Senr6447-01-00 - Manuals-Service-Modules - Troubleshooting (1) - 1-1

CATERPILLAR
A ®
November 1997
Electronic
Troulbleshoofting]
3408 & 3412 High Performance
Marine Engines
8RG116-UP
3JK172-UP
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“WARNING” as shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operation 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
warning in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1139F.
How To Use This Manual
GATHER « Talk to the operator directly, if possible.
INFORMATION « What exactly are the symptoms?
» When did the symptoms begin?
« Under what conditions does the problem
occur?
« Check the machines repair history.
« What happened, and in what order (be
specific)?
« Is the engine performing as expected? Refer

VERIFY to Section 1: System Overview.
OPERATIONAL « Could the problem be caused by the fuel
PROBLEM system? Referto Section 3: Troubleshooting
Without A Diagnostic Code.
« When possible, repeat conditions to repeat
problem.
« Repair any ACTIVE diagnostic codes first.

DETERMINE Refer to Section 4: Troubleshooting With A
Diagnostic Code and Section 5: Functional
PROBABLE
9
Tests.
CAUSES « What subsystem could cause the problem?
« What subsystem does the manual suggest?
« Use operator information gathered above.

NARROW » Check for LOGGED diagnostic codes.
e
LIST OF « If more than one symptom, are there any

CAUSES common causes?
« AVOID PRE-CONCEIVED IDEAS!

« Test the most likely cause first.
TEST « Perform a visual inspection.
SUBSYSTEM « Use the procedures in this manual.
« Connector checks are extremely important,
check every pin, socket, and wire. Refer to
Section 5: P-501: Inspecting Electrical
Connectors.
« Do not assume that all performance
problems are caused by the electronic
system.
Table Of Contents
Section 1:Electronic System Overview Section 2: Programming Parameters
System Operation ... 11 Programmable Parameters.
Electronic Control L1 System Configuration Parameters
Rack Controls .. 11 Customer Specified Parameters....
Customer Parameters Passwords ..........ccc.ccoocirienis
Effect On Engine Governing ... 1-2 Customer Passwords................
Self Diagnostics ............ccocceue w12
Factory Passwords ...
Diagnostic Fault Codes..... S1-2
Customer Passwords
Programmable Parameters 12 ECM Replacement Procedure...............cc.occeueee.
24
Passwords.. 212
Replacing The Electronic Control
Engine Sensors.... 1-3 Module With A New ECM
Overspeed Protection System .15 Personality Module .
Engine Synchronization . .15 Factory Password Worksheet
Diagnostic Warning Outputs .16 Lifetime Totals Worksheet ..
Data Connections.. 17 Customer Parameter Worksheet
Communications Data Link
CAT Data Link Schematic..
3408 & 3412 High Performance
Marine Block Diagram
Sensor and Connector Location ...
3408 & 3412 High Performance Marine
Connectors
Operator Station Groundmg Connections
Wire Size Requirements
Wiring Harness .....
OEM Harness Routing/Design
Service Tools ....
ECAP Parts Required .
Connecting ECAP Electronic Service Tool
and Communication Adapter Tool ...........
Connecting ET Electronic Service Tool
and Communication Adapter Tool ............c..ccuee. 1-17
Service Tools ...
Service Information Report
3408 & 3412 High Performance Marine Engines Troubleshooting

Table Of Contents
Section 3: Troubleshooting Without A P-326: Coolant In Lubrication Oil.
Diagnostic Code P-327: Fuel Dilution Of Lubrication Oil
Operator Information.................. P-328: Engine Has Early Wear..............
Operator Questionnaire P-329: Engine Has Low Oil Pressure .....
Questionnaire Responses. P-330: Engine Uses Too Much Lubrication Oil
P-301: Engine Will Not Crank P-331: Engine Coolant Is Too Hot e
P-302: Engine Cranks But Will Not Start . P-332: Exhaust Temperature Is Too High ...........
P-303: Engine Misfires, Runs Rough P-333: Oil At The Exhaust

Or Is Unstable P-339: Engine Has A Fuel Supply Problem..
P-304: Low Power/Poor Or No P-341: Indicator Lamp Not
Response To Throttle.. Functioning Properly
P-305: Intermittent Englne Shutdowns.. P-342: Switch Fault......
P-306: Intermittent Low Power Or P-343 Engine Synchronize Switch Not
Power Cutouts ........ Functioning Properly ...
P-307: Electronic Service Tool Will P-344: Cannot Communicate Over
Not Communicate With ECM...........cccccoorueninnnne 3-10 The CAT DATA Link
P-308: ECM Will NotAccept Factory P-346: Electrical Power Supply to The ECM
Passwords .. .31
P-347: Engine Has A Low Coolant Level
P-310: Excessive Black Smoke .31
P-350: Engine Has A High
P-311: Excessive White Smok 312 Transmission Oil Temperature
P-312: Can Not Reach Top Engine Rpm............. 3-13 P-351: Engine Has A High
P-313: Poor Acceleration Or Response .3-14 Transmission Oil Pressure
P-314: Poor Fuel Consumption .3-15 P-374: Engine Speed Switch Crank Terminate
P-318: Engine Stalls At Low RPM . 3-15 P-375: Engine Speed Switch Overspeed Test ....3-
P-319: Too Much Vibration.. 3-16 P-376: Engine Overspeed Switch Calibration...... -
P-320: Noise Coming From Cyllnder .37 P-377: Engine Speed Switch Crank
Terminate Calibration
P-321: Too Much Valve Lash .3-18
P-378: Rack Position Sensor Calibration
P-322: Valve Rotocoil Or Spring Lock Is Free . 3-18
P-379: Dynamic Rack Controls..............c.cccceueueae
P-323: Mechanical Noise (Knock) In Engine ...... 3-19
P-380: Speed Switch Calibration...............coccc....
P-324: Qil In Cooling System... .3-19
P-325: Fuel In Cooling System .3-20
3408 & 3412 High Performance Marine Engines 5 Troubleshooting

Section 4: Troubleshooting With A Section 5: System Functional Tests
Diagnostic Code
P-500: How To Use Tests...................
Diagnostic Codes..........coowwimiirninininicsiscins P-501: Inspecting Electrical Connectors
Active Diagnostic Codes ..., P-504: Throttle Position Sensor .............ccccc.......
Logged Diagnostic Codes. P-513: ECM/Personality Module .
Events... P-514: Engine Speed Sensor...
Diagnostic Codes Effect on P-515: Rack Position Sensor ..o
Engine Performance
P-521: Analog Sensor Supply
Event Codes..
P-522: Digital Sensor Supply
Using The ET and ECAP To Dnsplay Active
Diagnostic Codes . P-542: Rack Solenoid ....
Using ET and ECAP To Dlsplay Logged P-552: Shutoff Solenoid
Diagnostic Codes P-591: Engine Sensor OPEN/SHORT
Using ET and ECAP To Display Status ..
Diagnostic Terminology...
Section 6: Sensor Calibrations
Reference Sheet For DlagnosncCodes.. P-600: How To Use Tests
P-602: Boost Pressure Sensor Calibration ...
P-604 Throttle Position Sensor Calibration...
Section 7: Glossary Of Terms

Glossary of TermMS.......ccovvvvviieiiiiiciieeceiceien 71

Diagnostic Terminology
Component Identifier (CID) - Two or three digit code which is assigned to each component or system.
Event Identifier (EID) - Two or three digit code which is assigned to each component or system.
Failure Mode Identifier (FMI) - Type of failure the component experienced (adopted from SAE standard practice
J1587 diagnostics).
Failure Mode Identifier Description

00 Data Valid, but above normal operational range
01 Data Valid, but below normal operational range

02 Data Erratic, Intermittent, or Incorrect
03 Voltage above normal or shorted high
04 Voltage below normal or shorted low

05 Current below normal or open circuit
06 Current above normal or grounded circuit
07 Mechanical System not responding properly
08 Abnormal Frequency, Pulse Width, or Period
09 Abnormal Update
10 Abnormal Rate of Change
1" Failure Mode not identifiable

12 Faulty Device or Component
13 Uncalibrated device or component
14-31 Reserved for future assignment

Active Code - The CID and FMI can be sent through the data link through the display module or through the
Communication Adapter Tool, then to the Electronic Service Tool or various electronic display modules.
Logged Code - The diagnostic will be entered into the permanent memory (Diagnostic Log) when it becomes
active. The number of occurrences will be saved in the “good to faulty counter” in the permanent memory
(Diagnostic Log). First and last occurrence time (engine hours) will also be saved in the permanent memory
(Diagnostic Log). This information is then available for display on the Electronic Service Tool.

Reference Sheet For Diagnostic Codes
CID-FMI FLASH CODES DESCRIPTION PROCEDURE NO
17-05 . Shutoff Solenoid Open Circuit .
Shutoff Solenoid Short Circuit..
Excessive ENging POWET ..........ccoccoveuiviiciiinininiiiceeciciens
... Rack BTM Open Circuit
... Rack BTM Short Circu!
... Rack Sensor Open CirCuit ..........cccoovveveecicniiiiceiicins
... Rack Sensor Short Circuit
... Rack System Fault
Rack Sensor Rate of Change
Secondary Speed Signal Rate of Change
Loss of Secondary Speed Signal
Secondary Speed Signal Out of Range................ccceeeenin
Invalid Throttle Signal
Throttle Sensor Rate of Chang
Throttle Sensor Calibration
Low Oil Pressure Warning
Oil Pressure Sensor Open
Oil Pressure Sensor Short....
Oil Pressure Rate of Change.
Very Low Oil Pressure...
Boost Sensor Open Circuit
Boost Sensor Short Circuit
Boost Sensor Calibration..
High Coolant Temperature Warning...
Coolant Temperature Sensor Open Circui
Coolant Temperature Sensor Short Circuit .............ccc.c..... P-591
Very High Coolant Temperature .
Low Coolant Level Warning.....
Very Low Coolant Level
High Transmission Oil Pressure Warning.

Reference Sheet For Diagnostic Codes (Continued)
168-01 ... (51) Battery Voltage Below Normal .P-346
168-02 (51) Intermittent Battery . .P-346
177-00 ... (81) High Transmission Oil Temperature Warnin, .P-350
177-03 (67) Transmission Oil Temperature Open . .P-591
177-04 (67) Transmission Oil Temperature Short . .P-591
177-11 (81) Very High Transmission Oil Temperature .P-350
190-00 (35) Engine Overspeed Warning.... .P-303
190-02 (84) Loss of Primary Engine Speed Signal .P-514
190-08 (33) Engine Speed Out of Range........... .P-514
190-10 Engine Speed Rate of Change .P-514
241-00 +5 VDC Supply Above Normal. .P-521
241-01 .o +5 VDC Supply Below Normal...........c.ccoomeieiniiiiniiccicicnns P-521
241-02 +8 VDC Supply Above Normal.. .P-522
241-03 +8 VDC Supply Below Normal . .P-522
252-12 Personality Module Fault ..............ccccooevevicciiicnncininnn.
P-613
253-02 Check Customer/System Parameters .P-513
254-12 ECMFault ....coooiiccccicie .P-513

