Professional Documents
Culture Documents
Renr9346 06 00 All
Renr9346 06 00 All
Renr9346 06 00 All
December 2009
Troubleshooting
C27 and C32 Engines for 773F and
777F Off-Highway Truck/Tractors and
for the 775F Quarry Truck
EED1-Up (Machine)
EXD1-Up (Machine)
EYG1-Up (Machine)
JRP1-Up (Machine)
JXP1-Up (Machine)
DLS1-Up (Machine)
LJW1-Up (Engine)
EHX1-Up (Engine)
LJX1-Up (Engine)
SAFETY.CAT.COM
i03684547
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR9346-06 3
Table of Contents
CID 0190 FMI 08 Engine Speed signal abnormal .. 62 CID 1795 FMI 04 Turbo #2 Outlet Pressure Sensor
CID 0253 FMI 02 Personality Module mismatch .. 62 voltage below normal .......................................... 73
CID 0261 FMI 11 Engine Timing Offset fault ........ 63 CID 1795 FMI 10 Turbo #2 Outlet Pressure Sensor
CID 0261 FMI 13 Engine Timing Calibration abnormal rate of change ..................................... 74
required ............................................................... 64 CID 1796 FMI 03 Intake Manifold #2 Air Temperature
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Sensor voltage above normal ............................. 74
short to +batt ....................................................... 64 CID 1796 FMI 04 Intake Manifold #2 Air Temperature
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Sensor voltage below normal .............................. 74
short to ground .................................................... 64 CID 2271 FMI 05 Engine Oil Renewal System
CID 0267 FMI 02 Incorrect Engine Shutdown Switch Actuation Solenoid current below normal ........... 75
inputs .................................................................. 65 CID 2271 FMI 06 Engine Oil Renewal System
CID 0268 FMI 02 Check Programmable Actuation Solenoid current above normal ........... 75
Parameters ......................................................... 65 CID 2350 FMI 03 Left Exhaust #2 Temperature
CID 0274 FMI 03 Atmospheric Pressure open/short voltage above normal .......................................... 75
to +batt ................................................................ 65 CID 2350 FMI 04 Left Exhaust #2 Temperature
CID 0274 FMI 04 Atmospheric Pressure short to voltage below normal .......................................... 76
ground ................................................................. 66 CID 2350 FMI 08 Left Exhaust #2 Temperature
CID 0291 FMI 05 Engine Cooling Fan Solenoid open abnormal frequency, pulse width, or period ........ 76
circuit ................................................................... 66 CID 2351 FMI 03 Right Exhaust #2 Temperature
CID 0291 FMI 06 Engine Cooling Fan Solenoid short voltage above normal .......................................... 76
to ground ............................................................. 66 CID 2351 FMI 04 Right Exhaust #2 Temperature
CID 0342 FMI 08 Secondary Engine Speed signal voltage below normal .......................................... 77
abnormal ............................................................. 66 CID 2351 FMI 08 Right Exhaust #2 Temperature
CID 0533 FMI 09 Brake Control abnormal update abnormal frequency, pulse width, or period ........ 77
rate ...................................................................... 67 CID 2417 FMI 05 Ether Injection Control Solenoid
CID 0533 FMI 14 Brake Control special current low .......................................................... 77
instruction ............................................................ 67 CID 2417 FMI 06 Ether Injection Control Solenoid
CID 0544 FMI 02 Engine Cooling Fan Speed Sensor current high ......................................................... 78
loss of signal ....................................................... 67 CID 2533 FMI 05 Compression Brake Low/High
CID 0544 FMI 08 Engine Cooling Fan Speed signal Solenoid #1 current below normal ...................... 78
abnormal ............................................................. 68 CID 2533 FMI 06 Compression Brake Low/High
CID 0569 FMI 05 Oil Injection Solenoid current below Solenoid #1 current above normal ...................... 78
normal ................................................................. 68 CID 2534 FMI 05 Compression Brake Low/High
CID 0569 FMI 06 Oil Renewal Solenoid short to Solenoid #2 current below normal ...................... 78
ground ................................................................. 68 CID 2534 FMI 06 Compression Brake Low/High
CID 0827 FMI 03 Left Exhaust Temperature Solenoid #2 current above normal ...................... 79
open/short to +batt .............................................. 69 CID 2535 FMI 05 Compression Brake Medium/High
CID 0827 FMI 04 Left Exhaust Temperature short to Solenoid #1 current below normal ...................... 79
ground ................................................................. 69 CID 2535 FMI 06 Compression Brake Medium/High
CID 0827 FMI 08 Left Exhaust Temperature signal Solenoid #1 current above normal ...................... 79
abnormal ............................................................. 69 CID 2536 FMI 05 Compression Brake Medium/High
CID 0828 FMI 03 Right Exhaust Temperature Solenoid #2 current below normal ...................... 79
open/short to +batt .............................................. 70 CID 2536 FMI 06 Compression Brake Medium/High
CID 0828 FMI 04 Right Exhaust Temperature short Solenoid #2 current above normal ...................... 80
to ground ............................................................. 70
CID 0828 FMI 08 Right Exhaust Temperature signal Troubleshooting with an Event Code
abnormal ............................................................. 70 Event Codes ........................................................ 81
CID 1273 FMI 09 Unable to Communicate with E096 High Fuel Pressure ...................................... 84
Chassis Control Module ...................................... 71 E171 Low Engine Oil Level ................................... 84
CID 1273 FMI 14 Chassis Control Module special E172 High Air Filter Restriction ............................. 85
instruction ............................................................ 71 E194 High Exhaust Temperature .......................... 85
CID 1589 FMI 03 Turbo Inlet Air Pressure Sensor E321 High Right Exhaust Temperature ............... 87
open/shrt to +bat ................................................. 71 E322 High Left Exhaust Temperature .................. 88
CID 1589 FMI 04 Turbo Inlet Air Pressure Sensor E360 Low Engine Oil Pressure ............................. 90
short to ground .................................................... 72 E361 High Engine Coolant Temperature .............. 90
CID 1785 FMI 03 Intake Manifold Pressure Sensor E362 Engine Overspeed ....................................... 92
voltage high ......................................................... 72 E363 High Fuel Supply Temperature .................... 92
CID 1785 FMI 04 Intake Manifold Pressure Sensor E390 Fuel Filter Restriction .................................. 93
voltage low .......................................................... 72 E539 High Intake Manifold Air Temperature ......... 93
CID 1785 FMI 10 Intake Manifold Pressure Signal E540 Low Engine Oil Refill Tank Level ................. 94
abnormal rate of change ..................................... 72 E775 High Left Exhaust #2 Temperature .............. 95
CID 1795 FMI 03 Turbo #2 Outlet Pressure Sensor E776 High Right Exhaust #2 Temperature ........... 96
voltage above normal .......................................... 73 E1000 High Left Intake Manifold Air Temperature .. 98
RENR9346-06 5
Table of Contents
Calibration Procedures
Engine Speed/Timing Sensor - Calibrate ............ 192
Index Section
Index ................................................................... 194
6 RENR9346-06
Troubleshooting Section
Most of the tools that are listed in Table 1 are required 129-2018 Power Cable
in order to enable a service technician to perform the Stand-alone cable for ADEM 2 ECM
test procedures that are found in this manual. Some 217-0113 Wiring Harness (ECM BYPASS)
of the devices are specific to the type of Electronic The bypass harness connects to the
Control Module (ECM) that is being used. battery. The bypass harness is used
with the following harnesses for different
types of electronic control modules.
328-2292 Harness (ENGINE ECM BYPASS)
For ADEM 3 ECM and ADEM 4 ECM
277-4734 Harness (ENGINE ECM BYPASS)
For A4:E2 ECM (Two 64-pin connectors)
• Diagnostic codes
• Engine configuration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Software, JEBD3003, “CATERPILLAR
ELECTRONIC TECHNICIAN”
Note: Items (7), (8), and (9) are part of the 261-3363
Wireless Communication Adapter Gp.
g01163897
Illustration 3
Perform the following procedure in order to replace d. Remove the mounting bolts from the ECM.
the ECM:
e. Disconnect the ECM ground strap from the
engine.
a. If the old mounting hardware is in good repair, d. If necessary, program the engine monitoring
you can use the old mounting hardware to system.
install the replacement ECM.
8. Program the injector trim files. Refer to
b. Reconnect the fuel lines (if equipped). programming parameters Troubleshooting,
“Injector Trim File”.
c. Ensure that the ECM mounting hardware is
installed correctly. The fuel lines must not put 9. Check for an active diagnostic code for timing
tension on the ECM. The rubber grommets calibration.
are used to protect the ECM from excessive
vibration. The ECM must be able to drift in If the diagnostic code is active, calibrate the
the rubber grommets. If the ECM cannot be injection timing. Refer to calibration procedures
moved slightly in the grommets, check that the Troubleshooting, “Engine Speed/Timing Sensor -
fuel lines (if equipped) are not pulling the ECM Calibrate”.
against one side of the grommets.
10. Check for diagnostic codes and for event codes.
d. Connect the ECM ground strap.
i02378227
e. Connect the J1/P1 and J2/P2 ECM connectors.
Tighten the allen head screw on each of the
ECM connectors to the proper torque. Refer to
Self-Diagnostics
the diagnostic functional test Troubleshooting, SMCS Code: 1901
“Electrical Connectors - Inspect” for the correct
torque value. The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
5. Program the flash file into the ECM. Refer to with engine operation. When a problem is detected, a
programming parameters Troubleshooting, “Flash code is generated. An alarm may also be generated.
Programming”. There are two types of codes:
6. If the replacement ECM was used previously for
a different application, use Cat ET to match the
• Diagnostic
engine application and the flash file.
• Event
7. Configure the ECM. Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
a. If the “Load from ECM” process from Step diagnostic code. This indicates the specific problem
2 was successful, return to the “Copy with the circuitry.
Configuration/ECM Replacement” screen on
Cat ET and select “Program ECM”. Diagnostic codes can have two different states:
After using the “Program ECM” feature, be sure
to cycle the power to the ECM. Wait at least
• Active
15 seconds after turning the keyswitch to the
OFF position.
• Logged
Active Code
Note: Some control modules have a power off delay.
The 15 seconds will be sufficient to cover this delay. An active diagnostic code indicates that an active
problem has been detected. Active codes require
b. If the “Program ECM” process was successful, immediate attention. Always service active codes
proceed to Step 9. prior to servicing logged codes.
c. If the “Program ECM” process was Logged Code
unsuccessful, manually program the ECM
parameters into the replacement ECM. The Every generated code is stored in the permanent
parameters must match the parameters from memory of the ECM. The codes are logged.
Step 1.
Event Code
i02819587
g01406305
Illustration 4
Components for the engine's control system
RENR9346-06 15
Troubleshooting Section
g01270303
Illustration 5
(1) Engine coolant temperature sensor (5) Turbocharger #2 outlet pressure (C32 (7) Primary engine speed/timing sensor
(2) Atmospheric pressure sensor only) (8) Engine oil level switch
(3) Intake manifold pressure sensor (6) Intake manifold #2 air temperature (9) Engine oil pressure sensor
(4) Intake manifold air temperature sensor sensor (C32 only)
16 RENR9346-06
Troubleshooting Section
g01269662
Illustration 6
(6) Intake manifold #2 air temperature (12) J2/P2 ECM connectors (16) Fuel pressure sensor
sensor (C32 only) (13) J1/P1 ECM connectors (17) Fuel temperature sensor
(10) Connector for the left bank valve cover (14) Secondary engine speed/timing sensor
(11) Connector for the right bank valve cover (15) Fuel filter differential pressure switch
RENR9346-06 17
Troubleshooting Section
g01406392
Illustration 7
(18) “FRONT LEFT EXHAUST TC” (20) Engine oil level switch (C32 only)
(19) Engine oil renewal soleniod (C32 only) (21) “REAR LEFT EXHAUST TC”
18 RENR9346-06
Troubleshooting Section
g01406395
Illustration 8
Cooling fan drive assembly
(22) Cooling fan drive assembly
(23) Connector for the engine fan speed sensor
(24) Engine fan control solenoid
g01406396
Illustration 9
Air cleaner assembly
(25) Turbocharger inlet pressure sensor
RENR9346-06 19
Troubleshooting Section
Note: If a newer software version is available for the If the problem is resolved with the new ECM,
engine, install the newest software on the suspect remove the original ECM and permanently install
ECM. If the new software does not fix the problem the new ECM.
continue with this procedure.
20 RENR9346-06
Troubleshooting Section
If the new ECM does not fix the problem, the i02419726
original ECM is not the problem. Remove the new
ECM before the 24 hour timer expires. Reconnect Flash Programming
the original ECM.
SMCS Code: 1901-591
Factory passwords are required in order to b. Press the “Browse” button in order to select the
unlock certain system configuration parameters. name of the flash file that will be programmed
Refer to Troubleshooting, “System Configuration into the ECM.
Parameters”.
c. When the correct flash file is selected, press
Since factory passwords contain alphabetic the “Open” button.
characters, the Caterpillar Electronic Technician (ET)
must be used to perform these functions. In order to d. Verify that the “File Values” match the
obtain factory passwords, proceed as if you already application. If the “File Values” do not match
have the password. If factory passwords are needed, the application, obtain the correct flash file.
Cat ET will request the factory passwords and Cat ET
will display the information that is required to obtain e. When the correct flash file is selected, press
the passwords. For the worksheet that is used for the “Begin Flash” button.
acquiring factory passwords, refer to programming
parameters Troubleshooting, “Factory Passwords f. Cat ET will indicate when flash programming
Worksheet”. has been successfully completed.
“WinFlash” Error Messages 5. Connect Cat ET to the service tool connector. Refer
to electronic troubleshooting Troubleshooting,
If you receive any error messages during flash “Electronic Service Tools”.
programming, click on the “Cancel” button in order
to stop the process. Access the information about 6. Select the following menu options on Cat ET:
the “ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for • Service
your engine.
• Calibrations
i02490769
• Injector Trim Calibration
Injector Trim File 7. Select the appropriate cylinder.
SMCS Code: 1290
8. Click on the “Change” button.
The Caterpillar Electronic Technician (ET) is used to
load the injector trim files into the Electronic Control 9. Select the appropriate injector trim file from the
Module (ECM). PC.
The injector trim files must be loaded into the ECM if 10. Click on the “Open” button.
any of the following conditions occur:
11. If you are prompted by Cat ET enter the injector
confirmation code into the field.
• An injector is replaced.
