P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 9: Measure The Sensor Supply Voltage With A
Voltmeter
* Tum the keyswitch to the ON position, engine OFF. OK = The sensor supply voltage is
« Install Signal Reading Probes and use a voltmeter on the correct. Proceed to next
DC setting and measure the voltage at the suspect step.
sensor connector on the sensor side from pin-A (+5 VDC) NOTOK = The +5 VDC Sensor Supply
or (+8 VDC) to pin-B (Sensor Common). (ANALOG) voltage is out of range. Refer
See Figure P-591.5. to P-521: Analog Sensor
Supply. STOP.
The voltage from pin-A to pin-B should measure from
4.5 to 5.5 VDC for a Analog Sensor or from 7.5 to 8.5 NOT OK = The +8 VDC Sensor Supply
VDC for a Digital Sensor. (DIGITAL) voltage is out of range. Refer
to P-522: Digital Sensor
Supply. STOP.

Figure P-591.5: Sensor Connector Views

Pressure Sensor Connector Temperature Sensor Connector

3408 & 3412 High Performance Marine Engines 5-55 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 10: Install Short Circuit Between pin-C And pin-B

Of The Sensor Harness Connector And Check For An
Active Short Circuit Diagnostic Code
* Tumn keyswitch to the ON position, engine OFF. OK = | The engine harness and ECM
* Make a jumper wire 100 to 150 mm (4 to 6 in) long with a have checked OK.The Open
Deutsch Pin (for Temperature Sensors) or Deutsch C"CU_" D'ag'_"OS“C_ Code
Socket (for Pressure Sensors) on both ends. femla'"s AF;:“VIE with the sensor
* Monitor the Electronic Service Tool Active Diagnostic QT%?E' eplace the Sensor.
Code screen before and after installing the jumper wire .
(short circuit). NOT OK = | The open Diagnostic Code
« Install the jumper between pin-C (Sensor Signal) and Semalns_AC;rIVE gnh the h
pin-B (Sensor Common) on the connector. Wait at least Jumper Ig pl ace.‘:I temso!ve t“;,‘
15 seconds for the Short Circuit Diagnostic Code to umper. Proceed to Step 13.
become Active.
See Figure P-591.4.
A sensor Short Circuit Diagnostic Code becomes
Active with the jumper in place, and with it removed is
an Open Circuit Diagnostic Code Active.

Step 11: Compare Temperature Shown On Electronic

Service Tool To Actual Temperature
* Tum keyswitch OFF. OK = | The two measurements are
« Install a 6V9110 Temperature Adapter Group near the within = 5°C (+ 9°F). There is
Temperature Sensor. not an Electrical problem at
i this time. STOP.
* Start the engine.
NOT OK = | The two measurements are
* Compare Temperature shown on the Electronic Service
not within + 5°C (+ 9°F).
Tool Display Status to actual temperature as measured
by the 6V9110 Temperature Adapter Group.
Proceed to next step.
The two measurements should agree within + 5°C
(= 9°F) as the operating temperature changes.
NOTE: At coolant temperature below 0°C (32°F) the
measurements should agree within + 15°C (+ 27°F). If
diagnostic codes 110-03 (Coolant Temperature Sensor
Open Circuit), 110-04 (Coolant Temperature Sensor Short
Circuit, or 241-01 (+5 VDC Short Circuit) are active, the
Coolant Temperature will be set by the ECM to 90°C
(194°F). The Electronic Service Tool status screens will
also display this temperature regardless of the actual
temperature.

