disconnect each pressure sensor
connector. Check for an active 262-03 code or an
active 262-04 code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
a. Disconnect the following sensors one at a
time:
• Atmospheric pressure sensor
• Intake manifold pressure sensor
• Engine oil pressure sensor
• Fuel pressure sensor
• Turbocharger inlet pressure sensor
C. Remove electrical power from the ECM.
Expected Result:
The diagnostic code deactivates when a particular
sensor is disconnected.
Results:
• OK – The 262-03 or 262-04 diagnostic code
deactivates when a particular sensor is
disconnected.
Repair: Connect the suspect sensor. If the code
returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved.
STOP.
• Not OK – The 262-03 or 262-04 diagnostic code
remains active after all of the sensors are
87
Diagnostic Functional Tests
disconnected. Leave the sensors disconnected.
Proceed to Test Step 4.
Test Step 4. Check the Supply Voltages at
the ECM
A. Disconnect the J1/P1 and J2/P2 ECM connectors.
B. Fabricate four jumper wires that are long enough to
be used to measure the supply voltage at the ECM
connectors. Crimp connector sockets to one end of
each jumper wire.
C. Remove the wires from terminal locations P1-2 (5
V sensor supply) and P1-3 (sensor return). Install a
jumper wire into each of these terminal locations.
D. Remove the wires from terminal locations P2-72 (5
V sensor supply) and P2-17 (sensor return). Install
a jumper wire into each of these terminal locations.
E. Connect the J1/P1 and J2/P2 ECM connectors.
F. Restore electrical power to the engine ECM.
G. Measure the voltage between the jumper wire in
P1-2 (5 V sensor supply) and the jumper wire in
P1-3 (sensor return).
H. Measure the voltage between the jumper wire in
P2-72 (5 V sensor supply) and the jumper wire in
P2-17 (sensor return).
I. Remove electrical power from the ECM.
Expected Result:
Each voltage measurement is 5.0 ± 0.2 VDC.
Results:
• OK – The voltage measurement is 5.0 ± 0.2 VDC.
The ECM is operating correctly.
Repair: One of the supply wires is shorted to
another wire in the harness or one of the supply
wires is shorted to engine ground. To isolate the
problem to a specific harness, perform the
following test steps:
A. One at a time, install the wiring for each 5 V
supply while you check Cat ET for an active
262-03 or 262-04 diagnostic code.
a. Disconnect the particular ECM
connectors.
b. Install the wires that were removed for
the 5 V supply at this ECM connector.
Refer to Illustration 15 for wiring
information.
88 RENR9318
Diagnostic Functional Tests

Note: This procedure checks for an open circuit or for

c. Connect the ECM connectors.
d. Restore electrical power to the engine
ECM.
e. Monitor the active diagnostic code
screen on Cat ET. Check for an active
262-03 code or an active 262-04 code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
f. If a diagnostic code becomes active
for this 5 V supply, there is a problem
in this harness between the ECM and
the sensor connector.
a short circuit in the Cat Data Link. If you are
experiencing problems with communications between
the Caterpillar Electronic Technician (ET) and the
Electronic Control Module (ECM), refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM” before you use this
procedure.
The Cat Data Link is the standard Data Link that is
used by the ECM to communicate with Cat ET. The
ECM communicates with Cat ET in order to share
status information and diagnostic information. Cat
ET can also be used to configure the ECM
parameters. This information will not be available if
communication fails between the ECM and Cat ET.

B. Repair the wiring and/or the connector.

Replace parts, if necessary. Verify that the
problem is resolved.

STOP.

• Not OK – The voltage measurement is not 5.0 ±

0.2 VDC.

Repair: Replace the ECM. Refer to

Troubleshooting, “Replacing the ECM”.

STOP.
i02402200

Cat Data Link Circuit - Test

SMCS Code: 1901-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the Cat Data Link.

Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:

• 296-09Unable to communicate with Transmission

ECM
• 296-12Transmission ECM Failed

• 596-09Unable to communicate with Implement

ECM

• 596-12Wrong Respnse from Implement ECM

RENR9318 89
Diagnostic Functional Tests

Illustration 21 g01199731
Schematic for the Cat Data Link

Test Step 1. Inspect the Electrical B. Thoroughly inspect connector (1). Refer to
Connectors and the Wiring Troubleshooting, “Electrical Connectors - Inspect”.

A. Remove electrical power from the ECM.

Illustration 22 g01167488
Engine view (typical example)
(1) J1/P1ECM connectors
90 RENR9318
Diagnostic Functional Tests

Illustration 24 g01199734
Terminals that are associated with the Cat Data
Link on the machine connector
(P1-26) Cat Data Link +
(P1-27) Cat Data Link −

C. Perform a 45 N (10 lb) pull test on each of the

Illustration 23 g01104274
wires that are associated with the Cat Data Link.
P1 terminals that are associated with the Cat Data
Link D. Check the allen head screw on each ECM
(P1-8) Cat Data Link + connector for the proper torque. Also, check the
(P1-9) Cat Data Link −
allen head screw on the customer connector for
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.

Expected Result:

All connectors, pins, and sockets are completely

inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK Proceed to Test Step 2.

• Not OK – The connectors and/or the wiring are not

OK.

Repair: Repair the connectors and/or the

wiring. Replace parts, if necessary. Ensure that
all of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the original problem is resolved.
RENR9318
STOP. STOP
Test Step 2. Check for a Short Circuit
A. Disconnect the P1 ECM connector.
B. Disconnect Cat ET from the service tool
connector.
C. Disconnect any other control modules from the Cat
Data Link. Refer to Illustration 21 .
D. Measure the resistance between the points that
are listed in Table 20 . Be sure to wiggle the wires
in the harnesses as you make each resistance
measurement.
Table 20
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
P1-9 (Cat Data Link -) All of the other terminals on the
P1 connector
Ground stud
Expected Result:
Each check of the resistance indicates an open
circuit.
Results:
• OK Proceed to Test Step 3.
• Not OK – At least one check of the resistance does
not indicate an open circuit. There is a short circuit
in the harness or in a connector.
Repair: Repair the connectors and/or the
wiring. Replace parts, if necessary. Verify that
the original problem is resolved.
STOP. STOP
Test Step 3. Check for an Open Circuit
A. Fabricate a jumper wire. Use the jumper wire in
order to create a short circuit between terminals D
(Cat Data Link +) and terminal E (Cat Data Link −)
on the service tool connector.
B. Measure the resistance between P1-8 (Cat Data
Link +) and P1-9 (Cat Data Link −).
C. Measure the resistance between the terminals at
the connector for each control module that was
connected to the Cat Data Link. Refer to
Illustration 21 .
91
Diagnostic Functional Tests
Expected Result:
Each check of the resistance indicates a short circuit.
Results:
• OK – Each check of the resistance indicates a
short circuit.
Repair: Perform the following procedure:
A. Connect the J1/P1 connectors. Connect Cat
ET to the service tool connector.
B. Check the Cat Data Link for proper operation.
If the Data Link does not operate correctly,
there may be a problem with the ECM.
Temporarily install a new ECM. Check the
Cat Data Link again. If the new ECM solves
the problem, install the original ECM and
verify that the original problem returns. If the
new ECM operates correctly and the original
ECM does not operate correctly, replace the
original ECM. Verify that the problem is
resolved.
STOP. STOP
• Not OK – At least one check of the resistance does
not indicate a short circuit. There is an open circuit
or excessive resistance in the harness. There may
be a problem with a connector.
Repair: Repair the wiring and/or the
connectors. Replace parts, if necessary. Verify
that the original problem is resolved.
STOP. STOP
i02378207
Electrical Connectors - Inspect
SMCS Code: 7553-040-WW
System Operation Description:
Most electrical problems are caused by poor
connections. The following procedure will assist in
detecting problems with connectors and with wiring. If
a problem is found correct the condition and verify
that the problem is resolved.
92 RENR9318
Diagnostic Functional Tests

Intermittent electrical problems are sometimes

resolved by disconnecting and reconnecting
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly
crimped terminals, moisture, corrosion, and
inadequate mating of a connection.

Follow these guidelines:

• Always use a 1U-5804 Crimp Tool to service
Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.

• Always use a 147-6456 Wedge Removal Tool to

remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
Illustration 25 g01131211
• Always use a breakout harness for a voltmeter
probe or a test light. Never break the insulation of a Leaky seal at the connector (typical example)
wire in order to access to a circuit for
measurements. A. Inspect all wiring harnesses. Ensure that the
routing of the wiring harness allows the wires to
• If a wire is cut, always install a new terminal for the enter the face of each connector at a perpendicular
repair. angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 25 . This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.
The connection of any electrical equipment and
the disconnection of any electrical equipment
may cause an explosion hazard which may result
in injury or death. Do not connect any electrical
equipment or disconnect any electrical equipment
in an explosive atmosphere.

Test Step 1. Check Connectors for

Moisture and Corrosion

Illustration 26 g01131276
Diagram for the installation of a connector plug
(typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR9318 93
Diagnostic Functional Tests

B. Ensure that the sealing plugs are in place. If any of

the plugs are missing, replace the plug. Ensure
that the plugs are inserted correctly into the
connector. Refer to Illustration 26 .
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found
and the source of the moisture entry must be
repaired. If the source of the moisture entry is not
repaired, the problem will recur. Simply drying the
connector will not fix the problem. Check the
following items for the possible moisture entry
path:

• Missing seals

• Improperly installed seals

• Nicks in exposed insulation

• Improperly mated connectors

Moisture can also travel to a connector through the

inside of a wire. If moisture is found in a connector,
Illustration 27 g01131019
thoroughly check the connector's harness for
Seal for a three-pin connector (typical example) damage. Also check other connectors that share
the harness for moisture.
Note: The ECM is a sealed unit. If moisture is
found in an ECM connector, the ECM is not the
source of the moisture. Do not replace the ECM.

Expected Result:

The harness wiring, connectors, and seals are in

good condition. There is no evidence of moisture in
the connectors.

Results:

• OK – The harness wiring, connectors, and seals

are in good condition. Proceed to Test Step 2.

• Not OK – A problem has been found with the

harness or the connectors.

Repair: Repair the connectors or the wiring, as

Illustration 28 g01131165
Seal for ECM connector (typical example)
C. Disconnect the suspect connector and inspect the
connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.
required. Ensure that all of the seals are
properly in place. Ensure that the connectors
have been reattached.
If corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to
remove the corrosion. Use a cotton swab or a
soft brush to remove the corrosion.

D. Thoroughly inspect the connectors for evidence of
moisture entry.
Note: It is normal to see some minor seal
abrasion on connector seals. Minor seal abrasion
will not allow the entry of moisture.
If moisture was found in the connectors, run the
engine for several minutes and check again for
moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to
replace the wires.

Verify that the repair eliminates the problem.

STOP.
94
Diagnostic Functional Tests
Test Step 2. Check the Wires for Damage
to the Insulation
A. Carefully inspect each wire for signs of abrasion, of
nicks, and of cuts.
Inspect the wires for the following conditions:
• Exposed insulation
• Rubbing of a wire against the engine
• Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion of
wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
Expected Result:
The wires are free of abrasion, of nicks, and of cuts
and the harness is properly clamped.
Results:
• OK – The harness is OK. Proceed to Test Step 3.
• Not OK – There is damage to the harness.
Repair: Repair the wires or replace the wires,
as required. Verify that the repair eliminates the
problem.
STOP.
Test Step 3. Inspect the Connector
Terminals
A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged. Verify
that the terminals are properly aligned in the
connector and verify that the terminals are properly
located in the connector.
Expected Result:
The terminals are properly aligned and the terminals
appear undamaged.
Results:
• OK – The terminals are OK. Proceed to Test Step
4.
• Not OK – The terminals of the connector are
damaged.
RENR9318
Repair: Repair the terminals and/or replace the
terminals, as required.
Verify that the repair eliminates the problem.
STOP.
Test Step 4. Perform a Pull Test on Each
Wire Terminal Connection
Illustration 29 g01131435
Receptacle lock wedge (typical example)
A. Ensure that the locking wedge for the connector is
installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed properly.
B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test
checks whether the wire was properly crimped in
the terminal and whether the terminal was properly
inserted into the connector.
Expected Result:
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results:
• OK – All terminals pass the pull test. Proceed to
Test Step 5.
• Not OK – A wire has been pulled from a terminal or
a terminal has been pulled from the connector.
Repair: Use the 1U-5804 Crimp Tool to
replace the terminal. Replace damaged
connectors, as required. Verify that the repair
eliminates the problem.
STOP.
RENR9318 95
Diagnostic Functional Tests

Test Step 5. Check Individual Pin • OK – The connectors are in good repair. Proceed
Retention into the Socket to Test Step 7.

• Not OK – The connector's locking mechanism is

damaged or missing.

Repair: Repair the connector or replace the

connector, as required. Verify that the repair
eliminates the problem.

STOP.

Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the
ECM connectors. Ensure that the threads on each
allen head screw are not damaged.
Illustration 30 g01131604
Diagram for testing pin retention (typical A. Connect the ECM connectors.
example)

A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one at a
time in order to check for a good grip on the pin by
the socket.

Expected Result:

The sockets provide good retention for the new pin.

Results:

• OK – The terminals are OK. Proceed to Test Step

6.
Illustration 31 g01132827
• Not OK – Terminals are damaged. Allen head screw for the 120 pinECM connector
(typical example)
Repair: Use the 1U-5804 Crimp Tool to
replace the damaged terminals. Verify that the
repair eliminates the problem. a. Torque the allen head bolt for the 120 pinECM
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in).
STOP.

Test Step 6. Check the Locking

Mechanism of the Connectors
A. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.

B. Verify that the latch tab of the connector is properly

latched. Also verify that the latch tab of the
connector returns to the locked position.

Expected Result:
Illustration 32 g01132849
The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks. Allen head screw for the 70 pinECM connector
(typical example)
Results:
96
Diagnostic Functional Tests
b. Torque the allen head screw for the 70
pinECM connector to 6.0 + 1.5 - 0.5 N·m
(55 + 13 - 4 lb in).
Illustration 33
Allen head screw for the 40 pinECM connector
(typical example)
c. Torque the allen head screw for the 40
pinECM connector to 2.25 ± 0.25 N·m
(20 ± 2 lb in).
Illustration 34
Allen head screw for the 40 pincustomer
connector and the 70 pincustomer connector
(typical example)
B. Connect the customer connector.
Torque the allen head screw for the 40
pincustomer connector and the 70 pincustomer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).
Expected Result:
The ECM connector is secure and the allen head
screws are properly torqued.
Results:
RENR9318
• OK – The ECM connectors and the customer
connector is properly connected. Proceed to Test
Step 8.
• Not OK – The allen head screws for the ECM
connector or the customer connector is damaged.
Repair: Repair the connector or replace the
connector, as required. Verify that the repair
eliminates the problem.
STOP.
Test Step 8. Perform the “ Wiggle Test””
on the Caterpillar Electronic Technician
(ET)
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET.
g01132863
B. Choose the appropriate group of parameters to
monitor.
C. Press the “Start” button. Wiggle the wiring
harness in order to reproduce intermittent
problems.
If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard.
Expected Result:
No intermittent problems were indicated during the
“Wiggle Test” .
Results:
• OK – No intermittent problems were found. The
harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
g01133047
STOP.
• Not OK – At least one intermittent problem was
indicated.
Repair: Repair the harness or the connector.
Verify that the repair eliminates the problem.
STOP.
RENR9318 97
Diagnostic Functional Tests

i02401947

Electrical Power Supply Circuit

- Test
SMCS Code: 1401-038

System Operation Description:

Use this test to troubleshoot any suspect problems

with power to the Electronic Control Module (ECM).

This procedure covers the following diagnostic codes:

• 168-00 “System Voltage High”

• 168-01 “System Voltage Low”

• 168-02 “System Voltage intermittent/erratic”

Use this test if there are intermittent engine

shutdowns or if a difficulty in starting is not
accompanied by loss of electrical accessories.
Engine shutdowns that are accompanied by a loss of
other electrical accessories indicate a problem in the
keyswitch. This does not indicate a problem in the
wiring at the engine's ECM. Verify that there are no
problems with the starting system or the charging
system before you use this test.

Unswitched battery voltage is supplied to the ECM at

P1-48, P1-52, and P1-53. The negative battery is
supplied to the ECM at P1-61, P1-63, and P1-65. The
ECM receives the input from the keyswitch at P1-70
when the keyswitch is in the ON position or in the
START position. When the ECM detects battery
voltage at this input, the ECM will power up. When
battery voltage is removed from this input, the ECM
will power down. The ECM continuously receives
battery voltage through the circuit breaker for the
engine ECM.