NOTES:
Section 1: Electronic System Overview
System Operations The ECM determines a “Desired Engine Speed (rpm)”
based on the throttle position, and customer specified
The 3408 & 3412 High Performance Marine Engines parameters. The ECM maintains the desired engine
are electronically controlled. The Electronic Control speed (rpm) by sensing actual engine speed using the
Module (ECM) controls fuel rate instead of using Primary Speed Sensor or the Secondary Speed
flyweights and linkages. The electronics also replaces Sensor, then controlling the rack to achieve the desired
the mechanical fuel/air ratio, torque control group and engine speed.
various adjustment screws.
Desired
The ECM uses several sensors as inputs to control the Engine
rack. The ECM determines the position the rack should Speed [ E
be at then varies the voltage to the Brushless Torque L
Motor (BTM) to move the rack to the desired position. Primary Throttie and
Throttle Position Sensor
The rack position sensor tells the ECM when the rack Customer
Parameter
is at the determined position. Low idle
Engine Location
Primary
Electronic Controls Speed
Sensor
The 3408 & 3412 High Performance Marine Engines or I—> Engine
I-» Speed
electronic system consists of the Electronic Control Backup
Module (ECM) and engines sensors. The ECM is the Speed
Sensor
computer which controls the engine operating
parameters. The Personality Module in the ECM Figure 1.1 - Engine Speed Control Logic
contains the software which controls how the ECM
To move the rack, the ECM adjusts the voltage to the
behaves.
rack solenoid (BTM) to increase or decrease rack.
Increased voltage results in increased rack adjustment.
Rack Controls The ECM reads the rack movements from the Rack
Position Sensor. The ECM increases or decreases the
The rack mechanism on a 3408 & 3412 High
voltage to the rack solenoid until the desired position is
Performance Marine Engines is moved by a servo
reached.
valve which receives oil pressure from the fuel injection Rack Position Sensor
pump. However, the servo spool is moved by a
solenoid (BTM) rather than by a linkage controlled by
flyweights and springs.
Aciual
Rack
Desired Engine Speed Pasition Desice
e Desired Rack Electronic. | «—Engioe
Control Governor Speed
An input to the electronic governor within the ECM. The
electronic governor uses input from the Throttle
Position Sensor, Engine Speed Sensor and the 1[[] Rack 8TM
Customer Parameters to determine the Desired Engine
Engine
Speed. Speed
Desired Rack Position

The Desired Rack Position is where the ECM moves Pressure
Sensor
the rack based on engine governing. The Desired Rack
Position will not exceed the FRC Rack or Rated Rack. Figure 1.2 - ECM Electronic Governor
The ECM sets certain limits on rack motion. “FRC
Actual Rack
Rack” (Fuel Ratio Control Rack) is a rack limit used to
Actual Rack is the ECM'’s interpretation of the signal reduce the amount of acceleration smoke. This works
from the Rack Position Sensor which represents actual similar to a mechanical engine FARC (Fuel Air Ratio
position of the rack. Actual Rack should follow Desired Control) when the ECM senses a higher inlet manifold
Rack. pressure it increases the FRC “Rack Limit” which
allows more fuel into the cylinders. “Rated Rack” is a
Rated Rack Position rack limit based on rated power output limits and the
Rated Rack Position is a limit on the rack position from torque curves for a specific engine family and rating. All
maps programmed into the personality module on the of these limits are programmed by the factory into the
ECM. personality module.

Electronic System Overview
Customer Parameters Effect on Engine Programmable Parameters

Governing
Certain parameters that affect the operation of the
A unique feature with Caterpillar Electronic Engines is 3408 & 3412 High Performance Marine Engine may be
the Customer Specified Parameters. These changed with the Electronic Service Tools. The
parameters allow the engine owner to fine tune the parameters are stored in the ECM and are protected
ECM for engine operation to accommodate the typical from unauthorized changes by passwords. These
or specific usage of the engine. parameters are either “System Configuration
Parameters” or “Customer Parameters”.
Some parameters are intended to notify the operator of
potential engine damage such as Engine Monitoring System Configuration Parameters are set at the
Parameters. Other parameters are provided to factory and effect emissions or power ratings within a
enhance the engine installation or provide engine family of engines. Factor Passwords must be used to
change System Configuration Parameters.
operating information to the engine owner.
Customer Parameters are variable and can be used
to affect speed limits, rpm/power ratings within the
Self-Diagnostics limits set by the factory. Customer Passwords are
necessary to change Customer Specified parameters.
The electronic system has some ability to diagnose
itself. When a problem is detected, a diagnostic code is Some parameters may affect engine operation in ways
generated and the Diagnostic Lamp is illuminated. In a operator does not expect. Without adequate training,
most cases, the code is also stored in permanent these parameters may lead to power or performance
memory (Logged) in the ECM. complaints, even when the engine is performing to
specification.
Diagnostic Fault Codes For more information refer to Section 2:
Programming Parameters.
When diagnostic codes occur, they are called ACTIVE.
They indicate a problem of some kind currently exists.
They should always be serviced first. If the engine has
Passwords
an Active Code, find the code in Section 5: “System Configuration Parameters” are protected by
Troubleshooting With A Diagnostic Code and proceed Factory Passwords. Factory passwords are
to the appropriate Functional Tests to diagnose the calculated on a computer system available only to
cause. Caterpillar dealers. Since factory passwords contain
Diagnostic codes stored in memory are LOGGED. alphabetic characters, only an ECAP (Electronic
Since the problem may have been temporary or may Control Analyzer and Programmer) or ET (Electronic
Technician) may change System Configuration
have been repaired since the time it was logged,
Parameters. System Configuration Parameters affect
logged codes do not necessarily mean something
power family or emissions.
needs to be repaired. They are instead meant to be an
indicator of probable causes for intermittent problems. “Customer Parameters” are protected by Customer
Some of the codes require passwords to clear. Codes Passwords. The customer passwords are
programmed by the customer.
not requiring passwords to clear are automatically
deleted from memory after 100 engine operating hours. For more information refer to Section 2:
3408 & 3412 High Performance Marine Engines 1-2 Troubleshooting

Engine Sensors Atmospheric Pressure Sensor

The Atmospheric Pressure Sensor is an absolute
The 3408 & 3412 High Performance Marine Engines pressure sensor measuring crankcase pressure. Both
are an electronically controlled engine. The Electronic the boost (inlet manifold) pressure and oil pressure
Control Module (ECM) controls fuel rate instead of communicated to Electronic Service Tools and over the
using flyweights and linkages. The electronics also data link are calculated by subtracting the Atmospheric
replaces the mechanical fuel/air ratio, torque control Pressure Sensor reading.
group and various adjustment screws.
The ECM uses several sensors as inputs to control the The Atmospheric Pressure Sensor measures pressure
rack. The ECM determines the position the rack should from 0 to 116 kPa (0 to 16.8 psi). The sensor is
be at then varies the voltage to the Brushless Torque supplied by the ECM with 5 VDC.
Motor (BTM) to move the rack to the desired position.
The rack position sensor tells the ECM when the rack Coolant Temperature Sensor
is at the determined position. The standard Coolant Temperature Sensor can be
used for monitoring high coolant temperatures in
Coolant Level Sensor addition to enhancing cold starting.
The Coolant Level Sensor operates as a low coolant Coolant Temperature is used to indicate “Cold Mode”
level indicator. The sensor output will change status operation, Cold Elevated Idle, and for Engine
with the presence or absence of fluid at the sensing Monitoring.
probe tip.
Cold Mode Operation
« Coolant Level Sensor Outputs
Cold Mode Operation is activated whenever the
(All voltages are DC and referenced to -Battery Bus coolant temperature is below 60°C (140°F). During
Bar at the ECM Connector J14/P14, pin-21) Cold Mode the start rack is limited to 10mm during
A. Fluid Present engine start-up to 500 rpm.The engine will remain in a
Cold Mode state for a maximum of 5 minutes or when
Output voltage = 0.5 VDC MAXIMUM. the engine speed is above 1200 rpm the Cold Mode
B. Fluid Absent will deactivate.
Output voltage = 4.1 VDC MINIMUM. Qil Pressure Sensor

« Coolant Level Sensor Mounting Guidelines The Oil Pressure Sensor is an absolute pressure
sensor measuring oil pressure in the oil gallery. The
The sensor is supplied with thread sealant applied to difference between the pressure measured by this
the threads. No other tape or sealant should be applied sensor (oil pressure) and atmospheric pressure is oil
when mounting. Torque specifications are pressure as displayed on an Electronic Service Tool
30+ 5Nm(22£4Ibft). and communicated over the data link.
Boost Pressure Sensor The lack of oil pressure does not prevent the ECM from
starting the engine. The ECM monitors oil pressure
The Boost Pressure Sensor is an absolute pressure following engine start-up and may display a Low Oil
sensor measuring inlet air manifold pressure. The Pressure Alarm diagnostic code. The diagnostic code
difference between the pressure measured by this will not be logged for the first 15 seconds following
sensor (inlet air manifold pressure) and atmospheric engine start-up. The Oil Pressure Sensor measures
pressure is boost pressure. Boost pressure, as pressure from 0 kPa (O psi) to 690 kPa (100 psi). The
displayed on an Electronic Service Tool and sensor is supplied by the ECM with 5 VDC.
communicated over the data link, has
100 kPa (14.5 psi) subtracted from the absolute value
for all 3408 & 3412 High Performance Marine Engines.
The sensor measures pressure from 0 to 690 kPa
(0 to 100 psi). The sensor power is supplied by the
ECM with 5 VDC.

Engine Speed Sensors

The Engine Speed Sensor determines engine Speed PWM
by magnetically detecting the teeth on the flywheel PWM s Pulse Width Modulation 10% Duty Cycle
starter ring gear. The ECM will not try to start the
engine until it senses an engine Speed signal. Engine
Speed is determined by the frequency, not the voltage,
of the engine Speed sensor output signal. The output
frequency should be between 0 and 5 kHz.
Py
The 3408 & 3412 High Performance Marine Engine
uses two Speed Sensors: one the Primary Engine
Speed Sensor and the other is the Backup Engine
Speed Sensor. If the main engine Speed sensor signal
is not present the backup engine Speed sensor signal Time
will be used and the operator will be warned about the
main Speed Sensor failure. 9% Duty Cycle= HIP *100 90% Duty Cycle
H= High Porition of Signal
Rack Position Sensor P= Period of Signal
The ECM reads the rack movements from the rack Figure 1.4 - PWM Definition
position sensor. The ECM increases or decreases the
voltage to the rack solenoid until the desired position is PWM Input Requirements
reached.
* Open collector sinking Pulse Width Modulated (PWM)
Throttle Position Sensor output with pull up resistor.
The Throttle Position Sensor is used to provide a * Low sensor stop 7.5 + 2.5% and High sensor stop
throttle signal to the ECM. Sensor output is a constant 92.5 + 2.5%.
frequency signal with a pulse width that varies with * Output frequency of 300 Hz minimum, 500 Hz
throttle position. This output signal is referred to as nominal, 700 Hz maximum.
either Duty Cycle or a Pulse Width Modulated (PWM)
* Output voltage high minimum 4.0 VDC, nominal 5.0
signal and is expressed as a percentage between 0
and 100 percent. vDC.
* Ouput voltage LOW nominal 0.23 VDC, maximum
Throttle Position vs. PWM Input 0.25 VDC and 1.0mA sink current and nominal.65
VDC, maximum 0.7 VDC and 10.0 mA sink current.
100%
(Programmed » Output linearity +2.5 % (+ duty vs. throttle lever
High Idie) 7 position.
Throttle
Position %
PWM Generator ECM
0% (Throttle Position Sensor)
(Programmed
Low Idle) é. +VDC Sensor +VDC Control
0 5 10 90 95 100
PWM INput to ECM

(% Duty Cycle)
L o PUMSgnal |
. 5% "Deadband” Insures engine will reach Low and High Idle
I
. Engine drops to Low Idle and a fault is logged
Figure 1.3 - Speed Control with PWM Input