3408 & 3412 High Performance Marine Engines 5-56 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 12: Disconnect Sensor And Ensure An Open

Circuit Diagnostic Code Becomes Active
¢ Turn keyswitch OFF. OK = | A Short Circuit was active
« Disconnect the Sensor Connector of the Sensor with the before the sensor was
Short Gircuit Diagnostic code. g;l_scopnecte% but an SP?"
« Ensure this is done with the keyswitch OFF ircuit code became Active
. after the sensor was
+ Connect an Electronic Service Tool to the Data Link disconnected. Thoroughly
Connector. inspect the connector for
* Turn the keyswitch to the ON position, engine OFF. moisture. Inspect the seals
An Open Circuit Diagnostic Code is present for the and connect the sensor. If the
disconnected sensor and is Active. Short Circuit code reappears,
the sensor is the problem.
Temporarily replace the
Sensor (connect a sensor to
the harness, but do not install
into engine) and ensure the
code is no longer Active. If the
code disappears with a new
sensor, replace the old sensor.
Clear all logged diagnostic
codes. STOP.
NOT OK = | There is a short circuit
between the Sensor Harness
Connector and the ECM.
Leave the sensor
disconnected. Proceed to
next step.

3408 & 3412 High Performance Marine Engines 5-57 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 13: Disconnect ECM Connector J14/P14 And

Check For Active Diagnostic Codes
* Turn keyswitch OFF. OK = | The ECM is working properly.
« Disconnect ECM Connector J14/P14. Thoroughly inspect Proceed to next step.
both halves of the Connector J14/P14 for corrosion or NOT OK = | Either the Open Circuit
moisture. Diagnostic Code is not active
« With the keyswitch in the ON position and engine OFF, without the hamess
monitor the Electronic Service Tool Active Diagnostic connected, or the Short Circuit
Code screen. diagnostic code does not
appear with the short circuit in
NOTE: With the Engine Harness disconnected, all of the
place, or the short circuit
sensor open circuit diagnostic codes will be Active. Monitor
diagnostic code is Active
and concentrate on the Diagnostic Codes for the suspect
without the short circuit in
sensor only.
place. Replace the ECM.
* Tum keyswitch to the ON position, engine OFF, Refer to Section 2: ECM
« Wait 15 seconds. An Open Circuit Diagnostic Code Replacement Procedure.
should be Active. STOP.
Turn keyswitch OFF.
Make a jumper wire 100mm (4 in) long with a Deutsch Pin
(for Temperature Sensors) or Deutsch Socket (for
Pressure Sensors) on both ends. Insert the jumper
between the sensor signal pin of the ECM Connector J14
on the ECM side and pin-10 (Sensor Common). A Short
Circuit diagnostic code should be Active with the short
circuit in place.
An Open Circuit and Short Circuit Diagnostic Code
should be Active as indicated.

3408 & 3412 High Performance Marine Engines 5-58 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 14: Install Sensor Bypass Wiring

* Tum keyswitch OFF. OK = | There is a problem in the
« Disconnect ECM Engine Harness Connector J14/P14, wiring hamess. Either repairor
and the Sensor Connector. replace the harness. Clear all
* Using a Deutsch removal tool, remove the Sensor Signal diagnostic codles. STOP.
wire from the Engine Harness ECM Connector P14. NOT OK = !f "‘JU'?’SShODU"Q an
. z(::;c:éfotrhe signal
ignal wire
wi (Socket-C)
Ket-C) fi from the sensor intermittent problem refer to
P-501: Inspecting Electrical

Connectors. STOP.
Insert a 125-3662 3-Pin Engine Sensor Harness Bypass
or make a bypass wire long enough to reach from the
ECM to the Sensor.
NOTE: If making a bypass, crimp a Deutsch Socket on one
end to connect to the ECM, and a socket (for temperature
sensors) or pin (for pressure sensors) on the other end.
Insert the bypass into the ECM Connector P14, and the
sensor connector.
Connect the ECM Connector J14/P14 and sensor
connector.
Turn keyswitch to the ON position, Engine OFF.
Monitor the Electronic Service Tool Active Diagnostic
Code screen for either the Sensor Open Circuit or Short
Circuit Diagnostic Code.
The Sensor Diagnostic Code disappears with the
bypass installed.