12. Click on the “OK” button.
• The ECM is replaced.
The injector trim file is loaded into the ECM.
• “Injector Trim” is displayed below a 268-02
diagnostic code on Cat ET.
13. Repeat the procedure for each cylinder, as
required.
• Injectors are exchanged between cylinders.
Exchanging Injectors
• “Reman parts”
• “Performance data”
A link to TMI Web can be found on the web site for
the Service Information System (SIS).
Total Tattletale
The total tattletale counts the number of changes to
system parameters.
Parameter Table
Table 6
Parameter Worksheet
Record the following information before you change
any programmable parameter.
RENR9346-06 25
Troubleshooting Section
Table 7
Engine Parameters
Equipment ID
Total Tattletale
FLS
FTS
Ether Solenoid
Configuration
Table 8
Information From Engine Information Plate
FLS
FTS
3. Ensure that the belts are in proper alignment. Cold Mode Operation
Inspect the alternator mounting bracket for cracks
and wear. Repair the mounting bracket or replace Use Cat ET to verify that the engine has exited
the mounting bracket in order to ensure that the cold mode. Cold mode operation may cause a slow
belts and the alternator drive pulley are aligned. throttle response. Engine speed may also be limited
during cold mode operation.
Alternator Drive Pulley
Throttle Signal
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the Use Cat ET in order to monitor the throttle position
pulley by the belt. If there is excessive wear, replace while you operate the throttle pedal. Ensure that the
the pulley. Check that the nut for the pulley has not throttle position sensor is operating correctly. Refer
become loose. If necessary, tighten the nut. to Troubleshooting, “Throttle Position Sensor Circuit -
Test”.
Alternator Bearings
Intake Manifold Pressure Sensor and
Check the alternator bearings for signs of wear. Atmospheric Pressure Sensor
Repair the alternator or replace the alternator, as
needed. 1. Monitor the status of “Fuel Position”, of “Rated
Fuel Limit”, and of “FRC Fuel Limit” on Cat ET
while the engine is operating under full load. These
i02433834 parameters must reflect the information below.
Can Not Reach Top Engine Table 9
RPM “Fuel Position” = “Rated Fuel Limit”
and
SMCS Code: 1915-035 “Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and Air Inlet and Exhaust System
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise, 1. Check for an air filter restriction indicator. Clean
proceed with the next Step. plugged air filters or replace plugged air filters.
Refer to the Operation and Maintenance Manual.
2. Use Cat ET in order to monitor the status of the
“Boost Pressure”. With the engine stopped, the 2. Check the air inlet and exhaust system for
correct “Boost Pressure” is 0 kPa (0 psi). restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
3. Start the engine and monitor the status of “Boost Exhaust System”.
Pressure” while you vary the engine speed.
Ensure that the pressure reading is fluctuating Accessory Equipment
with the engine speed.
Check all accessory equipment for problems that
4. Use Cat ET in order to check the status of the may create excessive load on the engine. Make the
“Atmospheric Pressure”. Verify that the pressure necessary repairs to damaged components. Replace
reading is reasonable for the current conditions. parts, if necessary.
Fuel Supply
i02381103
2. Check the fuel tank for foreign objects or debris Probable Causes
which may block the fuel supply.
• Engine oil cooler core
3. Prime the fuel system if any of the following items
have been serviced recently: • Cylinder head gasket
• Fuel filters • Cylinder head
Cylinder Block
Note: Low coolant level can be the result of
Inspect the cylinder block for cracks. If a crack is overheating rather than the cause.
found, repair the cylinder block or replace the cylinder
block. Check the coolant level.
SMCS Code: 1395-035 Determine whether the leak occurs before the engine
overheats.
Probable Causes Add coolant, if necessary. If leaking is found, make
the necessary repairs.
• Low coolant level
• Air in coolant Air in Coolant
Air can enter the cooling system if the pressure cap
• Water pump is not operating properly. Check the operation of the
pressure cap. Replace the pressure cap, if necessary.
• Environmental conditions
If the coolant has been changed recently, ensure that
• Shunt line restriction the air has been purged from the cooling system.
Refer to Systems Operation/Testing and Adjusting.
• Radiator or heat exchanger
The supply pressure to the water pump must be
• Water temperature regulator sufficient in order to prevent cavitation. Measure the
supply pressure at the inlet to the water pump.
• Coolant temperature sensor
• Engine coolant flow Water Pump
• Exhaust restriction The engine will overheat if the water pump is not
operating properly. Measure the coolant pressure
• Excessive load at the outlet of the water pump. Make sure that the
water pump is in good condition.
• Combustion gas in the coolant
Environmental Conditions
Determine if the ambient air temperature is within the
design specifications for the cooling system.
Determine the cause of the high air temperature. Engine Coolant Flow
Make corrections, when possible.
Insufficient coolant through the engine can be
Refer to Systems Operation/Testing and Adjusting. identified by checking the coolant temperature at
various points in the cooling system.
Shunt Line Restriction
During normal operation, measure temperatures at
If the cooling system is equipped with a shunt line, several different points in the cooling system. This
check for a restriction in the line. A restricted shunt will help to identify possible locations of restrictions.
line can cause cavitation in the water pump. Remove
the restriction or replace the shunt line. If a buildup of deposit in the cooling system is
suspected, clean the cooling system.
Radiator or Heat Exchanger If the flow of coolant through the engine is not
sufficient, determine the cause of the obstruction.
Measure the coolant temperature at the inlet to the
Make necessary repairs.
engine.
If the engine is equipped with a radiator, check the Check the back pressure of the exhaust system.
fins of the radiator for obstructions. Check the fan Refer to the engine's Technical Marketing Information.
for proper operation.
If the back pressure exceeds the specifications for
If the radiator fins are obstructed, clean the fins. If the the engine, determine the cause of the excessive
fan does not operate properly, make the necessary back pressure. Make the necessary repairs.
repairs.
Excessive Load
Heat Exchanger
Make sure that the load is not excessive. Reduce the
If the engine is equipped with a heat exchanger, load. If necessary, disengage the driven equipment
check for sufficient flow and temperature of the and test the engine for high coolant temperature.
cooling water through the heat exchanger. If the
flow of cooling water through the heat exchanger is Combustion Gas in the Coolant
insufficient, determine the location of the obstruction.
Check the cooling system for combustion gas. This
Water Temperature Regulator can be identified by small air bubbles in the coolant
during engine operation. Identify the source of the
Check the water temperature regulators for proper combustion gas. Make the necessary repairs.
operation. Refer to Systems Operation/Testing and
Adjusting.
i02826488
ECM Will Not Communicate • Electrical power supply to the Electronic Control
Module (ECM)
with Other Systems or Display
Modules • Flash file
SMCS Code: 1901-035 • Cat Data Link
2. Ensure that the following items are correctly 2. Verify that the correct “Communications Interface
installed and undamaged. Refer to the diagnostic Device” is selected.
functional test Troubleshooting, “Electrical
Connectors - Inspect”. 3. Verify that the correct port is selected for use by
the communication adapter.
• ECM connector J1/P1
Note: The most commonly used port is “COM 1”.
• Machine connector
• Wiring to display modules
RENR9346-06 31
Troubleshooting Section
4. Check for any hardware that is utilizing the Note: A new ECM is not programmed to any specific
same port as the communications adapter. If any engine until a flash file has been installed. The engine
devices are configured to use the same port, exit will not start and the engine will not communicate
or close the software programs for that device. with Cat ET until the flash file has been downloaded.
Refer to programming parameters Troubleshooting,
Electrical Connectors “Flash Programming”.
Check for correct installation of the J1/P1 and Cat Data Link
J2/P2 ECM connectors and of the service tool
connector. Refer to the diagnostic functional test Troubleshoot the Cat Data Link for possible
Troubleshooting, “Electrical Connectors - Inspect”. problems. Refer to the diagnostic functional test
Troubleshooting, “Cat Data Link Circuit - Test”.
Communication Adapter and/or Cables
i02881458
1. If you are using a “Communication Adapter II”,
ensure that the firmware and driver files for the Engine Cranks but Will Not
communication adapter are the most current files
that are available. If the firmware and driver files Start
do not match, the communication adapter will not
communicate with Cat ET. SMCS Code: 1000-035
Note: If the ECM is not receiving battery voltage, the Note: If Cat ET will not communicate with the
ECM will not communicate. ECM, the problem is most likely with the electrical
power supply to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test”.
Flash File
Ensure that the correct flash file is properly installed
in the ECM.
32 RENR9346-06
Troubleshooting Section
Starting Aids 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
1. If cold ambient conditions exist, check operation problems are found with the fuel lines, repair the
of starting aids. Verify that the ether system is lines and/or replace the lines.
operating correctly. Refer to Troubleshooting,
“Ether Injection System - Test”. 3. Check the fuel tank for foreign objects which may
block the fuel supply.
2. Ensure the proper operation of the jacket water
heater. Repair the jacket water heater and/or 4. Check for air in the low pressure fuel supply
replace the jacket water heater, if necessary. system if any of the following procedures have
been performed:
Engine Shutdown Switches (If Equipped)
• Replacement of the fuel filters
The engine shutdown switches should be in the
OFF position. Use Cat ET to verify the status of the • Service on the low pressure fuel supply circuit
shutdown switches. When a shutdown occurs, the
keyswitch must be turned to the OFF position for at • Replacement of unit injectors
least 15 seconds before restarting the engine.
Note: A sight glass in the low pressure supply line
Note: If Cat ET will not communicate with the is helpful in diagnosing air in the fuel. Refer to the
ECM, the problem is most likely with the electrical Systems Operation/Testing and Adjusting manual for
power supply to the ECM. Refer to Troubleshooting, more information.
“Electrical Power Supply Circuit - Test”.
NOTICE
Engine Speed/Timing Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
1. Crank the engine and observe the engine speed minutes before cranking the engine again.
on the Cat ET status screen. If Cat ET indicates
zero rpm, refer to Troubleshooting, “Engine 5. Purge air from the low pressure fuel supply circuit.
Speed/Timing Sensor Circuit - Test”. Refer to Operation and Maintenance Manual,
“Fuel System - Prime” for the correct procedure.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is 6. Cold weather adversely affects the characteristics
abnormal. This message will be replaced with an of the fuel. Check for presence of solidified fuel
engine speed once the ECM is able to calculate a (wax). Refer to the Operation and Maintenance
speed from the signal. Manual for information on improving the
characteristics of the fuel during cold weather
2. Ensure that the timing reference gear is installed operation.
correctly. The engine will not start if the gear was
installed backward. Check for proper orientation 7. Check the fuel pressure during engine cranking.
between the crankshaft and camshaft drive gears. Check the fuel pressure after the fuel filter. Refer
Correct the orientation and/or replace the drive to Systems Operation/Testing and Adjusting, “Fuel
gear, if necessary. Refer to the Disassembly and System” for the correct pressure values. If the fuel
Assembly manual for information that is related to pressure is low, replace the fuel filters. If the fuel
timing the engine's front gear train. pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
Unit Injectors fuel pressure regulating valve.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
RENR9346-06 33
Troubleshooting Section
1. Use Cat ET to determine if there are any active Engine Oil in Cooling System
diagnostic codes for the unit injectors.
SMCS Code: 1348-035; 1350-035
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids Probable Causes
are being energized by the ECM.
• Engine oil cooler core
3. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer • Cylinder head gasket
to the diagnostic functional test Troubleshooting,
“Injector Solenoid Circuit - Test”. • Water pump
Fuel Supply Recommended Actions
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
Engine Oil Cooler Core
problems are found with the fuel lines, repair the
1. Inspect the engine oil cooler core for leaks. If a
lines and/or replace the lines.
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
3. Prime the fuel system if any of the following
Refer to Operation and Maintenance Manual.
procedures have been performed:
• Service on the low pressure fuel supply circuit 1. Remove the cylinder head. Refer to Disassembly
and Assembly.
• Replacement of unit injectors
2. Check the cylinder liner projection. Refer to
Systems Operation/Testing and Adjusting.
RENR9346-06 35
Troubleshooting Section
Air Supply Check the alignment and the balance of the driven
equipment.
Check for restrictions in the air inlet system. Refer to
Systems Operation/Testing and Adjusting. Engine Misfiring or Running Rough
2. Verify that there are no active diagnostic codes for Check the engine oil level. Too much oil in the engine
the boost pressure sensor. crankcase can cause the engine to consume oil.
Remove excessive engine oil from the crankcase.
RENR9346-06 39
Troubleshooting Section
• Unit injectors 1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
• Air inlet and exhaust system or replace the air filter.
• Accessory equipment 2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting.
Recommended Actions
Accessory Equipment
Engine Operation
Check all accessory equipment for problems that
Use the Caterpillar Electronic Technician (ET) to may create excessive load on the engine. Repair
check the “Current Totals” for excessive idle time any damaged components or replace any damaged
and/or for a high load factor which would be indicative components.
of poor operating habits.
i02285926 i02711029
2. Cut out each individual cylinder for 30 to 60 • Air inlet and exhaust system
seconds. Verify that the smoke decreases.
Recommended Actions
Flash File
Diagnostic Codes
Verify that the correct flash file is installed. Refer to
Troubleshooting, “Flash Programing”. Connect the Caterpillar Electronic Technician (ET)
and check for active diagnostic codes. Troubleshoot
Fuel Supply any active diagnostic codes before continuing with
this procedure.
1. Inspect the fuel system components.
Electrical Connectors
2. Check the fuel pressure during engine cranking.
Check the filtered fuel pressure. Refer to Systems Check for correct installation of the J2/P2 Electronic
Operation/Testing and Adjusting for the correct Control Module (ECM) connector and of the
pressure values. If the fuel pressure is low, J300/P300 connector that is for the injectors. Refer
replace the fuel filters. If the fuel pressure is still to the diagnostic functional test Troubleshooting,
low, check the following items: fuel transfer pump, “Electrical Connectors - Inspect”.
fuel transfer pump coupling, and fuel pressure
regulating valve. Air Inlet and Exhaust System
3. Check the fuel quality. Low cetane fuel can create 1. Check the air inlet manifold pressure. Check for
white smoke. If necessary, replace the fuel with a air inlet restrictions and/or leaks. Refer to Systems
higher cetane fuel. Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and 2. Check for leaks between the exhaust manifold and
Maintenance Manual for information on improving the turbocharger. Check for exhaust restrictions.
the characteristics of the fuel during cold weather Refer to Systems Operation/Testing and Adjusting,
operation. “Air Inlet and Exhaust System”.