!
Figure 1.5 - PWM Input Requirements

Overspeed Protection System NOTE: The synchronization function can be activated

and deactivated when both the PORT AND
The Overspeed Protection System is designed with STARBOARD Desired Engine speeds are within 50
controls built into a single unit to monitor several rpm of each other.
functions at the same time. The functions that the
system monitor are: Trolling Mode Input
During Trolling Mode operation, the full range travel of
Engine Overspeed the throttle lever will cause the engine speed to change
This is an adjustable engine speed setting (normally from low idle engine speed to the maximum
127% of rated speed) that prevents the engine from programmed trolling speed. The Trolling Mode will only
running at a speed that could cause damage. engage when the engine speed is within 30 rpm of Low
An overspeed condition will cause relay SR1 to open Idle, it can also be activated when the engine is not
and de-energize the shutoff solenoid. The solenoid will running. The Trolling Mode Switch Input is connected
stop the fuel to the engine causing the engine to to ground when the marine gear is in Trolling Mode.
shutdown. The trolling valve activation MUST automatically
connect the Trolling Mode Switch Input to the minus
battery bus bar.
75% RESETOVER
VERFY SPEED
Minimum Maximum Default
900 rpm 1200 rpm 900 rpm
Figure 1.6 - Engine Speed Switch
Crank Termination
This is an adjustable engine speed setting that signals
the starter motor that the engine is firing and cranking
must be terminated. When the speed setting is
reached, a switch will close to start the engine
hourmeter.
Engine Synchronization
The purpose of engine synchronization is to link
multiple engine ECM's to a single throttle. This feature
adds operator convenience and is a standard practice
in marine applications to provide for either throttle to be
used in a backup situation. Engine synchronization can
be transferred to either throttle. The following code
determines throttle synchronization.
SYNCH 1 SYNCH 2 Throttle

J31 Pin-1 J31 Pin-2
-BATT OPEN Primary
OPEN -BATT Secondary

OPEN OPEN Primary

Diagnostic Warning Outputs Low Oil Pressure Lamp

The Low Oil Pressure Lamp is used to indicate engine
The electronic control system provides six different oil pressure status. Low engine oil pressure
warning lamps to warn the operator about engine and diagnostics provided by the ECM are based on engine
transmission conditions. These lamps can be used to rpm and actual engine oil pressure. On powerup
alert the operator that a limit has been reached. (keyswitch ON, engine OFF) the ECM will turn the lamp
The diagnostic lamp uses flash codes to show the ON for five seconds, then turn the lamp OFF unless the
different diagnostic conditions present in the system. ECM detects a low engine oil pressure condition.
The electronic control system provides five sinking and
one sourcing driver to annunciate the various High Coolant Temperature Lamp
conditions. The five sinking drivers are capable of The High Coolant Temperature Lamp is used to
sinking 300 mAmp and the sourcing driver is capable indicate engine coolant temperature status. On
of sourcing 300 mAmps. The wiring harness provides a powerup (keyswitch ON, engine OFF) the ECM will
diagnostic connector output and the customer can use turn the lamp ON for five seconds, then turn the lamp
the diagnostic connector outputs to drive a relay, alarm OFF unless the ECM detects a high coolant
or lamp. temperature condition.
To Switched +Batter
J31 Customer
Low Coolant Level Lamp
Connector Low Oil Pressure The Low Coolant Level Lamp is used to indicate
" engine coolant level status. On powerup (keyswitch
ON, engine OFF) the ECM will turn the lamp ON for
seeeedt
High Coolant Temperature five seconds, then turn the lamp OFF unless the ECM
detects a low coolant level condition.
Low Boost Transmission Warning Lamp

The Transmission Warning Lamp is used to indicate
engine Transmission status. On powerup (keyswitch
Transmission Warning ON, engine OFF) the ECM will turn the lamp ON for
five seconds, then turn the lamp OFF unless the ECM
detects a High Transmission Oil diagnostic code.
Diagnostic Lamp
Low Boost Lamp
The Low Boost Lamp is used to indicate engine Boost
Run Stop Lamp status. On powerup (keyswitch ON, engine OFF) the
ECM will turn the lamp ON for five seconds, then turn
the lamp OFF unless the ECM detects a Low Boost
Low Coolant Level condition.
Run/Stop Lamp
To -Battery Bus Bar
The Run/Stop Lamp is used to indicate engine status.
Figure 1.7 - Lamps When the Lamp is on the engine is off.
Warning Lamp Operation

Caterpillar Engine Monitoring System offers optional
OEM installed Warning/Alarm Lamps in order to alert
the operator of an engine problem detected by the
ECM. The action is furnished by the ECM in order to
protect the engine. The lamp output alerts the operator
that a limit has been reached.
Turn the keyswitch to the ON position, engine OFF.
The Warning Lamps will come ON for five seconds,
then turn OFF indicating the lamp circuit is functional.

Data Connections
Communication Data Link
The ECM provides output pins that are dedicated to the communication data link. The data link is available to
share data with other electronic display modules which allows a monitoring system display (GPS, EVIM, EMS, etc)
and the ECM to communicate when connected together.
ATA Data Link (SAE J1587/J1708)
Optional Electronic Service Tool Connection

NOTE: The optional electronic service tool connection is NOT recommended for the 3400 High Performance
Marine Engines.
The electronic control system has a standard data link available. The ATA (American Trucking Association), SAE
J1587/SAE J1708 Data Link is standard. The J1587/ATA Data Link communicates with Caterpillar Electronic
Service Tools.
SAE J1587 Data Link Broadcast Parameters
Broadcast Period | Parameter Name CID Size Scaling/bit

(bytes)
0.4 sec. Engine Speed 190 2 0.25 rpm

Coolant Level Status 1M1 1 0.5% full
0.5 sec. Throttle Position 091 1 0.4%
Fuel Rate 183 2 4.34X10e-6 gal/
Boost Pressure 102 1 0.125 psi
Transmission Pressure 127 1 2psi
Transmission Temperature 177 2 1 °C 2’'s compliment
0.6 sec. Coolant Temperature 110 1 1°F

Qil Pressure 100 1 0.5 psi
Atmospheric Pressure 106 1 0.25 psi
Engine running hourmeter 247 4 1hr
20.0 sec. ECM Serial Number 193 Variable | 10 characters

Engine Serial Number 195 3 8 characters
Personality module Part Number 192 Variable 10 characters
0.5 sec. Engine Diagnostic 194 Variable | CID & FMI

CAT Data Link

CAT data link is a proprietary communication medium
available on all Marine Engines. The connection is for
communication with other microprocessor based
devices such as the Electronic Control Module, GPS,
EMS, or the Engine Vision Display.
Engine Room
(CAT DatalLik- 00 CAT Deta Link+ 9
Data Bus 7
TemminalStip #1
Tvistd Par
18 AWG
PORTECM _ P14J14 P31 431 J31 P31 J14P14 STBDECM
(CAT DataLink- 1] 2N K| <caT DaaLik +

(AT DataLink +[58 L u foefcaT otaLink-
Figure 1.8 - Data Connections

NOTE: Proper wiring of the Cat Data Link System is
essential for proper display operation. The CAT Data
Link System should use the 143-5018 CAT Data Link
wire. The installation should use a dedicated terminal
strip for the CAT Data Link connections. This terminal
strip should be located in a location that minimizes the
length of the CAT Data Link data wire run. There
should be only one set of twisted pair data wires that
run to the bridge displays. If a second station is to
utilize a Caterpillar display group, then the Data wires
should be installed from the engine room terminal strip
to the first station and continued from the first station to
the second station.

CAT Data Link

PORT EMS
step EMs
ope 14 €o-
ol il H< |5 <o+
Twisted ar Tuisted Paic Engine Vision

BANG T8 AWG
EVIM
+BB D +D
Data Bus
Terminal Strp #4 8'0 0'8
o 0
— Twisted Pair
Twisted Pair 18 AWG
18ANG
CAT DataLink - o CAT Data Link +
PORT EMS STBDEMS

o (1 14 €0
D> 14 |5 <o+
Twisted Pair
BANG
Data Bus
T s 2 0-8
CAT DataLir o o ‘CAT Data Link +
Twisted Pait
18 A\
PORT ECM P14J14 P31J31 J31P31 J14 P14 STBD ECM
(CAT Data Link- [>-19] 2 1 lo <{CAT Data Link +

[CAT Data Link + [»9 18| 24 |19€{ CAT Data Link -
Figure 1.9 - CAT Data Link Schematic

3408 & 3412 High Performance Marine Block Diagram
Service Tool
P rimary Speed Sensor 10410 |

|
|
|
|
I
I
|
|
|
Coolant Temperature Sensor J12/P12 Customer |
Connector) |
I
R ac'fi Low Oil Pressure Lamp 1
Boost Pressure Sensor 1
fl‘aHigh Coolant Level Lamp I
|T
I
Oil Pressure Sensor I ’_mfimw Coolant Level Lamp
I T T I
*fi Low Boost Lamp |
Shut-Off Solenoid I” TR |
1
afi Transmission Warning Lamp |
| sz |
1 Diagnostic Lamp |
|e
U
Rack BTM 1
Trolling Mode I
I
Ll Synchronization Switch I
I
Rl Slow Vessel Mode 1

I
il
Rack Position Sensor Engine Shutdown Switch I
|
Primary Throttle and 1
I
090>
Throttle Position Sensor 1
I
— >
Figure 1.10 - Block Diagram

Sensor and Connector Locations
cusTouER c c
CORNECTION - =
@31 r 0
RACK_POSITION
SENSOR (P11)
ATA DATA
LiNk” (413):
S
COOLANT LEYEL
SENSOR' (P7,
&
J
PL
€ 5 o
e - — ENGINE_OIL
XUSN_ TEWP. I / F———— 5PRESSURE SENSOR
SENSOR (434)
A= = =
BACKUP SPEED
sensor (P16) |
RSTS)
ENGINE COOLANT
TEMPERATURE
sheon 1o LU ——-—
EHEb P Wlenon (es)

CYLINDER HEAD
VIEW €-£ e
RlBK BRTe) e
Beloho i
Bt T \
- /
VIEW D-D
Fol¥iE" as.
ViEW B-8
VIEW A=A
E10859
Figure 1.11 - Sensor and Connector Locations

3408 & 3412 High Performance Marine Connectors

Deutsch “HD” Receptacte Deutsch "HD" Plug
ECM Connector (Rear View)
—
Deutsch DT Connector Receptacle
Receptacle Wedge
ECM Connector (FrontView)
= - -
Mo s 7 e 5 482 1 2
oocooco | ©0000
Deutsch DT Connector Plug lm OO O O Ol o 150 O OO O)n
Plug Wedigo - : %O O O O Ofs :500000??'
Ll O0000O Q0000 |
|p> e 1 _40 39 38 av_és 3836 33 32 31
Deutsch Pin Contact Deutsch Socket Contact Gustomer Connecto (Fron Vew) Customer Connector (Rear View)
Deutsch Sealing Plug
Figure 1.12 - Connector Diagram

Operator Station Grounding Connections

Caterpillar recommends a dedicated -Battery Bus Bar for all Caterpillar electronics. This connection ensures that
the ECM and all components, including switches, sensors and electronic display modules have a common
reference point.
All -Battery connections should begin at the Engine Room -Battery Bus Bar and terminate at the Station -Battery
Bus Bar. The connection from the Engine Room -Battery Bus Bar to the Station -Battery Bus Bar should be made
with a minimum of 12 AWG wire. There should NOT be any other components connect to the Caterpillar -Battery
Bus Bar. Properly connected systems are a MUST to provide reliable operation.
12 AWG
Station 1 o Station 2
® -Battery Bus Bar @ @ - Battery Bus Bar
®
12 AWG Port
| P31/J31
-
19| -Battery
13| +Battery
STBD
P31/J31
= 0l |_ 13| +Battery
l_‘ J 19| -Battery
Engine Room | !
- Battery Bus Bar
Figure 1.13 Operator Station Battery Grounding