The engine ECM requires the keyswitch to be in the

ON position in order to maintain communications with
Caterpillar Electronic Technician (ET).
98 RENR9318
Diagnostic Functional Tests

Illustration 35 g01199554
Schematic for the electrical power supply circuit

Test Step 1. Inspect the Electrical
Connectors and the Wiring
A. Remove electrical power from the engine ECM.
B. Thoroughly inspect the J1/P1 ECM connectors.
Inspect all of the connectors that are in the circuit.
Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”
for details.

Illustration 36 g01183529
J1/P1 ECM connectors (typical left side engine
view)
RENR9318 99
Diagnostic Functional Tests

All connectors, pins, and sockets are completely

inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points. All
connections and grounds are tight and free of
corrosion.

Results:

• OK – The harness and wiring appear to be OK.

Proceed to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Battery Voltage at

the ECM
A. Remove electrical power from the engine ECM.

B. Disconnect the J1/P1ECM connector.

C. Restore electrical power to the engine ECM.

D. Measure the voltage between P1-48 (Unswitched

+Battery) and P1-61 (−Battery).

Illustration 37 g01112632
E. Measure the voltage between P1-52 (Unswitched
+Battery) and P1-63 (−Battery).
P1 connections for the electrical power supply
circuit F. Measure the voltage between P1-53 (Unswitched
(P1-48) +Battery +Battery) and P1-65 (−Battery).
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery G. Measure the voltage between P1-70 (Keyswitch)
(P1-63) −Battery and P1-63 (−Battery).
(P1-65) −Battery
(P1-70) Keyswitch Expected Result:
C. Perform a 45 N (10 lb) pull test on each of the The measured voltage is between 22 VDC and 27
wires in the ECM connector that are associated VDC.
with the circuit.
Results:
D. Check the allen head screw for each of the ECM
connectors for the proper torque. Refer to • OK – The ECM is receiving the correct voltage.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. Repair: There may be an intermittent electrical
problem in a harness or in a connector. If an
E. Check the harness and the wiring for abrasion and intermittent condition is suspected, refer to
for pinch points. Troubleshooting, “Electrical Connectors -
Inspect”.
Expected Result:
STOP.
100
Diagnostic Functional Tests
• Unswitched power out of range – The voltage is
not correct for one of the unswitched battery
circuits at the ECM. Proceed to Test Step 3.
• Keyswitch voltage out of range – The voltage is not
correct for the keyswitch circuit at the ECM.
Proceed to Test Step 4.
Test Step 3. Check the Batteries
A. Measure the no-load battery voltage at the battery
posts.
B. Load test the batteries. Use the 4C-4911 Battery
Load Tester. Refer to Special Instruction,
SEHS9249, “Use of 4C-4911 Battery Load Tester
for 6, 8 and 12 Volt Lead Acid Batteries” and
Special Instruction, SEHS7633, “Battery Test
Procedure”.
Expected Result:
The batteries pass the load test. The measured
voltage is the minimum specification for a 24V
system.
Results:
• OK – The batteries pass the load test.
Repair: The batteries are OK. There is an open
circuit or excessive resistance in the wiring or
connections between the batteries and the
ECM. Verify that the 15 Amp circuit breaker for
the ECM is not tripped. Verify that the
connection at the engine ground stud is clean
and tight and that the battery disconnect switch
is functioning properly. Repair the connectors or
wiring and/or replace the connectors or wiring
between the battery and the ECM connector J1/
P1.
STOP.
• Not OK – The battery voltage is low or the battery
did not pass the load test.
Repair: Recharge or replace the faulty
batteries. Verify that the repair eliminates the
problem.
STOP.
Test Step 4. Check the Voltage from the
Keyswitch to the ECM
A. Remove electrical power from the engine ECM.
B. Remove the wire from the terminal R of the
keyswitch.
C. Restore electrical power to the engine ECM.
RENR9318
D. Turn the keyswitch to the ON position.
E. Measure the voltage on terminal B of the keyswitch
to engine ground.
F. Measure the voltage on terminal R of the
keyswitch to engine ground.
G. Remove electrical power from the engine ECM.
Expected Result:
Voltage is present on terminal B and terminal R at the
keyswitch.
Results:
• OK – Voltage is present on terminal B and terminal
R at the keyswitch. Proceed to Test Step 5.
• Not OK – Voltage is not present on terminal B at
the keyswitch.
Repair: If voltage is not present on terminal B,
repair the circuit between the +Battery and the
keyswitch. Check the circuit protection for the
circuit. Verify that the problem is eliminated.
STOP.
• Not OK – Voltage is not present on terminal R at
the keyswitch.
Repair: If voltage is present on terminal B of the
keyswitch but not present on terminal R, replace
the keyswitch. Return all wiring to the original
configuration. Verify that the problem is
eliminated.
STOP.
Test Step 5. Check the Voltage from the
Main Relay to the “ ECM Switch Fuse””
A. Remove the wire 112-PU(Purple) from the
normally open terminal of the main relay.
B. Turn the keyswitch to the ON position.
C. Measure the voltage between the normally open
terminal of the main relay and engine ground.
D. Turn the keyswitch to the OFF position.
E. Reconnect all wires to the original configuration.
Expected Result:
The voltage measures 24 ± 3.0 VDC.
Results:
RENR9318
• OK – The voltage measures 24 ± 3.0 VDC.
Repair: Verify that the “ECM Switch Fuse” is
not blown. Repair the wire between the main
relay and the fuse for the engine control or
repair the wire between the fuse for the engine
control and the ECM connector P1.
STOP.
• Not OK – The voltage does not measure 24 ± 3.0
VDC. Proceed to Test Step 6.
Test Step 6. Check the Voltage at the Main
Relay
A. Remove the wire 308-YL(Yellow) from the coil of
the main relay.
B. Remove the wire 101-RD(Red) from the normally
open contact of the main relay.
C. Turn the keyswitch to the ON position.
D. Measure the voltage between wire 308-YL(Yellow)
and engine ground.
E. Measure the voltage between wire 101-RD(Red)
and engine ground.
F. Reconnect all wires to the original configuration.
Expected Result:
The voltage measures 24 ± 3.0 VDC.
Results:
• OK – The voltage measures 24 ± 3.0 VDC on both
wires.
Repair: Verify that the wire 200-BK(Black) has
continuity to engine ground. If wire
200-BK(Black) is OK, replace the main relay.
Verify that the problem is no longer present.
STOP.
• Not OK – The voltage does not measure 24 ± 3.0
VDC on wire 101-RD(Red).
Repair: Verify that the main circuit breaker is
not tripped. Repair the wire between the main
relay and the main circuit breaker or repair the
wire between the main circuit breaker and the
battery.
STOP.
• Not OK – The voltage does not measure 24 ± 3.0
VDC on wire 308-YL(Yellow).
101
Diagnostic Functional Tests
Repair: Repair the wire between the main relay
and terminal R of the keyswitch.
STOP.
i02431438
Engine Fan Control Solenoid
Circuit - Test
SMCS Code: 5479-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the engine fan control solenoid for the
engine cooling fan.
This procedure covers the following diagnostic codes:
• 291-05Engine Cooling Fan Solenoid open circuit
• 291-06Engine Cooling Fan Solenoid short to
ground
The Electronic Control Module (ECM) controls the
speed of the engine cooling fan in order to provide the
following benefits:
• Increased productivity
• Reduced noise
• Improved fuel economy
• Reduced overcooling of the engine
The ECM monitors engine coolant temperature,
intake manifold air temperature, and hydraulic oil
temperature in order to determine the correct speed
for the engine cooling fan.
The ECM controls the speed of the fan by controlling
the current to the engine fan control solenoid. As the
current to the control solenoid is changed, the angle
of the fan pump's swashplate changes proportionally.
This changes the output of hydraulic oil from the fan
pump to the cooling fan.
If the ECM detects a system fault, the ECM provides
minimum current to the solenoid. This ensures a
maximum fan speed while the fault condition exists.
An override is available with Caterpillar Electronic
Technician (ET). This allows the fan to be manually
changed from the minimum to the maximum possible
rpm.
102 RENR9318
Diagnostic Functional Tests

Illustration 38 g01194820
Schematic for the engine fan control solenoid

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.

Illustration 39 g01141049
J1/P1 ECM connector (typical left side engine
view)

B. Thoroughly inspect the J1/P1 ECM connectors.

Inspect all of the other connectors that are in the
circuit for the engine fan control solenoid. Refer to
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. Illustration 40 g01113249
P1ECM connector
(P1-43) Engine fan control solenoid
(P1-51) Solenoid return

C. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector that are associated
with the circuit.

D. Check the allen head screw on each of the ECM

connectors for the proper torque. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.
RENR9318
E. Check the harness and the wiring for abrasion and
for pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check for Active Diagnostic
Codes
A. Remove the electrical power from the ECM.
B. Connect Cat ET to the service tool connector.
C. Restore the electrical power to the ECM.
D. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
E. Determine if the problem is related to an open
circuit diagnostic code (05) or a short circuit
diagnostic code (06).
Expected Result:
No diagnostic codes are active.
Results:
• OK – No diagnostic codes are active.
Repair: The problem may have been related to
a faulty connection in the harness. Carefully
inspect the connectors and wiring. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
STOP.
• Not OK – A short circuit diagnostic code (06) is
active at this time. Proceed to Test Step 3.
103
Diagnostic Functional Tests
• Not OK – An open circuit diagnostic code (05) is
active at this time. Proceed to Test Step 4.
Test Step 3. Disconnect the Connector for
the Engine Fan Control Solenoid in Order
to Create an Open Circuit
A. Remove the electrical power from the ECM.
B. Disconnect the connector for the engine fan control
solenoid.
C. Restore the electrical power to the ECM.
D. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active open circuit
diagnostic code (05) for the engine fan control
solenoid. Wait at least 30 seconds for activation of
the diagnostic codes.
E. Remove the electrical power from the ECM.
Expected Result:
An open circuit diagnostic code (05) is now active for
the engine fan control solenoid.
Results:
• OK – A short circuit diagnostic code (06) was
active before disconnecting the connector. An
open circuit diagnostic code (05) became active
after disconnecting the connector.
Repair: Temporarily connect a new engine fan
control solenoid to the harness, but do not
install the new engine fan control solenoid.
Verify that there are no active diagnostic codes
for the engine fan control solenoid. If there are
no active diagnostic codes for the engine fan
control solenoid, permanently install the new
engine fan control solenoid. Clear any logged
diagnostic codes.
STOP.
• Not OK – There is a short circuit between the
harness connector for the engine fan control
solenoid and the ECM. Leave the connector
disconnected. Proceed to Test Step 5.
Test Step 4. Create a Short at the
Connector for the Engine Fan Control
Solenoid
A. Remove the electrical power from the ECM.
B. Fabricate a jumper wire that is long enough to
short the terminals of the connector for the engine
fan control solenoid. Crimp connector pins to each
end of the jumper wire.
104
Diagnostic Functional Tests
C. Install the jumper wire between terminal 1 (engine
fan control solenoid) and terminal 2 (solenoid
return) on the harness side of the connector.
D. Restore the electrical power to the ECM.
E. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active short circuit
diagnostic code (06) for the engine fan control
solenoid. Wait at least 30 seconds for activation of
the diagnostic codes.
F. Remove the jumper wire.
G. Remove the electrical power from the ECM.
Expected Result:
A short circuit diagnostic code (06) is active when the
jumper wire is installed. An open circuit diagnostic
code (05) is active when the jumper wire is removed.
Results:
• OK – A short circuit diagnostic code (06) is active
when the jumper wire is installed. An open circuit
diagnostic code (05) is active when the jumper
wire is removed.
Repair: The engine harness and the ECM are
OK. Temporarily connect a new engine fan
control solenoid to the harness, but do not
install the new engine fan control solenoid.
Verify that there are no active diagnostic codes
for the engine fan control solenoid. If there are
no active diagnostic codes for the engine fan
control solenoid, permanently install the new
engine fan control solenoid. Clear any logged
diagnostic codes.
STOP.
• Not OK – The open circuit diagnostic code (05)
remains active with the jumper in place. Proceed to
Test Step 5.
Test Step 5. Check the Operation of the
ECM
A. Disconnect the J1/P1 ECM connector.
B. Fabricate two jumper wires that are long enough to
connect terminals of the ECM connector. Crimp
connector sockets to one end of each of the
jumper wires.
C. Remove the wire from terminal location P1-43
(engine fan control solenoid) at the ECM
connector. Install a jumper wire into this terminal
location.
RENR9318
D. Remove the wire from terminal location P1-51
(digital return) at the ECM connector. Install a
jumper wire into this terminal location.
E. Connect the J1/P1 ECM connector.
F. Create an open at the ECM:
a. Restore the electrical power to the ECM.
In order to ensure that an open circuit condition
exists, do not allow the loose ends of the jumper
wires to connect.
b. Monitor the “Active Diagnostic Code” screen
on Cat ET. Wait at least 30 seconds for
activation of the code.
The correct status is an active open circuit
diagnostic code (05) for the engine fan control
solenoid.
G. Create a short at the ECM:
a. Short the jumper wires at the ECM connector.
b. Monitor the “Active Diagnostic Code” screen
on Cat ET. Wait at least 30 seconds for
activation of the code.
The correct status is an active short circuit
diagnostic code (06) when the wire jumper is
installed.
c. Remove the electrical power from the ECM.
H. Restore all wiring to the original configuration.
Expected Result:
An open circuit diagnostic code (05) is active when
the jumper wire from the engine fan control solenoid
is open. A short circuit diagnostic code (06) is active
when the wire for the engine fan control solenoid is
connected to the jumper wire for the digital return.
Results:
• OK – An open circuit diagnostic code (05) is active
when the jumper wire is open. A short circuit
diagnostic code 06 is active when the jumper wires
are connected.
Repair: The ECM is operating properly. The
problem is in the harness wiring between the
ECM and the connector for the engine fan
control solenoid. There may be a problem in
one of the connectors. Repair the connectors or
wiring and/or replace the connectors or wiring.
STOP.
RENR9318 105
Diagnostic Functional Tests

• Not OK – One of the following conditions exists:

The open circuit diagnostic code (05) is not active
when the wire for the engine fan control solenoid is
disconnected. The short circuit diagnostic code
(06) is not active when the wire jumper is installed.

Repair: Replace the ECM. Refer to electronic

troubleshooting Troubleshooting, “Replacing the
ECM”. Verify that the problem is resolved.

STOP.
i02404175

Engine Fan Reversing

Solenoid Circuit - Test
SMCS Code: 5479-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the engine fan reverse switch or the
engine fan reversing solenoid.

The engine fan reversing solenoid is controlled by the

Electronic Control Module (ECM). The purpose of a
reversing fan is to clean debris from the radiator. This
is done by temporarily reversing the direction of the
air flow through the radiator in order to eject the
debris. An automatic purge of the radiator will occur
after a specified length of time (purge interval). The
operator can manually purge the radiator by pressing
the engine fan reverse switch. If a manual purge of
the radiator is initiated, the ECM resets the timer for
the purge interval.

Illustration 41 g01200788
Schematic for the engine fan reversing solenoid

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the engine ECM.
106 RENR9318
Diagnostic Functional Tests

Illustration 42 g01183529
J1/P1 connector location (typical left side engine
view)

B. Thoroughly inspect the J1/P1 ECM connectors.

Inspect all of the other connectors that are in the
circuit. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.