Component Wear
i02281012
Remove the valve cover. Remove the fuel supply. Inspect the cooling system for contamination of fuel.
Disconnect the fuel return line from the cylinder head. Inspect the crankcase for dilution of the engine oil.
Cap the fuel return connector and apply 700 kPa This may be a sign of a cracked cylinder head or of a
(102 psi) maximum air pressure to the fuel supply leaking cylinder head gasket.
connector. Check for fuel leakage around each fuel
injector. If leakage is present, remove the leaking fuel Leakage of the Drive Shaft Seal on the
injector. Install a new O-ring seal onto the injector.
Install the injector. Connect the fuel return line. Install
Fuel Transfer Pump
the valve cover. Verify that the problem is resolved.
Ensure that the weep hole for the fuel transfer pump
is not plugged. Inspect the front of the pump for signs
i02360438 of leakage. If necessary, repair the fuel transfer pump
or replace the fuel transfer pump.
Fuel Dilution of Engine Oil
SMCS Code: 1348-035 i02881460
• Leakage of the drive shaft seal on the fuel transfer • Event codes
pump
• Electrical connectors
Recommended Actions • Air inlet and exhaust restrictions
Leaking Seals on the Body or the Sleeve • Circuit breakers
of the Unit Injector
• Fuel supply
Check the torque for the unit injector clamp retaining
bolts. Ensure that the unit injectors are properly Recommended Actions
installed into the cylinder head.
Diagnostic Codes and/or Event Codes
If damage to the unit injector sleeves or to the O-ring
seals is suspected, remove the unit injectors and/or Certain diagnostic codes and/or event codes may
the unit injector sleeves. Inspect the O-ring seals and cause an engine shutdown. Connect the Caterpillar
the unit injector sleeves for damage. Replace any Electronic Technician (ET) and check for active codes
seals or sleeves that show evidence of leakage. and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Excessive Leakage from the Unit Injector
Tip or a Broken Unit Injector Tip Electrical Connectors
Look for signs of damage to the unit injectors. 1. Check for correct installation of the J1/P1 and
If necessary, replace the unit injectors that have J2/P2 connectors for the Electronic Control Module
damaged tips. (ECM). Also, thoroughly inspect the connectors
for the engine speed/timing sensors. Refer to
Cracked Cylinder Head or Leaking the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
Cylinder Head Gasket
Check for symptoms of a damaged cylinder head or
cylinder head gasket.
RENR9346-06 43
Troubleshooting Section
2. Inspect the battery wires from the ECM to the 5. Check fuel quality. Cold weather adversely
battery compartment. Refer to the Schematic for affects the characteristics of the fuel. Refer to the
specific wiring information. Check the unit injector Operation and Maintenance Manual.
connectors and associated wiring for damage, or
for intermittent problems. Inspect the wires and 6. Check the filtered fuel pressure while the
connectors to all circuit protection for the engine. engine is being cranked. Refer to Systems
Check the power and ground connections to Operation/Testing and Adjusting.
the ECM. Check any engine shutdown switches
and associated wiring. Refer to the diagnostic If the fuel pressure is low, replace the fuel filters.
functional test Troubleshooting, “Electrical Power Clean the primary filter/water separator of debris.
Supply Circuit - Test”. Refer to the Operation and Maintenance Manual.
Air Inlet and Exhaust Restrictions If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
Check the air inlet system for the following problems: for the proper operation of the fuel transfer pump.
restrictions, collapse, and pinched line. Repair the Refer to Systems Operation/Testing and Adjusting.
lines and/or replace the lines.
i02430113
Check for an air filter restriction. Replace plugged air
filters and/or clean filters. Repair any leaks. Low Engine Oil Pressure
Circuit Breakers SMCS Code: 1348-035-LP
Fuel Supply
Probable Causes
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel • Engine oil level
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system. • Engine oil filters and oil filter bypass valve
Refer to the Operation and Maintenance Manual.
• Engine oil pump
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If • Engine oil cooler
problems are found with the fuel lines, repair the
lines and/or replace the lines. • Fuel dilution
3. Check the fuel tank for debris or foreign objects • Engine wear
which may block the fuel supply.
Recommended Actions
NOTICE
Do not crank the engine continuously for more than Engine Oil Level
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance
Manual.
4. Prime the fuel system if any of the following
procedures have been performed:
Engine Oil Filters and Oil Filter Bypass
• Replacement of the fuel filters Valve
• Service on the low pressure fuel supply circuit Check the service records of the engine for
information that is related to the last oil change. If
• Replacement of unit injectors necessary, perform an oil change on the engine and
replace the engine oil filters.
Note: Check the fuel system for air. Refer to the
Systems Operation/Testing and Adjusting manual.
44 RENR9346-06
Troubleshooting Section
Check the operation of oil filter bypass valve. Clean • Fuel supply
the bypass valve and the housing. If necessary,
install new parts.
Recommended Actions
Engine Oil Pump Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Check for blockage of the inlet screen for the engine Examples of certain conditions are high engine
oil pump. Check the components of the engine oil speed, full load, and engine operating temperature.
pump for excessive wear. If necessary, repair the oil Troubleshooting the symptoms under other
pump or replace the oil pump. conditions can give misleading results.
Probable Causes Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
• Engine derate or active codes and that the engine is able to reach high idle speed.
Refer to Troubleshooting, “Throttle Position Sensor
• Cold mode Circuit - Test” for the correct procedure.
NOTICE
If “Fuel Position” equals “Rated Fuel Limit” and
Do not crank the engine continuously for more than
“Fuel Position” is less than “FRC Fuel Limit”, the
30 seconds. Allow the starting motor to cool for two
electronics are operating correctly. Otherwise, minutes before cranking the engine again.
proceed with the next Step.
2. Monitor the status of “Boost Pressure” and 4. Prime the fuel system if any of the following
“Atmospheric Pressure” for normal operation procedures have been performed:
on Cat ET. When the engine is not running, the
correct value for “Boost Pressure” is 0 kPa (0 psi) • Replacement of the fuel filters
while the engine is off.
• Service on the low pressure fuel supply circuit
Air Inlet and Exhaust System
• Replacement of unit injectors
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the Note: Check the fuel system for air. Refer to Systems
Operation and Maintenance Manual for additional Operation/Testing and Adjusting, “Air in Fuel - Test”
information. for information that is related to checking the fuel
system for air.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems 5. Check fuel quality. Cold weather adversely
Operation/Testing and Adjusting, “Air Inlet and affects the characteristics of the fuel. Refer to the
Exhaust System”. engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.
Parameters
6. Check the filtered fuel pressure while the
If the ECM has been replaced, compare the values
engine is being cranked. Refer to Systems
that are on the engine information plate to following
Operation/Testing and Adjusting for the test
parameters from Cat ET:
procedure and for the correct pressure values.
• FRC offset If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
• Full Load Setting (FLS) Refer to the Operation and Maintenance Manual
for details.
• Full Torque Setting (FTS)
If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting
for test information.
46 RENR9346-06
Troubleshooting Section
1. Visually check the fuel level in the fuel tank. Do Valve Rotator or Spring Lock
not rely on the fuel gauge only. If necessary, add Is Free
fuel to the fuel tank. If the engine has been run
out of fuel, it will be necessary to purge the air SMCS Code: 1109-035
from the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for Use this procedure in order to troubleshoot a problem
the correct procedure. with the valve rotators or spring locks.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If Probable Cause
problems are found with the fuel lines, repair the
lines and/or replace the lines. • Valve Components
3. Check the fuel tank for debris or foreign objects Recommended Actions
which may block the fuel supply.
Valve components
NOTICE
Do not crank the engine continuously for more than 1. A valve rotator that is cracked or a valve rotator
30 seconds. Allow the starting motor to cool for two that is broken is an indication of an engine
minutes before cranking the engine again. overspeed. Determine the cause of the engine
overspeed. Repair the condition.
4. Prime the fuel system if any of the following 2. Inspect the following components for damage:
procedures have been performed:
• Valve rotators
• Replacement of the fuel filters
• Spring locks
• Service on the low pressure fuel supply circuit
• Valve springs
• Replacement of unit injectors
Note: Check the fuel system for air. Refer to Systems
• Valves
Operation/Testing and Adjusting, “Air in Fuel - Test” Note: Ensure that the valve has not contacted the
for information that is related to checking the fuel piston. If the valve has contacted the piston, check
system for air. the exhaust system for debris.
5. Check fuel quality. Cold weather adversely 3. Replace any damaged components.
affects the characteristics of the fuel. Refer to the
engine's Operation and Maintenance Manual for
information on improving the characteristics of the
fuel during cold weather operation.
Troubleshooting with a
Diagnostic Code
i02281051
Diagnostic Codes
SMCS Code: 1900
Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to
the service technician. The Caterpillar Electronic
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that
has Cat ET software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).
• The hour of the first occurrence of the code Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
• The hour of the last occurrence of the code
Results:
• The number of occurrences of the code
• OK – STOP.
This information is a valuable indicator for
troubleshooting intermittent problems.
i02504233
The ECM will log the diagnostic code. The ECM will Conditions Which Generate This Code:
continue to attempt to operate the injector after the
code has been logged. The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
RENR9346-06 51
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will CID 0003 FMI 05 Cylinder #3
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting
• Low power to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
The ECM will log the diagnostic code. The ECM will CID 0003 FMI 06 Cylinder #3
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting to
• Low power operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
• Engine misfires
• Low power
52 RENR9346-06
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
• Engine misfires The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• Low power code has been logged.
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.
RENR9346-06 53
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will CID 0006 FMI 06 Cylinder #6
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting to
• Low power operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
The ECM will log the diagnostic code. The ECM will CID 0007 FMI 05 Cylinder #7
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting
• Low power to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
• Engine misfires
• Low power
54 RENR9346-06
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.
• Engine misfires The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• Low power code has been logged.
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
RENR9346-06 55
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will CID 0010 FMI 05 Cylinder #10
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting
• Low power to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
The ECM will log the diagnostic code. The ECM will CID 0010 FMI 06 Cylinder #10
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting to
• Low power operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.
• Engine misfires
• Low power
56 RENR9346-06
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
• Engine misfires The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• Low power code has been logged.
The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.
RENR9346-06 57
Troubleshooting Section
The ECM will log the diagnostic code. The ECM will CID 0041 FMI 04 8 Volt DC
continue to attempt to operate the injector after the Supply short to ground
code has been logged.
SMCS Code: 1439-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The voltage level of the 8 volt supply is below normal.
• Low power
System Response:
Troubleshooting:
The Electronic Control Module (ECM) logs the
Perform the following diagnostic procedure: “Injector diagnostic code. The ECM flags all digital sensors
Solenoid Circuit - Test” as invalid data and all digital sensors are set to the
respective default values.
Results:
Possible Performance Effect:
• OK – STOP.
• The engine may experience low power.
i02419277
Troubleshooting:
CID 0041 FMI 03 8 Volt DC
Perform the following diagnostic procedure: “Digital
Supply short to +batt Sensor Supply Circuit - Test”
SMCS Code: 1439-038 Results:
Conditions Which Generate This Code:
• OK – STOP.
The voltage level of the 8 volt supply is above normal.
i02440965
System Response:
CID 0091 FMI 08 Throttle
The Electronic Control Module (ECM) will log the Position signal abnormal
diagnostic code. The ECM flags all digital sensors
as invalid data and all digital sensors are set to the SMCS Code: 1439-038; 1913-038
respective default values.
Conditions Which Generate This Code:
Possible Performance Effect:
The Electronic Control Module (ECM) detects an
• The engine may experience low power. incorrect frequency on the throttle signal or the
throttle position sensor is out of the acceptable range.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test” The code is logged. The ECM flags the throttle
position as invalid data and a default value of zero
Results: percent is used.
Results:
• OK – STOP.
58 RENR9346-06
Troubleshooting Section
i02424760 i02424766
CID 0094 FMI 03 Fuel Pressure CID 0100 FMI 03 Engine Oil
open/short to +batt Pressure open/short to +batt
SMCS Code: 1439-038; 1718-038 SMCS Code: 1439-038-OC; 1924-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) detects signal
voltage that is above normal. voltage that is above normal.
The ECM will log the diagnostic code. The ECM flags The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is oil pressure as invalid data.
used.
Possible Performance Effect:
Possible Performance Effect:
• There are no performance effects.
• There are no performance effects.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure: “Engine Pressure Sensor Open or Short Circuit - Test”
Pressure Sensor Open or Short Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02424648
Results: • OK – STOP.
• OK – STOP.
RENR9346-06 59
Troubleshooting Section
i02581776 i02427669
Conditions Which Generate This Code: Conditions Which Generate This Code:
This code indicates that the 5 volt supply is missing The signal voltage from the engine coolant
from the sensor connector. temperature sensor is above normal.
• There are no performance effects. Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Repair the Open Circuit
• OK – STOP.
A. Repair the supply wire or replace the supply wire
between the ECM and the sensor.
i02427678
System Response:
CID 0172 FMI 03 Intake Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Manifold Air Temp open/short
to +batt Results:
The Electronic Control Module (ECM) detects a CID 0174 FMI 03 Fuel
signal voltage that is above normal or the intake
manifold air temperature is below −35 °C (−31 °F) .
Temperature open/short to
+batt
System Response:
SMCS Code: 1439-038; 1922-038
The code is logged. The ECM will flag the intake
manifold air temperature as invalid data and the Conditions Which Generate This Code:
intake manifold air temperature is set to a default
value. The Electronic Control Module (ECM) detects a
signal voltage from the sensor that is above normal.
Possible Performance Effect:
System Response:
• There are no performance effects.
The ECM will log the diagnostic code. The ECM flags
Troubleshooting: fuel temperature as invalid data and fuel temperature
is set to a default value.
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” Possible Performance Effect:
i02424798 Results:
CID 0174 FMI 04 Fuel • OK – STOP.
Temperature short to ground
i02428636
SMCS Code: 1439-038; 1922-038
CID 0253 FMI 02 Personality
Conditions Which Generate This Code:
Module mismatch
The Electronic Control Module (ECM) detects signal
voltage that is below normal. SMCS Code: 1902-038
The ECM will log the diagnostic code. The ECM flags The flash file that is used for replacement is for
fuel temperature as invalid data and a default value a different engine family or for a different engine
is used. application.
The Electronic Control Module (ECM) receives erratic The correct flash file is installed in the ECM.
data from the engine speed/timing sensor.
Results:
System Response:
• OK – The correct flash file is installed in the ECM.