Wire Size Requirements

The wire size to all Caterpillar components must be of adequate size to handle the maximum current of the circuit.
All +Battery and -Battery connections to the ECM Customer connector should be made with
14 AWG wire, this includes the -Battery connections from the Engine Room -Battery Bus Bar. The connection from
the Engine Room -Battery Bus Bar to the Station -Battery Bus Bar displays should be made with a minimum of
12 AWG wire. The CAT Data Link connection should be made with the 143-5018 data wire. Caterpillar
recommends the use of 143-5018 for ALL Cat Data Link Connections.
All other connection should be made with 16 AWG wire minimum.
NOTE: No other components are allowed to be connected to the Caterpillar -Battery wire to the bridge displays.
P14 J14
To Bridge 21€] -Battery
Displays 1 <] +Battery
14 AWG
12AWG Minus Battery ECM

Bus Bar Circuit [( 15
Start (Ignition) Switch Breaker|
Common off
— b O+Run
|_| | ,,J Start
Figure 1.14 Wire Size Requirements

Wiring Harnesses Routing of the harness should ensure the connector

seal is not stressed because the harness wiring
The ECM uses an integral 40-Pin Deutsch Connector curvature is too close to the connector. This applies to
(J14/P14) and a 24-Pin Deutsch Customer Connector the engine sensors and all connections to the J31
(J31/P31) to interface the engine electronics to the Customer Connector.
customer wiring harness. The control system has been The previous diagram illustrates the problem if the
designed to operate on 12 VDC or 24 VDC electrical harness curvature is too close to the connector. When
systems. The control system is protected against jump this occurs the connector seal is stretched away from
start conditions and short circuits to the battery. As the wire, providing an opening for moisture entry. The
stated previously for ECM connectors J14/P14 and all wire should exit perpendicular to the connector with
unused J31/P31 Customer Connector socket slots 25 mm (1.0 in) of straight length before curving as
must be filled with plugs to ensure connector proper necessary for routing. The harness bundle should have
sealing. a bend radius greater than twice the harness diameter.
OEM Harness Routing/Design Correct

25 Installation
Incorrect
Installation
u
P Wire Exiting Straight Out
Of Connector Correctly
Harness Pulled Toward Center Harness Correctly Routed

Too Close To Connector
Figure 1.16 Harness Routing At ECM and Customer

Connectors
Twisted pair wiring should be used for the CAT Data
Harness Pulled Up Wire Exiting Pulled Link. There should be a minimum of three twist per
Too Close To Connector Up On Connector 25.4 mm (1.00 in) within the harness. All twisted pair
Incorrectly
wires should not be twisted within an in of the
connector to avoid seal stress.
Figure 1.15 Improper Harness Routing At ECM and
The acceptable range for the wire insulation outside
Customer Connectors
diameter is 2.54 to 3.43 mm (0.100 to 0.135 in) for the
J3/P31 40-Pin Customer Connector and 2.54 to 3.81
mm (0.100 to 0.150 in) for the HD Connectors. DT
Connectors wire insulation diameter is 2.4 to 3.68 mm
(0.088 to 0.145 in).
Caterpillar requires all ring terminals and splices
connected to the Customer Connector be sealed using
Raychem ES2000 adhesive lined heat shrink sleeve
(Caterpillar 1E2358 Specification) or equivalent.

Service Tools ECAP Parts Required

The Caterpillar Electronic Service Tools for the Service Tools - ECAP
electronic control system are designed to help the
service technician analyze and locate faults or Part No. Description
problems within the system. It is required to perform
8T8697" Electronic Control Analyzer Programmer
some sensor calibrations electronically, and to read or (ECAP)
change engine parameters.
NEXG451623 |Marine Engine Functions Service
The Electronic Control Analyzer Programmer (ECAP) Program Module (SPM) for 878697
tool has small plug-in modules, called Service Program ECAP
Modules (SPM), to adapt the basic tool to the specific
Caterpillar electronic control application. 875275 Harness Connector Cable (to haress
or adapter, plastic ECAP Port 1 Connector)
Caterpillar Electronic Technician (ET) requires a 139-4166% to ECM or Harness Connector Cable (to
personal computer with the ET software installed and harness adapter, metal ECAP Port 1
either a Caterpillar Communication Adapter to translate Communications Adapter Connector) to
from the data link to the computer RS-232 port. ECM
The ECAP or ET communicates with the Electronic 7X1180% Internal Expansion Board
Control Module to read diagnostic codes, to read the
SEHS8742 Special Instruction
various sensor output signals such as engine rpm, or
boost pressure, and controls electronic calibration of SEHS9199 Tool Operating Manual
the sensors through the ECM.
The ECAP (requires PWM adapter to measure at the " Refer to Special Instruction SEHS8742, Using the
sensor) can measure Pulse Width Modulated (PWM) 8T8697 Electronic Control Analyzer Programmer
signals, such as the signal produced by the Throttle
(ECAP).
Position Sensor. 2The NEXG4516 Service Program is a subscription
which will be updated regularly to service all 3406E
There are several adapter cables, breakout T cables, Marine engines.
probes, etc, that are used with the Electronic Service
Tools in order to access measurements of signals. 3 Refer to Operating Manual SEHS9199 to use the
NEXG4516 Marine/Industrial Functions Service
The Breakout T harness is inserted in series between a Program.
harness jack and plug to permit voltage measurement
“*The 139-4166 replaces the 7X1412 and the 7X1570.
on an operating system. The Bypass T harness is used
to bypass the harness signal lines for engine sensors 5 Referto Special Instruction SEHS8833 for installing
the 7X1180 Internal Expansion Board in the 8T8697
A heavy duty multimeter is suitable for making the ECAP Service Tool.
necessary measurements. Other Special Tools include
those needed to measure pressure or temperature.
8T8697 Electronic Control

Analyzer Program
Figure 1.17 - ECAP

Connecting ECAP Electronic Service Tool Connecting ET Electronic Service

and Communication Adapter Tool Tool and Communication Adapter Tool
The Electronic Control Analyzer & Programmer
(ECAP) is powered from the engine battery source. ET consists of an IBM compatible computer and
Use the following procedures to connect the ECAP to software. The software allows the laptop user to
the Service Tool data link Connector. program ECM parameters, read and display values
1. Tum the keyswitch to the OFF position. o e P
and switches, perform
9
diagnostic tests
and and calibrate
calibrat
2. Connect the Electronic Service Tool to the

electronic system through the J13 Data Link
Connector. Part Description
3. Connect the opposite end of the adapter cable to Number

the Electronic Service Tool. Turn the keyswitch to None'! IBM PC Compatible - Minimum of 486 (33
the ON position to begin testing. The Electronic MHz)
Service Tool will operate with the engine running
(keyswitch ON) or with the engine off (keyswitch None' 1BM PC compatible- Recommended
ON). If the Electronic Service Tool does not 133 MHz processor, 24 Mb RAM,
communicate with the ECM, Refer to Section 3 1Gb of available hard disk space
P-307: Electronic Service Tool Will Not Super VGA monitor or display,
Communicate With ECM. Windows NT, Windows 95 or
NOTE: The Electronic Service Tool may restart IBM OS/2 Warp 3.0,
during engine cranking due to a voltage dip on the RS232 port with 16550AF UART
battery line. Built in pointing device or mouse.
4X Speed CD Rom, 3.5 144 Mb drive.
JERD2124" | Single User License for ET Version 1.4 or

later (Main ET Program)
JERD2128 Truck and Commercial Engine Data

or Subscription
JERD2129' | Data Subscription for all engines.
NEXG4523% | SPM for 7X1700 Communication Adapter
Group Version 1.2.
7X17002 Communication Adapter Group for use

between ET and ECM. (Includes 7X1701
Communication Adapter Tool, 6V3072
Case, 7X1569 Fuse, NEEG2464, and
SEHS9264.)
7X1425" Connector Cable - Connects PC to
Communication Adapter Service Tool
Port.
139-4166" Cable Group connects Engine Harness

Service Tool Connector J13 to
communications Adapter Control Port.
1 Contact the PC hotline at 1-800-The PCDR

(1-800-843-7237) for more information.
2Refer to Tool Operating Manual SEHS9264,

Installation and Use of the 7X1701 Communication
Adapter Tool. The NEXG4523 Service Program
Module operates with 7X1700 Communication
Adapter to service all 3408 & 3412 High Performance
Marine Engines.
3|t is anticipated that the NEXG4523 will be updated

at regular intervals.

The Communication Adapter Tool uses DC power from

Part No. Description
the battery. Use the following procedure to connect ET
and the Communication Adapter service tools to the 1U54703 |Pressure Group (used to measure oil
engine. pressure).
1. Turn the keyswitch to the OFF position. 6V9130 |Temperature Adapter Group
NOTE: If the keyswitch is not placed in the OFF
position, the engine may start and run. 1 Refer to Special Instruction SEHS8740 for using the
9U7554 Rechargeable Portable Printer.
2. Connect the 139-4166 cable between the Engine
Service Tool Connector (9-Pin, gray plastic, 2Refer to Operating Manual SEHS8834 for using the
Deutsch) and the Communication Adapter NEXG4512 Customer Parameter Configuration Aid
CONTROL Connector. Service Program Module.
3. Connect the 7X1425 cable between the laptop 3 Refer to Special Instruction SEHS8907 for using the
RS232 serial port and the Communication Adapter 1U5470 Engine Pressure Group.
SERVICE Connector.
4. Turn the keyswitch (or ECS) to the ON position,
engine OFF to begin testing. This will provide
Battery voltage to the ECM. ET and the
Communication Adapter Tool will operate with or
without the engine running. If ET and
Communication Adapter Tool do not communicate
with the ECM, Refer to Section 3:
P-307: Electronic Service Tool Will Not
Communicate With ECM.
Optional Service Tools
Part No. Description

129-2018 |Power Cable (allows Electronic Service
Tool to be powered directly to a battery
source). This tool is used only when
viewing parameters and status screens
during engine cranking.
9U7554 ' |Rechargeable Portable Printer. Prints

parameters, sensor readings, etc.
6V7070 |Heavy Duty Digital Multimeter
7X1710 [Signal Reading Probes

5P7277 |Voltage Test Lamp
1U5805 |Pin Removal Tool (14 AWG wire) used
for removing pins and sockets from
Deutsch Connectors.
8T5318 |Pin Removal Tool (16 & 18 AWG wire)
used for removing pins and sockets
from Deutsch Connectors.
4C3406 |Connector Repair Kit (includes 1U5804
crimping tool).
9U5103 |Slotted Socket (for Coolant
Temperature Sensor Removal).
9S9082 | Turning Tool (permits turning engine by
hand).

Service Tools
N 7X1701
8T8697 Electronic Control P
Analyzer Program Communication
Adapter
igital Muliti 6V7070 Heavy Duty

igital Mulitimeter ®ry ital Mulitimeter
T T
1U5804 8T5318 Pin Removal Tool ~ 1U5718 Extraction Pump
7X710 Signal Reading Prob 8C9801 PWM

—?Igna eaging Frobe Signal Adapter Group
/= —c——
Electronic Technician
Figure 1.18 - Service Tools

Service Information Report

After verifying the correct repair has been performed
on the vessel it is important to provide concise, detailed
information to Caterpillar. This information helps
Caterpillar better serve you and the Customer.
Recommendations
Provide a copy of the ‘Customer Questionnaire’ located
on in Section 3: Troubleshooting Without A
Diagnostic Code in this manual. Include comments for
the Customer’s Complaint section of the report
indicating if the Diagnostic/Warning Lamp was on
continuously or intermittently and if symptoms such
as low power are present.
Failure Cause
Comments on Failure cause should include the
number of diagnostic codes that were logged and if
the code was Active. Indicate the source of the
problem and how it was discovered, such as followed
procedure P-514, or a visual inspection revealed
wire abrasion on the engine harness.
How you repaired the engine

Include comments about your actions such as repaired
the wiring harness or changed FLS/FTS as per factory
instructions, etc.