Illustration 43 g01194451
P1ECM connector
(P1-5) Digital return
(P1-10) Engine fan reversing solenoid
(P1-18) Digital return
(P1-46) Engine fan reverse switch (N/C)
(P1-47) Engine fan reverse switch (N/O)
RENR9318
Illustration 44 g01200789
Machine connector
(Terminal 23) Digital return
(Terminal 32) Engine fan reverse switch (N/C)
(Terminal 33) Engine fan reverse switch (N/O)
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the circuit.
D. Check the allen head screw of each ECM
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
E. Check the harness and the wiring for abrasion and
for pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the problem that has been found
with the connectors and/or the wiring. If
necessary, replace any damaged components.
107
Diagnostic Functional Tests
Ensure that all of the connector seals are
properly in place and ensure that the connectors
are completely coupled. Verify that the repair
eliminates the problem.
STOP.
Test Step 2. Verify Operation of the
Engine Fan Reverse Switch
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Restore electrical power to the engine ECM.
C. Use Cat ET to check the status of the engine fan
reverse switch while you operate the switch.
Expected Result:
The status changes accordingly as you operate the
switch.
Results:
• OK – The status changes accordingly with the
switch position. Proceed to Test Step 3.
• Not OK – The status does not change with the
switch position. Proceed to Test Step 5.
Test Step 3. Check the Circuit for
Continuity
A. Remove electrical power from the engine ECM.
B. Disconnect the J1/P1 ECM connector.
C. Measure the resistance between P1-10 and P1-18
on ECM connector P1.
Expected Result:
The resistance measures 36.6 ± 1.6 Ohms.
Results:
• OK – The resistance measures 36.6 ± 1.6 Ohms.
Repair: There may be an intermittent problem.
The problem may have been related to a faulty
connection in the harness or in a connector.
Carefully inspect the connectors and the wiring.
Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
STOP.
• Not OK – The resistance does not measure 36.6 ±
1.6 Ohms. Proceed to Test Step 4.
108
Diagnostic Functional Tests
Test Step 4. Check the Engine Fan
Reversing Solenoid
A. Disconnect the harness connector for the engine
fan reversing solenoid.
B. Measure the resistance between terminal 1 and
terminal 2 at the connector for the engine fan
reversing solenoid. Measure the resistance of the
coil of the engine fan reversing solenoid.
Expected Result:
The resistance measures 36.6 ± 1.6 Ohms.
Results:
• OK – The resistance measures 36.6 ± 1.6 Ohms.
Repair: There is a problem in the harness
between the ECM and the connector for the
engine fan reversing solenoid. The problem
may be related to a faulty connection in the
harness or in a wire. Carefully inspect the
connectors and the wiring. Refer to
Troubleshooting, “Electrical Connectors -
Inspect”.
STOP.
• Not OK – The resistance does not measure 36.6 ±
1.6 Ohms.
Repair: Replace the engine fan reversing
solenoid.
STOP.
Test Step 5. Short the Harness at the
Engine Fan Reverse Switch
A. Remove electrical power from the engine ECM.
B. Fabricate a jumper wire that is long enough to
short circuit two terminals of the harness connector
for the engine fan reverse switch. Crimp connector
pins to each end of the jumper wire.
C. Install the jumper wire between terminal 3 (engine
fan reverse switch (N/O)) and terminal 2 (digital
return) on the harness side of the connector for the
engine fan reverse switch.
D. Restore electrical power to the engine ECM.
E. Check the status of the engine fan reverse switch
on Cat ET.
The correct status of the switch is “On” .
F. Remove electrical power from the engine ECM.
RENR9318
G. Install the jumper wire between terminal 1 (engine
fan reverse switch (N/C)) and terminal 2 (digital
return) on the harness side of the connector for the
engine fan reverse switch.
H. Restore electrical power to the engine ECM.
I. Check the status of the engine fan reverse switch
on Cat ET.
The correct status of the switch is “Off” .
J. Remove electrical power from the engine ECM.
Expected Result:
The status changes correctly on Cat ET.
Results:
• OK – The status changes correctly.
Repair: There is a problem with the switch.
Replace the switch. Verify that the repair
eliminates the problem.
STOP.
• Not OK – The status does not change correctly.
Proceed to Test Step 6.
Test Step 6. Check the Operation of the
Engine Fan Reverse Switch at the ECM
A. Remove electrical power from the engine ECM.
B. Disconnect the J1/P1 ECM connector.
C. Fabricate three jumper wires that are long enough
to connect terminals at the ECM connector. Crimp
a connector pin to one end of each of the wires.
D. Remove the wire from terminal location P1-47
(engine fan reverse switch (N/O)) of the ECM
connector. Install a jumper wire into this terminal
location.
E. Remove the wire from terminal location P1-46
(engine fan reverse switch (N/C)) of the ECM
connector. Install a jumper wire into this terminal
location.
F. Remove the wire from terminal location P1-5
(digital return) of the ECM connector. Install a
jumper wire into this terminal location.
G. Connect the J1/P1 ECM connector.
H. Check the operation of the engine fan reverse
switch at the ECM:
RENR9318
a. Short the jumper wires between terminal P1-
46 (engine fan reverse switch (N/C)) and
terminal P1-5 (digital return) at the P1 ECM
connector.
b. Restore electrical power to the engine ECM.
c. Monitor the status of the engine fan reverse
switch on Cat ET. Wait at least 30 seconds for
activation of the code.
The correct status is “Off” .
d. Remove electrical power from the engine
ECM.
e. Short the jumper wires between terminal P1-
47 (engine fan reverse switch (N/O)) and
terminal P1-5 (digital return) at the P1 ECM
connector.
f. Restore electrical power to the engine ECM.
g. Monitor the status of the engine fan reverse
switch on Cat ET. Wait at least 30 seconds for
activation of the code.
The correct status is “On” .
h. Remove electrical power from the engine
ECM.
I. Restore all wiring to the original configuration.
Expected Result:
The status changes correctly on Cat ET.
Results:
• OK – The status changes correctly.
Repair: There is a problem in the wiring or the
connectors between the switch and the ECM or
between the switch and the digital return. Repair
the wiring harness and/or the connectors. Verify
that the repair eliminates the problem.
STOP.
• Not OK – The status does not change correctly.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Verify
that the problem is resolved.
STOP.
109
Diagnostic Functional Tests
i02402329
Engine Pressure Sensor Open
or Short Circuit - Test
SMCS Code: 1439-038-PX
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the following sensors:
• Fuel pressure sensor
• Engine oil pressure sensor
• Atmospheric pressure sensor
• Right turbo inlet pressure sensor
• Intake manifold pressure sensor
Use this procedure to troubleshoot the system when
one of the following diagnostic codes is active or
easily repeated:
• 94-03Fuel Pressure open/short to +batt
• 94-04Fuel Pressure short to ground
• 100-03Engine Oil Pressure open/short to +batt
• 100-04Engine Oil Pressure short to ground
• 274-03Atmospheric Pressure open/short to +batt
• 274-04Atmospheric Pressure short to ground
• 275-03Right Turbo Inlet Pressure open/short to
+batt
• 275-04Right Turbo Inlet Pressure short to ground
• 1785-03Intake Manifold Pressure Sensor voltage
high
• 1785-04Intake Manifold Pressure Sensor voltage
low
The 5 volt sensor supply provides power to all 5 volt
sensors. The Electronic Control Module (ECM)
supplies 5.0 ± 0.2 VDC to terminal A of each sensor
connector. The sensor return from the ECM
connector goes to terminal B of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the ECM.
Pull-up Voltage
110 RENR9318
Diagnostic Functional Tests

The ECM continuously outputs a pull-up voltage on

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

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
disconnected at the sensor connector, the absence of
pull-up voltage at the sensor connector indicates a
problem in the signal wire. If the sensor is
disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
voltage, the signal wire may be shorted to another
wire in the harness.

Illustration 45 g01203122
Schematic for the engine pressure sensors

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the engine ECM.
RENR9318 111
Diagnostic Functional Tests

B. Thoroughly inspect connector (5) and (6). Also,

thoroughly inspect the connectors for sensors (1),
(2), (3), (4) and (7). Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.

Illustration 46 g01200216
Locations of the pressure sensors (typical left
side engine view)
(1) Atmospheric pressure sensor
(2) Fuel pressure sensor
(3) Intake manifold pressure sensor
(4) Engine oil pressure sensor
(5) J2/P2ECM connectors
(6) J1/P1ECM connectors

Illustration 48 g01024457
P2 ECM connector
(P2-15) Intake manifold pressure sensor
(P2-17) Sensor return
(P2-28) Engine oil pressure sensor
(P2-40) Fuel pressure sensor
(P2-57) Atmospheric pressure sensor
(P2-72) Sensor supply

Illustration 47 g01142856
Air filter assembly
(7) Right turbo inlet pressure sensor
112 RENR9318
Diagnostic Functional Tests

C. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector and on each of the
wires in the pressure sensor connectors.

D. Check the allen head screw for each of the ECM

connectors and the machine connectors for the
proper torque. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for the correct torque values.

E. Check the harness and wiring for abrasions and for

pinch points from each of the pressure sensors
back to the ECM.

Expected Result:

All connectors, pins, and sockets are completely

coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and wiring appear to be OK.

Proceed to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring. Ensure that all
of the seals for each of the connectors are
properly in place and ensure that the connectors
are completely coupled. Verify that the repair
eliminates the problem.

STOP.
Illustration 49 g01145897
P1ECM connector Test Step 2. Check the Supply Voltage at
(P1-2) Sensor supply the Sensor Connector
(P1-3) Sensor return
(P1-15) Right turbo inlet pressure sensor
A. Remove electrical power from the engine ECM.

B. Disconnect the harness connectors for the

following sensors:

• Fuel pressure sensor

• Engine oil pressure sensor

• Intake manifold pressure sensor

• Atmospheric pressure sensor

• Right turbo inlet pressure sensor

C. Restore electrical power to the engine ECM.

Note: The original diagnostic code may not stay

Illustration 50 g01159881 active. An open circuit diagnostic code for the
Sensor connector sensor supply may become active when all of the
(A) Sensor supply sensors are disconnected. Ignore the active
(B) Sensor return codes at this time and continue with this test step.
(C) Signal
RENR9318
Note: Be sure to wiggle the harness during the
following measurements in order to reveal an
intermittent condition.
D. Measure the voltage between terminals A and B at
each sensor connector on the engine harness.
E. Remove electrical power from the engine ECM.
F. Connect all of the sensors.
Expected Result:
Each voltage measurement is 5.0 ± 0.2 VDC.
Results:
• OK – Each voltage measurement is 5.0 ± 0.2 VDC.
The voltage is correct at the sensor connectors.
Proceed to Test Step 3.
• Not OK – The voltage is not 5.0 ± 0.2 VDC. The
voltage is incorrect.
Repair: Perform the diagnostic functional test
Troubleshooting, “5 Volt Engine Pressure
Sensor Supply Circuit - Test”.
STOP.
Test Step 3. Check for Active Diagnostic
Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.
B. Restore electrical power to the engine ECM.
Note: Wait at least 30 seconds so that any codes
may become active.
C. Monitor the active diagnostic code screen on Cat
ET. Look for an active diagnostic code for an
engine pressure sensor.
D. Determine if the problem is related to an open
circuit diagnostic code 03 or a short circuit
diagnostic code 04.
Expected Result:
No diagnostic codes are active.
Results:
• OK – No diagnostic codes are active for the engine
pressure sensors.
Repair: The problem may have been related to
a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to
Troubleshooting, “Electrical Connectors -
Inspect”.
113
Diagnostic Functional Tests
STOP.
• Not OK – A 03 diagnostic code is active at this
time. Proceed to Test Step 5.
• Not OK – A 04 diagnostic code is active at this
time. Proceed to Test Step 4.
Test Step 4. Disconnect the Suspect
Sensor in Order to Create an Open Circuit
A. Remove electrical power from the ECM.
B. Disconnect the harness connector of the sensor
with the 04 diagnostic code.
C. Restore electrical power to the ECM.
D. Use Cat ET to check for active diagnostic codes.
Wait at least 30 seconds for activation of the
diagnostic codes. Check for an active 03
diagnostic code for the disconnected sensor.
E. Remove electrical power from the ECM.
Expected Result:
A 04 diagnostic code was active before the sensor
was disconnected. A 03 diagnostic code became
active after the sensor was disconnected.
Results:
• OK – A 04 diagnostic code was active before the
sensor was disconnected. A 03 diagnostic code
became active after the sensor was disconnected.
Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor in
the engine. Verify that there are no active
diagnostic codes for the sensor. If there are no
active diagnostic codes for the sensor,
permanently install the new sensor. Clear any
logged diagnostic codes.
STOP.
• Not OK – When the sensor is disconnected, a 04
diagnostic code remains active for the suspect
sensor. Proceed to Test Step 6.
Test Step 5. Create a Short at the Suspect
Sensor Connector
A. Remove electrical power from the engine ECM.
B. Fabricate a jumper wire that is long enough to
connect two terminals at the sensor connector.
Crimp connector sockets to each end of the jumper
wire.
114
Diagnostic Functional Tests
C. Install the jumper wire between terminal B (sensor
return) and terminal C (sensor signal) on the
harness side of the connector for the suspect
sensor.
D. Restore electrical power to the engine ECM.
Note: Wait at least 30 seconds for activation of the
diagnostic code.
E. Monitor the “Active Diagnostic Codes” screen on
Cat ET before installing the jumper wire and after
installing the jumper wire.
Check for an active short circuit diagnostic code
04 while the jumper wire is installed.
F. Remove electrical power from the engine ECM.
G. Remove the jumper wire.
Expected Result:
A 04 diagnostic code was active when the jumper
wire was installed. A 03 diagnostic code became
active when the jumper wire was removed.
Results:
• OK – A 04 diagnostic code was active when the
jumper wire was installed. A 03 diagnostic code
became active when the jumper wire was
removed.
Repair: The engine harness and the ECM are
OK. Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged
diagnostic codes.
STOP.
• Not OK – The 03 diagnostic code remains active
with the jumper in place. Proceed to Test Step 6.
Test Step 6. Test the Operation of the
ECM
A. Remove electrical power from the engine ECM.
B. Fabricate a jumper wire that is long enough to
connect one of the terminals at the ECM connector
to the engine ground stud. Crimp a connector
socket to one end of the jumper wire.
C. Disconnect the appropriate ECM connector for the
signal wire of the suspect sensor.
D. Remove the signal wire for the suspect sensor
from the ECM connector.
RENR9318
E. Install the jumper wire into the terminal location of
the suspect sensor's signal wire at the ECM
connector.
F. Connect the ECM connectors.
G. Check the operation of the ECM by creating an
open at the ECM:
a. Hold the loose end of the jumper wire away
from any components in order to create an
open circuit condition.
b. Restore electrical power to the engine ECM.
Note: Wait at least 30 seconds so that any codes
may become active.
c. Monitor the “Active Diagnostic Code” screen
on Cat ET.
Check the suspect sensor for an active 03
diagnostic code.
d. Remove electrical power from the engine
ECM.
H. Check the operation of the ECM by creating a
short circuit at the ECM:
a. Connect the jumper wire to the engine ground
stud.
b. Restore electrical power to the engine ECM.
Note: Wait at least 30 seconds so that any codes
may become active.
c. Monitor the “Active Diagnostic Code” screen
on Cat ET.
d. Check the suspect sensor for an active 04
diagnostic code while the jumper wire is
installed.
e. Remove electrical power from the engine
ECM.
I. Remove the jumper wire. Return all wiring to the
original configuration.
Expected Result:
A 03 diagnostic code is active when the sensor signal
wire is removed from the ECM connector. A 04
diagnostic code is active when the signal wire is
connected to the engine ground stud.
Results:
• OK – A 03 diagnostic code is active when the
sensor signal wire is removed from the ECM
connector. A 04 diagnostic code is active when the
signal wire is connected to the engine ground stud.
RENR9318
Repair: The ECM is operating properly. The
problem is in the harness wiring between the
ECM and the sensor connector. If the code is
active for more than one sensor, the problem is
most likely in the return wire for the sensor.
Repair the return wire for the sensor or replace
the harness.
If the code is only active for one sensor, the
problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.
STOP.
• Not OK – One of the following conditions exists:
The 03 diagnostic code is not active when the
sensor signal wire is disconnected. The 04
diagnostic code is not active when the wire jumper
is installed.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Verify
that the problem is resolved.
STOP.
i02456587
Engine Speed/Timing Sensor
Circuit - Test
SMCS Code: 1439-038-VF; 1912-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the primary engine speed/timing
sensor or with the secondary engine speed/timing
sensor.
This procedure covers the following diagnostic codes:
• 190-08Engine Speed abnormal
• 342-08Secondary Engine Speed signal abnormal
The engine uses two engine speed/timing sensors.
The secondary engine speed/timing sensor monitors
the camshaft gear and the primary engine speed/
timing sensor monitors the crankshaft gear. Both of
the engine speed/timing sensors detect the reference
for engine speed and timing from a unique pattern on
the respective gear. The Electronic Control Module
(ECM) counts the time between pulses that is created
by the sensor as the gear rotates in order to
determine rpm.
115
Diagnostic Functional Tests
Under normal operation, the secondary engine
speed/timing sensor is used to determine timing for
starting purposes. The secondary engine speed/
timing sensor is used to determine when the piston in
the No. 1 cylinder is at the top of the compression
stroke. When the timing has been established, the
primary engine speed/timing sensor is then used to
determine engine speed and the signal from the
secondary camshaft sensor is ignored.
After locating the No. 1 cylinder, the ECM triggers
each injector in the correct firing order and at the
correct unit injector timing. The actual timing and
duration of each injection is based on engine rpm and
load. If the engine is running and the signal from the
primary engine speed/timing sensor is lost, a slight
change in engine performance will be noticed when
the ECM performs the changeover to the secondary
engine speed/timing sensor. Loss of the signal from
the secondary engine speed/timing sensor during
engine operation will not result in any noticeable
change in engine performance. However, if the signal
from the secondary engine speed/timing sensor is not
present during start-up the following conditions may
exist:
• The engine may require a slightly longer period of
time to start-up.
• The engine may run rough for a few seconds until
the ECM determines the proper firing order by
using the primary engine speed/timing sensor only.
The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
sensors during engine operation will result in the
termination of injection and the shutting down of the
engine by the ECM. The loss of the signal from both
of the sensors during start-up will prevent the engine
from starting.
Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.
Note: When the sensors are being installed,
complete all of the following tasks:
• Lubricate the O-ring with oil.
• Ensure that the sensor is fully seated into the
engine before tightening the bracket bolt.
• Ensure that the connector is properly latched.
• Ensure that the harness is properly secured, and
ensure that the tie-wraps are placed in the correct
location.
116 RENR9318
Diagnostic Functional Tests

Illustration 51 g01199875
Schematic

B. Restore electrical power to the ECM.

C. Start the engine and run the engine. The problem

may occur when the engine is at any operating
temperature. However, the problem is more likely
to occur when the engine is at the normal
operating temperature.