3408 & 3412 High Performance Marine Engines 5-59 Troubleshooting

NOTES:
P-600 P-600

P-600: HOW TO USE THE TESTS

System Operation

This area is used to describe subsystem component Figure P-600.1: How To Use Diagram
operation and other pertinent details for
troubleshooting.

post e
Fewer S

Figure P-600.2: How to Use Schematic

Teminal Strip Port Engine J31 Port Engine ECM

Port TPS 3 Customer Connector Connector J14/P14
Signal | C 9@ 9. 8 <]Primary Throttle
-Battery| B 37€]Secondary Throttle
+Battery| AEI 17€]Synch Input 1
\36€] Synch Input 2
‘Synchronization Switch
N

-Battery STBD Engine J31 STBD Engine ECM

Bus Bar 4 t Customer Connector Connector J14/P14
K[ ® <]synch Input 1
STBD TPS
<a7¢]synch Input 2
Signal | C 17&]Primary Throttle
-Battery | B 1 2 3
erminal Stip NYES -
., ¢}-Batt To Thottle 6€{Secondary Throttle
+Battery) A _l
— I K |3€ +Batt To Thottle

3408 & 3412 High Performance Marine Engines 6-1 Troubleshooting

P-600 P-600

Figure P-600.3: How To Use Pin Connector

Sockets to be accessed in test are highlighted

J14/P14 ECM Connector (Rear View) /

- —

!noooooy’s

31 32 33 3435

Drawing represents the rear (open sockef) view of P14

and P31 as seen when disconnected from the J side (side of connector
mounted to the ECM).This view is illustrated in the test steps
that require measurements at the P Conrector (Plug) while it
is unmated (disconnected) from the J side (Jack).
P31/J31 Customer Connector (Rear View)

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Procedure To Be Performed Is Named Here

Actual step by step instructions are listed here after OK = | Gives direction to next
each check. appropriate step in
* Follow each step in descending order. troubleshooting the subsystem
foran NOT OK result. STOP.
Expected Results are printed in bold type.

3408 & 3412 High Performance Marine Engines 6-2 Troubleshooting

P-602 P-602

P-602: BOOST PRESSURE SENSOR CALIBRATION

System Operation

The ECM system monitors boost pressure with a Figure P-603.1: Boost Sensor Calibration Diagram
sensor located at the front of the engine on the right
cylinder head. The Boost Pressure Sensor is supplied
2]
with electrical power by the + 5 VDC from the ECM.
The Boost Pressure measurement is used to reduce J14ipte
smoke emissions during acceleration. The ECM limits
the amount of fuel injected until certain boost pressures
are reached. It does this by converting boost pressure
to the FRC Rack, (Fuel Ratio Control) which is then
limited on rack position based on Boost Pressure. PBUS Boost Pressure Sensor
The ECM Boost Pressure Sensor must be calibrated
for a zero boost condition with the engine off.
Calibration is accomplished electronically without the
need for manual adjustments.
NOTE: The Sensor must be recalibrated automatically
using an Electronic Service Tool whenever the ECM or
the sensor has been replaced.

Figure P-603.2: Boost Sensor Calibration Schematic

ECM
Boost Pressure Sensor P8/J8 P14
Boost Pressure 25 €| Boost Pressure
Sensor Common B < | 35 €| Sensor Common
+5VDC 30 €/ +5VDC

Figure P-603.3: Boost Sensor Calibration ECM Connector

J14/P14 ECM Connector (Rear View)

31 32 33 34 35
—
B3 B BW

3408 & 3412 High Performance Marine Engines 6-3 Troubleshooting

P-602 P-602

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

120-13 | Boost Pressure Sensor Not Calibrated The fault is active and the Proceed with
The Boost Pressure Sensor is not calibrated. | ECM goes to low power, and | P-603: Boost
boost pressure is set to 0 kPa | Pressure Sensor
(0 psi). Calibration

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspecting Electrical Connectors And Wiring
* Tum keyswitch OFF. OK = | All connectors, pins, sockets
« Check ECM Connector, J14/P14 and the Boost Sensor are completely mated and the
Connector, J8/P8 for damage or incorrect attachment. hamess is free of corrosion,
Refer to the Electrical System Schematic for additional abrasion or pinched points.
information. Proceed to next step.
+ Refer to P-501: Inspecting Electrical Connectors for NOT OK => [ All connectors, pins, sockets
additional information. are not completely mated and
All connectors, pins, sockets should be completely the harnessbls not free of
mated and the harness should be free of corrosion, ;?n';f;'g”éo?ngs::p‘;r as
abrasion or pinched points. required. STOP.