Section 2: Programming Parameters
Programmable Parameters System Configuration Parameters
Many programmable parameters affect engine System Configuration Parameters affect emissions or
operation. Certain parameters affecting Marine Engine power of the engine. They are programmed at the
operation may be changed with an Electronic Service factory and would normally never need to be changed
Tool. Some parameters may affect engine operation in through the life of the engine. System Configuration
ways an operator does not expect. Without adequate Parameters must be reprogrammed if an ECM is
training, these parameters may lead to power or replaced. Proper values for these parameters are
performance complaints, even when the engine is stamped on the Engine Information Plate. The
performing to specification. following is a description of the System Configuration
Parameters.
The parameters are stored in the ECM, and are
protected from unauthorized changes by passwords. Full Load Setting
These parameters are either System Configuration
Parameters or Customer Specified Parameters. Any The setting number represents the fuel system
parameter can be read, however, passwords protect adjustment performed at the factory to fine tune the
parameters from unauthorized changes. fuel system. A new ECM must have this parameter
programmed to avoid generating a Diagnostic Code
Two categories contain various parameters, System 253-02 Check Customer Or System Parameters (56).
Configuration Parameters and Customer Specified
Parameters. System Configuration Parameters can be Full Torque Setting
altered only with the proper factory passwords using an
Electronic Control Analyzer & Programmer (ECAP) or Similar to Full Load Setting this parameter is
Caterpillar Electronic Technician (ET). Customer programmed at the factory. Factory level passwords
Specified Parameters can be changed using an are required to change the Full Torque Setting. A new
Electronic Service Tool only with the proper customer ECM must have this parameter programmed to avoid
passwords. generating a Diagnostic Code 253-02 Check Customer
Or System Parameters (56).
Refer to the topics, Passwords, System Configuration
Parameters and Customer Specified Parameters for Personality Module Code
more details on how to receive and use factory
passwords and customer passwords. Code which prevents use of incorrect Personality
Module for this engine. Each power family has a
System Configuration Parameters are set at the different code associated with it.
factory and affect emissions or power ratings within a
family of engines. Factory passwords must be obtained When a Personality Module is replaced, this code
and used to change System Configuration Parameters (stored in the ECM) must match the one in the
introduced Personality Module or the engine will only
Customer Specified Parameters are variable and can run at low idle and a Diagnostic Code 253-02 Check
be used to affect engine rpm limits, rpm/power ratings Customer Or System Parameters (56) will also be
within the limits set by the factory and Caterpillar generated.
Engine Monitoring. Customer passwords are
necessary to change Customer Specified Parameters. When rerating the engine, programming this code to
“0” will prompt the ECM to read and match its stored
code to the Personality Module Code.
Engine Serial Number

The engine serial number should be programmed to
match the engine serial number stamped on the
Engine Information Plate. A new ECM is delivered with
the engine serial number programmed to 0XX00000.

Programming Parameters
Customer Specified Parameters Transmission Oil Temperature

The ECM monitors Transmission oil temperature with
Customer Specified Parameters allow the engine
the Transmission Oil Temperature Sensor. The sensor
owner to influence how a unit operates. Some can measure temperatures up to 120°C (248°F). High
parameters may affect engine operation in ways an transmission oil temperature can be programmed to
inadequately trained operator does not expect. These any value from 50°C to 120°C (122°F to 248°F).
parameters may lead to power or performance
complaints, even when the engine is performing to Transmission Oil Pressure
specification.
The ECM monitors Transmission oil pressure with a
Customer parameters may be changed repeatedly as a sensor located on the high pressure side of the
customer changes his operation or as new operators Transmission. The high Transmission Oil Pressure
are assigned. Customer passwords are required to set point can be programmed to any value between
change these parameters. 700 kPa and 2963 kPa.
The following is a brief description of the Customer
Specified Parameters with the minimum and maximum Trolling Speed:
values for the parameter and the default value. MaximumTrollling speed can be programmed to any
The tables show values in metric units followed by an value from 900 to 1200 rpm.
approximate range for the US (or English) equivalent.
Engine Power Rating Selection Number Maximum Default

The rating # selected within the power family. The 1200 rpm 900 rpm
Personality Module defines the power family [such as
242 kW (325 hp)] and may contain only one or several
ratings. The rating number defines which rating is used Customer Passwords
[such as 242 kW (325 hp) and 1900 rpm or 242 kW Two eight character password that protects the
(325 hp) and 2100 rpm] within the family. Customer Programmable Parameters.
Vessel ID
Identification number (or name) of the vessel assigned
by the customer and used only for customer reference.
Not required by the ECM.
Low Idle Engine RPM

Minimum programmable engine rpm that the engine
will run with the throttle in the Low Idle Position.
Minimum Maximum Default

600 rpm 750 rpm 700 rpm
Engine Location
Identifies PORT, CENTER and STARBOARD
locations for multiple engine installations. This feature
must be programmed for Engine Vision and the EMS
Display to work properly.

Passwords Customer Passwords
Factory Passwords If customer passwords have been entered, they are

then required to change ANY Customer Specified
Factory passwords are required to perform each of the Parameter. Customer Specified Parameters are those
following four functions. that affect engine rpm limits and power rating within a
family. Refer to the Customer Specified Parameters for
1. Program a new ECM. more detail on what parameters are customer
- When an ECM is replaced, the System programmable.
Configuration Parameters must be programmed
The ECAP or ET Electronic Service Tools may change
into the new ECM. For a new ECM these
Customer Specified Parameters. To obtain customer
parameters can be programmed once without
passwords, contact the owner of the unit. If the owner
factory passwords, thereafter these parameters
has lost his passwords, customer passwords may be
are protected by factory passwords. read using an Electronic Service Tool (factory
Read customer passwords. passwords are required in order to read the customer
- If the owner loses his customer passwords, he passwords). Follow the procedure below.
will not be able to program Customer Specified 1. Use the Electronic Service Tool to access Read/
Parameters. Using factory passwords, one can Change System Configuration Parameters, then
read customer passwords, then use those read customer parameters.
customer passwords to program Customer
When the Factory Passwords screen appears,
Specified Parameters.
record the information listed on the Factory
Clear certain diagnostic codes. Passwords Worksheet.
- Diagnostic Code 190-00 (Engine Overspeed Obtain the factory passwords. The information
Warning) requires factory passwords to clear recorded above must be provided, and generates a
once it is logged. permanent record at Caterpillar of the access.
Enter the factory passwords from the Factory
NOTICE Passwords screen.
Installing an ECM with a 3400 Marine Engine When the Read Customer Passwords screen
Personality Module on another engine (or the appears, record the customer passwords. The
reverse) will damage the engine. Be sure the customer passwords may then be used to change
Personality Module is correct for your engine. Customer Specified Parameters.
To obtain factory passwords, proceed as if you already System Configuration Parameters are protected by
had the password. At some point, if factory passwords factory passwords. Factory passwords are calculated
are truly needed, the ECAP or ET will request factory on a computer system available only to Caterpillar
passwords and display the information required to dealers. Since factory passwords contain alphabetic
obtain the passwords. characters, only an ECAP or ET Electronic Service
Tool may change System Configuration Parameters.
System Configuration Parameters affect power family
or emissions.
Customer Specified Parameters are protected by
customer passwords. The customer passwords are
programmed by the customer. Refer to Programmable
Parameters, for more details when passwords are
needed and how to obtain them.

ECM Replacement Procedure (c) Remove the fuel lines, ECM mounting bolts and
disconnect the ECM ground strap.
Replacing The Electronic Control Module
With A New ECM
The Electronic Control Module (ECM) is the heart of
the electronic control system used on the 3408 and Use caution when removing fuel lines. The
3412 High Performance Marine Engine. The ECM fuel may be under pressure and can
contains no moving parts, has a very high reliability penetrate body tissue.
rating and replacement can be time consuming. Most
problems occur in the connectors, wiring, or sensors.
Follow the troubleshooting procedures outlined in this d) DO NOT lose any of the ECM mounting
guide. DO NOT replace an ECM on speculation! hardware (i.e. rubber grommets, spacers and
washers).
To ensure the suspect ECM is the cause of the
problem, temporarily connect a new or test (known e) Ensure the old ECM’s mounting hardware is free
good) ECM, before replacing the old ECM. To of damage and use it to install the new ECM.
temporarily connect a test ECM you must transfer the Reconnect the fuel lines. Ensure the ECM
Personality Model data from the old ECM to the test mounting hardware is installed correctly. Verify
ECM and program any necessary parameters required the fuel lines are not tugging or pulling on the
for testing (the parameters must be programmed ECM. The rubber grommets are used to protect
exactly as they were in the old ECM.) Refer to the the ECM from excessive vibration. When
following test steps for details. If the test ECM resolves installed correctly, the ECM can drift in the
the problem, reconnect the old ECM and verify the rubber grommets. If the ECM cannot be moved
problem returns. If the problem returns, replace the old slightly in the grommets, check that the fuel
ECM. lines are not pulling the ECM against one side
of the grommets.
The parameters stored in the ECM to be replaced,
must be read with an Electronic Service Tool and (f) Reconnect the 40-Pin Deutsch connector and
recorded. The Personality Module from the old ECM the ground strap to the ECM.
must be installed in the new ECM. After the new ECM Step 3: Calibrate the Rack Position Sensor.
is installed on the engine, the parameters recorded Use the Electronic Service Tool to select
from the old ECM must be programmed into the new
Monitor/Calibrate option to calibrate the sensor.
ECM and the Boost Pressure and Rack Position
(Refer To P-378: Rack Position Sensor
Sensor must be recalibrated.
Calibration).
NOTE: If the parameters cannot be read they must be
obtained elsewhere. Some parameters are stamped on Step 4: Calibrate the Boost Pressure Sensor. (Refer to
the Engine Information Plate, but most parameters P-602: Boost Pressure Sensor Calibration.)
must be obtained from the user or dealer that installed
the engine.
The following procedure is a summary of the basic
steps necessary to program a replacement ECM.
Step 1: Use a copy of the Read/Change Parameters
Worksheet in this manual to record the Parameters
from the ECM being replaced.
NOTE: It is recommended to record any Logged
Events also.
(a) Use an Electronic Service Tool to access
Parameters from the ECM being replaced.
(b) Record the Parameters listed on the worksheet.
Step 2: Replace the faulty ECM.
(a) Turn the keyswitch to the OFF position.
(b) Use a 4 mm Allen wrench to disconnect the
40-Pin Deutsch connector.

Personality Module Install the Personality Module Access cover.

Ensure the O-Ring is seated properly.
The Personality Module is the software which controls NOTE: Improper O-Ring placement could result in
how the ECM behaves. The Personality Module moisture damage form improper sealing.
consists of all of the software, or instructions for the - Program any parameters not previously in the old
ECM to operate correctly. When troubleshooting Personality Module if 253-02 Check Customer Or
indicates that a failure has occurred in the ECM or System Parameters (56) code is active. Read the
Personality Module then temporarily install a new part code from the Active diagnostic code screen of
and thoroughly retest. the Electronic Service Tool to determine the
NOTE: Updating the Personality Module to a different parameter(s) requiring programming.
version may cause some engine functions to behave in - Remember, on initial powerup of a new ECM,
a different manner. parameters must be programmed to avoid a 253-
1. Remove the Personality Module Access Cover. 02 Check Customer Or System Parameters (56)
code.
Start the engine and check for proper operation.
Personality/
Module
Access Cover
L o)
Personality Module
2. Firmly grasp the release clips on the old

Personality Module and detach the module from
the ECM.
3. Install the new Personality Module into the ECM
making sure it seats properly into the Personality
Module socket.
NOTE: The socket is keyed to accept the
Personality Module in one position only. A “Click”
can be felt when the module is pushed incorrectly.