D. If the engine will not start, monitor the engine

speed on Cat ET while the engine is being
cranked. Cat ET may need to be powered from
another battery while the engine is being cranked.
This is done so that Cat ET will not reset.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal
is abnormal. This message should be replaced
with an engine speed once the ECM is able to
calculate a speed from the signal.

E. Wait at least 30 seconds for activation of the

diagnostic codes. Look for these codes on Cat
ET:

• 190-08Engine Speed signal abnormal

• 342-08Secondary Engine Speed signal

abnormal

Expected Result:

One or both of the diagnostic codes that are listed

above are logged or active.
Note: If the engine will not start and Cat ET
Illustration 52 g01113625 displayed 0 rpm during cranking, select “No Engine
Engine speed/timing sensors rpm” .
(1) Brackets
(2) Integral connectors Results:
(3) O-ring seals
(4) Sensors • No Engine rpm – Engine rpm is not indicated on
Cat ET. Proceed to Test Step 2.
Test Step 1. Check for Diagnostic Codes
• Active Code or logged code – There is an active
A. Connect Caterpillar Electronic Technician (ET) to diagnostic code or a logged diagnostic code for an
the service tool connector.
RENR9318 117
Diagnostic Functional Tests

engine speed/timing sensor. Proceed to Test Step
3.
Test Step 2. Inspect the Sensor Assembly
A. Remove electrical power from the engine ECM.
B. Remove the engine speed/timing sensors from the
engine.
C. Ensure that one O-ring seal is installed on each
sensor, and ensure that the O-ring seals are free of
damage.
E. Ensure that the harness is properly secured,
and ensure that the harness is attached to
the harness clip.
Verify that the problem is resolved.
STOP. STOP
Test Step 3. Inspect the Electrical
Connectors and Wiring
A. Remove electrical power from the ECM.

Expected Result:

Two undamaged O-ring seals are properly installed.

The brackets are not bent. The flange for each sensor
can be flush against the housing.

Results:

• OK – Two undamaged O-ring seals are properly

installed. The brackets are not bent. The flange for
each sensor can be flush against the housing.

Repair: Perform the following procedure in

order to properly install a sensor assembly:

A. Lubricate the O-ring seal with oil.

B. Fully seat the sensor into the housing.

C. Tighten the bracket bolt.

D. Connect the connector and verify that the Illustration 53 g01200239

latch tab of the connector is latched on both
sides.
E. Ensure that the harness is properly secured,
and ensure that the harness is attached to
the harness clip.
Proceed to Test Step 3.
Typical location of sensors
(5) Secondary engine speed/timing sensor
(6) Primary engine speed/timing sensor
B. Thoroughly inspect the connectors for the engine
speed/timing sensors (5) and (6). Refer to
Troubleshooting, “Electrical Connectors - Inspect”.

• Not OK – The sensor assembly has a mechanical

problem.

Repair: Replace the sensor assembly.

Note: Do not switch the positions of the
sensors. The sensors are not
interchangeable. A timing calibration is not
required when the sensors are replaced.

A. Lubricate the O-ring with oil.

B. Fully seat the sensor into the housing.

C. Tighten the bracket bolt.

D. Connect the connector and verify that the

latch tab of the connector is latched on both
sides.
118
Diagnostic Functional Tests
Illustration 54 g01113575
P2 connector
(P2-25) Primary engine speed/timing signal (−)
(P2-26) Timing calibration probe (+)
(P2-35) Primary engine speed/timing signal (+)
(P2-36) Timing calibration probe (−)
(P2-46) Secondary engine speed/timing signal (+)
(P2-47) Secondary engine speed/timing signal (−)
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the
engine speed/timing sensor.
D. Check the ECM connector (allen head screw) for
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.
E. Check the harness and wiring for abrasion and for
pinch points from the engine speed/timing sensors
to the ECM.
Expected Result:
RENR9318
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The harness and wiring are OK. Proceed to
Test Step 4.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 4. Measure the Sensor
Resistance through the Engine Harness
A. Remove electrical power from the ECM.
B. Disconnect the J2/P2 ECM connector.
C. If you are troubleshooting a problem with the
primary engine speed/timing sensor, perform the
following procedure:
a. Measure the resistance from P2-35 (Primary
engine speed/timing +) to P2-25 (Primary
engine speed/timing −).
b. Check for an intermittent open circuit or for a
short circuit by moving the harness while you
take the resistance measurement. Pull the
wires that are directly behind the sensor or
shake the wires that are directly behind the
sensor.
Resistance ...................................110 to 200 Ohms
D. If you are troubleshooting a problem with the
secondary engine speed/timing sensor, perform
the following procedure:
a. Measure the resistance from P2-46
(secondary engine speed/timing +) to P2-47
(secondary engine speed/timing −).
b. Check for an intermittent open circuit or for a
short circuit by moving the harness while you
take the resistance measurement. Pull the
wires that are directly behind the sensor or
shake the wires that are directly behind the
sensor.
Resistance ...............................1000 to 1200 Ohms
RENR9318 119
Diagnostic Functional Tests

Expected Result: STOP. STOP

The resistance measurements are within the
specifications.
Results:
• OK – The resistance measurements are within the
specifications. The wiring appears to be OK.
Repair: The sensors and the harness are OK.
A. Temporarily connect a test ECM.
• Not OK – The resistance measurement for the
suspect sensor is not within the specification.
There is a problem with the sensor.
Repair: Replace the sensor assembly.
Do not switch the positions of the sensors. The
sensors are not interchangeable. A timing
calibration is not required when the sensors are
replaced. Perform the following procedure in
order to replace the sensor assembly:

B. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
C. If the problem returns with the suspect ECM,
replace the ECM.
A. Lubricate the O-ring seal with oil.
B. Fully seat the sensor into the housing.
C. Tighten the bracket bolt.

STOP. STOP D. Connect the connector and verify that the

• Not OK – At least one of the resistance
measurements is not within the specifications.
Proceed to Test Step 5.
Test Step 5. Measure the Resistance of
the Sensor
A. Disconnect the engine harness from the suspect
sensor.
B. For the primary engine speed/timing sensor,
measure the resistance between terminal 2
(Primary engine speed/timing +) to terminal 1
(Primary engine speed/timing −).
Resistance ..........................110 to 200 Ohms
C. For the secondary engine speed/timing sensor,
measure the resistance between terminal 2
(secondary engine speed/timing +) to terminal 1
(secondary engine speed/timing −).
Resistance ......................1000 to 1200 Ohms
Expected Result:
The resistance measurement for the suspect sensor
is within the specification.
latch tab of the connector is latched on both
sides.
E. Ensure that the harness is properly secured,
and ensure that the harness is attached to
the harness clip.
Verify that the problem is resolved.
STOP. STOP
i02403285
Engine Temperature Sensor
Open or Short Circuit - Test
SMCS Code: 1439-038-TA; 1906-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the following sensors:
• Intake manifold air temperature sensor
• Coolant temperature sensor
• Fuel temperature sensor
This procedure covers the following diagnostic codes:

Results:

• OK – The resistance measurement for the suspect

sensor is within the specification. There is a
problem with the wiring or there may be a problem
with a connector.

Repair: Repair the connection and/or the wiring,

when possible. Replace parts, if necessary.
Twisted pair wiring is required. The wiring must
have at least one twist per inch. Verify that the
problem is resolved.
120 RENR9318
Diagnostic Functional Tests

• 110-03Engine Coolant Temperature open/short to

+batt

• 110-04Engine Coolant Temperature short to

ground

• 172-03Intake Manifold Air Temp open/short to

+batt
• 172-04Intake Manifold Air Temp short to ground

• 174-03Fuel Temperature open/short to +batt

• 174-04Fuel Temperature short to ground

The troubleshooting procedures for the diagnostic

codes of each temperature sensor are identical. The
temperature sensors are passive sensors that have
two terminals. The temperature sensors do not
require supply voltage from the Electronic Control
Module (ECM).

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on

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

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

Illustration 55 g01200240
Schematic for the engine temperature sensors

Test Step 1. Inspect Electrical Connectors A. Remove electrical power from the engine ECM.
and Wiring
RENR9318 121
Diagnostic Functional Tests

Illustration 56 g01200241
Sensor locations (typical left side engine view)
(1) Engine coolant temperature sensor
(2) Intake manifold air temperature sensor
(3) Fuel temperature sensor

B. Thoroughly inspect the connectors for sensors (1),

(2), and (3). Also, thoroughly inspect ECM
connector J2/P2. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.

Illustration 57 g01193814
P2 ECM connector
(P2-13) Engine coolant temperature
(P2-30) Common for the engine temperature sensors
(P2-56) Intake manifold air temperature
(P2-62) Fuel temperature
122
Diagnostic Functional Tests
Illustration 58 g01155187
Connector for the temperature sensors
(1) Sensor signal
(2) Sensor return
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the temperature
sensors.
D. Check the allen head screws for each ECM
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
E. Check the harness and the wiring for abrasions
and for pinch points from each of the temperature
sensors to the ECM connector.
Expected Result:
All connectors, pins, and sockets are completely
coupled and inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The connectors and wiring appear to be OK.
Proceed to Test Step 2.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check for Active Diagnostic
Codes
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector.
B. Restore electrical power to the engine ECM.
C. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
RENR9318
D. Look for a 03 diagnostic code or a 04 diagnostic
code.
Expected Result:
No diagnostic codes are active.
Results:
• OK – No diagnostic codes are active. The problem
appears to be resolved.
Repair: The problem may have been related to
a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to
Troubleshooting, “Electrical Connectors -
Inspect” for additional information.
STOP.
• Not OK – A 04 diagnostic code is active at this
time. Proceed to Test Step 3.
• Not OK – A 03 diagnostic code is active at this
time. Proceed to Test Step 4.
Test Step 3. Disconnect the Suspect
Sensor in Order to Create an Open Circuit
A. Remove electrical power from the engine ECM.
B. Disconnect the suspect sensor from the engine
harness.
C. Restore electrical power to the engine ECM.
D. Access the “Active Diagnostic Codes” screen on
Cat ET and check for an active 03 diagnostic
code for the suspect sensor.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
E. Remove electrical power from the engine ECM.
Expected Result:
A 03 diagnostic code is now active for the suspect
sensor.
Results:
• OK – A 04 diagnostic code was active before
disconnecting the sensor. A 03 diagnostic code
became active after the sensor was disconnected.
There may be a problem with the sensor.
Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor in
the engine. Verify that there are no active
diagnostic codes for the new sensor. If there are
no active diagnostic codes for the sensor,
RENR9318
permanently install the new sensor. Clear any
logged diagnostic codes.
STOP.
• Not OK – The 04 diagnostic code is still present.
Leave the sensor disconnected. Proceed to Test
Step 5.
Test Step 4. Create a Short at the Sensor
Connector
A. Remove electrical power from the engine ECM.
B. Disconnect the suspect sensor at the sensor
connector.
C. Fabricate a jumper wire that can be used to create
a short between terminal 1 (signal) and terminal 2
(sensor return) at the suspect sensor's connector.
Crimp connector pins to each end of the jumper
wire.
D. Install the jumper into the harness side of the
sensor connector.
E. Restore electrical power to the engine ECM.
F. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active 04 diagnostic code
for the suspect sensor.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
G. Remove electrical power from the engine ECM.
Expected Result:
A 04 diagnostic code is now active for the suspect
sensor.
Results:
• OK – A 03 diagnostic code was active before
creating the short at the sensor connector. A 04
diagnostic code became active after creating the
short at the sensor connector.
Repair: Temporarily connect a new sensor to
the harness, but do not install the new sensor in
the engine. Verify that there are no active
diagnostic codes for the new sensor. If there are
no active diagnostic codes for the sensor,
permanently install the new sensor. Clear any
logged diagnostic codes.
STOP.
• Not OK – A 03 diagnostic code is still active for the
suspect sensors. Proceed to Test Step 5.
123
Diagnostic Functional Tests
Test Step 5. Check the Operation of the
ECM
A. Remove electrical power from the engine ECM.
B. Check the operation of the ECM by creating an
open at the ECM.
a. Disconnect the ECM connector for the suspect
sensor.
b. Fabricate a jumper wire that is long enough to
reach from a terminal at the ECM connector to
the engine ground stud. Crimp a connector
socket to one end of the jumper wire.
c. Remove the signal wire for the suspect sensor
from the ECM connector. Install the jumper
wire into the terminal location for the signal
wire of the suspect sensor.
d. Connect the ECM connectors.
e. Restore electrical power to the engine ECM.
f. Monitor the “Active Diagnostic Code” screen
on Cat ET. Wait at least 30 seconds for
activation of the code.
An open circuit diagnostic code (03) will be
active for the suspect sensor.
C. Check the operation of the ECM by creating a
short at the ECM.
a. Short the jumper wire that is installed into the
ECM connector to engine ground.
b. Monitor the “Active Diagnostic Code” screen
on Cat ET. Wait at least 30 seconds for
activation of the code.
A short circuit diagnostic code (04) will be active
for the suspect sensor.
c. Remove electrical power from the engine
ECM.
D. Remove the wire jumper. Reconnect all wires and
connectors.
Expected Result:
A 03 diagnostic code is active when the sensor signal
wire is open. A 04 diagnostic code is active when the
jumper wire is shorted to engine ground.
Results:
• OK – The ECM is working properly. The problem is
in the wiring between the ECM and the sensor
connector.
124 RENR9318
Diagnostic Functional Tests

Repair: If the code is active for more than one

sensor, the problem is most likely in the return
wire for the sensor. Repair the return wire for the
sensor or replace the harness.

If the code is only active for one sensor, the

problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.
Verify that the repair eliminates the problem.

STOP.

• Not OK – One of the following conditions exists:

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

Repair: Replace the ECM. Refer to

Troubleshooting, “Replacing the ECM”. Verify
that the original problem is resolved.

STOP. STOP
i02426564

Ether Injection System - Test

SMCS Code: 1456-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the electrical circuit for the ether
injection system.

This procedure covers the following diagnostic codes:

• 2417-05Ether Injection Control Solenoid current
low
• 2417-06Ether Injection Control Solenoid current
high

The ether injection system improves cold weather

starting of the engine. The Electronic Control Module
(ECM) controls the ether injection system.

The ether injection system is disabled if there is an

active engine shutdown.

A test on Caterpillar Electronic Technician (ET)

allows the technician to activate the ether system.
The test is functional when the engine speed is zero
rpm. Access the test via the “Override Parameters”
screen on Cat ET.
RENR9318 125
Diagnostic Functional Tests

Illustration 59 g01200244
Schematic of the ether injection system

Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unauthor-
ized personnel.
Illustration 60 g01144470
To avoid possible injury, be sure the brakes are Left side engine view (typical example)
applied and all controls are in HOLD or NEUTRAL
when starting the engine. (1) J1/P1 ECM connectors

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the ECM.
126 RENR9318
Diagnostic Functional Tests

Illustration 61 g01160988
Components for the ether injection system
(typical location)
(2) Ether injection solenoid

B. Thoroughly inspect connectors (1). Inspect the

connector for ether solenoid (2). Refer to
Troubleshooting, “Electrical Connectors - Inspect”.

