Service Information System Page 1 of 7

Troubleshooting
C7 Engine for 12K, 120K, 120K Series 2, 140K, 140K Series 2, and 160K Motor Graders
Media Number -KENR5407-04 Publication Date -01/01/2011 Date Updated -03/01/2011

i04407990

Diagnostic Trouble Codes

SMCS - 1900

Diagnostic Codes
Diagnostic codes alert the operator that a problem in the electronic system has been detected. Diagnostic
codes are also used by the service technician to identify the nature of the problem. The technician must
have access to a diagnostic tool in order to read diagnostic information. The Cat Data Link is used for
communication with the engine ECM. The data link is described below.

Cat Data Link

The Cat Data Link is used by the engine's Electronic Control Module (ECM) to communicate with
Caterpillar controllers or display modules. Caterpillar Electronic Technician (ET) is a software program
that is designed to run on a personal computer. The software can be used by the service technician in
order to view the diagnostic code information that is generated by the engine's ECM. The diagnostic
code is displayed as a two-element code. The following terms describe the elements of the code:

Component Identifier (CID) - The CID indicates the component that generated the code.

Failure Mode Identifier (FMI) - The FMI indicates the type of failure.

Cross-Reference Information for Diagnostic Codes

Table 1 is a list of the diagnostic codes for the engine. The diagnostic codes are cross-referenced with
the appropriate procedure that can be used to troubleshoot the code.

Further explanations of diagnostic codes are explained after Table 1.

Table 1

Cross-Reference from CID-FMI Code on Cat Data Link to Troubleshooting Procedure

Code and Description Procedure

1-5 Cylinder #1 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

1-6 Cylinder #1 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

2-5 Cylinder #2 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

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2-6 Cylinder #2 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

3-5 Cylinder #3 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

3-6 Cylinder #3 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

4-5 Cylinder #4 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

4-6 Cylinder #4 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

5-5 Cylinder #5 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

5-6 Cylinder #5 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

6-5 Cylinder #6 Injector : Current Below Normal Troubleshooting, "Injector Solenoid - Test"

6-6 Cylinder #6 Injector : Current Above Normal Troubleshooting, "Injector Solenoid - Test"

41-3 8 Volt DC Supply : Voltage Above Normal Troubleshooting, "Sensor Supply - Test"

41-4 8 Volt DC Supply : Voltage Below Normal Troubleshooting, "Sensor Supply - Test"

42-5 Injector Actuation Valve : Current Below Troubleshooting, "Injection Actuation

Normal Pressure Control Valve - Test"

42-6 Injector Actuation Valve : Current Above Troubleshooting, "Injection Actuation

Normal Pressure Control Valve - Test"

91-8 Throttle Position Sensor : Abnormal Frequency, Troubleshooting, "Speed Control (Switch) -
Pulse Width, or Period Test"

94-3 Fuel Delivery Pressure Sensor : Voltage Above Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

94-4 Fuel Delivery Pressure Sensor : Voltage Below Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

100-3 Engine Oil Pressure Sensor : Voltage Above Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

100-4 Engine Oil Pressure Sensor : Voltage Below Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

100-10 Engine Oil Pressure Sensor : Abnormal Rate Troubleshooting, "Sensor Signal (Analog,
of Change Active) - Test"

110-3 Engine Coolant Temperature Sensor : Voltage Troubleshooting, "Sensor Signal (Analog,
Above Normal Passive) - Test"

110-4 Engine Coolant Temperature Sensor : Voltage Troubleshooting, "Sensor Signal (Analog,
Below Normal Passive) - Test"

164-3 Injector Actuation Pressure : Voltage Above Troubleshooting, "Sensor Signal (Analog,

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Normal Active) - Test"

164-4 Injector Actuation Pressure : Voltage Below Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

Troubleshooting, "Electrical Power Supply -

168-0 Electrical System Voltage : High
Test"

Troubleshooting, "Electrical Power Supply -

168-1 Electrical System Voltage : Low
Test"

168-2 Electrical System Voltage : Erratic, Troubleshooting, "Electrical Power Supply -

Intermittent, or Incorrect Test"

172-3 Intake Manifold Air Temperature Sensor : Troubleshooting, "Sensor Signal (Analog,
Voltage Above Normal Passive) - Test"

172-4 Intake Manifold Air Temperature Sensor : Troubleshooting, "Sensor Signal (Analog,
Voltage Below Normal Passive) - Test"

190-8 Engine Speed Sensor : Abnormal Frequency,

Troubleshooting, "Speed/Timing - Test"
Pulse Width, or Period

253-2 Personality Module : Erratic, Intermittent, or

Troubleshooting, "ECM Software - Install"
Incorrect

261-11 Engine Timing Offset fault Troubleshooting, "Timing - Calibrate"

261-13 Engine Timing Calibration : Calibration

Troubleshooting, "Timing - Calibrate"
Required

262-3 5 Volt Sensor DC Power Supply : Voltage

Troubleshooting, "Sensor Supply - Test"
Above Normal

262-4 5 Volt Sensor DC Power Supply : Voltage

Troubleshooting, "Sensor Supply - Test"
Below Normal

267-3 Remote Shutdown Input : Voltage Above Troubleshooting, "Shutdown (Ground Level)
Normal - Test"

267-4 Remote Shutdown Input : Voltage Below Troubleshooting, "Shutdown (Ground Level)
Normal - Test"

268-2 Programmed Parameter Fault : Erratic, Troubleshooting, "Configuration Parameters"

Intermittent, or Incorrect

269-3 Sensor Power Supply : Voltage Above Normal

Troubleshooting, "Sensor Supply - Test"

269-4 Sensor Power Supply : Voltage Below Normal

Troubleshooting, "Sensor Supply - Test"