The ECM will log the diagnostic code. The check
engine lamp will illuminate after a delay. The ECM Repair: The engine will not start until the 253-02
will default to the signal from the secondary engine diagnostic code is cleared. Clearing this code
speed/timing sensor. requires factory passwords.
Repair: Flash program the ECM with the correct B. Check for the correct installation of the sensor's
flash file. Refer to programming parameters connectors. Ensure that the electrical connector
Troubleshooting, “Flash Programming”. Verify that is securely latched. Check for the correct polarity
the problem is resolved. in the wiring at each sensor connector and at the
ECM connector.
STOP.
C. Ensure that the harness is properly secured, and
ensure that each tie-wrap is placed in the correct
i02437198
location.
CID 0261 FMI 11 Engine Timing Expected Result:
Offset fault
The sensors, the connectors, and the wiring are
SMCS Code: 1439-038; 1912-038 correctly installed.
The signals from the engine speed/timing sensors • OK – The sensors and the harness are OK. The
indicate that the expected position of the camshaft is problem is not with the sensor or the harness.
incorrect with respect to the crankshaft, or the polarity There may be a mechanical problem with the
of the wiring to one of the speed/timing sensors is engine's front gear train. Proceed to Test Step 2.
reversed.
• Not OK – A problem has been identified with the
System Response: installation of the sensors and/or the harness.
The Electronic Control Module (ECM) will log the Repair: Correct the problem that has been
diagnostic code. identified. Replace parts, if necessary. Ensure that
the diagnostic code is no longer active.
The ECM sets engine timing calibration to zero
degrees. A timing calibration is necessary after this
diagnostic code has become active. Refer to the
Possible Performance Effect: diagnostic functional test Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
• The engine may misfire.
STOP.
• The engine may experience low power and/or
reduced speed. Test Step 2. Check the Condition of the
Engine's Front Gear Train
• The engine may experience increased exhaust
emissions and/or white exhaust smoke. The problem may be due to the incorrect orientation
of the camshaft gear with respect to the orientation of
Troubleshooting: the crankshaft gear during engine operation. Check
the front gear train for damage and excessive wear:
Test Step 1. Check the Installation of the
Speed/Timing Sensors Refer to Disassembly and Assembly.
A. Visually inspect the sensors for correct installation: A. Remove the cover from the front gear housing.
a. Ensure that the sensor's mounting flanges are B. Check for correct timing between the crankshaft
fully seated onto the surface of the engine. gear and the camshaft gear.
b. Ensure that the locating notch on the flange of C. Check the gear train for gear tooth failure.
each sensor is oriented correctly.
D. Check the gear train for excessive gear tooth
c. Ensure that the sensor's brackets are not wear and gear tooth failure. Perform a timing gear
bent or broken. Ensure that the brackets are backlash check.
securely holding the sensor in place.
E. Check each idler gear assembly for excessive
d. Ensure that the sensors are tight in the housing wear to the bearing and/or the idler stub shaft.
bore. If a sensor is loose in the bore, check the Check for correct bearing clearance.
condition of the sensor's O-ring seals. Ensure
that the seals are not missing. Also, inspect the
seals for damage.
64 RENR9346-06
Troubleshooting Section
The mechanical condition of the gear train is within Perform the following diagnostic procedure: “Engine
specifications. Speed/Timing Sensor - Calibrate”
Results: Results:
Note: A timing calibration is required for a new CID 0262 FMI 04 5 Volt Sensor
engine, replacing an ECM that fails to communicate
or following work on the front gear train, the camshaft,
DC Power Supply short to
or the crankshaft. ground
System Response: SMCS Code: 1439-038
The check engine lamp will illuminate while this Conditions Which Generate This Code:
diagnostic code is active. The ECM uses default
timing. Timing may be off as much as three degrees. The 5 volt sensor supply voltage drops below normal.
• The engine may run rough and/or the engine may The Electronic Control Module (ECM) logs the
emit white smoke in the exhaust. diagnostic code. The ECM flags all 5 volt sensors
as invalid data and the respective default values are
used.
RENR9346-06 65
Troubleshooting Section
• The engine may experience low power. The diagnostic code will only be active. The check
engine lamp will illuminate while this diagnostic code
Troubleshooting: is active. Any unprogrammed parameters are set to
the default value.
Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test” Possible Performance Effect:
Results:
The engine is running. Both inputs from the engine
shutdown control (ground level) are connected to
ground or both inputs are an open circuit. • OK – STOP.
The Electronic Control Module (ECM) will log the CID 0274 FMI 03 Atmospheric
diagnostic code. The engine shutdown control
(ground level) will not operate. Therefore, the
Pressure open/short to +batt
keyswitch or the engine shutdown control on the SMCS Code: 1439-038-AI; 1923-038
engine control panel must be used to shut down the
engine.
Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) detects a
signal voltage that is above normal.
Perform the following diagnostic procedure: “Engine
Shutdown Switch Circuit - Test”
System Response:
Results: The code is logged. The ECM will use the default
value for atmospheric pressure.
• OK – STOP.
Possible Performance Effect:
i02445689
• The engine power is derated.
CID 0268 FMI 02 Check
Programmable Parameters Troubleshooting:
i02416783 Results:
CID 0274 FMI 04 Atmospheric • OK – STOP.
Pressure short to ground
i02455005
SMCS Code: 1439-038-AI; 1923-038
CID 0291 FMI 06 Engine
Conditions Which Generate This Code:
Cooling Fan Solenoid short to
The Electronic Control Module (ECM) detects a ground
signal that is below normal.
SMCS Code: 5479-038
System Response:
Conditions Which Generate This Code:
The code is logged. The ECM will use the default
value for atmospheric pressure. The Electronic Control Module (ECM) detects a
short to ground condition in the circuit for the engine
Possible Performance Effect: cooling fan solenoid.
Perform the following diagnostic procedure: “Engine • All features that depend on the missing data will
Speed/Timing Sensor Circuit - Test” be affected.
Results: Troubleshooting:
The engine Electronic Control Module (ECM) loses All of the flash files for the machine are the latest part
communication with the brake ECM. number.
The engine ECM will log the diagnostic code. • OK – The flash files are the latest part number.
Possible Performance Effect: Repair: Contact the Dealer Solution Network (DSN)
for information that is related to troubleshooting
• All features that depend on input from the brake the problem further.
ECM will be affected.
STOP.
Troubleshooting:
After successful communication has been The ECM will log the diagnostic code. The ECM will
established, the engine Electronic Control Module default to maximum fan speed.
(ECM) has not received all the information that was
requested over the Cat Data Link from the brake Possible Performance Effect:
(ECM).
• The engine may experience overcooling.
System Response:
Troubleshooting:
The engine ECM will log the diagnostic code.
Perform the following diagnostic procedure: “Engine
Fan Speed Sensor Circuit - Test”
68 RENR9346-06
Troubleshooting Section
Results: Troubleshooting:
The ECM will log the diagnostic code. The ECM will S/N: JXP1-Up
default to maximum fan speed. S/N: JRP1-Up; LJW1-Up
Possible Performance Effect: Conditions Which Generate This Code:
• The engine may experience overcooling. The Electronic Control Module (ECM) detects
excessive current in the circuit.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Engine
Fan Speed Sensor Circuit - Test” The code is logged.
Results: Possible Performance Effect:
• OK – STOP. • The oil renewal system is disabled.
i02521218 Troubleshooting:
CID 0569 FMI 05 Oil Injection Perform the following diagnostic procedure: “Engine
Oil Renewal Solenoid Circuit - Test”
Solenoid current below normal
Results:
SMCS Code: 1349-038-OD; 5479-038-OC
S/N: EXD1-Up • OK – STOP.
S/N: EYG1-Up
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up
System Response:
Conditions Which Generate This Code: CID 0827 FMI 08 Left Exhaust
Temperature signal abnormal
The Electronic Control Module (ECM) detects a
signal voltage that is above normal. SMCS Code: 1439-038-TA; 1919-038
The code is logged. The ECM will flag the exhaust S/N: EYG1-Up
temperature as invalid data. S/N: JXP1-Up
Possible Performance Effect: S/N: JRP1-Up; LJW1-Up
• OK – STOP. The code is logged. The ECM will flag the exhaust
temperature as invalid data.
i02817787
Possible Performance Effect:
CID 0827 FMI 04 Left Exhaust
• There are no performance effects.
Temperature short to ground
Troubleshooting:
SMCS Code: 1439-038-TA; 1919-038
Perform the following diagnostic procedure: “Sensor
S/N: EXD1-Up
Signal (PWM) - Test”
S/N: EYG1-Up
Results:
S/N: JXP1-Up
• OK – STOP.
S/N: JRP1-Up; LJW1-Up
System Response:
Conditions Which Generate This Code: CID 0828 FMI 08 Right Exhaust
Temperature signal abnormal
The Electronic Control Module (ECM) detects a
signal voltage that is above normal. SMCS Code: 1439-038-TA; 1919-038
The code is logged. The ECM will flag the exhaust S/N: EYG1-Up
temperature as invalid data. S/N: JXP1-Up
Possible Performance Effect: S/N: JRP1-Up; LJW1-Up
• OK – STOP. The code is logged. The ECM will flag the exhaust
temperature as invalid data.
i02817799
Possible Performance Effect:
CID 0828 FMI 04 Right Exhaust
• There are no performance effects.
Temperature short to ground
Troubleshooting:
SMCS Code: 1439-038-TA; 1919-038
Perform the following diagnostic procedure: “Sensor
S/N: EXD1-Up
Signal (PWM) - Test”
S/N: EYG1-Up
Results:
S/N: JXP1-Up
• OK – STOP.
S/N: JRP1-Up; LJW1-Up
System Response:
System Response: • OK – The flash files are the latest part number.
The engine ECM will log the diagnostic code. Repair: Contact the Dealer Solution Network (DSN)
for information that is related to troubleshooting
Possible Performance Effect: the problem further.
Troubleshooting: i02443808
Troubleshooting:
i02445694 Results:
CID 1589 FMI 04 Turbo Inlet • OK – STOP.
Air Pressure Sensor short to
ground i02407894
The ECM will log the diagnostic code. The ECM flags The Electronic Control Module (ECM) detects a
turbocharger inlet pressure as invalid data and a signal voltage below the normal.
default value is used.
System Response:
Possible Performance Effect:
The code is logged. The ECM flags intake manifold
pressure as invalid data and a default value is used.
• The engine may have low power.
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: “Engine • The engine power will be derated.
Pressure Sensor Open or Short Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
• OK – STOP.
Results:
i02407892
• OK – STOP.
CID 1785 FMI 03 Intake
Manifold Pressure Sensor i02487751
voltage high CID 1785 FMI 10 Intake
SMCS Code: 1439-038-IL Manifold Pressure Signal
Conditions Which Generate This Code: abnormal rate of change
The Electronic Control Module (ECM) detects a SMCS Code: 1439-038-IL
signal voltage above normal.
Conditions Which Generate This Code:
System Response:
This code indicates that the 5 volt supply is missing
The code is logged. The ECM flags intake manifold from the sensor connector.
pressure as invalid data and a default value is used.
During normal engine operation, the intake manifold
Possible Performance Effect: pressure fluctuates slightly. When the 5 volt supply is
missing from the intake manifold pressure sensor, the
signal from the pressure sensor floats to a midrange
• The engine power will be derated. value. The signal does not fluctuate. If the signal
Troubleshooting: from the intake manifold pressure sensor remains
abnormally steady for more than 30 seconds, the
Perform the following diagnostic procedure: “Engine Engine Control Module (ECM) activates this code.
Pressure Sensor Open or Short Circuit - Test”
RENR9346-06 73
Troubleshooting Section
The ECM uses a default value for the intake manifold Perform the following diagnostic procedure: “Engine
pressure. Pressure Sensor Open or Short Circuit - Test”
CID 1795 FMI 03 Turbo #2 The code is logged. The ECM flags intake manifold
pressure as invalid data and a default value is used.
Outlet Pressure Sensor
voltage above normal Possible Performance Effect:
System Response:
i02509473 i02509512
Conditions Which Generate This Code: Conditions Which Generate This Code:
This code indicates that the 5 volt supply is missing The Electronic Control Module (ECM) detects a
from the sensor connector. signal voltage that is above normal or the intake
manifold air temperature is below −35 °C (−31 °F) .
During normal engine operation, the intake manifold
pressure fluctuates slightly. When the 5 volt supply is System Response:
missing from the intake manifold pressure sensor, the
signal from the pressure sensor floats to a midrange The code is logged. The ECM will flag the intake
value. The signal does not fluctuate. If the signal manifold air temperature as invalid data and the
from the intake manifold pressure sensor remains intake manifold air temperature is set to a default
abnormally steady for more than 30 seconds, the value.
Engine Control Module (ECM) activates this code.
Possible Performance Effect:
System Response:
• There are no performance effects.
The ECM uses a default value for the intake manifold
pressure. Troubleshooting:
The Electronic Control Module (ECM) will log the CID 2271 FMI 06 Engine Oil
diagnostic code. The ECM will flag the intake Renewal System Actuation
manifold air temperature as invalid data and a default
value is used. Solenoid current above normal
Possible Performance Effect: SMCS Code: 5479-038-OC
S/N: EXD1-Up
• There are no performance effects.
S/N: EYG1-Up
Troubleshooting:
S/N: JXP1-Up
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” S/N: JRP1-Up; LJW1-Up
System Response:
The Electronic Control Module (ECM) detects a • There are no performance effects.
signal voltage that is below normal.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Sensor
The code is logged. The ECM will flag the exhaust Signal (PWM) - Test”
temperature as invalid data.
Results:
Possible Performance Effect:
• OK – STOP.
• There are no performance effects.
i02817762
Troubleshooting:
CID 2351 FMI 03 Right Exhaust
Perform the following diagnostic procedure: “Sensor
Signal (PWM) - Test” #2 Temperature voltage above
Results:
normal
SMCS Code: 1919-038-RI
• OK – STOP.
S/N: EXD1-Up
S/N: EYG1-Up
S/N: JXP1-Up
S/N: JRP1-Up; LJW1-Up
The code is logged. The ECM will flag the exhaust CID 2351 FMI 08 Right Exhaust
temperature as invalid data. #2 Temperature abnormal
Possible Performance Effect: frequency, pulse width, or
period
• There are no performance effects.