Illustration 62 g01142845
P1 terminals for the ether injection system
(P1-18) Solenoid return (ether start valve)
(P1-20) Ether injection solenoid
RENR9318 127
Diagnostic Functional Tests

All connectors, pins, and sockets are completely

coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points.

Results:

• OK – The connectors and the wiring appear to be

OK. Proceed to Test Step 2.

• Not OK – The connectors and/or the wiring are not

OK.

Repair: Repair the connectors and/or the

wiring. Replace parts, if necessary. Verify that
the problem is resolved.

STOP. STOP

Test Step 2. Check for Active Diagnostic

Codes
Note: Remove the ether canister before you
perform this procedure.

A. Connect Cat ET to the service tool connector.

Refer to Troubleshooting, “Electronic Service
Tools”.

Illustration 63 g01200245 B. Restore electrical power to the engine ECM.

Machine connector
(Terminal 17) Ether injection solenoid
C. Proceed to the “Diagnostic Overrides” screen on
(Terminal 35) Solenoid return (ether start valve) Cat ET.

D. Activate the ether injection system. The system will

activate for ten seconds.

E. Monitor the active diagnostic code screen on Cat

ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.

F. Look for a 05 diagnostic code or a 06 diagnostic

Illustration 64 g01160725
code.
Connector for the Ether start valve
(Terminal 1) Ether start valve Expected Result:
(Terminal 2) Solenoid return (ether start valve)
No diagnostic codes are active.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the ether injection Results:
system.
• No active codes – Neither diagnostic code is
D. Check the torque of the allen head screws for the active.
ECM connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct Repair: The problem may have been caused by
torque values. a poor electrical connection. Carefully reinspect
the connectors and the wiring. Refer to
E. Check the harness and the wiring for abrasion and Troubleshooting, “Electrical Connectors -
for pinch points from the ether injection solenoid to Inspect”.
the ECM.
STOP.
Expected Result:
128
Diagnostic Functional Tests
• Not OK – A 06 code is active at this time. Proceed
to Test Step 3.
• Not OK – A 05 code is active at this time. Proceed
to Test Step 4.
Test Step 3. Create an Open at the
Harness Connector for the Ether Injection
Solenoid
A. Remove electrical power from the engine ECM.
B. Disconnect the connector for the solenoid.
C. Restore electrical power to the engine ECM.
D. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
E. Activate the ether injection system. The system will
activate for ten seconds.
F. Monitor the active diagnostic code screen on Cat
ET. Look for a 05 code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
G. Remove electrical power from the engine ECM.
Expected Result:
A 05 code is now active.
Results:
• OK – A 06 code was active before the connector
was disconnected. A 05 code became active after
the connector was disconnected.
Repair: Temporarily connect a new solenoid to
the harness, but do not install the new solenoid.
Verify that there are no active codes for the
ether injection system.
If there are no active codes for the ether
injection system, permanently install the new
solenoid. Clear any logged diagnostic codes.
STOP.
• Not OK – A 06 code was active before the
connector was disconnected. The 06 code
remained active after the connector was
disconnected. Proceed to Test Step 5.
Test Step 4. Create a Short at the
Connector for the Ether Injection
Solenoid
A. Remove electrical power from the engine ECM.
RENR9318
B. Disconnect the connector for the solenoid.
C. Fabricate a jumper wire that can be used to create
a short between terminal 1 and terminal 2 at the
connector for the solenoid. Crimp connector pins to
each end of the jumper wire.
D. Install the jumper wire between terminals 1 and 2
of the harness connector.
E. Restore electrical power to the engine ECM.
F. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
G. Activate the ether injection system. The system will
activate for ten seconds.
H. Monitor the active diagnostic code screen on Cat
ET. Look for a 06 code.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
I. Remove electrical power from the engine ECM.
Remove the jumper wire from the connector.
Expected Result:
A 06 code is now active.
Results:
• OK – A 05 code was active before the jumper wire
was installed. A 06 code became active after the
jumper wire was installed.
Repair: The engine harness and the ECM are
OK. Temporarily connect a new solenoid to the
harness, but do not install the new solenoid.
Verify that there are no active diagnostic codes
for the solenoid. If there are no active diagnostic
codes for the solenoid, permanently install the
new solenoid. Clear any logged diagnostic
codes.
STOP.
• Not OK – A 05 code was active before the jumper
wire was installed. The 05 code remained active
after the jumper wire was installed. Proceed to Test
Step 5.
Test Step 5. Check the Operation of the
ECM
A. Remove electrical power from the engine ECM.
B. Check the operation of the ECM by creating an
open at the ECM.
a. Disconnect the J1/P1 ECM connectors.
RENR9318 129
Diagnostic Functional Tests

connectors or wiring and/or replace the

b. Fabricate a jumper wire that is long enough to
reach from a terminal at the ECM connector to
the engine ground stud. Crimp a connector
socket to one end of the jumper wire.
• Not OK – One of the following conditions exists: A
c. Remove the wire from terminal P1-20 at the
ECM connector. Install the jumper wire into the
terminal location for the solenoid. Ensure that
the jumper wire is isolated from any other wire
and that the jumper wire is isolated from
engine ground.
d. Connect the J1/P1 connectors.
e. Restore electrical power to the engine ECM.
connectors or wiring.
STOP.
05 code is not active when the wires are removed
from the ECM connector. A 06 code is not active
when the wire jumper is shorted to engine ground.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”. Verify
that the problem is resolved.
STOP.
i02403515

f. Proceed to the “Diagnostic Overrides” screen Fuel Filter Differential Pressure

on Cat ET.
Switch Circuit - Test
g. Activate the ether injection system. The
system will activate for ten seconds. SMCS Code: 1435-038-FI

h. Monitor the active diagnostic code screen on System Operation Description:

Cat ET. Look for a 05 code. Record the result.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
C. Check the operation of the ECM by creating a
short at the ECM.
a. Short the jumper wire that is installed into the
ECM connector to engine ground.
b. Proceed to the “Diagnostic Overrides” screen
on Cat ET.
c. Activate the ether injection system. The
system will activate for ten seconds.
Perform this procedure if you suspect that there is a
problem in the circuit for the fuel filter differential
pressure switch. Perform this procedure if the
E390Fuel Filter Restriction event code is active.
The fuel filter differential pressure switch is used to
monitor the differential pressure across the filter
element. The switch is normally closed. When the
differential pressure at the switch reaches
103 ± 14 kPa (15 ± 2 psi) the switch will open. The
Electronic Control Module (ECM) will alert the
operator of fuel restriction. Use this test in order to
verify that the fuel filter differential pressure switch is
operating correctly.

d. Monitor the active diagnostic code screen on

Cat ET. Look for a 06 code. Record the result.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.

D. Remove electrical power from the engine ECM.

Expected Result:

A 05 code is active when the solenoid wire is open. A

06 code is active when the jumper wire is shorted to
engine ground.

Results:

• OK – A 05 code is active when the solenoid wire is

open. A 06 code is active when the jumper wire is
shorted to engine ground.

Repair: The ECM is operating properly. The

problem is in the wiring between the ECM and
the connector for the solenoid. Repair the
130 RENR9318
Diagnostic Functional Tests

Illustration 65 g01027829
Schematic

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove electrical power from the engine ECM.

Illustration 67 g01161069
Typical location of the fuel filter differential
pressure switch
(2) Fuel filter differential pressure switch

Illustration 66 g01200372 B. Thoroughly inspect connector (1). Also, thoroughly

Left side engine view (typical example) inspect the connector for switch (2).
(1) J2/P2 ECM connectors
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.
RENR9318 131
Diagnostic Functional Tests

C. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.

D. Check the ECM connector (allen head screw) for

the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for details.

E. Check the harness and wiring for abrasions and for

pinch points from the sensors back to the ECM.

Expected Result:

All connectors, pins, and sockets are completely

coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and wiring are OK. Proceed to

Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Switch Circuit

A. Install a wire jumper between the terminals of the
connector for the fuel filter differential pressure
switch.

Illustration 68 g01027831
B. Start the engine. Increase the engine speed to
high idle.
P2 ECM connector
(P2-65) Fuel filter differential pressure switch C. Check for an event code for the engine fuel filter
(P2-83) Common
restriction.

Expected Result:

The event code is not active.

Results:

• OK – The event code is not active. The wiring

between the connector and the ECM is OK.
Illustration 69 g01160725
Repair: Check for a plugged fuel filter. If the fuel
Connector for the fuel filter differential pressure filter is OK, temporarily replace the fuel filter
switch differential pressure switch. Verify that the
(Terminal 1) Fuel filter differential pressure switch problem is resolved before permanently
(Terminal 2) Signal return
replacing the fuel filter differential pressure
switch.
132 RENR9318
Diagnostic Functional Tests

STOP. i02431633

• Not OK – The event code is still active. There is an Indicator Lamp Circuit - Test
open circuit in the wiring for the fuel filter
differential pressure switch between the connector SMCS Code: 7431-038
and the ECM. Proceed to Test Step 3.
System Operation Description:
Test Step 3. Check the ECM Use this procedure to troubleshoot any suspect
problems with the following indicator lamps:
A. Remove electrical power from the engine ECM.
• “Air Filter Restriction Lamp”
B. Disconnect the J2/P2 ECM connector.
• “Start Aid Lamp”
C. Fabricate a jumper wire with Deutsch sockets on
each end that is long enough to reach from the Use this procedure to troubleshoot the system when
ECM connector to engine ground. Install the one of the following diagnostic codes is active or
jumper wire into the socket for the signal wire of easily repeated:
the fuel filter differential pressure switch.
• 283-05Filter Restrict Lamp open/short to +batt
D. Connect the jumper wire to engine ground.
• 283-06Filter Restrict Lamp short to ground
E. Start the engine. Increase the engine speed to
The indicator lamps are activated by the Electronic
high idle.
Control Module (ECM) in order to inform the operator
of various engine events.
F. Check for an event code for the engine fuel filter
restriction.
The most likely cause of a problem with an indicator
lamp is the bulb or a connector. The next most likely
Expected Result:
cause is a problem with a wire or with a fuse. The
least likely cause is a problem with the ECM.
The event code is not active.

Results:

• OK – The event code is not active.

Repair: There is an open in the wiring between

the connector for the fuel filter differential
pressure switch and the ECM connector P2.
Repair the connectors or wiring and/or replace
the connectors or wiring. Check the harness
connector to the fuel filter differential pressure
switch for a good connection.

Verify that the repair eliminates the problem.

STOP.

• Not OK – The event code is still active.

Repair: Replace the ECM. Refer to

Troubleshooting, “Replacing the ECM”. Verify
that the problem is resolved.

STOP.
RENR9318 133
Diagnostic Functional Tests

Illustration 70 g01200515
Schematic for the indicator lamps

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.
134 RENR9318
Diagnostic Functional Tests

Illustration 71 g01167488
Engine view (typical example)
(1) J1/P1 ECM connector

B. Thoroughly inspect connectors (1). Refer to the

diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.

Illustration 72 g01200518
P1 terminals for the indicator lamps
(P1-29) “Air Filter Restriction Lamp””
(P1-30) “Start Aid Lamp””
RENR9318
Illustration 73 g01200519
Machine connector
(8) “Air Filter Restriction Lamp””
(18) “Start Aid Lamp””
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the indicator lamps.
D. Check the allen head screw on each ECM
connector for the proper torque. Also, check the
allen head screw on the customer connector for
the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
E. Check the harness and wiring for abrasions and for
pinch points from the indicator lamps to the ECM.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The connectors and wiring appear to be OK.
Proceed to Test Step 2.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
135
Diagnostic Functional Tests
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check for Normal Operation
of the Lamp
A. Restore the electrical power to the ECM and
monitor the indicator lamps.
Expected Result:
The indicator lamps turn on for five seconds. Then,
the indicator lamps turn off.
Results:
• OK – The indicator lamps turn on for five seconds.
Then, the indicator lamps turn off.
Repair: The problem appears to be resolved.
The original problem was probably caused by a
poor electrical connection. If an intermittent
problem is suspected, refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
STOP.
• Not OK – An indicator lamp does not turn on.
Proceed to Test Step 3.
Test Step 3. Check the Wiring to the Lamp
Socket
A. Use a test lamp in order to check for voltage at the
suspect lamp socket. Connect the test lamp
between the suspect lamp terminals.
B. Restore the electrical power to the ECM and
monitor the test lamp.
Expected Result:
The test lamp illuminates during the first five seconds
after the electrical power is returned to the ECM.
Results:
• OK – The test lamp illuminates during the first five
seconds after the electrical power is returned to
the ECM.
Repair: Replace the bulb.
Verify that the repair eliminates the problem.
STOP.
136
Diagnostic Functional Tests
• Not OK – The test lamp did not illuminate during
the first five seconds after the electrical power is
returned to the ECM. Proceed to Test Step 5.
Test Step 4. Check for Electrical Power to
the Lamp Socket
A. Use a test lamp to check for voltage at the suspect
lamp socket.
B. Connect the test lamp between terminal 1 at the
suspect lamp socket and engine ground.
C. Restore the electrical power to the ECM and
monitor the test lamp.
Expected Result:
The test lamp illuminates after the electrical power is
returned to the ECM.
Results:
• OK – The test lamp illuminates after the electrical
power is returned to the ECM. Proceed to Test
Step 5.
• Not OK – The test lamp did not illuminate after the
electrical power was returned to the ECM.
Repair: Verify that the fuse for the “LH/RH
Dash Indicator” is not blown. If voltage is not
present at the fuse, refer to the diagnostic
functional test Troubleshooting, “Electrical
Power Supply Circuit - Test” for the procedure to
check the electrical power to the indicator
lamps. Refer to Illustration 70 .
STOP.
Test Step 5. Bypass the ECM in order to
Test the Lamp Circuit
A. Connect a jumper wire between the terminals at
the suspect lamp socket.
B. Disconnect the J1/P1 connectors.
C. Remove the wire for the suspect lamp from ECM
connector P1. Refer to Table 21 for the
appropriate wire terminals.
Table 21
P1 Terminals for the Connection of the Jumper Wire
Indicator Lamp Terminals
“Air Filter Restriction Lamp”” P1-29
“Start Aid Lamp”” P1-30
RENR9318
D. Connect a test lamp between the wire that was
removed from the ECM connector and engine
ground.
E. Restore the electrical power to the ECM and
observe the test lamp.
Expected Result:
The test lamp turned on.
Results:
• OK – The test lamp turned on.
Repair: If the indicator lamps turn on, there may
be a problem with the ECM. It is unlikely that the
ECM has failed. Exit this procedure and perform
this entire procedure again.
If the problem is not resolved, replace the ECM.
Refer to electronic troubleshooting
Troubleshooting, “Replacing the ECM”.
STOP. STOP
• Not OK – The test lamp does not turn on for five
seconds.
Repair: Check for an open in the wire between
the indicator lamp and the ECM.
STOP.
i02602834
Injector Solenoid Circuit - Test
SMCS Code: 1290-038
System Operation Description:
Use this procedure for the following conditions:
• A suspected problem with an injector solenoid
• You have been directed to this procedure from
Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
• There is an active diagnostic code for an injector
solenoid.
Use this procedure for the following diagnostic codes:
RENR9318
• 1-05Injector Cylinder 1 open circuit
• 1-06Injector Cylinder 1 short
• 2-05Injector Cylinder 2 open circuit
• 2-06Injector Cylinder 2 short
• 3-05Injector Cylinder 3 open circuit
• 3-06Injector Cylinder 3 short
• 4-05Injector Cylinder 4 open circuit
• 4-06Injector Cylinder 4 short
• 5-05Injector Cylinder 5 open circuit
• 5-06Injector Cylinder 5 short
• 6-05Injector Cylinder 6 open circuit
• 6-06Injector Cylinder 6 short
Perform this procedure under conditions that are
identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when the
engine is under vibration (heavy loads).
These engines have Electronic Unit Injectors (EUI)
that are mechanically actuated and electronically
controlled. The Engine Control Module (ECM) sends
a 105 volt pulse to each injector solenoid. The pulse
is sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid is
mounted on top of the fuel injector body.
If an open is detected in the solenoid circuit, a
diagnostic code is generated. The ECM continues to
try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will periodically try to
fire the injector. If the short circuit remains, this
sequence of events will be repeated until the problem
is corrected.
Note: Refer to Illustration 75 . Two injector solenoids
share a supply wire. For this reason, an open circuit
or a short circuit in a supply wire could cause
diagnostic codes for two injector solenoids.
When an injector is replaced, you must program the
new injector trim files into the ECM. If the ECM is
replaced, all injector trim files must be programmed
into the new ECM. Refer to Troubleshooting, “Injector
Trim File” for more information.
The Caterpillar Electronic Technician (ET) includes
the following tests that aid in troubleshooting the
injector solenoids:
“ Cylinder Cutout Test””
137
Diagnostic Functional Tests
The “Cylinder Cutout Test” is used on an engine in
order to determine the individual cylinder
performance while the engine is running. As one or
more cylinders are cut out during the test, the
“Cylinder Cutout Test” uses the “Fuel Position” of
each injector in order to evaluate the performance of
the remaining cylinders that are firing. As the different
cylinders are cut out, a comparison of the change in
“Fuel Position” is used to identify cylinders that are
weak or misfiring. One reason for a cylinder that is
weak or misfiring is an injector that is malfunctioning
mechanically.
During the test, when a good injector is cut out, the
“Fuel Position” of the remaining injectors will show a
consistent change. This consistent change in the
“Fuel Position” is caused by the remaining injectors
that are compensating for the cut out injector. If a
malfunctioning injector is cut out, the “Fuel Position”
will not show a proportional change. This unbalanced
change is the result of the smaller quantity of fuel that
is needed to compensate for the power loss from the
malfunctioning injector. The “Cylinder Cutout Test” is
used to isolate a malfunctioning injector in order to
avoid replacement of injectors that are in good repair.
Note: Prior to running the “Cylinder Cutout Test” , all
active diagnostic codes must be repaired.
“ Injector Solenoid Test””
Use the “Injector Solenoid Test” to diagnose an open
circuit or a short circuit in the wiring for the injector
solenoids. While the engine is off, the “Injector
Solenoid Test” briefly activates each injector
solenoid. A good solenoid will create an audible click
when the solenoid is activated. After performing the
test, Cat ET will indicate the status of the solenoid as
“OK” , “Open” , or “Short” .
138 RENR9318
Diagnostic Functional Tests