Step 2: Calibrate The Boost Sensor

« Connect an Electronic Service Tool to the J13 Service OK = | The screen displays
Tool Connector. “Calibrated” when finished.
Tum keyswitch to the ON position, engine OFF. Proceed to next step.
« Select the Boost Sensor calibration screen on the NOT OK = | The screen does not display
Electronic Service Tool. “Calibrated” when finished.
* Wait several seconds for the automatic calibration to Proceed to Step 4.
occur.

The screen will display “Calibrated” when finished.

Step 3: Boost Pressure Sensor Test

* Remove the Sensor from the engine and connect the OK = | The Electronic Service Tool
FT190 fuel Ration control Pressure Kit to the sensor. displays 0 kPa (O psi) when no
« Close the pressure cock valve on the test kit and apply pressure is applied and agrees
100 kPa (14.5 psi) to the sensor while observing the with £ 7 kPa (1.0 psi) of the
display on the Electronic Service Tool status screen. :;-‘St kit a‘; :Ogtkpas(u'5 psi).
* Compare the readings from the Electronic Service Tool roceed to Step 5.
with the test kit. NOT OK = | The electronic Service Tool
does not display 0 kPa (0 psi)
The electronic Service Tool should display 0 kPa (0 psi)
when no pressure is applied
when no pressure is applied and agree with = 7 kPa (1.0
and does not agree with + 7
psi) of the test kit at 100 kPa (14.5 psi).
kPa (1.0 psi) of the test kit at
100 kPa (14.5 psi). The ECM
is not receiving a proper
signal. Reinstall the sensor.
Proceed to next step.

3408 & 3412 High Performance Marine Engines 6-4 Troubleshooting

P-602 P-602

TEST STEP RESULT DIAGNOSIS/ACTION

Step 4: Check The Sensor Supply Voltage
* Using Signal Reading Probes measure the supply OK = | The voltage is in range.
voltage at the Boost Sensor Connector J8/P8 between Proceed to Step 6.
pin-A and pin-B. NOT OK = | The voltage is out of range.
See Figure P-603.4. Refer to P-521: Analog
The voltage should measure +5 VDC = 0.25 VDC. Sensor Supply. STOP.

Figure P-603.4: Boost Sensor Calibration Sensor Connector

Pressure Sensor Connector

A Signal
B Sensor Common
C +5VDC

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Leakage Test
« Close the pressure cock on the test kit and apply 100 kPa OK = | The leakage rate does not
(14.5 psi) to the boost pressure port. exceed 20 kPa (3.0 psi) in 30
« Observe the pressure reading on the electronic Service seconds. The sensor is
tool for 30 seconds before releasing the pressure. operating correctly. STOP.
The leakage rate should not exceed 20 kPa (3.0 psi) in NOT OK = | The leakage rate exceeds 20
30 seconds. kPa (3.0 psi) in 30 seconds.
Check for leaks in the hose or
the test kit. If no leaks are
found then replace the sensor
and recalibrate. STOP.

Step 6: Check Boost Signal At Boost Senors

* Remove the boost signal wire (pin-C of J8). OK = | The resistance is greater than
« Measure the resistance from the signal wire to the case of 250 k Ohms and the voltage is
the sensor. between 0.4 and 4.4 VDC.
* Measure the voltage from pin-C to pin-B of the sensor Proceed to "e{“ step.
connector J8. NOT OK = | The resistance is less than
250 k Ohms and the voltage is
* Reinsert the signal wire into pin-C of J8.
not between 0.4 and 4.4 VDC.
See Figure P-603.4. Replace the sensor and verify
The resistance should be greater than 250 k Ohms and that the repair eliminates the
the voltage should be between 0.4 and 4.4 VDC. problem. STOP.