Factory Passwords Worksheet Lifetime Totals Worksheet
NOTE: A mistake in recording these parameters will Total HOUrs ........cccocuuvunnaes

result in incorrect passwords.
P Total Idle HOUTS ...
Dealer Code
Average Load Factor (%) ....
Customer name .....
Total Fuel ....
Address ...
Total Idle Fuel .........ccoooveiiiiinniinies
Total Max Fuel ..........cccccooecueinnnee
Phone Number
From Engine Information Plate Customer Parameter Worksheet
Engine SIN ...
Selected Engine Rating
Full Load Setting
. Rating # ....
Full Torque Setting ........... K
. ECM Identification Parameters
From Unit Hour Meter Unit ID
ni
Engine Hours
. Engine Monitoring Parameters
From Factory Passwords Screen on Electronic
Service Tool Engine Monitoring Mode................
Electronic Service Tool S/N . Coolant Level Sensor ...................
Engine Serial Number Maintenance Indicator Parameters
Electronic Control Module S/N Maintenance Indicator Mode

Total Tattletale .................. PM1 Interval (Hours)
Reason Code PM1 Reset

NOTE: The following two parameters are necessary, Customer Passwords
and therefore only displayed, when re-rating an engine. customer Password #1 ..o,
From Interlock ................... Customer Password #2 ...........ccccoeeeinens
To Interlock ......covvvieiieici
Factory Passwords
Factory Password #1
Factory Password #2

SECTION 3: Troubleshooting Without A Diagnostic Code
This section is to be used for troubleshooting problems Operator Information
that have symptoms but do not have ACTIVE
diagnostic codes. Some engine symptoms are caused + What happened, and when?
by conditions or components other than the electronic * Under what conditions?
control system, such as poor fuel quality or improperly
adjusted valves. Was the engine speed (rpm) high or low?
Before using this section, be sure that you have Was the engine under load?
gathered information about the complaint to adequately « Are there any customer or dealer installed systems
describe the symptoms, verify that the complaint is not that could cause this symptom?
due to normal engine operation and repair all ACTIVE
Diagnostic Codes. Refer to Section 4: * What else occurred?
Troubleshooting With A Diagnostic Code. « When did the symptoms begin (and what else
The basic philosophy of troubleshooting this engine is happened at that time)?
to follow the three steps listed below FIRST to
diagnose a malfunctioning engine: LOGGED Diagnostic Codes
1. Gather Operator Information. Verify complaint is not + Do they correlate to probable causes?
due to normal engine operation. « Did they occur at the same time as the symptoms?
2. Perform a visual inspection of the engine. Check « Are some codes Logged repeatedly?
fuel and oil level, supply and/or condition. Check for
visible wiring and connector problems or damaged Other Symptoms
components.
* Are they related to this symptom?
. Check and repair all ACTIVE/LOGGED Diagnostic
Codes using the troubleshooting procedures in « Do they have common probable causes?
Section 4: Troubleshooting With A Diagnostic Finally, test each probable cause using the tests
Code. suggested by the procedure. Be sure to check
If ALL three of these inspections reveal no problems, connectors, especially on intermittent problems!
identify probable causes using the procedure or Refer to Section 5: P-501: Inspecting Electrical
procedures in this section that best describes the Connectors for details.
symptoms. Narrow the probable causes given in the
procedure by considering operator information,
operating conditions, and repair history of the vessel.

Troubleshooting Without A Diagnostic Code
Operator Questionnaire
Ask the operator to answer the following question before attempting to repair an intermittent problem, or a problem
with symptoms but no diagnostic codes. Use this and the response guidelines to these questions on the next
page.Questionnaire Response
Question Yes/No Comments

1. Does the Diagnostic/Warning Lamp come ON during
or after the problem occurs? How long does it stay
ON?
2. How often does the problem occur? Can the problem

be demonstrated within one hour?
3. Has the vessel been to other shops for the same

problem? If so, when and where?
4. Did the engine completely shut down, requiring a

restart?
5. How long did you have to wait before you could

restart the engine?
6. Did the engine hesitate/burp/misfire without a

complete shutdown?
7. Did one set of gauge displays turn OFF when the

problem occurred? Did the gauges display an
ERROR message?
8. Did both sets of gauge displays turn OFF when the

problem occurred? Did both sets of gauge displays
display an ERROR message when the problem
occurred?
9. Does the problem occur at a specific engine rpm? If
so, at what engine rpm?
10. Does the problem occur only at specific engine

loads? If so, at what load? Is it light, medium, or
heavy?
11. Does the problem occur at a specific engine

operating temperature? If so, at what engine
temperature?
12. Does the problem occur only when above or below

specific outside temperature? In what temperature
range?
13. Does the problem occur during other conditions

(during or after rain, or spray washing)?

Question Yes/No Comments

14. Does the problem occur when the engine are in
synchronization? If so, synchronized to the PORT
engine or the STBD engine?
15. Does the vessel kick out of synchronization, trolling

or slow vessel mode?
Response
1. If the Diagnostic/Warning Lamp illuminated there will be a logged diagnostic code. If the operators
symptoms do not match the symptoms for the diagnostic code, troubleshooting the diagnostic code will not
correct the problem.
2. If the problem is easily repeatable, take the vessel for a test run with an Electronic Service Tool and not the
conditions when the problem occurs.
3. If the vessel has been to other shops for the same problem, call the other shop and find out what has been
done. Avoid replacing the same components again unless absolutely sure they are the problem. It is unlikely
a component will fail again after a recent replacement.
4. If the engine shuts down completely, check the ECM battery connections, -Battery Bus Bar connections, fuel
system, fuel and engine Speed Sensors. Refer to P-305: Intermittent Engine Shutdowns.
5. If the engine will not restart. Repair as required. If the engine shuts down completely, check the ECM battery
connections, -Battery Bus Bar connections, fuel system, fuel, and engine Speed Sensors. If the engine will
not restart, refer to P-302: Engine Cranks, But Will Not Start.
6. Check for Cold Mode operation. The engine will operate in Cold Mode when the coolant temperature is
below 60 °C. During cold Mode the start rack is limited to 10 mm during engine start-up to 500 rpm. The
engine will remain in Cold Mode for a maximum of 5 minutes or when the engine speed is above 1200 rpm
the Cold Mode will deactivate. If the engine is not operating in Cold Mode, check the ECM battery
connections,
-Battery Bus Bar connections, fuel system, fuel and engine Speed Sensors. Refer to P-303: Engine
Misfires Runs Rough Or Is Unstable.
7. If one set of gages tuned off, after the power up sequence, check the battery connection to the display. If one
set of gauges displayed an ERROR message, check the battery connection to the ECM. If one set of gauges
turned off, after the power up sequence and the engine burped when the display turned off, check the
-Battery Bus Bar connections for that engine. Refer to P-346: Electrical Power Supply To The ECM.
8. If both sets of gauges turned off after the power up sequence, check the battery connection to the display. If
both sets of gauges turned off after the power up sequence, and the engine burped when the display turned
off, check the -Battery Bus Bar connections to the engines. Refer to P-346: Electrical Power Supply To
The ECM. If both sets of gauges displayed and ERROR message, check the -Battery bus Bar connections
to the ECM. Refer to P-346: Electrical Power Supply To The ECM. If the battery connections to the ECM
and displays are OK, then refer to P-344: Cannont Communicate Over The CAT Data Link.
9. If the problem occurs at a specific engine speed, check the Top Engine Limit and set it to the maximum value
and verify the problem is corrected.
10. Operate the engine under similar load conditions. Check the low pressure fuel lines for restriction, fuel/water
separator, and fuel tanks/lines for foreign objects blocking the fuel supply.

Response
the Cold Mode will deactivate.
the Cold Mode will deactivate.
13. If the problem occurs after the vessel has been subject to rain/spray washing, thoroughly inspect the
connector for moisture entry. Refer to P-501: Inspecting Electrical Connectors.
14. If the problem occurs when the engines are synchronized check the -Battery Bus Bar connections to both
ECM's ensure that both ECM's and the Throttle Position Sensors are connected directly to the -Battery Bus
Bar. Refer to P-346: Electrical Power Supply To The ECM.
15. If the engines kick out of a switch feature while the switch is supposed to be engaged, check the -Battery
Circuit to the switches. Refer to P-342: Switch Fault or P-343: Engine Synchronize Switch Not
Functioning Properly.

P-301: Engine Will Not Crank . Verify timing pin was not left in the flywheel housing
after setting valve lash. Visually inspect timing hole
NOTE: This is NOT an electronic system problem. to verify pin is not present. Use the 959082 Engine
Refer to the Systems Operation, Testing & Turning Tool and attempt to manually turn the
Adjusting Manual for additional information on the engine. If unable to turn the engine, remove and
following tests. inspect engine accessories that can lock up the
engine (air compressor, oil pump, seawater pump,
Probable root causes: etc). Repair or replace as necessary. Refer to the
engine System Operation Testing & Adjusting
« Battery Cables/Batteries Manual.
« Starting motor solenoid or circuit problem (in system 6. Check for fluid in the cylinders.
wiring)
. Disassemble engine to inspect for internal
« Starting motor/flywheel ring gear components that may be seized, broken, bent, out
of alignment, etc. Refer to the Disassembly &
« Engine accessory
Assembly Manual.
* Hydraulic cylinder lock
« Internal engine problem
+ OEM Neutral Safety Switch
Perform the following tests in order:
1. Check shutdown switch, battery posts and battery
starter cables for loose connections and corrosion.
Remove and clean cables and connections if
corroded. Load test batteries, Refer to Special
Instruction, SEHS9249 Use Of 4C4911 Battery
Load Tester. If necessary, charge the batteries.
Refer to Special Instruction, SEHS7633 Battery
Test Procedure.
2. Test starting motor solenoid operation. Check
system wiring to starting motor solenoid. Ensure the
Starting Motor Mag Solenoid is receiving the correct
voltage. Turn the keyswitch to the ON position,
Engine OFF. With the Start switch in the start
position measure the voltage between TS1 pin-1
and TS1 pin-5, the voltage should be between 11
VDC and 25 VDC. Measure the voltage at C1 pin-2
(+Battery) to C1 pin-1 (-Battery). If the +Battery
voltage is not present check the wiring. If the
+Battery is present and the engine will not crank,
replace the Starting Motor Mag Solenoid.
3. Test starting motor operation. Refer to Systems
Operation, Testing & Adjusting Manual. Inspect
starting motor pinion and ring gear for damage.
4. Ensure free movement of driveline. If not free,
Refer to the Unit Systems Operation, Testing &
Adjusting Manual. Check transmission neutral
gear indicator for proper operation and adjustment,
repair or replace as required.