SMCS Code: 1919-038-RI
Troubleshooting:
S/N: EXD1-Up
Perform the following diagnostic procedure: “Sensor
Signal (PWM) - Test” S/N: EYG1-Up
Perform the following diagnostic procedure: “Sensor Conditions Which Generate This Code:
Signal (PWM) - Test”
The Electronic Control Module (ECM) detects low
Results: current in the circuit.
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: “Ether Perform the following diagnostic procedure:
Injection System - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02418652 i02510965
The Electronic Control Module (ECM) detects Conditions Which Generate This Code:
excessive current flow in the circuit.
The Electronic Control Module (ECM) detects
System Response: excessive current in the circuit.
System Response:
The code is logged.
The code is logged.
Possible Performance Effect:
Possible Performance Effect:
• The engine may be difficult to start.
Troubleshooting: • The engine compression brake may not activate.
Troubleshooting:
Perform the following diagnostic procedure: “Ether
Injection System - Test”
Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
i02511159
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02511529 i02511535
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects The Electronic Control Module (ECM) detects
excessive current in the circuit. excessive current in the circuit.
• The engine compression brake may not activate. • The engine compression brake may not activate.
Troubleshooting: Troubleshooting:
Perform the following diagnostic procedure: Perform the following diagnostic procedure:
“Compression Brake Solenoid Circuit - Test” “Compression Brake Solenoid Circuit - Test”
Results: Results:
• OK – STOP. • OK – STOP.
i02511361 i02511372
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects low The Electronic Control Module (ECM) detects low
current in the circuit. current in the circuit.
• The engine compression brake may not activate. • The engine compression brake may not activate.
80 RENR9346-06
Troubleshooting Section
Troubleshooting:
Results:
• OK – STOP.
i02511545
System Response:
Results:
• OK – STOP.
RENR9346-06 81
Troubleshooting Section
Troubleshooting with an Derate (2) – For this condition, the engine's power
is reduced in order to help prevent possible engine
Event Code damage. However, this condition does not require
a shutdown.
i02815105 Shutdown (3) – For this condition, the operator is
Event Codes alerted of the event. The operator must shut down the
engine in order to prevent possible engine damage.
SMCS Code: 1901
Logged Event Codes 2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
When the ECM generates an event code the code is due to error of the operator.
logged into permanent memory. The ECM has an
internal diagnostic clock that is used to time stamp 3. Narrow the probable cause. Consider the operator
the activation of the event. The ECM will record information, the conditions of operation, and the
the following information when an event code is history of the engine.
generated:
4. Perform a visual inspection. Inspect the following
• The hour of the first occurrence of the code items:
• The hour of the last occurrence of the code • Condition of the fuel and fuel system
components
• The number of occurrences of the code
• Oil level and condition of the oil
Logged events are listed in chronological order. The
most recent event code is listed first. • Engine wiring and condition of the connectors
This information can be helpful for troubleshooting Be sure to check the connectors. This is very
intermittent problems. Logged codes can also be important for problems that may be logged several
used to review any performance problems with the times over a long period of time. This may indicate
engine. that an intermittent problem exists. If an intermittent
condition is suspected, refer to Troubleshooting,
“Electrical Connectors - Inspect”.
Clearing Event Codes
If these steps do not resolve the problem, identify
A code is cleared from memory when one of the
the procedures in this manual that best describe the
following conditions occur:
event. Check each probable cause according to the
tests that are recommended.
• The code does not recur for 100 hours.
• A new code is logged and there are already ten Trip Points for the Monitoring
codes in memory. In this case, the oldest code is System
cleared.
The monitoring system determines the level of action
• The service technician manually clears the code. that is taken by the ECM in response to a condition
that can damage the engine. When any of these
Always clear logged event codes after investigating conditions occur, the appropriate event code will trip.
and correcting the problem which generated the
code. Table 12 contains the conditions that are monitored
and the default trip points for each condition. Each
Troubleshooting condition has an associated parameter. The settings
for each parameter can be viewed with Cat ET.
For basic troubleshooting of the engine, perform the The trip points for some of the parameters may be
following steps in order to diagnose a malfunction: adjustable.
Table 12
Trip Points for the Monitoring System
Time Delay in
Event Default Set Points
Parameter Action Seconds
Code Value
Range Default Range Default
Always 758 kPa
High Fuel Pressure E096 Warning None 8 None
On (110 psi)
Switch Switch Open
Low Engine Oil Level E171 Warning None N/A N/A
Closed on Low Level
7.5 kPa
Warning
(1.1 psi)
High Air Filter Restriction E172 On None 30 None
9.0 kPa
Derate
(1.3 psi)
High Exhaust Temperature E194 Refer to Troubleshooting, “E194 High Exhaust Temperature” for information.
760 °C
Warning
High Right Exhaust Always (1400 °F)
E321 None 15 None
Temperature On 805 °C
Derate
(1481 °F)
760 °C
Warning
High Left Exhaust Always (1400 °F)
E322 None 15 None
Temperature On 805 °C
Derate
(1481 °F)
760 °C
Warning
High Left Exhaust #2 Always (1400 °F)
E775 None 15 None
Temperature On 805 °C
Derate
(1481 °F)
760 °C
Warning
High Right Exhaust #2 Always (1400 °F)
E776 None 15 None
Temperature On 805 °C
Derate
(1481 °F)
Warning Always 8 Maps are not programmable. (1)
Low Engine Oil Pressure E360 None
Shutdown On 4 Maps are not programmable. (2)
i02490670 STOP.
E096 High Fuel Pressure
i02512722
SMCS Code: 1250-038-HQ
E171 Low Engine Oil Level
Conditions Which Generate This Code:
SMCS Code: 1348-038-LO
The Electronic Control Module (ECM) detects a
problem with the engine's fuel pressure. Information Conditions Which Generate This Code:
on default settings and ranges for this event code
can be found in Troubleshooting, “Event Codes”. The Electronic Control Module (ECM) detects a low
oil condition. Information on default settings and
System Response: ranges for this event can be found in Troubleshooting,
“Event Codes”.
The event code will be logged.
RENR9346-06 85
Troubleshooting Section
The following conditions can cause the event code. Check for Restrictions in the Air Inlet
System
• Low oil level
A. Inspect the air filter for restrictions and/or clogging.
• Faulty low oil level switch Clean the air filter or replace the air filter.
Check the Engine Oil Level B. Check the air inlet piping for restrictions and for
damage. Refer to Systems Operation/Testing and
A. Check the engine oil level. Adjusting.
The engine oil level is low. The air filter was cleaned or the air filter was
replaced. No restrictions have been found in the air
Results: inlet system.
Repair: Add oil to the engine. Check for leaks that • OK – The air filter and the air inlet system are OK.
might cause the low oil level.
Repair: If an electrical problem with the sensor is
STOP. suspected, refer to the diagnostic functional test
Troubleshooting, “Engine Pressure Sensor Open
• Not OK – The engine had the proper amount of oil. or Short Circuit - Test”.
The code is logged. Passwords are not required in B. Measure the value of the 5 volt supply at the
order to clear the logged code. harness connector for the atmospheric pressure
sensor.
Possible Performance Effect:
Expected Result:
Engine power is reduced.
The voltage is approximately five volts.
Test Step 1. Determine the Operating
Conditions Results:
Interview the operator, when possible. Determine if • OK – The supply voltage at the atmospheric
the engine was under heavy load or the engine is pressure sensor is approximately five volts. There
operating at a high altitude. are no further troubleshooting procedures for this
event. Clear the event and return the engine to
Expected Result: service. STOP.
The event occurred because of normal engine • Not OK – The supply voltage at the atmospheric
operation. pressure sensor is not approximately five volts.
There is a problem with the wiring for the 5 volt
Results: supply between the atmospheric pressure sensor
and the ECM.
• OK – The event occurred because of normal
engine operation. Clear the logged event and Repair: Identify the wiring problem and make the
return the engine to service. STOP. necessary repairs.
• Not OK – The event should not have occurred. When the 5 volt supply is present at the
Proceed to Test Step 2. atmospheric pressure sensor, clear the event and
return the engine to service.
Test Step 2. Check the Air-to-Air
Aftercooler (ATAAC) STOP.
Expected Result:
Results:
STOP.
RENR9346-06 87
Troubleshooting Section
i02817265 Results:
E321 High Right Exhaust • OK – There are no active diagnostic codes.
Temperature Proceed to Test Step 2.
S/N: JRP1-Up; LJW1-Up Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will
Conditions Which Generate This Code: increase the exhaust temperature by approximately
three degrees. Check for leaks between the exhaust
The Electronic Control Module (ECM) detects an manifold and the turbocharger. Check for exhaust
excessive exhaust temperature for the engine at restrictions. Refer to the Systems Operation/Testing
the “FRONT RIGHT EXHAUST TC”. This sensor and Adjusting manual for more information on
is located in the exhaust manifold below the inspecting the air inlet and exhaust system.
turbocharger. This sensor measures the exhaust gas
temperature for cylinders 2, 4, and 6. Information Results:
on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”. • OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3.
System Response:
• Not OK – A problem has been identified with the
The event code will be logged. air inlet or the exhaust system.
Possible Performance Effect: Repair: Resolve the problem and verify if the E321
code has been eliminated.
E321(1)
STOP.
• There are no performance effects.
Test Step 3. Check for Faults with the
E321(2) Fuel Injectors
• The engine power will be derated. Faulty injectors that deliver too much fuel will
increase exhaust temperatures. Connect Cat ET in
Troubleshooting: order to determine if any diagnostic codes for the
injector solenoids are present. Perform the “Injector
High exhaust temperature can be caused by Solenoid Test”. Observe that the injector solenoids
problems with the following. are being energized on Cat ET. Perform the “Cylinder
Cutout Test”. Locate the misfiring cylinder. Refer to
• Diagnostic codes Troubleshooting, “Injector Solenoid - Test”.
Test Step 1. Check for Diagnostic Codes Repair: Resolve the problem and verify if the E321
code has been eliminated.
Connect Cat ET and check for active and/or logged
diagnostic codes. Troubleshoot any active diagnostic STOP.
codes before continuing with this procedure.
88 RENR9346-06
Troubleshooting Section
• Not OK – A problem has been identified with the The Electronic Control Module (ECM) detects an
aftercooler. excessive exhaust temperature for the engine at the
“FRONT LEFT EXHAUST TC”. This sensor is located
Repair: Resolve the problem and verify if the E321 in the exhaust manifold below the turbocharger.
code has been eliminated. This sensor measures the exhaust gas temperature
for cylinders 1, 3, and 5. Information on default
STOP. settings and ranges for this event can be found in
Troubleshooting, “Event Codes”.
Test Step 5. Check the Exhaust
Temperature Sensor System Response:
Use Cat ET to check the status of the exhaust The event code will be logged.
temperature.
Possible Performance Effect:
A. Start the engine.
E322(1)
B. Use Cat ET to monitor the status of the exhaust
temperature while the engine is warming to • There are no performance effects.
operating temperature.
E322(2)
C. Ensure that the reading that is displayed is
reasonable. • The engine power will be derated.
Results: Troubleshooting:
• The temperature indicated by the sensor is not High exhaust temperature can be caused by
within reasonable expectations. problems with the following.
STOP.
90 RENR9346-06
Troubleshooting Section
i02486798 C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This
E360 Low Engine Oil Pressure restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
SMCS Code: 1348-038-LP the oil pickup tube and remove any material that
may be restricting engine oil flow. Low engine oil
Conditions Which Generate This Code: pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
The Electronic Control Module (ECM) detects a oil pickup tube for cracks or a damaged O-ring
problem with the engine's oil pressure. Information seal.
on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”. D. If the engine oil bypass valves are held in the open
position, a reduction in the oil pressure can be the
System Response: result. This may be due to debris in the engine
oil. If the engine oil bypass valves are stuck in
The event code will be logged. the open position, remove each engine oil bypass
valve and clean each bypass valve in order to
Possible Performance Effect: correct this problem. You must also clean each
bypass valve bore.
E360(1)
E. Engine oil that is contaminated with fuel or coolant
• There are no performance effects. will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of
E360(3) contamination.
• The engine will be shut down. F. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the engine
Troubleshooting: components for excessive bearing clearance.
There may be a problem with the engine's lubrication G. An oil line that is open, broken, or disconnected
system. will cause low engine oil pressure.
Check the Engine's Lubrication System Expected Result:
A. Check the engine oil level. If the oil level is below An inspection of the engine's lubrication system
the oil pump's supply tube, the oil pump will not indicated a problem.
have the ability to supply enough lubrication to
the engine components. If the engine oil level is Results:
low, add engine oil in order to obtain the correct
engine oil level. • OK – There is a problem in the engine's lubrication
system.
B. Check the following problems that may occur to
the engine oil pump: Repair: Repair the problem. Ensure that the repair
eliminates the problem.
a. Air leakage in the supply side of the oil pump
will also cause cavitation and loss of oil STOP.
pressure. Check the supply side of the oil pump
and make necessary repairs.
i02498357
b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the E361 High Engine Coolant
engine oil pump. Temperature
c. If the engine is equipped with a scavenge SMCS Code: 1395-038-TA
pump, the scavenge pump may not be
supplying oil to the main engine oil pump. Conditions Which Generate This Code:
• There are no performance effects. G. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
E361(2) common causes of air in the cooling system are
the incorrect filling of the cooling system and
• The engine power will be derated. combustion gas leakage into the cooling system.
Combustion gas can get into the system through
E361(3) inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket.
• The engine may be derated or shut down.
H. Check the cooling system hoses and clamps.
Note: For certain applications, the ECM may only Damaged hoses with leaks can normally be seen.
derate the engine. The ECM will notify the operator Hoses that have no visual leaks can soften during
that the condition exists and that the engine must be operation. The soft areas of the hose can become
shutdown. kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses
Troubleshooting: become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
There may be a problem with the engine's cooling loose particles of the hose can restrict the coolant
system. flow.
Check the Engine's Cooling System I. If the cooling system for this application is
equipped with an expansion tank, check the shunt
A. Verify that the cooling system is filled to the proper line for the expansion tank. The shunt line must be
level. If the coolant level is too low, air will get into submerged in the expansion tank. A restriction of
the cooling system. Air in the cooling system will the shunt line from the expansion tank to the inlet
cause a reduction in coolant flow. of the jacket water pump will cause a reduction in
water pump efficiency. A reduction in water pump
B. Check the radiator or the heat exchanger for a efficiency will result in low coolant flow.
restriction to coolant flow.