Illustration 74 g01147070
Electronic unit injector

Illustration 75 g01161139
Schematic for the injector solenoids
RENR9318 139
Diagnostic Functional Tests

Test Step 1. Inspect the Electrical

Connectors and the Wiring

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

A. Remove electrical power from the engine ECM.

Illustration 76 g01200438
Left side engine view (typical example)
(1) J2/P2ECM connector
(2) J300/P300Injector valve cover entry connector

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

to Troubleshooting, “Electrical Connectors -
Inspect” for details.
Illustration 77 g01099568
Terminal locations at the P2 ECM connector
(P2-99) Injector 5 & 6 supply
(P2-104) Injector 1 & 2 supply
(P2-105) Injector 6 return
(P2-106) Injector 3 return
(P2-107) Injector 5 return
(P2-108) Injector 4 return
(P2-115) Injector 3 & 4 supply
(P2-116) Injector 1 return
(P2-118) Injector 2 return
140 RENR9318
Diagnostic Functional Tests

Test Step 2. Check for Logged Diagnostic

Codes for the Injector Solenoids
A. Connect Cat ET to the data link connector. Refer
to Troubleshooting, “Electronic Service Tools”.

B. Restore electrical power to the engine ECM.

C. Check for logged diagnostic codes for the injector

solenoids on Cat ET.

Expected Result:

There are no logged diagnostic codes for the injector

solenoids.
Illustration 78 g01161269
Terminal locations at the J300injector valve cover Results:
entry connector
(J300-1) Injector 5 & 6 supply • OK – No diagnostic codes have been logged.
(J300-2) Injector 6 return Proceed to Test Step 3.
(J300-6) Injector 3 & 4 supply
(J300-7) Injector 5 return • Not OK – One or more diagnostic codes have
(J300-8) Injector 1 return
(J300-9) Injector 1 & 2 supply
been logged. Proceed to Test Step 4.
(J300-10) Injector 2 return
(J300-11) Injector 3 return Test Step 3. Perform the “ Cylinder Cutout
(J300-12) Injector 4 return
Test””
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and each of the wires A. Start the engine.
that are associated with injector solenoids.
B. Allow the engine to warm up to normal operating
D. Check the allen head screw on each ECM temperature (approximately 77 °C (171 °F)).
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect” C. After the engine is warmed to operating
for the correct torque values. temperature, access the “Cylinder Cutout Test” by
accessing the following display screens in order:
E. Check the harness and wiring for abrasions and for
pinch points from the injectors to the ECM. • “Diagnostics”

Expected Result: • “Diagnostic Tests”

• “Cylinder Cutout Test”

All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
D. Shut off all parasitic loads such as the air
free of corrosion, of abrasion, and of pinch points.
conditioning and the air compressors which could
affect the results of the test.
Results:
E. Select the start button at the bottom of the screen
• OK – The connectors and the wiring appear to be
for the cylinder cutout test on Cat ET.
OK. Proceed to Test Step 2.
F. Follow the instructions that are provided in the
• Not OK – There is a problem with the connectors
cylinder cutout test. The cylinder cutout tests are
and/or wiring.
interactive so the procedure is guided to the finish.
The cylinder cutout test will set the correct engine
Repair: Repair the connectors or wiring and/or
speed for the application.
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
Expected Result:
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
The variation of the fuel rate for all cylinders is within
specifications.
STOP.
Results:
RENR9318 141
Diagnostic Functional Tests

• OK – The cylinder cutout test indicates that all of
the injectors are operating correctly.
Repair: If a problem with the fuel system is
suspected and diagnostic codes are not active
or logged, refer to Systems Operation/Testing
and Adjusting for information that is related to
the low pressure fuel system.
Proceed to Test Step 4.
• Not OK – The cylinder cutout test indicates that at
least one of the injectors is not operating correctly.
Repair: Verify that the engine valve lash for that
injector is set correctly. Rerun the “Cylinder
Cutout Test” . If the problem is still present,
replace the injector. Change the injector trim file
in the ECM. Refer to Troubleshooting, “Injector
Trim File”.
STOP.
Repair: The problem appears to be resolved.
The problem was probably caused by a poor
electrical connection in a connector.
If the codes continue to be logged, refer to
Troubleshooting, “Electrical Connectors -
Inspect”.
If the engine is misfiring or if the engine has low
power, refer to Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable” or
Troubleshooting, “Low Power/Poor or No
Response to Throttle”.
STOP. STOP
• Not OK - “Open” – Note the cylinder that indicates
“Open” . Proceed to Test Step 5.
• Not OK - “Short” – Note the cylinder that indicates
“Short” . Proceed to Test Step 6.

Test Step 4. Perform the “ Injector Test Step 5. Check the Harness between
Solenoid Test”” the ECM and the Valve Cover Base for an
Open Circuit
A. Start the engine.

B. Allow the engine to warm up to normal operating

temperature (approximately 77 °C (171 °F)).
Electrical shock hazard. The electronic unit injec-
C. Stop the engine. tor system uses 90-120 volts.

D. Restore electrical power to the engine ECM.

E. Access the “Injector Solenoid Test” by accessing
the following display screens in order:
• “Diagnostics”
• “Diagnostic Tests”
• “Injector Solenoid Test”
F. Activate the “Injector Solenoid Test” .
A. Remove electrical power from the engine ECM.
B. Disconnect the J300/P300injector valve cover
entry connector at the valve cover base.
C. Restore electrical power to the engine ECM.
D. Fabricate a jumper wire that will be long enough to
short circuit the different terminal locations at the
P300 connector. Crimp connector pins on both
ends of the jumper wire.

G. As each solenoid is energized by the ECM an

audible click can be heard at the valve cover.
Ensure the activation of each solenoid by
comparing the location of the click with the
progress that is displayed on Cat ET.

H. Perform the injector solenoid test at least two

times.

Expected Result:

All cylinders indicate “OK” on Cat ET.

Results:

• OK – There is not an electronic problem with the

injectors at this time.
142 RENR9318
Diagnostic Functional Tests

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

A. Remove electrical power from the engine ECM.

B. Disconnect the P300 connector.

C. Restore electrical power to the engine ECM.

D. Perform the “Injector Solenoid Test” at least two

times.

Illustration 79 g01161290 Expected Result:

Terminal locations for P300Injector valve cover
entry connector (terminal side) All of the cylinders indicate “Open” on Cat ET.
(P300-1) Injector 5 & 6 supply
(P300-2) Injector 6 return Results:
(P300-6) Injector 3 & 4 supply
(P300-7) Injector 5 return
(P300-8) Injector 1 return
• OK – All cylinders indicate “Open” on Cat ET.
(P300-9) Injector 1 & 2 supply The harness between the ECM and the P300
(P300-10) Injector 2 return connector does not have a short circuit. Proceed to
(P300-11) Injector 3 return Test Step 7.
(P300-12) Injector 4 return
• Not OK – One or more cylinders indicate “Short”
E. Insert one end of the jumper wire into the P300 on Cat ET. Note the cylinders that indicate
connector socket for the suspect injector's supply “Short” . Proceed to Test Step 8.
wire. Insert the other end of the jumper wire into
the P300 connector socket for the suspect
injector's return wire. This will replace the injector Test Step 7. Check the Injector Harness
solenoid with a short circuit. Under the Valve Cover for an Open
Circuit or a Short Circuit
F. Perform the “Injector Solenoid Test” at least two
times.

G. Repeat this test for each suspect circuit. Stop the

“Injector Solenoid Test” before handling the Electrical shock hazard. The electronic unit injec-
jumper wire. Restore the wiring to the original tor system uses 90-120 volts.
configuration.

Expected Result: A. Remove electrical power from the engine ECM.

Cat ET displays “Short” for each of the circuits that B. Remove the valve cover in order to gain access to
were jumpered. the suspect injector.

Results: C. Disconnect the harness connector from the

suspect injector.
• OK – Cat ET displays “Short” for each circuit that
was jumpered. Proceed to Test Step 7.

• Not OK – Cat ET displays “Open” for the cylinder

with the jumper wire. Proceed to Test Step 8.

Test Step 6. Check the Harness between

the ECM and the Valve Cover Base for a
Short Circuit
RENR9318
Illustration 80 g01147088
Connector terminals for the injector solenoid
D. Thoroughly clean the terminals on the injector
solenoid and on the harness connector.
E. Use a jumper wire to short circuit the connector
terminals for the suspect injector. This will
effectively replace the injector solenoid with a short
circuit.
F. Restore electrical power to the engine ECM.
G. Perform the “Injector Solenoid Test” at least two
times.
Note: The injector solenoid that shares the supply
wire of the injector that is short circuited may
indicate a false test result. Disregard this test
result.
H. Remove electrical power from the engine ECM.
I. Remove the jumper wire from the injector
connector. This will effectively replace the injector
solenoid with an open circuit.
J. Restore electrical power to the engine ECM.
K. Perform the “Injector Solenoid Test” at least two
times.
L. Remove electrical power from the engine ECM.
Expected Result:
Cat ET displays “Short” for the cylinder with the
jumper wire and “Open” when the jumper wire is
removed.
Results:
• OK – Cat ET correctly displays the correct status
during the test. The harness wiring is OK.
Repair: Use a multimeter to check the
resistance of the suspect injector solenoid.
143
Diagnostic Functional Tests
The correct resistance of each injector solenoid
is 1.06 ± 0.05 Ohms.
If the resistance of the solenoid is not within
specifications replace the faulty injector. Verify
that the problem is resolved.
If the resistance of the solenoid is within
specifications the problem may be intermittent.
If the problem is intermittent, refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. Verify that the
repair eliminates the problem.
STOP. STOP
• Not OK – Cat ET did not correctly display the
correct status during the test. There is a problem
with the injector harness under the valve cover.
There may be a problem with a connector.
Repair: Repair the wiring and/or the connector,
when possible. Replace parts, if necessary.
Verify that the problem is resolved.
STOP. STOP
Test Step 8. Check the ECM for Proper
Operation
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Remove electrical power from the engine ECM.
B. Fabricate a jumper that is long enough to reach
from the P2ECM connector to the engine ground
stud. Crimp a socket terminal to one end of the
jumper wire.
C. Disconnect the P2 connector.
D. Remove the supply wire for the suspect injector
from the ECM connector. Install the jumper wire
into the socket.
E. Connect the J2/P2 ECM connector.
F. Verify that the ECM will detect an open circuit for
the suspect injector:
a. Ensure that the jumper wire is not in contact
with a ground source or another circuit. Do not
touch the jumper wire during the test. A strong
electrical shock hazard is present at the
jumper wire while the test is running.
b. Restore electrical power to the engine ECM.
144
Diagnostic Functional Tests
c. Perform the “Injector Solenoid Test” at least
two times.
d. Remove electrical power from the engine
ECM.
Cat ET displays “ Open”” for the two
injectors that share the supply wire.
G. Verify that the ECM detects a short circuit for the
suspect injector:
a. Connect the jumper wire to the engine ground
stud. Do not touch the jumper wire during the
test. A strong electrical shock hazard is
present at the jumper wire while the test is
running.
b. Restore electrical power to the engine ECM.
c. Perform the “Injector Solenoid Test” at least
two times.
d. Remove electrical power from the engine
ECM.
Cat ET displays “ Short”” for the two
injectors that share the supply wire.
Expected Result:
Cat ET displays the correct status for each test
circuit.
Results:
• OK – The ECM detects the correct status of the
circuit. There is an open circuit or a short circuit in
the engine harness. There may be a problem with
a connector.
Repair: Inspect the connectors for moisture and
for corrosion. Repair the wiring and/or the
connector, when possible. Replace parts, if
necessary. Clear all diagnostic codes after you
complete this test step.
Verify that the problem is resolved.
STOP. STOP
• Not OK – The ECM does not detect the correct
status of the circuit.
Repair: There is a problem with the ECM.
Replace the ECM. Refer to Troubleshooting,
“Replacing the ECM”. Verify that the problem is
resolved.
STOP. STOP
RENR9318
i02401950
Throttle Position Sensor
Circuit - Test
SMCS Code: 1439-038; 1913-038
System Operation Description:
Use this procedure to troubleshoot any suspect
problems with the circuit for the throttle position
sensor. This procedure covers the following
diagnostic codes:
• 41-038 Volt DC Supply short to +batt
• 41-048 Volt DC Supply short to ground
• 91-08Throttle Position Signal abnormal
The throttle position sensor provides the throttle
signal to the Electronic Control Module (ECM). The
throttle position sensor is mounted to a pedal
assembly that allows the operator to control the
speed of the engine. The geometry of the pedal
assembly controls both the travel of the sensor and
the range of the output signal. The throttle position
sensor cannot be adjusted.
The output from the throttle position sensor is a PWM
signal that varies with the position of the throttle
pedal. The throttle position sensor produces a
minimum duty cycle in the released position and a
maximum duty cycle in the fully depressed position.
When the pedal is released, the ECM translates the
sensor's output signal to a throttle position of 0
percent. When the pedal is fully depressed, the ECM
translates the output signal to a throttle position of
100 percent.
The throttle position sensor is powered by 8.0 ± 0.4
VDC that is provided by the ECM. A digital return for
the sensor is also provided by the ECM.
The ECM uses an automatic calibration function that
allows the ECM to minimize the deadband of the
sensor. The automatic calibration function assumes a
range of PWM duty cycle at powerup. If the duty cycle
of the sensor exceeds this initial range, the automatic
calibration function adjusts the limits of the duty cycle
in order to adjust for the new range.
RENR9318 145
Diagnostic Functional Tests

Illustration 81 g01199555
Schematic for throttle position sensor

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Turn the keyswitch to the OFF position.