3408 & 3412 High Performance Marine Engines 6-5 Troubleshooting

P-602 P-602

TEST STEP RESULT DIAGNOSIS/ACTION

Step 7: Check Signal At The ECM

¢ Turn keyswitch OFF. OK = | The voltage is between 0.4
+ Remove the Boost signal wire (pin-25) at the ECM and 4.4 VDC. The sensor is
Connector J14/P14. operating normally. STOP.
« Tumn keyswitch to the ON position, engine OFF. NOT OK = | The voltage is not between 0.4
. and 4.4 VDC. Replace the
* Measure the voltage between the removed wire and ECM. Refero Section 2: ECM
pin-35 of the ECM Connector J14/P14.
. . . Replacement Procedure.
* Reinsert the Signal wire to the ECM Connector J14/P14 STOP.
pin-25.
See Figure P-603.3.
The voltage should be between 0.4 and 4.4 VDC.

3408 & 3412 High Performance Marine Engines 6-6 Troubleshooting

P-604 P-604

P-604: THROTTLE POSITION SENSOR CALIBRATION

System Operation

The Throttle Position Sensor is used to provide a Figure P-604.1: Throttle Position Sensor
throttle signal to the ECM. Sensor output is a constant Diagram
frequency signal with a pulse width that varies with
throttle position. This output signal is referred to as
either Duty Cycle or a Pulse Width Modulated (PWM)
signal and is expressed as a percentage between 0
and 100 percent.
The sensor can be replaced separately from throttle
assembly. The throttle assembly can be calibrated
using the stop adjust screws on the throttle assembly
block if available.
The sensor will produce a Duty Cycle of 5 to 10 percent
at Low Idle and 90 to 95 percent at High Idle. The
percent duty cycle is translated in the ECM into throttle
position of 0 to 100 percent. The sensor is powered by
a 12 VDC or 24 VDC switched battery connection to
pin-A.
NOTE: The ECM may not respond to the Throttle
Position Sensor if there is an Active 253-02 Check
Customer or System Parameters (56) Diagnostic Code.

Figure P-604.2: Throttle Position Sensor Schematic

Port TPS Terminal Strip Port Engine J31 Port Engine ECM
12 3 Customer Connector Connector J14/P14
Signal | C o S8 <Jprimary Throtte
Battery| B & 37€] Secondary Throttle
+Batten] Ajy 17| Synch Input 1
36€{ Synch Input 2
Synchronization Switch 7€
+Batt To Thottle T
Pl

-Battery STBD Engine J31 STBD Engine ECM

e

Bus Bar 1 Connector J14/P14

Customer Connector
8 €{synch Input 1
STBD TPS {37€] Synch Input 2
Signal | C 0-0-9-
12 3 9 €¢—————————K17¢]primary Throtte
-Battery | B - K s ¥
Srminal Strip K< To Thottl 36<] Secondary Throttle
+Battery] A _|
K|3€
+Batt To Thottle

3408 & 3412 High Performance Marine Engines 6-7 Troubleshooting

P-604 P-604

Figure P-604.3: Throttle Position Sensor Pin Connector

J14/P14 ECM Connector (Rear View)

—

':t OOOOO“@”0.000”
21(@ O O O O )2
O 0
OO O)»

Diagnostic Codes

CID-FMI | Conditions Which Generate This Code: | Systems Response: Troubleshooting

91-13 Throttle Sensor Calibration The fault is active and Proceed with P-604:
The Throttle Signal is several out of logged. Throttle Position
calibration (duty cycle is less than 5% or Sensor Calibration.
greater than 95%).

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspect The Throttle Linkage

« Inspect the throttle linkage for loose, bent, broken, OK = | The throttle linkage functions
missing, or worn components. properly. Proceed to next
* Also check for interference with the linkage or step.
return spring. the throttle linkage should work NOT OK = | The throttle linkage functions
smoothly without excessive drag, and return to low improperly. Make repairs to
idle position without assistance in less than one the linkage or return spring.
second. STOP.
The throttle linkage should function properly.