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271-5 Action Alarm : Current Below Normal Troubleshooting, "Action Alarm - Test"

271-6 Action Alarm : Current Above Normal Troubleshooting, "Action Alarm - Test"

274-3 Atmospheric Pressure Sensor : Voltage Above Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

274-4 Atmospheric Pressure Sensor : Voltage Below Troubleshooting, "Sensor Signal (Analog,
Normal Active) - Test"

286-5 EMS Oil Lamp open/short to ground Troubleshooting, "Indicator Lamp - Test"

286-6 EMS Oil Lamp short to +batt Troubleshooting, "Indicator Lamp - Test"

296-9 Transmission Control : Abnormal Update Rate

Troubleshooting, "Cat Data Link - Test"

324-5 Warning Lamp open/short to ground Troubleshooting, "Indicator Lamp - Test"

324-6 Warning Lamp short to ground Troubleshooting, "Indicator Lamp - Test"

342-8 Secondary Engine Speed Sensor : Abnormal

Troubleshooting, "Speed/Timing - Test"
Frequency, Pulse Width, or Period

548-5 Throttle Lock Lamp : Current Below Normal

Troubleshooting, "Indicator Lamp - Test"

548-6 Throttle Lock Lamp : Current Above Normal

Troubleshooting, "Indicator Lamp - Test"

549-2 Throttle Lock Switch : Erratic, Intermittent, or

Troubleshooting, "Throttle Lock - Test"
Incorrect

1589-3 Turbocharger Inlet Air Pressure Sensor : Troubleshooting, "Sensor Signal (Analog,
Voltage Above Normal Active) - Test"

1589-4 Turbocharger Inlet Air Pressure Sensor : Troubleshooting, "Sensor Signal (Analog,
Voltage Below Normal Active) - Test"

Troubleshooting, "Fuel Transfer Pump - Test"

1627-5 Fuel Pump Relay : Current Below Normal

Troubleshooting, "Fuel Transfer Pump - Test"

1627-6 Fuel Pump Relay : Current Above Normal

1785-3 Intake Manifold Pressure Sensor : Voltage Troubleshooting, "Sensor Signal (Analog,
Above Normal Active) - Test"

1785-4 Intake Manifold Pressure Sensor : Voltage Troubleshooting, "Sensor Signal (Analog,
Below Normal Active) - Test"

1785-10 Intake Manifold Pressure Sensor : Abnormal Troubleshooting, "Sensor Signal (Analog,
Rate of Change Active) - Test"

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2417-5 Ether Injection Control Solenoid : Current

Troubleshooting, "Starting Aid - Test"
Below Normal

2417-6 Ether Injection Control Solenoid : Current

Troubleshooting, "Starting Aid - Test"
Above Normal

2756-5 Engine System Warning Indicator : Current

Troubleshooting, "Indicator Lamp - Test"
Below Normal

2756-6 Engine System Warning Indicator : Current

Troubleshooting, "Indicator Lamp - Test"
Above Normal

2757-5 Transmission System Warning Indicator :

Troubleshooting, "Indicator Lamp - Test"
Current Below Normal

2757-6 Transmission System Warning Indicator :

Troubleshooting, "Indicator Lamp - Test"
Current Above Normal

2770-3 Throttle Lock Resume/Decel Switch :

Troubleshooting, "Throttle Lock - Test"
Voltage Above Normal

2770-4 Throttle Lock Resume/Decel Switch :

Troubleshooting, "Throttle Lock - Test"
Voltage Below Normal

2771-3 Throttle Lock Set/Accel Switch : Voltage

Troubleshooting, "Throttle Lock - Test"
Above Normal

2771-4 Throttle Lock Set/Accel Switch : Voltage

Troubleshooting, "Throttle Lock - Test"
Below Normal

2869-5 System Air Pressure Indicator : Current

Troubleshooting, "Indicator Lamp - Test"
Below Normal

2869-6 System Air Pressure Indicator : Current

Troubleshooting, "Indicator Lamp - Test"
Above Normal

Active Diagnostic Codes

An active diagnostic code represents a problem with the electronic control system. Correct the
problem as soon as possible.

When the engine's ECM generates an active diagnostic code, the "Active Alarm" indicator ("Engine
Control Alarm Status" on Cat ET) is activated in order to alert the operator. If the condition that
generated the code is momentary, the message disappears from the list of active diagnostic codes. The
diagnostic code becomes logged.

Refer to Illustration 1 for an example of the operating ranges of a sensor.

View Image

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Illustration 1 g01785898
Example of the typical operating range of a sensor

(1) This area represents the normal operating range of the engine parameter.

(2) In this area, the engine is operating in an unsafe operating range of the monitored parameter. An event code will be
generated for the monitored parameter. The sensor circuit does not have an electronic problem. Refer to Troubleshooting,
"Event Codes" for additional information on event codes.

(3) In these areas, the signal from the sensor is outside of the operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the sensor circuit.

Logged Diagnostic Codes

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

 The hour of the first occurrence of the code

 The hour of the last occurrence of the code

 The number of occurrences of the code

This information is a valuable indicator for troubleshooting intermittent problems.

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A code is cleared from memory when one of the following conditions occur:

 The service technician manually clears the code.

 The code does not recur for 100 hours.

 A new code is logged and there are already ten codes in memory. In this case, the oldest code is
cleared.

Some diagnostic codes may be easily triggered. Some diagnostic codes may log occurrences that did not
result in complaints. The most likely cause of an intermittent problem is a faulty connection or damaged
wiring. The next likely cause is a component failure. The least likely cause is the failure of an electronic
module. Diagnostic codes that are logged repeatedly may indicate a problem that needs special
investigation.

Note: Always clear logged diagnostic codes after investigating and correcting the problem which
generated the code.

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