Illustration 82 g01141049
J1/P1 ECM connector

B. Thoroughly inspect the J1/P1 ECM connector and

the connector for the throttle position sensor.
Inspect the machine connector for damage or
corrosion. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
Illustration 83 g01143213
P1 ECM connector
(P1-4) 8 VDC supply
(P1-5) Digital return
(P1-66) Throttle position
146
Diagnostic Functional Tests
Illustration 84
Terminals on the machine connector
(Terminal 15) Throttle position
(Terminal 19) 8 VDC supply
(Terminal 23) Digital return
Illustration 85
J403/P403 for the throttle position sensor
(A) 8 V supply
(B) Digital return
(C) Throttle position
C. Perform a 45 N (10 lb) pull test on each of the
wires in the circuit.
D. Check the allen head screw from each ECM
connector for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value.
RENR9318
E. Check the harness and the wiring for abrasion and
for pinch points.
Expected Result:
All of the connectors, pins and sockets are
completely coupled and/or inserted and the harness
and wiring are free of corrosion, of abrasion and of
pinch points.
Results:
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 2.
• Not OK – The connectors and/or wiring are not OK.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP. STOP
Test Step 2. Inspect the Throttle Pedal
Assembly
g01199556
A. Inspect the throttle pedal assembly for
components that are loose, bent, missing, or worn.
B. Slowly depress the pedal and release the pedal.
Expected Result:
The throttle pedal assembly operates smoothly
without excessive drag. The pedal springs back
smoothly to the LOW IDLE position without
assistance.
Results:
• OK – The throttle pedal assembly functions
properly. Proceed to Test Step 3.
• Not OK – The throttle pedal assembly is in poor
repair.
Repair: Repair the throttle pedal assembly or
g01159881
replace the throttle pedal assembly, as required.
STOP.
Test Step 3. Check the Status for
“ Throttle Position””
A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector.
B. Turn the keyswitch to the ON position.
RENR9318
C. Observe the status for “Throttle Position” on Cat
ET while you operate the throttle pedal through the
entire range of travel.
Expected Result:
The status is zero percent when the throttle pedal is
released. The status progressively increases to 100
percent when the throttle pedal is fully depressed.
Results:
• OK – The throttle position sensor is working
properly.
Repair: There may be an intermittent electrical
problem with the harness or the connectors.
Refer to Troubleshooting, “Electrical Connectors
- Inspect” if the problem is intermittent.
STOP.
• Not OK – The throttle position that is displayed on
Cat ET does not correspond to the movement of
the throttle pedal. Proceed to Test Step 4.
Test Step 4. Check the Supply Voltage at
the Sensor
A. Disconnect the connector for the throttle position
sensor.
B. Turn the keyswitch to the ON position.
C. Measure the voltage across terminal A (8 V
supply) and terminal B (digital return) on the
harness side of the connector.
D. Turn the keyswitch to the OFF position.
Expected Result:
The supply voltage measures 8.0 ± 0.4 VDC at the
sensor connector.
Results:
• OK – The correct voltage is measured at the
sensor connector. Proceed to Test Step 5.
• Not OK – The voltage is not correct at the sensor
connector. Proceed to Test Step 7.
Test Step 5. Check the Signal Frequency
and the Duty Cycle at the Sensor
A. Install a 7X-6370 Adapter Cable As (3-PIN
BREAKOUT) at the connector for the throttle
position sensor.
147
Diagnostic Functional Tests
B. Remove the signal wire from terminal C of the
connector for the throttle position sensor. Remove
the wire from the harness side of the connector.
C. Turn the keyswitch to the ON position.
D. Measure the frequency and the duty cycle
between terminal B (digital return) and terminal C
(throttle position) at the 7X-6370 Adapter Cable
As (3-PIN BREAKOUT) while you operate the
throttle pedal.
E. Turn the keyswitch to the OFF position.
F. Remove the breakout harness. Restore the wires
to the original configuration.
Expected Result:
The frequency is between 150 and 1000 Hz. The duty
cycle is between 7 and 95 percent.
Results:
• OK – The frequency and the duty cycle are within
specifications for the entire range of the pedal.
Proceed to Test Step 6.
• Not OK – The frequency and the duty cycle are not
within specifications.
Repair: The sensor is not producing a valid
signal. Replace the throttle position sensor.
Verify that the repair eliminates the problem.
STOP.
Test Step 6. Check the Signal Frequency
and the Duty Cycle at the ECM
A. Install a 208-0059 Adapter Cable As (70-PIN
BREAKOUT) between the J1 and the P1 ECM
connectors.
B. Turn the keyswitch to the ON position.
C. Measure the frequency between terminals P1-66
(throttle position) and P1-5 (digital return) on the
breakout harness while you operate the throttle
pedal.
D. Measure the duty cycle of the sensor. Measure the
duty cycle between terminals P1-66 (throttle
position) and P1-5 (digital return) on the breakout
harness while you operate the throttle pedal.
E. Turn the keyswitch to the OFF position.
Expected Result:
The frequency is between 150 and 1000 Hz. The duty
cycle is between 7 percent and 95 percent.
148
Diagnostic Functional Tests
Results:
• OK – The frequency and the duty cycle are within
specifications for the entire range of the pedal.
Repair: A valid signal appears at the ECM, but
the ECM is not reading the signal properly.
Replace the ECM. Refer to Troubleshooting,
“Replacing the ECM” for complete instructions.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The frequency and the duty cycle are not
within specifications.
Repair: There is not a valid signal at the ECM
connector. Repair the signal wire in the harness.
Verify that the repair eliminates the problem.
STOP.
Test Step 7. Check the Supply Voltage at
the ECM
A. Disconnect the J1/P1 ECM connector.
B. Remove the wires from terminals P1-4 (8 VDC
supply) and P1-5 (digital return). Install jumper
wires into the terminal locations for the digital
return wire and the supply wire.
C. Reconnect the J1/P1 ECM connector.
D. Turn the keyswitch to the ON position.
E. Measure the voltage between the wire jumpers in
terminals P1-4 (8 VDC supply) and P1-5 (digital
return).
F. Turn the keyswitch to the OFF position.
Expected Result:
The supply voltage measures 8.0 ± 0.4 VDC at the
ECM.
Results:
• OK – The correct voltage is measured at the ECM.
Repair: There is an open circuit or excessive
resistance in the harness between the ECM and
the sensor. Repair the circuit. Verify that the
repair eliminates the problem.
STOP.
• Not OK – The voltage is not correct at the ECM.
Repair: The ECM does not appear to be
producing the correct supply voltage. Replace
RENR9318
the ECM. Refer to Troubleshooting, “Replacing
the ECM” for complete instructions. Verify that
the repair eliminates the problem.
STOP.
i02412815
User Defined Shutdown Input
Circuit - Test
SMCS Code: 1901-038
System Operation Description:
Use this procedure in order to troubleshoot a problem
with the circuit for the user defined shutdown switch.
Use this procedure if the 267-02Incorrect Engine
Shutdown Switch inputs diagnostic code is active or if
the E265User Defined Shutdown event code is
active.
The user defined shutdown switch provides the ability
to shut down the engine. The engine's Electronic
Control Module (ECM) remains active. The Caterpillar
Electronic Technician (ET) can be used to
communicate with the ECM. The user defined
shutdown switch must be returned to the RUN
position and the keyswitch must be cycled to the OFF
position before the ECM will allow the engine to start.
To shut down the engine, lift the red cover guard and
toggle the user defined shutdown switch to the
SHUTDOWN position. The ECM reads the position of
the user defined shutdown switch. If the engine is
running, the ECM disables the fuel injection. The
ECM will not allow the engine to start if the engine is
not running.
The voltage at the ECM input P1-40 of the user
defined shutdown switch should be 11.5 ± 0.5 VDC
with the user defined shutdown switch in the RUN
position. The voltage at the ECM input P1-23 of the
user defined shutdown switch should be less than 0.5
VDC with the user defined shutdown switch in the
RUN position.
RENR9318
Illustration 86
Schematic
Illustration 87
P1 ECM connector
(P1-5) Digital return
(P1-40) user defined shutdown (NO)
(P1-23) user defined shutdown (NC)
Test Step 1. Inspect Electrical Connectors
and Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect the ECM connector J1/P1.
Thoroughly inspect the connectors for the user
defined shutdown switch. Refer to
Troubleshooting, “Inspecting Electrical
Connectors” for details.
149
Diagnostic Functional Tests
g01205965
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
with the circuit.
D. Check the ECM connector (allen head screw) for
the proper torque. Refer to Troubleshooting,
“Inspecting Electrical Connectors” for details.
E. Check the harness and the wiring for abrasion and
for pinch points.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The harness and wiring are OK. Proceed to
Test Step 2.
• Not OK – There is a problem in the connectors
and/or wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all
of the seals are properly in place and ensure
g01205967 that the connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP. Repair Complete
Test Step 2. Check the Status of the User
Defined Shutdown Switch on Cat ET
A. Connect Cat ET to the service tool connector.
Start Cat ET.
B. Turn the keyswitch to the ON position.
C. Operate the user defined shutdown switch.
Observe the status for the user defined shutdown
switch on Cat ET.
150
Diagnostic Functional Tests
Expected Result:
The status of the user defined shutdown switch reads
“ON” with the user defined shutdown switch in the
SHUTDOWN position. The status of the user defined
shutdown switch reads “OFF” when the user defined
shutdown switch is in the RUN position.
Results:
• OK – The status of the user defined shutdown
switch reads “ON” with the user defined shutdown
switch in the SHUTDOWN position. The status of
the user defined shutdown switch reads “OFF”
when the user defined shutdown switch is in the
RUN position. The user defined shutdown switch is
operating normally.
Repair: There may be an intermittent problem.
If the problem is intermittent, refer to
Troubleshooting, “Inspecting Electrical
Connectors”.
STOP. OK
• Not OK – The status of the user defined switch
does not read “ON” with the user defined
shutdown switch in the SHUTDOWN position. The
status of the user defined shutdown switch does
not read “OFF” when the user defined shutdown
switch is in the RUN position. The user defined
shutdown switch is not operating normally.
Proceed to Test Step 3.
Test Step 3. Short the Wires together at
the User Defined Shutdown Switch
A. Turn the keyswitch to the OFF position.
B. Record the position of the wiring on the user
defined shutdown switch before removing the
wires.
C. Disconnect the wires from the user defined
shutdown switch.
D. Create a short circuit at the user defined shutdown
switch between the wire X919-WH(White) and the
digital return wire H795-PK(Pink). Leave the wire
X918-PU(Purple) open.
E. Turn the keyswitch to the ON position.
F. Observe the status of the user defined shutdown
switch on Cat ET.
G. Remove the short between the wire
X919-WH(White) and the wire H795-PK(Pink).
H. Create a short circuit at the user defined shutdown
switch between the wire X918-PU(Purple) and the
digital return wire H795-PK(Pink).
RENR9318
I. Observe the status of the user defined shutdown
switch on Cat ET.
J. Turn the keyswitch to the OFF position.
K. Remove the wire short.
Expected Result:
The status of the user defined shutdown switch reads
“OFF” when the wire X919-WH(White) and the wire
H795-PK(Pink) are shorted together. The user
defined shutdown switch status reads “ON” when
the wire X918-PU(Purple) and the wire
H795-PK(Pink) are shorted together.
Results:
• OK – The status of the user defined shutdown
switch reads “OFF” when the wire
X919-WH(White) and the wire H795-PK(Pink) are
shorted together. The user defined shutdown
switch status reads “ON” when the wire
X918-PU(Purple) and the wire H795-PK(Pink) are
shorted together. The problem is not with the
harness or the ECM.
Repair: Temporarily connect a new user
defined shutdown switch. Verify that the new
user defined shutdown switch solves the
problem before you permanently install the new
user defined shutdown switch.
STOP. Repair Complete
• Not OK – The status of the user defined shutdown
switch does not read “OFF” when the wire
X919-WH(White) and the wire H795-PK(Pink) are
shorted together. The user defined shutdown
switch status does not read “ON” when the wire
X918-PU(Purple) and the wire H795-PK(Pink) are
shorted together. There is a problem in the
harness and/or the ECM. Proceed to Test Step 4.
Test Step 4. Short the User Defined
Shutdown Switch at the ECM
A. Disconnect the ECM connector J1/P1.
B. Remove the wire X918-PU(Purple) at the ECM
connector P1-40. Remove the wire
X919-WH(White) at the ECM connector P1-23 and
the digital return wire H795-PK(Pink) from ECM
connector P1-5.
C. Insert a wire with socket terminals at each end into
the ECM connector P1-23, P1-40 and P1-5. Short
the wire jumpers in P1-23 and P1-5.
D. Reconnect all the connectors.
E. Turn the keyswitch to the ON position.
RENR9318 151
Diagnostic Functional Tests

Note: The digital return will no longer be

connected to the other sensors and switches.
Additional diagnostic codes will be generated
from the ECM. Clear the codes after you complete
this test.

F. Observe the status of the user defined shutdown

switch on Cat ET.

G. Turn the keyswitch to the OFF position.

H. Remove the short between P1-23 and P1-5.

I. Short the wire jumpers in P1-40 and P1-5.

J. Turn the keyswitch to the ON position.

K. Observe the status of the user defined shutdown

switch on Cat ET.

L. Turn the keyswitch to the OFF position.

M.Remove the short between P1-40 and P1-5.

Expected Result:

The status reads “OFF” when the short is between

P1-23 and P1-5. The status reads “ON” when the
short is between P1-40 and P1-5.

Results:

• OK – The status reads “OFF” when the short is

between P1-23 and P1-5. The status reads “ON”
when the short is between P1-40 and P1-5. The
status is correct on Cat ET.

Repair: The problem is in the harness between

the ECM connector and the user defined
shutdown switch. Repair the harness or the
connector.

STOP. Repair Complete

• Not OK – The status does not read “OFF” when

the short is between P1-23 and P1-5. The status
does not read “ON” when the wire short is
inserted between P1-40 and P1-5. The status is
incorrect on Cat ET.

Repair: Replace the ECM. Refer to

Troubleshooting, “Replacing the ECM”.

STOP. Repair Complete

152 RENR9318
Calibration Procedures

Calibration Procedures

i03660625

Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1439-524; 1912-524

System Operation Description:

Use this procedure if the diagnostic code in Table 22

is active.
Table 22
Diagnostic Codes Table

Description Conditions which Generate this Code System Response

22-13 “Engine Timing Calibration Not
Performed”
261-13Engine Timing Calibration calibration
required
261-11Engine Timing Offset fault
A timing calibration is required for a new en- The code is logged.
gine. A timing calibration is also required after a
repair to the front gear train, the camshaft, or
the crankshaft has been completed. The code
may also become active after replacing an
Electronic Control Module (ECM) that fails to
communicate.
The wiring to the sensors may have the wrong The code is logged.
polarity. There may be a mechanical problem
with the front gear train.

The ECM has the ability to compensate for Table 23

mechanical differences between the Top Center (TC) Required Special Tools
of the flywheel and the TC of the timing gear on the
camshaft. Part Number Description

7X-1171 Transducer Adapter

An “Engine Timing Calibration Not Performed” code
is activated if a timing calibration is required. 6V-2197 Transducer

TC of the Flywheel – The ECM determines the 7X-1695 Cable As

TC of the flywheel via a signal from a magnetic 170-3519 Harness(1)
transducer. The transducer is installed into the (1)
side of the engine block. The transducer creates This item is not required if the engine harness has a connector
for timing calibration.
a signal as a notch on a crankshaft
counterweight rotates past the transducer.
Test Step 1. Install the Transducer
TC of the Timing Gear – The ECM determines
the TC of the timing gear by signals from the Adapter
engine speed/timing sensors.
A. Remove the electrical power from the ECM.

Any offset between the TC of the flywheel and the TC
of the timing gear is stored into the memory of the
ECM.
Note: A timing calibration will not increase the
available engine power.
Table 23 lists the special tools that are required in
order to perform this procedure.
B. Use the appropriate engine turning tool to put
either the No. 1 piston or the No. 6 piston at top
center. Refer to the Systems Operation/Testing
and Adjusting.
C. Refer to Table 24 . After the top center position has
been located, rotate the crankshaft for the number
of degrees that is applicable to your engine model.
Be sure to rotate the crankshaft in the direction of
rotation that is specified in the Table.
RENR9318 153
Calibration Procedures

Table 24 A. Apply clean engine oil to a 2D-6392 O-Ring Seal.

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

C13 75 Normal Rotation Results:

C-15 60 Opposite Normal Rotation
Test Step 3. Connect the 7X-1695Cable
C15 60 Opposite Normal Rotation
As
C-16 60 Opposite Normal Rotation

C18 30 Opposite Normal Rotation

A. If the engine harness is equipped with a connector
for timing calibration, connect the 7X-1695 Cable
As to the connector for timing calibration and to the
D. Refer to Table 25 . Locate the engine's timing transducer.
calibration port.
Note: In certain applications, the engine uses the
port as a return for the crankcase breather fumes.
Detach the hose fitting in order to install the
timing probe.
Table 25
Location of the Timing Calibration Port

Engine Crankshaft Engine Location

Model Counterweight
C7 3 Left Side
C-9 3 Left Side
C-10 8 Right Side

C11 8 Left Side

C-12 8 Right Side

C13 8 Left Side

C-15 2 Left Side
C15 2 Left Side
C-16 2 Left Side
C18 2 Left Side

E. Remove the plug from the timing calibration port.

F. Thread the transducer adapter into the port. Illustration 88 g01963414

Connecting the 7X-1695 Cable As to an ADEM III
Results: ECM

Test Step 2. Install the Transducer

NOTICE
If the crankshaft is not in the correct position
when the transducer is installed, the transducer
will be damaged when the engine is started.
154 RENR9318
Calibration Procedures

d. Install the YL(Yellow) wire of the 170-3519

Harness into the appropriate location.
Note: Ensure that each wire is installed into the
correct location. The timing calibration will not be
successful if the wires are installed incorrectly.

e. Connect the 7X-1695Cable As to the

connector for timing calibration and to the
transducer.