3408 & 3412 High Performance Marine Engines 6-8 Troubleshooting

P-604 P-604

TEST STEP RESULT DIAGNOSIS/ACTION

Step 2: Adjustment At Low Idle Position
* Tum keyswitch to the OFF position. OK = Proceed to next step.
Install the Electronic Service Tool. NOTOK = Refer to P-504: Throttle
Turn Keyswitch to the On position, engine OFF. Position Sensor. STOP.
Select the screen that is used to monitor the throttle
position sensor signal.
Adjust the pedal stop or the throttle linkage until the
.

DUTY CYCLE reading on the Electronic Service Tool

is between 5% and 10% with the throttle pedal at the
LOW IDLE position. Slight movement of the throttle
pedal off the LOW IDLE linkage stop should increase
the DUTY CYCLE reading.
NOTE: The roll pin must NEVER contact the
mechanical stop on the rotary disc or the sensor may
fail.
When properly adjusted, the rotary disc should be
positioned as shown above when the pedal is in the
low idle position.
Step 3: Adjustment At High Idle Position
* With the Pedal in the HIGH IDLE STOP position, OK = Proceed to next step.
adjust the pedal stop or the throttle linkage until an NOT OK = Refer to P-504: Throttle
90% to 95% DUTY CYCLE is achieved. Slight Position Sensor. STOP.
movement of the throttle pedal off of the high idle
stop position should decrease the DUTY CYCLE
reading.
NOTE: The roll pin must NEVER contact the
mechanical stop on the rotary disc or the sensor may
fail.

Step 4: Recheck Low Idle Position

* Repeat Adjustment at Low Idle Position to verify that OK = STOP.
the low idle stop is still properly adjusted. On some NOT OK = Refer to P-504: Throttle
linkage designs, changing the high idle adjustment Position Sensor. STOP.
can affect the low idle adjustment.

3408 & 3412 High Performance Marine Engines 6-9 Troubleshooting

NOTES:
SECTION 7: Glossary of Terms
Active Diagnostic Code
Describes a condition that is currently present to alert
the operator or service technician of an abnormal
engine operation parameter. Refer to Diagnostic Fault
Code.
Aftermarket Device
As used here, a device or accessory installed by the
customer or vessel OEM after the engine is delivered.
Air To Air Aftercooler (ATAAC)
A means of cooling inlet air after the turbocharger,
using ambient air for cooling. The inlet air is passed
through an aftercooler (heat exchanger) mounted in
front of the radiator before going to the inlet manifold.
Alternating Current (AC)
The direction of current flow changes (alternates)
regularly and constantly in a circuit.
American Wire Gauge (AWG)
A measure of the diameter (and therefore the current
carrying ability) of electrical wire. The smaller the AWG
number, the larger the wire.
Atmospheric Pressure Sensor
Analog sensor generates a signal proportional to
atmospheric (barometric) air pressure in the crankcase
and sends a signal to the ECM.
Boost Pressure Sensor
The Boost Pressure Sensor is an absolute pressure
sensor measuring inlet air manifold pressure. The
difference between the pressure measured by this
sensor (inlet air manifold pressure) and atmospheric
pressure is boost pressure.
Breakout T Harness
A test harness designed to connect into a machine or
engine harness which allows normal circuit operation
while providing a breakout or T to measure signals.
Bypass Circuit
A circuit, usually temporary, to substitute for an existing
circuit, typically for test purposes.
3408 & 3412 High Performance Marine Engines
Calibration
As used here, is an electronic adjustment of a sensor
signal.
CAT Data Link
A two wire electrical connection for communication with
other microprocessor based devices such as EMS II.
The Data Link is also the serial communication medium
used for programming and troubleshooting with
Caterpillar Electronic Service Tools.
Caterpillar Engine Monitoring
The part of the Electronic Control Module that monitors
Coolant Temperature, Filtered Fuel Pressure, Inlet
Manifold Air Temperature and Coolant Level to alert
the operator of detected problems. The Coolant
Temperature, Inlet Manifold Air Temperature, and
Filtered Fuel Pressure Sensors are supplied by
Caterpillar and monitored by the ECM. The Coolant
Level Sensor is vessel OEM installed, but still
monitored by the ECM. Aftermarket engine monitoring
systems do not interface with the Caterpillar Electronic
Engine Control Module.
Check Engine Lamp
Sometimes referred to as the “Diagnostic Lamp”, it is
used to alert the operator of the presence of an active
event and is used to flash a diagnostic code.
Cold Mode
A mode of engine operation where the timing is
retarded and the low idle may be raised for engine
protection, reduced smoke emissions and faster
warm up time.
Component Identifier (CID)
Two or three digit code which is assigned to each
component to identify data via data link to ECM.
Coolant Level Sensor
This sensor detects the absence/presence of coolant
at the probe and sends a signal to the ECM.
Troubleshooting
Coolant Temperature Sensor Electronic Engine Control
This sensor detects the engine coolant temperature for The complete electronic system that monitors and
Cold Mode operation and Caterpillar Engine controls engine operation under all conditions.
Monitoring.
Electronic Technician (Cat ET)
Customer Specified Parameter
A software program to run on a service tool like a
A parameter value that can be changed and whose personal computer (PC).
value is set by the customer.
Event Code
Data Link
These codes indicate an event that describe an
Refer to CAT Data Link. abnormal engine condition, such as an Idle Shutdown
Occurrence. They are not necessarily (or usually) an
Desired RPM indication of problems within the Electronic System.