P-302: Engine Cranks But Will Not Start 6. Observe the engine rpm on an Electronic Service
Tool Status screen while cranking the engine. If the
Probable root causes: Electronic Service Tool displays 0 rpm while
« Overspeed Switch cranking the engine, there is a problem in the
Speed Sensor circuit. Refer to P-514: Engine
« Starting aids/fuel gel (cold temperature operation) Speed Sensor.
» Engine Shutdown Switch Setting . Check for a fuel supply problem. Refer to P-339:
* Vessel/Engine wiring Engine Has A Fuel Supply Problem.
+ Personality Module or ECM . If an overspeed condition is detected by the
Overspeed switch, the relay in the overspeed switch
« Speed Signal box will open causing the shutoff solenoid to
« Fuel supply release and the engine to shut down. Cycle the
power to the ECM ro reset the overspeed switch
« Combustion problem
and verify the problem is present. If the problem still
« Shutoff Solenoid exsits refer to P-375: Engine Speed Switch
Overspeed Test.
1. Reset the Overspeed Switch if applicable. If the
condition is a result of a an engine overspeed and
the resetting the Overspeed Switch does not
eliminate the problem refer to P-375: Engine
Speed Switch Overspeed Test.
. If cold ambient conditions exist, check operation of
starting aids. Check cylinder block jacket water
heater for malfunction and replace if required.
Check for presence of congealed fuel (wax).
. Make sure the Engine Shutdown Switch is in the
RUN position. Connect an Electronic Service Tool
and verify Shutdown Switch position status. If
Electronic Service Tool does not operate, Refer to
P-307: Electronic Service Tool Will Not
Communicate With ECM. If a shutdown occurs,
the keyswitch must be turned to the OFF position,
then to the ON position before the engine will start.
NOTE: Aftermarket engine protection devices
usually interrupt power to the ECM and prevent
communications with the Electronic Service Tool.
Check for correct installation and operation of
Aftermarket engine protection devices. Aftermarket
devices may need to be bypassed to continue.
. Check for correct installation of the ECM connector
J14/P14, Speed Sensor connector J10/P10. Refer
to P-501: Inspecting Electrical Connectors. If the
problem occurs only after the engine is warmed up,
the circuit breakers may be exceeding the trip point
because of overheating. Check the circuit breakers
on the vessel, reset if required.
. Verify there is not an Active 253-02 Diagnostic
Code. If the diagnostic code is present, Refer to
Section 2: Programming Parameters.

P-303: Engine Misfires, Runs Rough Or Is . Inspect ECM connector J14/P14 and the Rack
Unstable Solenoid connector J6/P6 for proper connection.
Repair or replace as required. Refer to P-501:
NOTE: If the problem is intermittent and cannot be Inspecting Electrical Connectors. Check for
re-created, Refer to P-306: Intermittent Low Power active or recently logged Rack Solenoid diagnostic
Or Power Cutouts. If the problem is consistent and codes.Check for a fuel supply problem.
can be re-created, continue with this procedure. Refer to P-339: Engine Has A Fuel Supply
Problem.
Probable root causes:
. Check air inlet and exhaust systems for restrictions
« Engine Overspeed Warning (CID-FMI) 190-00 and leaks. Refer to Systems Operation, Testing
Engine Overspeed Warning. The Electronic control & Adjusting Manual. Look for a Check Engine
Module (ECM) detects engine speed greater than Lamp indication, or tripped restriction indicators (if
2700 rpm for 0.6 seconds. The CID-FMI may be equipped) associated with plugged air filters.
viewed on the display modules or an Electronic Replace plugged air filters, or clean filters as per
Service Tool. It is logged in memory. The ECM will operation and maintenance guidelines, and repair
attempt to limit Top Engine Limit by not allowing the any leaks found. Also, refer to P-521: Analog
vessel BTM to open. The ECM will de energize the Sensor Supply. Refer to Systems Operation,
Shutoff Solenoid to shut off the Fuel Supply. Testing & Adjusting Manual if an internal engine
problem is suspected.
* Cold Mode Operation (Normal Operation, if the
problem occurs only after start-up)
« Throttle Input Signal
« Faulty Rack Solenoid
+ Fuel supply
* Airinlet or exhaust restrictions or air system leaks
< Internal engine problem
NOTE: If the problem only occurs under certain
conditions (high rpm, full load, engine operating
temperature, etc), test the engine under those
conditions. Troubleshooting the symptoms under other
conditions can give misleading results.
1. Monitor the Electronic Service Tool Status screen to
verify the engine has exited Cold Mode Operation.
Observe the coolant temperature reading on the
Electronic Service Tool. If incorrect, Refer to P-591:
Engine Sensor Open/Short.
2. Observe the throttle position input reading on the
Electronic Service Tool Status screen. If incorrect or
erratic, refer to P-504: Throttle Position Sensor.

P-304: Low Power/Poor Or No Response 6. Monitor Actual Fuel, Max Fuel, and FRC Limit on
To Throttle the Electronic Service Tool. These parameters
should be as follows while the vessel is operating
Probable root causes: under full load.
+ Cold Mode Operation (Normal operation if the
Actual Fuel = Max Fuel
problem occurs only after start-up in cold weather)
AND
« Engine is in a derated mode Actual Fuel < FRC Limit
« Throttle input signal to the ECM
If the parameters are as indicated above, the
« Faulty electronic unit injector (individual cylinder electronics are operating correctly. If these
malfunction) parameters are not as indicated, verify proper Inlet
« Inlet Air Manifold Pressure Sensor signal Air Manifold Pressure Sensor (boost) operation.
Check inlet air and exhaust systems for restrictions
+ Airinlet or exhaust system restrictions or leaks
and leaks. Refer to Systems Operation, Testing
« Improper adjustment of FRC Offset, Full Load & Adjusting Manual. Look for a Check Engine
Setting, Full Torque Setting Lamp indication, or tripped restriction indicators
+ Fuel supply (if equipped) associated with plugged air filters.
Replace plugged air filters, or clean filters as per
Perform the following tests in order: operation and maintenance guidelines, and repair
1. If ECM has been replaced, check Read/Change any leaks found. Refer to P-591: Engine Sensor
parameters and compare to values on Engine Open/Short.
Information Plate. Make sure the correct personality 7. Check for a fuel supply problem. Refer to P-339:
module is installed. Refer to Section 2: Engine Has A Fuel Supply Problem.
. Monitor the Electronic Service Tool Status screen to
verify the engine has exited Cold Mode. During
Cold Mode, engine power and response may be
limited. Observe the coolant temperature reading
on the Electronic Service Tool. If incorrect, refer to
P-591: Engine Sensor Open/Short.
. Connect an Electronic Service Tool and check for
Active engine derates.
. Monitor the Throttle Status on an Electronic Service
Tool. Observe throttle position and verify it is stable
and can reach 100 percent. Refer to P-504:
Throttle Position Sensor.
. Ensure the engine is not synchronized to another
throttle. If the Desired Engine Speed does not
change when the throttle is adjusted, move the
Secondary throttle and watch the Desired Engine
Speed. If the Desired Engine Speed does not
change refer to Section 5: P-504: Throttle
Position Sensor.

P-305: Intermittent Engine Shutdowns P-306: Intermittent Low Power Or Power

NOTE: Use this procedure only if the engine shut down Cutouts
completely and had to be restarted. NOTE: Use this procedure only if the engine DOES
Probable root causes: NOT shut down completely (the engine did not have to
be restarted).
« Faulty electrical connections, Electrical Power
Supply to the ECM Probable root causes:
+ Shutoff Solenoid Connections * An engine Derate is occurring
* Speed Sensor * Throttle Input signal
* Fuel supply Faulty electrical connections
Perform the following tests in order: « Fuel supply
1. Check for correct installation of ECM connector Perform the following tests in order:
J14/P14, J31 Customer connector, and Speed
Sensor connectors J10/P10, J16/P16. Refer to P- 1. The engine may be derating due to, dirty air filters,
501: Inspecting Electrical Connectors. low boost or other factors. Use an Electronic
Service Tool or Display Module (such as VIMS) to
Check the Electronic Service Tool for logged
check for logged engine Derate events.
Diagnostic Codes 168-02 Battery Voltage
Intermittent. Follow battery wires from the ECM 2. Monitor the Throttle Status on an Electronic Service
back to the battery compartment. Refer to Electrical Tool. Observe throttle position and verify it is stable
System Schematic. Inspect wires and power relay. and can reach 100 percent. Check for logged
Check ECM power and ground connections. diagnostic codes related to the throttle position
Refer to P-346: Electrical Power Supply to the sensor. Refer to P-504: Throttle Position Sensor.
ECM, if not already done. If the problem occurs only 3. Check the Electronic Service Tool for logged
after the engine is warmed up and disappears after Diagnostic Codes 168-02, Battery Voltage
the has been allowed to cool, the circuit breakers Intermittent. Follow battery wires from the ECM
may be exceeding the trip point because of back to the battery compartment. Refer to
overheating. Check the circuit breakers on the Electrical System Schematic. Inspect wires and
vessel, reset if required. power relay. Check ECM power and ground
NOTE: Aftermarket engine protection devices connections. .
usually interrupt power to the ECM. Check for Refer to P-346: Electrical Power Supply to the
correct installation and operation of Aftermarket ECM, if not already done
engine protection devices. Aftermarket devices may NOTE: Aftermarket engine protection devices
need to be bypassed to continue. usually interrupt power to the ECM. Check for
2. Check the Electronic Service Tool for logged correct installation and operation of Aftermarket
Diagnostic Codes 190-02 Loss of Primary Engine engine protection devices. Aftermarket devices may
Speed Signal. need to be bypassed to continue.
Refer to P-514: Engine Speed Sensor. 4. Check for a fuel supply problem. Refer to P-339:
3. Check for a fuel supply problem. Refer to P-339: Engine Has A Fuel Supply Problem.
Engine Has A Fuel Supply Problem.

P-307: Electronic Service Tool Will Not 5. Turn keyswitch OFF. Remove pin-D and pin-E from
Communicate With ECM the J13 Service Tool connector. Attempt to
communicate with the ECM. If the Electronic
NOTE: The Remote Optional Electronic Service Tool Is Service Tool communicates with the ECM, replace
Not Recommended For The 3400 High Performance the wires from pin-D and pin-E. If the Electronic
Marine Engine. Service Tool does not communicate with the ECM,
proceed to next step.
Probable root causes:
. Turn keyswitch OFF. Disconnect the J14 ECM
« Electronic Service Tool or Communication Adapter connector and remove the service tool from the J13
Service Tool cable problem Service Tool Connector. Make a jumper and short
« Personality Module or ECM Problem J14 pin-29 to J14 pin-38. Measure the resistance
between J14 pin-29 and J14 pin-38. the resistance
+ DataLink should be less than 10 Ohms. If the resistance is in
* Electrical Power Supply to the ECM Connector or range proceed to next step. If the resistance is out
wiring problem in electronic system wiring harness of range there is a short in the harness. Repair as
required.
. Set the Ohmmeter on the 20k ohms scale and
1. Turn keyswitch OFF and check ECM Connector measure the resistance at the J13 service tool
J14/P14, Customer Connector J31/P31, Service connector, between
Tool Connector J13 and associated wiring for pin-J and pin-A
damage, abrasion, corrosion or incorrect pin-J and Pin-B
attachment. Refer to P-501: Inspecting Electrical pin-H and pin-A
Connectors for details. pin-H and Pin-B.
2. Be sure the correct Personality Module is properly The resistance should measure greater than 20k
installed in the ECM. In the event that the ECM on ohms. If the resistance is less than 20k ohms there
the engine is new, the engine will not start or is a short in the wiring harness. Repair as required.
communicate until the Personality Module is If the resistance is in range and the problem is still
installed. Refer to Section 2: Programming present, refer to Section 2: ECM Replacement
Parameters. Procedure.
3. Turn keyswitch ON, engine OFF. Use signal
reading probes to measure the battery voltage at
the J13 Service Tool Connector. Connect the
positive probe to pin-A and the negative probe to
Pin-B. The voltage should be greater than 11 VDC
for a 12 volt system and greater than 22 VDC for a
24 Volt system. If the voltage is in range proceed to
next step. If the voltage is out of range refer to
P-346: Electrical Power Supply To The ECM.
. Turn keyswitch ON, engine OFF. Use signal
reading probes to measure the voltage at the J14
ECM Connector. Connect the positive probe to the
J14 pin-1 and the negative probe to J1 pin-21. The
voltage should be greater than 11 VDC for a 12 volt
system and greater than 22 VDC for a 24 Volt
system. If the voltage is in range proceed to next
step. If the voltage is out of range refer to
P-346: Electrical Power Supply To The ECM.