J. If the cooling system for this application
a. Check for debris or damage between the fins is equipped with an aftercooler, check the
of the radiator core. Debris between the fins of aftercooler. A restriction of air flow through the air
the radiator core restricts air flow through the to air aftercooler can cause overheating. Check
radiator core. for debris or deposits which would prevent the free
flow of air through the aftercooler.
b. Check internally for debris, dirt, or deposits on
the radiator core. Debris, dirt, or deposits will K. Check for a restriction in the air inlet system. A
restrict the flow of coolant through the radiator. restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
C. Check the mixture of antifreeze and water. cylinder temperatures cause higher than normal
Make sure that the coolant mixture meets temperatures in the cooling system.
recommendations.
L. Check for a restriction in the exhaust system.
D. Check the water temperature regulator. A water A restriction of the air that is coming out of the
temperature regulator that does not open, or a engine can cause high cylinder temperatures.
water temperature regulator that only opens part
of the way can cause overheating. M. Consider high ambient temperatures. When
ambient temperatures are too high for the rating
E. Check the water pump. A water pump with a of the cooling system, there is not enough of a
damaged impeller does not pump enough coolant. temperature difference between the ambient air
Remove the water pump and check for damage and coolant temperatures.
to the impeller.
92 RENR9346-06
Troubleshooting Section
N. Consider high altitude operation. The cooling The driven equipment may have caused the
capability of the cooling system is reduced at overspeed.
higher altitudes. A pressurized cooling system that
is large enough to keep the coolant from boiling Determine the events that caused the overspeed.
must be used. Make corrections in order to prevent the overspeed
from recurring.
O. The engine may be running in the lug condition.
When the load that is applied to the engine is Results:
too large, the engine will run in the lug condition.
When the engine is running in the lug condition, • OK – STOP.
engine rpm does not increase with an increase of
fuel. This lower engine rpm causes a reduction in
i02437229
coolant flow through the system.
Expected Result:
E363 High Fuel Supply
Temperature
A thorough inspection of the cooling system revealed
a problem. SMCS Code: 1250-038-TA
• OK – There is a problem with the cooling system. The Electronic Control Module (ECM) detects
an excessive fuel temperature for the engine.
Repair: Repair the problem. Ensure that the repair Information on default settings and ranges for this
eliminates the problem. event code can be found in troubleshooting with an
event code Troubleshooting, “Event Codes”.
STOP.
System Response:
i02510596 The event code is logged.
E362 Engine Overspeed Possible Performance Effect:
SMCS Code: 7410-038; 7427-038
E363-1 (Warning)
Conditions Which Generate This Code:
• There are no performance effects.
The Electronic Control Module (ECM) detects an
E363-2 (Derate)
engine overspeed. Information on default settings
and ranges for this event code can be found in
Troubleshooting, “Event Codes”. • The engine power is derated.
Troubleshooting:
System Response:
Expected Result:
E362-1 (Warning)
A thorough inspection of the fuel system revealed
• There are no performance effects. a problem.
E362-2 (Derate)
Results:
• The ECM will stop sending signals to the injector
solenoids until the engine speed is 200 rpm below • OK – There is a problem with the fuel system.
the trip point.
Repair: Make the necessary repairs. Verify that
Troubleshooting: the repair eliminates the problem.
STOP.
The operator may be operating the engine incorrectly.
i02637267 i02486656
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
abnormal fuel filter differential pressure. Information
The Electronic Control Module (ECM) detects
on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”. an excessive intake manifold air temperature.
Information on default settings and ranges for this
event can be found in troubleshooting with an event
System Response:
code Troubleshooting, “Event Codes”.
The ECM will log the event.
System Response:
Possible Performance Effect:
The event code will be logged.
390(1)
Possible Performance Effect:
• There are no performance effects. E539(1)
The delay time for this event code is one hour.
• There are no performance effects.
390(2)
E539(2)
• The engine power is derated.
• The engine power will be derated.
The delay time for this event code is four hours.
Troubleshooting:
Troubleshooting:
Intake manifold air temperature can be high for the
following reasons:
The fuel filter element may need to be replaced.
A. Replace the fuel filter element. • High inlet air restriction and/or high altitude
Refer to the Operation and Maintenance Manual . • Restriction in the exhaust system
B. Restart the engine and check for an active event • Problem with the aftercooler
code.
• Faulty inlet air temperature sensor and/or circuit
Expected Result:
Perform the following Inspections
The event code is no longer active.
A. Check for High Ambient Air Temperature
Results:
a. Determine if the ambient air temperature is
within the design specifications for the inlet
• OK – The event code is no longer active. STOP. air system. When ambient temperatures
are too high for the rating of the inlet air
• Not OK – The event code is active. system, there is not enough of a temperature
difference between the ambient air and inlet
Repair: There may be an electrical problem with
air temperatures.
the circuit for the fuel filter differential pressure
switch. Refer to Troubleshooting, “Fuel Filter
b. Determine the cause of the high inlet air
Differential Pressure Switch Circuit - Test” for
temperature. Correct the situation, when
diagnostic information.
possible.
STOP.
B. Check for High Inlet Air Restriction and/or
High Altitude Operation
94 RENR9346-06
Troubleshooting Section
When inlet air pressure is low, the turbocharger Repair: Connect Caterpillar Electronic Technician
works harder in order to achieve the desired (ET) to the service tool connector. Check Cat ET
inlet manifold pressure. This increases inlet air for active/logged diagnostic codes related for the
temperature. inlet air system. If an active/logged code is found,
refer to the appropriate troubleshooting procedure.
a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer STOP.
to the Technical Marketing Information for the
engine.
i02513156
If the air inlet system for this application The oil level in the makeup oil tank is low.
is equipped with an aftercooler, check the
aftercooler. A restriction of air flow through the air Results:
to air aftercooler can cause overheating. Check
for debris or deposits which would prevent the free • OK – The oil level in the makeup oil tank is low.
flow of air through the aftercooler. If the engine
is equipped with a liquid cooled aftercooler verify Repair: Refill the makeup oil tank to the proper
that the coolant flow is unobstructed. level.
A problem has been found in the inlet air system • Not OK – The oil level in the makeup oil tank is
and/or the related engine systems. not low.
STOP.
i02817689 Results:
E775 High Left Exhaust #2 • OK – There are no active diagnostic codes.
Temperature Proceed to Test Step 2.
S/N: JRP1-Up; LJW1-Up Check for air inlet restrictions and/or leaks. A one
degree increase in the inlet manifold temperature will
Conditions Which Generate This Code: increase the exhaust temperature by approximately
three degrees. Check for leaks between the exhaust
The Electronic Control Module (ECM) detects an manifold and the turbocharger. Check for exhaust
excessive exhaust temperature for the engine at the restrictions. Refer to the Systems Operation/Testing
“REAR LEFT EXHAUST TC”. This sensor is located and Adjusting manual for more information on
in the exhaust manifold below the turbocharger. inspecting the air inlet and exhaust system.
This sensor measures the exhaust gas temperature
for cylinders 7, 9, and 11. Information on default Results:
settings and ranges for this event can be found in
Troubleshooting, “Event Codes”. • OK – There are no problems with the air inlet and
exhaust system. Proceed to Test Step 3.
System Response:
• Not OK – A problem has been identified with the
The event code will be logged. air inlet or the exhaust system.
Possible Performance Effect: Repair: Resolve the problem and verify if the E775
code has been eliminated.
E775(1)
STOP.
• There are no performance effects.
Test Step 3. Check for Faults with the
E775(2) Fuel Injectors
• The engine power will be derated. Faulty injectors that deliver too much fuel will
increase exhaust temperatures. Connect Cat ET in
Troubleshooting: order to determine if any diagnostic codes for the
injector solenoids are present. Perform the “Injector
High exhaust temperature can be caused by Solenoid Test”. Observe that the injector solenoids
problems with the following. are being energized on Cat ET. Perform the “Cylinder
Cutout Test”. Locate the misfiring cylinder. Refer to
• Diagnostic codes Troubleshooting, “Injector Solenoid - Test”.
Test Step 1. Check for Diagnostic Codes Repair: Resolve the problem and verify if the E775
code has been eliminated.
Connect Cat ET and check for active and/or logged
diagnostic codes. Troubleshoot any active diagnostic STOP.
codes before continuing with this procedure.
96 RENR9346-06
Troubleshooting Section
• Not OK – A problem has been identified with the The Electronic Control Module (ECM) detects an
aftercooler. excessive exhaust temperature for the engine at the
“REAR RIGHT EXHAUST TC”. This sensor is located
Repair: Resolve the problem and verify if the E775 in the exhaust manifold below the turbocharger.
code has been eliminated. This sensor measures the exhaust gas temperature
for cylinders 8, 10, and 12. Information on default
STOP. settings and ranges for this event can be found in
Troubleshooting, “Event Codes”.
Test Step 5. Check the Exhaust
Temperature Sensor System Response:
Use Cat ET to check the status of the exhaust The event code will be logged.
temperature.
Possible Performance Effect:
A. Start the engine.
E776(1)
B. Use Cat ET to monitor the status of the exhaust
temperature while the engine is warming to • There are no performance effects.
operating temperature.
E776(2)
C. Ensure that the reading that is displayed is
reasonable. • The engine power will be derated.
Results: Troubleshooting:
• The temperature indicated by the sensor is not High exhaust temperature can be caused by
within reasonable expectations. problems with the following.
STOP.
98 RENR9346-06
Troubleshooting Section
SMCS Code: 1050-038-TA a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer
Conditions Which Generate This Code: to the Technical Marketing Information for the
engine.
The Electronic Control Module (ECM) detects
an excessive intake manifold air temperature. b. Check for plugged air filters. Check for
Information on default settings and ranges for this obstructions to the air inlet. A restriction of
event can be found in troubleshooting with an event the air that enters the engine can cause
code Troubleshooting, “Event Codes”. high cylinder temperatures. High cylinder
temperatures cause higher than normal
System Response: temperatures in the cooling system.
The event code will be logged. c. Replace the air filters and/or remove the
obstruction from the air inlet.
Possible Performance Effect:
d. Consider high altitude operation. The cooling
E539(1) capability of the cooling system is reduced
at higher altitudes. A pressurized cooling
• There are no performance effects. system that has been designed for the higher
altitudes must be used. Ensure that the engine
E539(2) is configured for high altitude operation.
• The engine power will be derated. C. Check for Exhaust System Restriction
A. Check for High Ambient Air Temperature A problem has been found in the inlet air system
and/or the related engine systems.
a. Determine if the ambient air temperature is
within the design specifications for the inlet Results:
air system. When ambient temperatures
are too high for the rating of the inlet air • OK – A thorough inspection revealed a problem.
system, there is not enough of a temperature
difference between the ambient air and inlet Repair: Repair the problem.
air temperatures.
STOP.
b. Determine the cause of the high inlet air
temperature. Correct the situation, when • Not OK – A thorough inspection did not reveal a
possible. problem.
STOP.
100 RENR9346-06
Troubleshooting Section
g01259598
Illustration 12
Schematic for the 5 volt pressure sensor supply
g01270567 g01270590
Illustration 13 Illustration 14
Air cleaner assembly (2) J2/P2 ECM connector
(3) J1/P1 ECM connector
(1) Turbocharger inlet pressure sensor
102 RENR9346-06
Troubleshooting Section
g01270593
Illustration 15
Left side engine view
(4) Turbocharger outlet pressure (No. 2) (6) Atmospheric pressure sensor (8) Engine oil pressure sensor
(5) Intake manifold pressure sensor (7) Fuel pressure sensor
RENR9346-06 103
Troubleshooting Section
g01212799
Illustration 17
P1 ECM connector
(P1-2) +5 V supply
(P1-3) Sensor return
(P1-15) Turbocharger inlet pressure
g01259697
Illustration 16
P2 terminal locations
(P2-15) Intake manifold pressure
(P2-41) Turbocharger outlet pressure (No. 2)
(P2-17) Sensor return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-57) Atmospheric pressure
(P2-72) +5 V supply
g01159881
Illustration 18
Sensor connector
(Terminal A) +5 V supply
(Terminal B) Sensor return
(Terminal C) Sensor signal
D. Check the allen head screw of each ECM If the engine is running properly at this time, there
connector for the proper torque. Refer to may be an intermittent problem in a harness
Troubleshooting, “Electrical Connectors - Inspect” that is causing the codes to be logged. Refer to
for the correct torque values. Troubleshooting, “Electrical Connectors - Inspect”.
Note: Wait at least 30 seconds in order for the • OK – The 262-03 or 262-04 diagnostic
diagnostic codes to become active. code deactivates when a particular sensor is
disconnected.
D. Remove electrical power from the ECM.
Repair: Connect the suspect sensor. If the code
Expected Result: returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved.
No diagnostic codes are active.
STOP.
Results:
• Not OK – The 262-03 or 262-04 diagnostic
• OK – No diagnostic codes are active. code remains active after all of the sensors are
disconnected. The sensors are not the cause of the
Repair: If any of the above codes are logged diagnostic code. Leave the sensors disconnected.
and the engine is not running properly, refer to Proceed to Test Step 4.
Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
RENR9346-06 105
Troubleshooting Section
• Not OK – The voltage measurement is not 5.0 ± • Truck Payload Monitoring System (TPMS)
0.2 VDC at one or both of the ECM connectors.
• Advisor
Repair: There is a problem with the ECM. Replace
the ECM. Refer to Troubleshooting, “Replacing • Messenger
the ECM”.
STOP.
106 RENR9346-06
Troubleshooting Section
g01263929
Illustration 19
g01214624
Illustration 20
J1/P1 ECM connectors (typical left side engine view)
STOP.
Expected Result:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated Each check of the resistance indicates an open
with the circuit. circuit.
D. Check the allen head screw for each of the Results:
ECM connectors for the proper torque. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
• OK – Each check of the resistance indicates an
open circuit. There does not appear to be a short
in the harness. Proceed to Test Step 3.
E. Check the harness and the wiring for abrasion
and for pinch points.
• Not OK – At least one check of the resistance
does not indicate an open circuit.
Expected Result:
Repair: There is a short circuit in one of the
All of the connectors, pins and sockets are completely harnesses. There may be a problem with a
coupled and/or inserted and the harness and wiring connector. Repair the wiring and/or the connector.
are free of corrosion, of abrasion and of pinch points. Replace parts, if necessary. Verify that the problem
is resolved.
Results:
STOP.
• OK – The harness and connectors appear to be
OK. Proceed to Test Step 2.