Results:

Test Step 4. Start the Engine and Check

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

B. Start the engine and run the engine until the

engine is at the normal operating temperature.

C. Check for active diagnostic codes. Wait at least 30

seconds in order for the codes to become active.

The engine must not have any active diagnostic

Illustration 89 g01345359
codes during the timing calibration except for a
Connecting the 7X-1695 Cable As to an ADEM IV 261-13Engine Timing Calibration required.
ECM
Expected Result:
B. If the engine harness is not equipped with a
connector for timing calibration, perform the
There are no active diagnostic codes or there is only
following procedure:
a code for timing calibration that is active at this time.
Note: Refer to Illustration 88 or Illustration 89 .
The 170-3519 Harness can be connected to the Results:
P1 connector or to the P2 connector. Select the
connector with the easiest access. • OK – There are no active diagnostic codes or there
is only a code that is active for timing calibration at
a. this time. Proceed to Test Step 5.
Table 26
• Not OK – There is at least one active code that is
Locations for Connection of the 170-3519 Harness
not a code for timing calibration.
Locations on Locations Locations on
the 70−pin P2 on the 120 the P1 Repair: Troubleshoot and repair any active
Wire Color
Connector −pin P2 Connector diagnostic codes before you continue with this
Connector procedure.
White 22 26 24
STOP. STOP
Yellow 23 36 25

Test Step 5. Calibrate the Engine Speed/

b. Refer to Table 26 . Remove the sealing plugs
from the appropriate terminals. Do not discard
the sealing plugs. The sealing plugs may be
reinstalled when the timing calibration is
complete.
c. Disregard the pin-outs on the label of the
harness. Install the WH(White) wire of the
170-3519Harness into the appropriate
location.
Timing Sensor
A. Set the engine speed to 1100 ± 50 rpm. The
engine speed must be steady within this rpm range
in order for the calibration to be successful.
B. After the engine has warmed up, access the
“Timing Calibration” screen on the Cat ET.
Access the following display screens in order:
RENR9318 155
Calibration Procedures

• Service • If the crankshaft and camshaft gears have

been reassembled incorrectly, the timing
• Calibrations will not calibrate.
• Timing Calibration • Verify that the timing calibration probe is
installed correctly.
C. To calibrate the timing, select “Continue” on Cat
ET. Wait until Cat ET indicates that the timing is • Verify that the engine speed is correct and
calibrated. that the engine speed is stable. If the
engine speed is unstable, refer to
Expected Result: troubleshooting without a diagnostic
code Troubleshooting, “Engine Misfires,
Cat ET indicates that the timing is calibrated. Runs Rough or Is Unstable”.

Results: • There may be a problem with the

transducer or with the cables. Obtain a
• OK – Cat ET indicates that the timing is new transducer and/or a new cable and
calibrated. repeat the timing calibration.

Repair: Perform the following procedure: STOP. STOP

A. Set the engine speed to low idle.

Note: Disconnect the 7X-1695 Cable As
before you exit the “ Timing Calibration””
screen. Otherwise, diagnostic codes may be
activated.

B. Disconnect the 7X-1695 Cable As.

C. Exit the “Timing Calibration” screen on Cat

ET.

D. Remove the electrical power from the ECM.

E. Remove the transducer and remove the

adapter.

F. Install the plug into the timing calibration port.

G. If you installed a 170-3519 Harness, you

may remove the harness or you may
permanently install the harness for future
use. If you remove the harness, install the
sealing plugs into the unused cavities of the
ECM connector. Otherwise, moisture and
debris will enter the connector.

If you choose to permanently install the

harness, fasten the harness to the existing
engine wiring harness with cable ties. Also,
install a 3E-3364 Receptacle and two
8T-8737 Seal Plugs on the 2-pin connector
in order to prevent moisture and debris from
entering the connector.

H. Return the engine to service.

STOP. STOP

• Not OK – The timing calibration was unsuccessful.

Repair: The following conditions can cause the

timing calibration to fail:
156
Index Section
Index
Numerics
5 Volt Engine Pressure Sensor Supply
Circuit - Test ................................................... 83
A Temperature open/short to +batt.................... 61
Alternator (Charging Problem and/or Noisy
Operation)...................................................... 26
Probable Causes ......................................... 26
Recommended Actions................................ 26
C CID 0172 FMI 03 Intake Manifold Air Temp
Calibration Procedures.................................. 152
Can Not Reach Top Engine RPM .................... 26
Probable Causes ......................................... 26
Recommended Actions................................ 26
Cat Data Link Circuit - Test .............................. 88
CID 0001 FMI 05 Cylinder #1 Injector open
circuit.............................................................. 56
CID 0001 FMI 06 Cylinder #1 Injector short..... 56
CID 0002 FMI 05 Cylinder #2 Injector open
circuit.............................................................. 56
CID 0002 FMI 06 Cylinder #2 Injector short..... 57
CID 0003 FMI 05 Cylinder #3 Injector open
circuit.............................................................. 57
CID 0003 FMI 06 Cylinder #3 Injector short..... 57
CID 0004 FMI 05 Cylinder #4 Injector open
circuit.............................................................. 57
CID 0004 FMI 06 Cylinder #4 Injector short..... 58
CID 0005 FMI 05 Cylinder #5 Injector open
circuit.............................................................. 58
CID 0005 FMI 06 Cylinder #5 Injector short..... 58
CID 0006 FMI 05 Cylinder #6 Injector open
circuit.............................................................. 58
CID 0006 FMI 06 Cylinder #6 Injector short..... 59
CID 0041 FMI 03 8 Volt DC Supply short to
+batt............................................................... 59
CID 0041 FMI 04 8 Volt DC Supply short to
ground............................................................ 59
CID 0091 FMI 08 Throttle Position signal
abnormal........................................................ 59
CID 0094 FMI 03 Fuel Pressure open/short
to +batt........................................................... 60
CID 0094 FMI 04 Fuel Pressure short to
ground............................................................ 60
CID 0100 FMI 03 Engine Oil Pressure
open/short to +batt......................................... 60
RENR9318
CID 0100 FMI 04 Engine Oil Pressure short to
ground............................................................ 60
CID 0100 FMI 10 Engine Oil Pressure
Sensor abnormal rate of change.................... 61
CID 0110 FMI 03 Engine Coolant
CID 0110 FMI 04 Engine Coolant
Temperature short to ground.......................... 61
CID 0168 FMI 00 System Voltage High ........... 62
CID 0168 FMI 01 System Voltage Low............ 62
CID 0168 FMI 02 System Voltage
intermittent/erratic .......................................... 62
open/short to +batt......................................... 63
CID 0172 FMI 04 Intake Manifold Air Temp
short to ground............................................... 63
CID 0174 FMI 03 Fuel Temperature open/
short to +batt.................................................. 63
CID 0174 FMI 04 Fuel Temperature short to
ground............................................................ 63
CID 0253 FMI 02 Personality Module
mismatch ....................................................... 64
CID 0261 FMI 11 Engine Timing Offset fault.... 64
CID 0261 FMI 13 Engine Timing Calibration
required.......................................................... 65
CID 0262 FMI 03 5 Volt Sensor DC Power
Supply short to +batt...................................... 66
CID 0262 FMI 04 5 Volt Sensor DC Power
Supply short to ground................................... 66
CID 0267 FMI 02 Incorrect Engine
Shutdown Switch inputs................................. 66
CID 0268 FMI 02 Check Programmable
Parameters .................................................... 66
CID 0274 FMI 03 Atmospheric Pressure
open/short to +batt......................................... 67
CID 0274 FMI 04 Atmospheric Pressure
short to ground............................................... 67
CID 0275 FMI 03 Right Turbo Inlet Pressure
open/short to +batt......................................... 67
CID 0275 FMI 04 Right Turbo Inlet Pressure
short to ground............................................... 68
CID 0283 FMI 05 Filter Restrict Lamp open/
short to +batt.................................................. 68
CID 0283 FMI 06 Filter Restrict Lamp short
to ground........................................................ 68
CID 0291 FMI 05 Engine Cooling Fan
Solenoid open circuit ..................................... 68
CID 0291 FMI 06 Engine Cooling Fan
Solenoid short to ground................................ 69
RENR9318
CID 0296 FMI 09 Unable to communicate
with Transmission ECM ................................. 69
CID 0296 FMI 12 See Service Manual ............ 69
CID 0342 FMI 08 Secondary Engine Speed
signal abnormal ............................................. 70
CID 0596 FMI 09 Unable to communicate
with Implement ECM...................................... 70
CID 0596 FMI 12 Wrong Response from
Implement ECM ............................................. 70
CID 1639 FMI 02 Machine Security System
incorrect ......................................................... 71
CID 1639 FMI 09 Machine Security System
Module not communicating on link ................ 71
CID 1785 FMI 03 Intake Manifold Pressure
Sensor voltage high ....................................... 71
CID 1785 FMI 04 Intake Manifold Pressure
Sensor voltage low ........................................ 71
CID 1785 FMI 10 Intake Manifold Pressure
Signal abnormal rate of change..................... 72
CID 2417 FMI 05 Ether Injection Control
Solenoid current low ...................................... 72
CID 2417 FMI 06 Ether Injection Control
Solenoid current high..................................... 72
Coolant in Engine Oil ....................................... 27
Probable Causes ......................................... 27
Recommended Actions................................ 28
Coolant Temperature Is Too High .................... 29
Probable Causes ......................................... 29
Recommended Actions................................ 29
D Engine Has Early Wear ................................... 33
Diagnostic Codes ............................................ 55
Active Diagnostic Codes.............................. 55
Diagnostic Codes......................................... 55
Logged Diagnostic Codes............................ 56
Diagnostic Functional Tests............................. 83
E Recommended Actions................................ 36
E096 High Fuel Pressure ................................ 76
E1171 Engine Idle Shutdown Occurred........... 81
E1172 Engine Idle Shutdown Pending ............ 82
E172 High Air Filter Restriction........................ 77
E194 High Exhaust Temperature..................... 77
E265 User Defined Shutdown ......................... 78
E360 Low Engine Oil Pressure........................ 78
E362 Engine Overspeed ................................. 79
E390 Fuel Filter Restriction ............................. 80
E441 Idle Elevated to Increase Battery
Voltage........................................................... 80
157
Index Section
E539 High Intake Manifold Air Temperature.... 80
ECM Will Not Accept Factory Passwords........ 30
Probable Causes ......................................... 30
Recommended Actions................................ 30
ECM Will Not Communicate with Other
Systems or Display Modules ......................... 30
Probable Causes ......................................... 30
Recommended Actions................................ 30
Electrical Connectors - Inspect........................ 91
Electrical Power Supply Circuit - Test .............. 97
Electronic Display Module (If Equipped).......... 12
Electronic Service Tool Will Not
Communicate with ECM ................................ 31
Probable Causes ......................................... 31
Recommended Actions................................ 31
Electronic Service Tools .................................... 7
Caterpillar Electronic Technician (Cat-ET ) ... 8
Optional Service Tools ................................... 8
PL1000E Communication ECM (If so
equipped) ................................................... 12
Service Tools.................................................. 7
Electronic Troubleshooting ................................ 6
Elevated Idle.................................................... 32
Conditions.................................................... 32
Probable Causes ......................................... 32
Engine Cranks but Will Not Start ..................... 32
Probable Causes ......................................... 32
Recommended Actions................................ 32
Engine Fan Control Solenoid Circuit - Test.... 101
Engine Fan Reversing Solenoid Circuit -
Test .............................................................. 105
Probable Causes ......................................... 33
Recommended Actions................................ 33
Engine Misfires, Runs Rough or Is Unstable... 35
Probable Causes ......................................... 35
Recommended Actions................................ 35
Engine Oil in Cooling System .......................... 36
Probable Causes ......................................... 36
Engine Oil Temperature Is Too High ................ 36
Probable Causes ......................................... 36
Recommended Actions................................ 37
Engine Pressure Sensor Open or Short
Circuit - Test ................................................. 109
Engine Speed/Timing Sensor - Calibrate ...... 152
Engine Speed/Timing Sensor Circuit - Test ....115
Engine Stalls at Low RPM ............................... 37
Probable Causes ......................................... 37
Recommended Actions................................ 37
158 RENR9318
Index Section

Engine Temperature Sensor Open or Short I

Circuit - Test ..................................................119
Important Safety Information ............................. 2
Engine Vibration .............................................. 39
Indicator Lamp Circuit - Test .......................... 132
Probable Causes ......................................... 39
Injector Solenoid Circuit - Test ....................... 136
Recommended Actions................................ 40
Injector Trim File .............................................. 20
Engine Will Not Crank...................................... 40
Intermittent Engine Shutdown ......................... 46
Probable Causes ......................................... 40
Probable Causes ......................................... 46
Recommended Actions................................ 40
Recommended Actions................................ 46
Engine Wiring Information ............................... 17
Intermittent Low Power or Power Cutout ......... 47
Harness Wire Identification.......................... 17
Probable Causes ......................................... 47
Ether Injection System - Test ......................... 124
Recommended Actions................................ 47
Event Codes .................................................... 73
Active Event Codes...................................... 73
Clearing Event Codes .................................. 74 L
Logged Event Codes ................................... 74
Low Engine Oil Pressure ................................. 48
Trip Points for the Monitoring System .......... 74
Probable Causes ......................................... 48
Troubleshooting ........................................... 74
Recommended Actions................................ 49
Excessive Black Smoke .................................. 41
Low Power/Poor or No Response to Throttle .. 49
Probable Causes ......................................... 41
Probable Causes ......................................... 49
Recommended Actions................................ 41
Recommended Actions................................ 49
Excessive Engine Oil Consumption ................ 42
Probable Causes ......................................... 42
Recommended Actions................................ 42 M
Excessive Fuel Consumption.......................... 43
Probable Causes ......................................... 43 Mechanical Noise (Knock) in Engine............... 51
Recommended Actions................................ 43 Probable Causes ......................................... 51
Excessive Valve Lash...................................... 43 Recommended Repairs ............................... 51
Probable Causes ......................................... 43
Recommended Actions................................ 43 N
Excessive White Smoke.................................. 44
Probable Causes ......................................... 44 Noise Coming from Cylinder............................ 51
Recommended Actions................................ 44 Probable Causes ......................................... 51
Exhaust Temperature Is Too High ................... 45 Recommended Actions................................ 51
Probable Causes ......................................... 45
Recommended Actions................................ 45 P
Poor Acceleration or Response....................... 52
F Probable Causes ......................................... 52
Factory Passwords .......................................... 19 Recommended Actions................................ 52
Flash Programming ......................................... 20 Programming Parameters ............................... 19
Programming a Flash File............................ 20
Fuel Dilution of Engine Oil ............................... 46 R
Probable Causes ......................................... 46
Recommended Actions................................ 46 Replacing the ECM.......................................... 12
Fuel Filter Differential Pressure Switch
Circuit - Test ................................................. 129
S
Fuel in Cooling System.................................... 45
Probable Causes ......................................... 45 Self-Diagnostics............................................... 14
Recommended Actions................................ 45 Sensors and Electrical Connectors ................. 15
C11 and C13 Engines ................................. 16
System Configuration Parameters................... 22
RENR9318 159
Index Section

Parameter Descriptions ............................... 22

Parameter Table........................................... 24
Parameter Worksheet.................................. 24
System Overview............................................... 6
Passwords ..................................................... 7
Programmable Parameters............................ 6
System Operation .......................................... 6

T
Table of Contents............................................... 3
Test ECM Mode ............................................... 19
Throttle Position Sensor Circuit - Test ........... 144
Troubleshooting Section.................................... 6
Troubleshooting with a Diagnostic Code ......... 55
Troubleshooting with an Event Code............... 73
Troubleshooting without a Diagnostic Code .... 26

U
User Defined Shutdown Input Circuit - Test... 148

V
Valve Rotator or Spring Lock Is Free............... 53
Probable Cause ........................................... 53
Recommended Actions................................ 54
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