P-308: ECM Will Not Accept Factory P-310: Excessive Black Smoke
Passwords Probable root causes:
Probable root causes: Air inlet restriction or air system leaks
« Error entering password Speed Signal; injection timing or calibration, Speed
* Incorrect Serial Number (Engine, ECM, or Sensor calibration error after replacement
Electronic Service Tool), Total Tattletale, or Reason Faulty Inlet Air Manifold Pressure Sensor,
Code used to obtain password Atmospheric Pressure Sensor, or sensor calibration
Perform the following tests in order: Personality Module
1. Verify correct passwords were entered. Check each Fuel supply: low supply pressure, air in low
character in passwords for accuracy (for instance pressure fuel system, poor fuel quality
letter | vs. number 1, Z vs. 2, O vs. 0, etc). Turn the
Incorrect valve adjustment
keyswitch to the OFF/RESET position for 30
seconds and then retry. Perform the following tests in order:
2. Verify the Electronic Service Tool is on the Factory 1. Connect an Electronic Service Tool and compare
Passwords screen. Verify Engine serial number atmospheric and inlet pressure readings. Check for
used to calculate password is correct. Verify the filter restriction derates and alarms. Check air inlet
Total Tattletale, Reason Code, Electronic Service and exhaust systems for restrictions and leaks.
Tool Serial Number and ECM Serial Number is Check for a failed turbocharger. Refer to Systems
correct. Refer to Factory Passwords in Section 2: Operation, Testing & Adjusting Manual. Replace
Programming Parameters for more details. plugged air filters, or clean filters as per operation
and maintenance guidelines, and repair any leaks
found. Verify proper operation of the Inlet Air
Manifold Pressure and Atmospheric Pressure
Sensors. Refer to P-521: Analog Sensor Supply.
. Check calibration of the Speed Sensor, recalibrate if
required. Check for proper orientation between
crankshaft and camshaft drive gears, repair as
required. Refer to procedure in Disassembly &
Assembly Manual.
. Monitor Atmospheric Pressure with an Electronic
Service Tool. Observe Inlet Air Manifold Pressure,
Fuel Pos, Rated Fuel Pos and FRC Fuel Pos while
the vessel is operating under full load.
Fuel Pos = Rated Fuel Pos
AND
FRC Fuel Pos > Rated Fuel Pos
NOTE: A problem with the FRC will only create
black smoke problems on acceleration, not steady
state operation. Check for a restriction in the
Atmosphere path, remove dirt and debris, if
required. Atmospheric pressure should range from
50 to 100 kPa (7.5 to 15 psi) depending on your
area of operation. Refer to P-521: Analog Sensor
Supply.
. Check for a fuel supply problem. Refer to P-339:
. Check valve adjustment.

P-311: Excessive White Smoke

NOTE: Some white smoke may be present during cold
start-up conditions when the engine is operating
normally.
Probable root cause:
* Faulty Coolant Temperature Sensor
+ Speed Signal; injection timing or calibration,
incorrect Speed wheel orientation assembly, Speed
Sensor calibration error after replacement
* Personality Module
* Fuel Supply
« Combustion system problem
1. Verify Cold Mode is active when the engine is cold.
Monitor Coolant temperature status on an
Electronic Service Tool. Observe coolant
temperature and ensure the reading is reasonable.
If temperature reading is incorrect,
refer to P-591: Engine Sensor Open/Short.
2. Check for proper orientation between crankshaft
and camshaft drive gears, repair as required. Refer
to procedure in Disassembly & Assembly
Manual.
3. Connect an Electronic Service Tool and verify the
correct Personality Module is installed for the
engine configuration and application. Refer to
Section 2: Programming Parameters.
4. Check for a fuel supply problem. Refer to P-339:
5. Excessive valve, piston, ring and/or liner wear, or
low cranking speed can result in reduced
compression pressure, resulting in white smoke.
Coolant leakage into the cylinder or exhaust system
can also produce symptoms similar to white smoke
emissions from unburned fuel. Refer to the
Systems Operations, Testing & Adjusting
Manual.

P-312: Can Not Reach Top Engine RPM 4. Check for a fuel supply problem. Refer to P-339:
NOTE: If this problem occurs only under load, Refer to
5. Check air inlet and exhaust systems for restrictions
P-304: Low Power/Poor Or No Response to
Throttle.
& Adjusting Manual. Look for a Check Engine
Probable root causes: Lamp indication, or tripped restriction indicators (if
equipped) associated with plugged air filters.
« Engine is in Cold Mode or derated
Replace plugged air filters, or clean filters as per
Personality Module operation and maintenance guidelines, and repair
Throttle Position Sensor signal any leaks found. Also, Refer to P-521: Analog
Sensor Supply.
Faulty Inlet Air Manifold Pressure Sensor or
Atmosphere signal or calibration . Check all accessory equipment. Remove and
inspect engine accessories that may create
Fuel supply excessive load on the engine (air compressor,
Air inlet or exhaust restriction or air system leaks power steering pump, oil pump, etc). Repair or
replace as required. Refer to the Systems
Air supply/low boost Operation, Testing & Adjusting Manual.
Faulty Accessory Equipment
High Engine Load
Perform the following tests:
1. Connect an Electronic Service Tool screen and
verify the engine has exited Cold Mode, check for
Active engine derates. Verify the programming
parameters are correct. Refer to Section 2:
NOTE: Engine performance may be reduced due
to, dirty air filters, high exhaust temperatures or
other factors.
. Monitor the Throttle Status on an Electronic Service
Tool. Observe throttle position and verify it can
reach 100 percent. Operate the engine at high idle
with the vessel in neutral. If the engine can not
reach programmed high idle or if the Electronic
Service Tool reading is unstable, Refer to P-504:
Throttle Position Sensor.
. Monitor Actual Fuel, Max Fuel, and FRC Limit on
the Electronic Service Tool. These parameters
should be as follows while the engine is operating
under full load.
Actual Fuel = Max Fuel
AND
Actual Fuel < FRC Limit
If the parameters are as indicated above, the
electronics are operating correctly. If these
parameters are not as indicated check the following.
Monitor boost pressure and atmospheric pressure
on the Electronic Service Tool Status screen for
normal operation. Verify proper Inlet Air Manifold
Pressure Sensor (boost) operation.

P-313: Poor Acceleration or Response . Monitor Atmospheric Pressure with an Electronic

Service Tool. Observe Inlet Air Manifold Pressure,
Probable root causes: Fuel Pos, Rated Fuel Pos and FRC Fuel Pos while
* The engine is in Cold Mode or a Derate mode. the vessel is operating under full load. Atmospheric
pressure should range from 50 to 100 kPa (7.5 to
« Personality Module 15 psi). Refer to Systems Operation, Testing &
« Throttle Position Sensor signal Adjusting Manual.
+ Faulty Rack Solenoid NOTE: A problem with the FRC will only create
black smoke problems on acceleration, not steady
* Incorrect Inlet Air Manifold Pressure Sensor or state operation. Check for a restriction in the
Atmosphere signal or improper adjustment of FRC Atmosphere path, remove dirt and debris, if
value required
+ Airinlet or exhaust restriction or leaks Refer to P-591: Engine SensorOpen/Short.
. Check air inlet and exhaust systems for restrictions
» Fuel supply
« High Engine Load & Adjusting Manual. Look for a Check Engine
Perform the following tests in order: Lamp indication, or tripped restriction indicators (if
equipped) associated with plugged air filters.
1. Connect an Electronic Service Tool and verify the Replace plugged air filters, or clean filters as per
engine has exited Cold Mode operation. The engine operation and maintenance guidelines, and repair
will not respond as fast until it is warmed to any leaks found. Also, Refer to P-521: Analog
operating temperature. Sensor Supply.
NOTE: Engine performance may be reduced due . Check for a fuel supply problem.
to, dirty air filters, high exhaust temperatures or Refer to P-339: Engine Has A Fuel Supply
other factors. Check Acceleration Delay and Problem.
Acceleration Ramp Rate settings if applicable.
2. Verify the correct Personality Module is installed.
Refer to Section 2: Programming Parameters.
3. Monitor the Throttle Position Status on an Electronic
Service Tool. Observe throttle position and verify
the reading is stable and can reach 100 percent. If a
problem with the sensor is suspected, Refer to P-
504: Throttle Position Sensor.
4. Inspect ECM connectors J14/P14, vessel Interface
connectors, and the Unit Rack connectors J6/P6 for
proper connection. Repair or replace as required.

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CATERPILLAR

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

« Is the engine performing as expected? Refer

« Repair any ACTIVE diagnostic codes first.

« Use operator information gathered above.

LIST OF « If more than one symptom, are there any

« AVOID PRE-CONCEIVED IDEAS!

3408 & 3412 High Performance Marine Engines Troubleshooting

Operator Questionnaire P-329: Engine Has Low Oil Pressure .....

Questionnaire Responses. P-330: Engine Uses Too Much Lubrication Oil

P-303: Engine Misfires, Runs Rough P-333: Oil At The Exhaust

3408 & 3412 High Performance Marine Engines 5 Troubleshooting

Section 7: Glossary Of Terms

3408 & 3412 High Performance Marine Engines Troubleshooting

Failure Mode Identifier Description

01 Data Valid, but below normal operational range

03 Voltage above normal or shorted high

04 Voltage below normal or shorted low

08 Abnormal Frequency, Pulse Width, or Period

10 Abnormal Rate of Change

1" Failure Mode not identifiable

14-31 Reserved for future assignment

3408 & 3412 High Performance Marine Engines 7 Troubleshooting

3408 & 3412 High Performance Marine Engines 8 Troubleshooting

3408 & 3412 High Performance Marine Engines 9 Troubleshooting

Desired Rack Position

3408 & 3412 High Performance Marine Engines Troubleshooting

Customer Parameters Effect on Engine Programmable Parameters

3408 & 3412 High Performance Marine Engines 1-2 Troubleshooting

Engine Sensors Atmospheric Pressure Sensor

Output voltage = 4.1 VDC MINIMUM. Qil Pressure Sensor

3408 & 3412 High Performance Marine Engines 1-3 Troubleshooting

Engine Speed Sensors

PWM INput to ECM

Figure 1.3 - Speed Control with PWM Input

3408 & 3412 High Performance Marine Engines 14 Troubleshooting

Overspeed Protection System NOTE: The synchronization function can be activated

Figure 1.6 - Engine Speed Switch

SYNCH 1 SYNCH 2 Throttle

-BATT OPEN Primary

OPEN -BATT Secondary

3408 & 3412 High Performance Marine Engines Troubleshooting

Diagnostic Warning Outputs Low Oil Pressure Lamp

Low Boost Transmission Warning Lamp

Warning Lamp Operation

3408 & 3412 High Performance Marine Engines Troubleshooting

ATA Data Link (SAE J1587/J1708)

Optional Electronic Service Tool Connection

SAE J1587 Data Link Broadcast Parameters

Broadcast Period | Parameter Name CID Size Scaling/bit

0.4 sec. Engine Speed 190 2 0.25 rpm

0.6 sec. Coolant Temperature 110 1 1°F

20.0 sec. ECM Serial Number 193 Variable | 10 characters

Personality module Part Number 192 Variable 10 characters

0.5 sec. Engine Diagnostic 194 Variable | CID & FMI

3408 & 3412 High Performance Marine Engines 1-7 Troubleshooting

CAT Data Link

PORTECM _ P14J14 P31 431 J31 P31 J14P14 STBDECM

(CAT DataLink- 1] 2N K| <caT DaaLik +

Figure 1.8 - Data Connections

3408 & 3412 High Performance Marine Engines 1-8 Troubleshooting

CAT Data Link