An input to the electronic governor within the ECM. The Failure Mode Identifier (FMI)
electronic governor uses inputs from the Throttle
Position Sensor, Engine Speed Sensor and Customer Type of failure the component experienced (adopted
Parameters to determine “Desired RPM". from SAE standard practice J1587 diagnostics).

Diagnostic Flash Code Fault Code

These codes are flashed out using the Check Engine/
Diagnostic Lamp to indicate an electronic system
malfunction or an event detected by the Electronic
System.
Diagnostic Lamp
Sometimes referred to as the “check engine light”, it is
used to warn the operator of the presence of an active
diagnostic code.
Direct Current (DC)
The type of current where the direction of current flow
is consistently in one direction only.
Sometimes referred to as a diagnostic fault code.
These codes indicate an electronic system malfunction
or problem with the engine electronic system.
Flash Code (FC)
The Caterpillar proprietary code numbers which are
flashed out on the diagnostic lamp.
Fuel Position
An internal signal within the ECM, from the Electronic
Governor to Fuel Injection Control. It is based on
Desired RPM, FRC Fuel Position, rated fuel position
and engine rpm.

Duty Cycle Fuel Ratio Control (FRC)

Refer to Pulse Width Modulation.
Electronic Control Analyzer & Programmer
(ECAP)
An electronic service tool developed by Caterpillar
used for programming and diagnosing a variety of
Caterpillar electronic controls using RS-232 data link.
FRC Fuel Pos is a limit based on control of the fuel to
air ratio and is used for emissions control purposes.
When the ECM senses a higher boost pressure (more
air into cylinder), it increases the “FRC Fuel Pos” limit
(allows more fuel into cylinder).

Electronic Control Module (ECM)

The engine control computer that provides power to the
truck engine electronics. It accepts inputs that monitor
and outputs that control or change to act as a governor
to control engine rpm.

3408 & 3412 High Performance Marine Engines 7-2 Troubleshooting

Full Load Setting (FLS) Original Equipment Manufacturer (OEM)
Number representing fuel system adjustment made at As used here, the customer or manufacturer of a unitin
the factory to “fine tune” the fuel system maximum fuel which a Caterpillar engine is installed.
delivery. Correct value for this parameter is stamped
on the engine information ratings plate. This parameter Parameter
must be programmed or a Diagnostic Code 253-02
Check Customer Or System Parameters (56) will be A programmable value or limit which determines the
generated. characteristics or behavior of the engine and/or
machine.
Full Torque Setting (FTS)
Passive Speed Sensor
Similar to Full Load Setting. This parameter must be
programmed or a Diagnostic Code 253-02 Check A speed sensor not requiring a power and ground
Customer Or System Parameters (56) will be connection. It produces a signal based on the change
generated. in magnetic flux of a ferrous metal gear near the
sensing tip.
Harness
Password
The wiring bundle (loom) connecting all components of
the Electronic System. A group of numeric or alphanumeric characters,
designed to restrict access to parameters. The
Hertz (Hz) electronic system requires correct passwords in order
to change certain engine specifications (Factory
Measure of frequency in cycles per second. Passwords). Passwords are also required to clear
certain diagnostic codes.
Histogram
A bar graph indicating the relative frequency of Personality Module or Ratings Personality
machine operation in specific operating ranges. Module
Idle RPM Limit The module inside of the ECM which contains all the
instructions (software) for the ECM and performance
Programmable parameter which indicates the maps for a specific power family.
maximum allowable engine rpm when an engine rpm is
set using the Cruise Control On/Off switch and SET/ Pulse Width Modulation (PWM)
RESUME switch.
A signal consisting of variable width pulses at fixed
Integrated Electronic Controls intervals, whose ratio of “TIME ON” versus total “TIME
OFF” can be varied (also referred to as “duty cycle”).
The engine is designed with the electronic controls as
a necessary part of the system. The engine will not ON
operate without the electronic controls. I I I I 10%
OFF
TIME
ON
Logged Diagnostic Codes
Describes codes which are stored in memory. They are
OFF! Lmn%
TIME
meant to be an indicator of possible causes for
ON
intermittent problems. Refer to Diagnostic Fault Code.
OFF .-.900/“
Open Circuit TIME

Condition where an electrical wire or connection is Example of Pulse Width

Modulation (PWM) Signals
broken or a switch is open, so that the signal or the
supply voltage can no longer reach its intended
destination.

3408 & 3412 High Performance Marine Engines 7-3 Troubleshooting

Rated Fuel Position
(“Rated Fuel Pos” on ECAP) this indicates the
maximum allowable fuel position (longest injection
pulse). It will produce rated power for this engine
configuration.
Reference Voltage
A regulated, unchanging voltage supplied by the ECM
to a sensor. The reference voltage is used by the
sensor to generate a signal voltage.
Remote Station Operation
Engine speed control from a location outside of the
vessel cab, typically for some type of PTO operation for
pumping or other application using engine power.
Sensor
A device used to detect and convert a change in
pressure, temperature, or mechanical movement into
an electrical signal.
Service Program Module (SPM)
A software program on a factory programmable
computer chip, designed to adapt an Electronic Service
Tool to a specific application.
Short Circuit
A condition where an electrical circuit is unintentionally
connected to an undesirable point. Example: a wire
which rubs against a vessel frame until it wears off its
insulation and makes electrical contact with the frame.
Signal
A voltage or waveform used to transmit information
typically from a sensor to the ECM.
Standard SAE Diagnostic
Communications Data Link
Refer to CAT Data Link.
Subsystem
As used here, it is a part of the Electronic System that
relates to a particular function, for instance throttle
subsystem, etc.
3408 & 3412 High Performance Marine Engines
Supply Voltage
A constant voltage supplied to a component to provide
electrical power for its operation. It may be generated
by the ECM, or it may be vessel battery voltage
supplied by the vessel wiring.
System Configuration Parameters
Parameters which affect power rating family or
emissions.
Throttle Position
The ECM interpretation of the signal from the Throttle
Position Sensor.
Throttle Position Sensor
An electronic sensor which is connected to an
accelerator pedal or a hand lever and sends a Pulse
Width Modulated Signal to the ECM.
Torque Limit
Programmable parameter which limits the maximum
torque based on PTO Configuration and operation.
Total Tattletale
Total number of changes to all Customer Specified
Parameters stored in the ECM.
Transducer
A device which converts a mechanical signal to an
electrical signal. Requires an external power source to
operate.
Warning Lamp
Used to warn the operator of the presence of a
Caterpillar Engine Monitoring detected problem.
7-4 Troubleshooting
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