108 RENR9346-06
Troubleshooting Section
Test Step 3. Check for an Open in the • 2533-05 Compression Brake Low/High Solenoid
Harness #1 current below normal
A. Fabricate a jumper wire that is long enough to • 2533-06 Compression Brake Low/High Solenoid
create a short across two terminals at the service #1current above normal
tool connector. Crimp connector sockets to each
end of the jumper wire. • 2534-05 Compression Brake Low/High Solenoid
#2 current below normal
B. Install the jumper wire between terminals D and
E at the service tool connector. • 2534-06 Compression Brake Low/High Solenoid
#2 current above normal
C. Measure the resistance between P1-8 and P1-9.
• 2535-05 Compression Brake Medium/High
D. Measure the resistance at the connectors of all of Solenoid #1 current below normal
the other control modules.
• 2535-06 Compression Brake Medium/High
Expected Result: Solenoid #1 current above normal
The resistance is less than 5 Ohms for each • 2536-05 Compression Brake Medium/High
measurement. Solenoid #2 current below normal
Repair: Repair the connectors or wiring and/or The “Compression Brake Solenoid Test” is a
replace the connectors or wiring. Verify that the diagnostic test that is available on Caterpillar
problem is resolved. Electronic Technician (ET). Use the “Compression
Brake Solenoid Test” to assist in troubleshooting
STOP. problems in the circuit for the compression brake.
The engine Electronic Control Module (ECM) will only
detect shorts in the circuit for the compression brake
i02520778
when the test is active. “Current high” diagnostic
Compression Brake Solenoid codes (short circuits) will be logged once the test has
been deactivated. The ECM will only detect opens
Circuit - Test in the circuit for the compression brake when the
test is not active. The test must be activated and
SMCS Code: 5479-038-BRK then deactivated before the ECM will detect an open
circuit. “Current low” diagnostic codes (open circuits)
System Operation Description: will be active once the test has been deactivated.
Use this procedure to troubleshoot any suspect Note: The engine speed must be zero before the
problems with the compression brake solenoids. “Compression Brake Solenoid Test” will function.
g01199118
Illustration 22
Location of the compression brake solenoid (typical example)
g01268745
Illustration 23
Schematic for the compression brake circuit
110 RENR9346-06
Troubleshooting Section
g01270061
Illustration 24
Right top side engine view (typical example)
(1) Connector for the left bank valve cover
(2) Connector for the right bank valve cover
(3) J2/P2 ECM connectors
(4) J1/P1 ECM connectors
g01195659
Illustration 28
Connector for the right bank valve cover
(10) Compression brake solenoid med/high
(11) Compression brake solenoid low/high
(12) Digital return
g01270811
Illustration 26
P1Connector for the Engine ECM
(P1-8) Cat data link +
(P1-9) Cat data link −
g01195659
Illustration 27
g01270814
Illustration 29
Connector for the left bank valve cover
P1Connector for the Brake ECM
(10) Compression brake solenoid med/high
(11) Compression brake solenoid low/high (10) Cat data link +
(12) Digital return (20) Cat data link−
(34) Compression brake switch
(45) Sensor return
112 RENR9346-06
Troubleshooting Section
• OK – The harness and connectors appear to be C. Fabricate a jumper wire in order to create a short
OK. Proceed to Test Step 12. between the supply and the return for the suspect
compression brake solenoid.
• Not OK – There is a problem with the connectors
and/or wiring. D. Turn the keyswitch to the ON position.
Repair: Repair the connectors or wiring and/or E. Access the “Special Tests” under the “Diagnostics”
replace the connectors or wiring. Ensure that menu.
all of the seals for each of the connectors are
properly in place and ensure that the connectors F. Start the “Compression Brake Solenoid Test” on
are completely coupled. Verify that the repair Cat ET.
eliminates the problem.
G. Once Cat ET displays the status of the
STOP. compression brake solenoid, stop the
“Compression Brake Solenoid Test”.
Test Step 2. Check for Active Diagnostic
Codes and/or Logged Diagnostic Codes H. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the
A. Connect Cat ET to the service tool connector. compression brake solenoids.
C. Access the “Special Tests” under the “Diagnostics” A high current diagnostic code (06) is logged at this
menu. time.
No diagnostic codes are active. Test Step 4. Create a Short Circuit at the
ECM
A. Turn the keyswitch to the OFF position.
RENR9346-06 113
Troubleshooting Section
B. Disconnect the J2/P2 ECM connector. Check continuity of the return wire for the suspect
compression brake solenoid between the valve
C. Inspect the terminals on the J2 and P2 ECM cover connector for the suspect compression brake
connectors for damage. solenoid and P2. If the wire is open, replace the
wire.
Note: Refer to the Figure 25 for pin locations.
STOP.
D. Remove the return wire and the supply wire for
the suspect compression brake solenoid from the • Not OK – A low current diagnostic code 05 is
P2 ECM connector. active at this time. The ECM did not detect the
short circuit.
E. Fabricate a jumper wire in order to short the two
pins for the suspect compression brake solenoid Repair: Replace the ECM. Refer to
at the ECM. Crimp a socket to each end of the Troubleshooting, “Replacing the ECM”.
jumper wire. Insert the jumper wire into the P2 Verify that the problem is resolved.
ECM connector.
STOP.
F. Reconnect the P2 ECM connector.
Test Step 5. Open the Wires of the
G. Turn the keyswitch to the ON position. Suspect Compression Brake Solenoid at
the Valve Cover Connector
H. Access the “Special Tests” under the “Diagnostics”
menu. A. Turn the keyswitch to the OFF position.
I. Start the “Compression Brake Solenoid Test” on B. Disconnect the valve cover connector for the
Cat ET. suspect compression brake solenoid.
J. Once Cat ET displays the status of the C. Turn the keyswitch to the ON position.
compression brake solenoid, stop the
“Compression Brake Solenoid Test”. D. Access the “Special Tests” under the “Diagnostics”
menu.
K. Check for active diagnostic codes and/or logged
diagnostic codes that are associated with the E. Start the “Compression Brake Solenoid Test” on
compression brake solenoids. Cat ET.
Test Step 6. Create an Open at the ECM Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”.
A. Turn the keyswitch to the OFF position. Verify that the problem is resolved.
C. Inspect the terminals on the J2 and P2 ECM Test Step 7. Create a Short Circuit at the
connectors for damage. Compression Brake Solenoid
Note: Refer to the Figure 25 for pin locations. A. Turn the keyswitch to the OFF position.
D. Remove the return wire and the supply wire for B. Remove the valve cover.
the suspect compression brake solenoid from the
P2 ECM connector. C. Reconnect the valve cover connector.
J. Check for active diagnostic codes and/or logged Note: Worn terminals and/or damaged terminals on
diagnostic codes that are associated with the the solenoid connector could cause an intermittent
compression brake solenoids. “Open”.
A low current diagnostic code (05) is active at this I. Access the “Special Tests” under the “Diagnostics”
time. menu.
Verify that the repair eliminates the problem. • Not OK – A high current diagnostic code (06) is
logged at this time. The ECM did not detect the
STOP. open.
Test Step 8. Create an Open Circuit at the Repair: Repair the harness between the connector
Compression Brake Solenoid for the compression brake solenoid and the valve
cover connector for the suspect compression brake
A. Turn the keyswitch to the OFF position. solenoid.
B. Reconnect the valve cover connector. Verify that the repair eliminates the problem.
D. Disconnect the connector on the suspect Test Step 9. Check the Status of the
compression brake solenoid. Compression Brake Switch
E. Inspect the terminals on the solenoid connector Note: A switch input to the brake electronic control
for damage. module sets the status of the compression brake.
The status is off or automatic. Software for the
F. Turn the keyswitch to the ON position. brake electronic control module controls the level of
braking. The levels of braking are low, medium and
G. Access the “Special Tests” under the “Diagnostics” high. The brake electronic control module requests
menu. the engine electronic control module in order to
actuate the compression brake solenoids. The
H. Start the “Compression Brake Solenoid Test” on request is sent over the Cat data link.
Cat ET.
A. Turn the keyswitch to the ON position.
I. Once Cat ET displays the status of the
compression brake solenoid, stop the B. Use Cat ET in order to connect to the brake ECM.
“Compression Brake Solenoid Test”.
C. Operate the compression brake switch and
J. Check for active diagnostic codes and/or logged monitor the status for the compression brake.
diagnostic codes that are associated with the
compression brake solenoids. Expected Result:
Expected Result: The status for the compression brake switch changes
from the off state to the automatic state.
A low current diagnostic code (05) is active at this
time. Results:
Repair: If the problem is intermittent, refer to B. Disconnect ECM connectors P1and P2.
Troubleshooting, “Electrical Connectors - Inspect”.
C. Measure the resistance between P1-34 and
STOP. every terminal on ECM connector P1 and ECM
connector P2.
• Not OK – There is a problem in the circuit for the
compression brake switch. Proceed to Test Step Expected Result:
10.
The measured resistance indicates an open circuit.
Test Step 10. Short the Wires at the
Compression Brake Switch Results:
A. Turn the keyswitch to the OFF position. • OK – The resistance measurement indicates an
open circuit. Proceed to Test Step 12.
B. Disconnect the connector for the compression
brake switch. • Not OK – The resistance measurement indicates
a short circuit.
C. Insert a jumper wire between the following
terminals of the connector on the harness side: Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
• Terminal 2
STOP.
• Terminal 3
Test Step 12. Check for an Open in Wiring
D. Turn the keyswitch to ON position. Harness
E. Check the status for the compression brake switch A. Disconnect the connector for the compression
on Cat ET. brake switch.
F. Remove the jumper wire. B. Short the wires of the compression brake switch
at the compression brake switch. Insert a jumper
G. Check the status for the compression brake switch wire between the following terminals of the
on Cat ET. connector for the harness side:
Repair: Temporarily replace the switch. Verify that • Not OK – The resistance measurement indicates
the new switch solves the problem before you an open circuit. There is an open circuit or
permanently install the new switch. excessive resistance in the wiring harness.
STOP.
STOP.
118 RENR9346-06
Troubleshooting Section
g01260600
Illustration 30
Schematic for the digital sensor supply
g01193730
Illustration 32
Mounting location of the throttle position sensor on the throttle
pedal (typical example)
g01267106
Illustration 31
Cooling fan drive assembly
(1) Cooling fan drive assembly
(2) Connector for the engine fan speed sensor
RENR9346-06 119
Troubleshooting Section
g01270661
Illustration 33
ECM connectors (typical example)
(3) J1/P1 ECM connector
g01260697
Illustration 34
P1 ECM connector
(P1-5) Sensor return
(P1-4) +8 V digital supply
(P1-32) Engine fan speed
(P1-66) Throttle position
g01159881
Illustration 35
Sensor connector
(Terminal A) +8 V supply
(Terminal B) Sensor return
(Terminal C) Sensor signal
120 RENR9346-06
Troubleshooting Section
C. Perform a 45 N (10 lb) pull test on each of the Repair: If any of the above codes are logged
wires that are associated with the digital sensor and the engine is not running properly, refer to
supply. Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
D. Check the allen head screw on the ECM connector
for the proper torque. Refer to Troubleshooting, If the engine is running properly at this time, there
“Electrical Connectors - Inspect” for the correct may be an intermittent problem in a harness
torque values. that is causing the codes to be logged. Refer to
Troubleshooting, “Electrical Connectors - Inspect”.
E. Check the harness and wiring for abrasions and
for pinch points from the battery to the ECM. STOP.
Repair: Repair the connectors or wiring and/or Note: Wait at least 30 seconds in order for the
replace the connectors or wiring. Ensure that all of diagnostic codes to become active.
the seals are properly in place and ensure that the
connectors are completely coupled. Verify that the a. Disconnect the following sensors one at a time:
repair eliminates the problem.
• Throttle position sensor
STOP.
• Engine fan speed sensor
Test Step 2. Check for Active Diagnostic
Codes Expected Result:
A. Connect the Caterpillar Electronic Technician The diagnostic code deactivates when a particular
(ET) to the service tool connector. Refer to sensor is disconnected.
Troubleshooting, “Electronic Service Tools”.
Results:
B. Restore electrical power to the ECM.
• OK – The 41-03 or 41-04 diagnostic code
C. Monitor the active diagnostic code screen on Cat deactivates when a particular sensor is
ET. Check for an active 41-03 code and an active disconnected.
41-04 code.
Repair: Connect the suspect sensor. If the code
Note: Wait at least 30 seconds in order for the returns, replace the sensor. The fan speed sensor
diagnostic codes to become active. is nonserviceable. The fan speed sensor is integral
to the fan drive assembly. Replace the fan drive
D. Remove electrical power from the ECM. assembly. Connect all of the connectors. Verify that
the problem is resolved.
Expected Result:
STOP.
No diagnostic codes are active.
• Not OK – The 41-03 or 41-04 diagnostic code
Results: remains active after all of the sensors are
disconnected. The sensors are not the cause of the
• OK – No diagnostic codes are active. diagnostic code. Leave the sensors disconnected.
Proceed to Test Step 4.
RENR9346-06 121
Troubleshooting Section
E. Remove the wires from terminal locations P1-4 (8 Intermittent electrical problems are sometimes
V sensor supply) and P1-5 (sensor return). Install resolved by disconnecting and reconnecting
a jumper wire into each of these terminal locations. connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
F. Connect the J1/P1 and J2/P2 ECM connectors. Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
G. Restore electrical power to the ECM. changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
H. Measure the voltage between the jumper wire in likely reasons are loose terminals, improperly crimped
P1-4 (8 V sensor supply) and P1-5 (sensor return). terminals, moisture, corrosion, and inadequate
mating of a connection.
I. Remove electrical power from the ECM.
Follow these guidelines:
Expected Result:
• Always use a 1U-5804 Crimp Tool to service
The voltage measurement is 8.0 ± 0.4 VDC at the Deutsch HD and DT connectors. Never solder the
ECM connector. terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
Results:
• Always use a 147-6456 Wedge Removal Tool to
• OK – The voltage measurement is 8.0 ± 0.4 VDC remove wedges from DT connectors. Never use a
at the ECM connectors. screwdriver to pry a wedge from a connector.
Repair: The ECM is operating correctly. The • Always use a breakout harness for a voltmeter
supply wires are shorted to another wire in the probe or a test light. Never break the insulation
harness or the supply wires are shorted to engine of a wire in order to access to a circuit for
ground. Repair the wiring and/or the connector. measurements.
Replace parts, if necessary. Verify that the problem
is resolved. • If a wire is cut, always install a new terminal for
the repair.
STOP.
Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If
Moisture and Corrosion any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 37.
g01131019
Illustration 38
Seal for a three-pin connector (typical example)
g01131211
Illustration 36
Leaky seal at the connector (typical example)
g01131165
Illustration 39
Seal for ECM connector (typical example)
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.
STOP.
g01131604
Illustration 41
Diagram for testing pin retention (typical example)
A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.
Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.
Results:
STOP.
• OK – The connectors are in good repair. Proceed
to Test Step 7.
RENR9346-06 125
Troubleshooting Section
STOP.
g01132827
Illustration 42
Allen head screw for the 120 pin ECM connector (typical example)
g01133047
a. Torque the allen head bolt for the 120 pin ECM Illustration 45
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)
Expected Result:
Results:
Illustration 43
g01132849
• OK – The ECM connectors and the customer
Allen head screw for the 70 pin ECM connector (typical example) connector is properly connected. Proceed to Test
Step 8.
b. Torque the allen head screw for the 70
pin ECM connector to 6.0 + 1.5 - 0.5 N·m • Not OK – The allen head screws for the ECM
(55 + 13 - 4 lb in). connector or the customer connector is damaged.
126 RENR9346-06
Troubleshooting Section
Repair: Repair the connector or replace the • 168-00 “System Voltage High”
connector, as required. Verify that the repair
eliminates the problem. • 168-01 “System Voltage Low”
STOP. • 168-02 “System Voltage intermittent/erratic”
Test Step 8. Perform the “Wiggle Test” (if Use this test if there are intermittent engine
applicable) on the Caterpillar Electronic shutdowns or if a difficulty in starting is not
Technician (ET) accompanied by loss of electrical accessories.
Engine shutdowns that are accompanied by a loss of
Note: Some applications support the “Wiggle Test” other electrical accessories indicate a problem in the
on Cat ET. The “Wiggle Test” (if applicable) can be keyswitch. This does not indicate a problem in the
used to determine if an intermittent problem exists. wiring at the engine's ECM. Verify that there are no
problems with the starting system or the charging
A. Select the “Wiggle Test” from the diagnostic tests system before you use this test.
on Cat ET.
Unswitched battery voltage is supplied to the ECM
B. Choose the appropriate group of parameters to at P1-48, P1-52, and P1-53. The negative battery
monitor. is supplied to the ECM at P1-61, P1-63, and P1-65.
The ECM receives the input from the keyswitch at
C. Press the “Start” button. Wiggle the wiring harness P1-70 when the keyswitch is in the ON position or in
in order to reproduce intermittent problems. the START position. When the ECM detects battery
voltage at this input, the ECM will power up. When
If an intermittent problem exists, the status will be battery voltage is removed from this input, the ECM
highlighted and an audible beep will be heard. will power down. The ECM continuously receives
battery voltage through the 15 Amp circuit breaker
Expected Result: for the ECM.
No intermittent problems were indicated during the The engine ECM requires the keyswitch to be in the
“Wiggle Test”. ON position in order to maintain communications with
Caterpillar Electronic Technician (ET).
Results:
STOP.
i02527741
g01264617
Illustration 46
Schematic for the electrical power supply circuit
Test Step 1. Inspect the Electrical B. Thoroughly inspect the J1/P1 ECM connectors.
Connectors and the Wiring Inspect all of the connectors that are in the
circuit. Refer to the diagnostic functional test
A. Remove electrical power from the engine ECM. Troubleshooting, “Electrical Connectors - Inspect”
for details.
g01270849
Illustration 47
Location of the J1/P1 ECM connectors
128 RENR9346-06
Troubleshooting Section
Results:
STOP.
Illustration 48
g01112632 G. Measure the voltage between P1-70 (Keyswitch)
and P1-63 (−Battery).
P1 connections for the electrical power supply circuit
(P1-48) +Battery Expected Result:
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery The measured voltage is between 22 VDC and 27
(P1-63) −Battery VDC.
(P1-65) −Battery
(P1-70) Keyswitch
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
• OK – The ECM is receiving the correct voltage.
with the circuit. Repair: There may be an intermittent electrical
problem in a harness or in a connector. If an
D. Check the allen head screw for each of the intermittent condition is suspected, refer to
ECM connectors for the proper torque. Refer to Troubleshooting, “Electrical Connectors - Inspect”.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. STOP.
E. Check the harness and the wiring for abrasion
and for pinch points.
• Unswitched power out of range – The voltage
is not correct for one of the unswitched battery
circuits at the ECM. Proceed to Test Step 3.
Expected Result:
A. Measure the no-load battery voltage at the battery Voltage is present on terminal B and terminal R at
posts. the keyswitch.
C. Restore electrical power to the engine ECM. This procedure covers the following diagnostic codes:
D. Measure the voltage on terminal B of the keyswitch • 291-05 Engine Cooling Fan Solenoid open circuit
to engine ground.
• 291-06 Engine Cooling Fan Solenoid short to
E. Measure the voltage on terminal R of the ground
keyswitch to engine ground.
• Increased productivity
• Noise from the fan is reduced.
• Improved fuel economy
• Overcooling of the engine is reduced.
The ECM monitors engine coolant temperature and
intake manifold air temperature in order to determine
the correct fan rpm. When a system fault is detected,
fan rpm is increased. When the engine is lugging,
the fan rpm is reduced in order to reduce the load
on the engine.
g01113248
Illustration 49
Schematic
RENR9346-06 131
Troubleshooting Section
g01258956
Illustration 50
(1) Location of the J1/P1 ECM connectors
g01266779
Illustration 52
Cooling fan drive assembly
(2) Engine fan control solenoid
(3) Connector for the engine fan speed sensor
(4) Cooling fan drive assembly
Expected Result:
Illustration 51
g01113249 All connectors, pins, and sockets are completely
P1 ECM connector
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
(P1-43) Engine fan control solenoid
(P1-51) Solenoid return
132 RENR9346-06
Troubleshooting Section
A. Connect Caterpillar Electronic Technician (ET) to • OK – A short circuit diagnostic code (06) was
the service tool connector. active before disconnecting the connector. An open
circuit diagnostic code (05) became active after
B. Restore the electrical power to the ECM. disconnecting the connector.
C. Monitor the active diagnostic code screen on Cat Repair: Temporarily connect a new fan control
ET. Check and record any active diagnostic codes. solenoid to the harness, but do not install the
new fan control solenoid. Verify that there are no
Note: Wait at least 30 seconds in order for the active diagnostic codes for the solenoid. If there
diagnostic codes to become active. are no active diagnostic codes for the solenoid,
permanently install the new solenoid. Clear any
D. Determine if the problem is related to an open logged diagnostic codes.
circuit diagnostic code (05) or a short circuit
diagnostic code (06). STOP.
A. Remove the electrical power from the ECM. F. Remove the electrical power from the ECM.
RENR9346-06 133
Troubleshooting Section
A. Disconnect the J1/P1 ECM connector. Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
B. Remove the wire for the fan control solenoid from ECM”. Verify that the problem is resolved.
P1-43. Install a jumper wire with Deutsch sockets
on each end into P1-43. STOP.
g01258227
Illustration 53
Schematic for the fan speed sensor
g01167488
Illustration 54
Left side engine view (typical example)
g01267039
(1) J1/P1 ECM connector Illustration 55
Cooling fan drive assembly
(2) Connector for the engine fan speed sensor
(3) Cooling fan drive assembly
STOP.
Test Step 4. Check the Signal Frequency C. Fabricate a jumper wire that is long enough to be
for the Engine Cooling Fan Speed Sensor used in order to measure the signal frequency at
at the Sensor Connector the ECM connector. Crimp a connector socket to
one end of the jumper wire.
A. Remove the electrical power from the ECM.
D. Install the jumper wire into terminal location P1-32.
B. Remove the wire from terminal 1 (engine fan Connect the J1/P1 connectors.
speed) on the sensor side of the connector for
the engine cooling fan speed sensor. Connect the E. Restore the electrical power to the ECM.
sensor connector.
F. Access the “Fan Override Test” under the
C. Restore the electrical power to the ECM. “Diagnostics” menu on Cat ET.
D. Access the “Fan Override Test” under the G. Start the “Fan Override Test” on Cat ET. Set the
“Diagnostics” menu on Cat ET. fan speed to 800 rpm.
E. Start the “Fan Override Test” on Cat ET. Set the H. Measure the frequency between the jumper wire
fan speed to 800 rpm. at P1-32 and engine ground.
F. Use a multimeter to measure the frequency I. Deactivate the “Fan Override Test”.
between the signal wire from the sensor and
engine ground. J. Remove the electrical power from the ECM.
G. Deactivate the “Fan Override Test”. K. Reconnect all connectors and wires.
I. Restore all connectors and wiring to the original The frequency is approximately 13.3 Hz.
configuration.
Results:
Expected Result:
• OK – The frequency is approximately 13.3 Hz.
The frequency is approximately 13.3 Hz.
RENR9346-06 137
Troubleshooting Section
STOP.
STOP.
i02515157
The E171 Low Engine Oil Level will disable the Oil
Renewal System (ORS).
g01258295
Illustration 57
Schematic
g01270952
Illustration 58
(1) Engine oil level switch
RENR9346-06 139
Troubleshooting Section
Expected Result:
Results:
STOP.
Expected Result:
Results:
g01258299
Illustration 59
P2 ECM connector • OK – The engine oil level is correct. Proceed to
(P2-94) Low oil level Test Step 3.
(P2-83) Digital return
• Not OK – The engine oil level is low.
Test Step 1. Inspect Electrical Connectors
and Wiring Repair: Add oil to the engine.
B. Thoroughly inspect the ECM connector J2/P2. Test Step 3. Check the Engine Oil Level
Inspect the connector for the low oil level switch. on Caterpillar Electronic Technician (ET)
Refer to Troubleshooting, “Inspecting Electrical
Connectors” for details. A. Connect Cat ET to the service tool connector.
C. Perform a 45 N (10 lb) pull test on each of the B. Turn the keyswitch to the ON position.
wires in the ECM connector that are associated
with the circuit. C. Observe the “Engine Oil Level” reading on Cat ET.
STOP. B. Remove the wire from P2-94 (low oil level). Install
a wire jumper with a socket on one end into P2-94.
• Not OK – The “Engine Oil Level” does not read
“OK”. The switch signal is not correct. Proceed to C. Remove the wire from P2-83 (digital return). Install
Test Step 4. a wire jumper with a socket on one end into P2-83.
Test Step 4. Short the Wires at the Low D. Connect a wire jumper between the wire jumpers
Oil Level Switch in P2-94 and P2-83.
Cat ET indicates “OK” when the wire short is L. Observe the status of the “Engine Oil Level” on
installed. Cat ET indicates “LOW” when the wire short Cat ET.
is removed.
M. Turn the keyswitch to the OFF position.
Results:
N. Reconnect all connectors.
• OK – Cat ET indicates “OK”, when the wire short
is in place. Cat ET indicates “LOW”, when the wire Expected Result:
short is removed. Cat ET recognized the input from
the switch. Cat ET indicates “OK” when the wire short is
installed. Cat ET indicates “LOW” when the wire short
Repair: Temporarily replace the switch. Verify that is removed.
the new switch solves the problem before you
permanently install the new switch. Results:
STOP.
RENR9346-06 141
Troubleshooting Section
STOP.
i02526938
g01264034
Illustration 60
Typical schematic
g01270974
Illustration 61
(1) Engine oil renewal solenoid
RENR9346-06 143
Troubleshooting Section
Expected Result:
Results:
STOP.
Illustration 62
g01264035 Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
P1 ECM connector
(P1-18) Solenoid return D. Determine if the problem is related to an open
(P1-11) Engine oil renewal solenoid
circuit diagnostic code (05) or a short circuit
diagnostic code (06).
Test Step 1. Inspect Electrical Connectors
and Wiring Expected Result:
A. Remove the electrical power from the ECM. No diagnostic codes are active.
B. Thoroughly inspect the ECM connector J1/P1. Results:
Inspect all of the other connectors for the
circuit. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”. • OK – No diagnostic codes are active.
Repair: The problem may have been related
C. Perform a 45 N (10 lb) pull test on each of the to a faulty connection in the harness. Carefully
wires in the ECM connector that are associated reinspect the connectors and wiring. Refer to
with the circuit. the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to the diagnostic STOP.
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
• Not OK – A short circuit diagnostic code (06) is
active at this time. Proceed to Test Step 3.
E. Check the harness and the wiring for abrasion
and for pinch points.
• Not OK – An open circuit diagnostic code (05) is
active at this time. Proceed to Test Step 4.
144 RENR9346-06
Troubleshooting Section
Test Step 3. Disconnect the Connector Note: Monitor the “Active Diagnostic Codes” screen
for the Engine Oil Renewal Solenoid in on Cat ET before installing the jumper wire and after
Order to Create an Open Circuit installing the jumper wire.
A. Remove the electrical power from the ECM. E. Remove the jumper wire.
B. Disconnect the connector for the engine oil F. Remove the electrical power from the ECM.
renewal solenoid.
Expected Result:
C. Restore the electrical power to the ECM. Wait at
least 30 seconds for activation of the diagnostic A short circuit diagnostic code (06) is active when the
codes. jumper wire is installed. An open circuit diagnostic
code (05) is active when the jumper wire is removed.
D. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active open circuit diagnostic Results:
code (05) for the engine oil renewal solenoid.
• OK – The engine harness and the ECM are OK.
E. Remove the electrical power from the ECM.
Repair: Temporarily connect a new engine oil
Expected Result: renewal solenoid to the harness, but do not
install the new engine oil renewal solenoid. Verify
An open circuit diagnostic code (05) is now active for that there are no active diagnostic codes for the
the engine oil renewal solenoid. solenoid. If there are no active diagnostic codes for
the solenoid, permanently install the new solenoid.
Results: Clear any logged diagnostic codes.
D. Wait at least 30 seconds for activation of the short a. Install a wire jumper between the jumper wire
circuit diagnostic code (06). for the engine oil renewal solenoid and the
jumper wire for the solenoid return.
RENR9346-06 145
Troubleshooting Section
c. Remove the wire jumpers. Reconnect all wires • 94-03 Fuel Pressure open/short to +batt
and connectors.
• 94-04 Fuel Pressure short to ground
Expected Result:
• 100-03 Engine Oil Pressure open/short to +batt
An open circuit diagnostic code (05) is active when
the wire from the engine oil renewal solenoid is • 100-04 Engine Oil Pressure short to ground
removed from the ECM connector. A short circuit
diagnostic code (06) is active when the wire for the • 274-03 Atmospheric Pressure open/short to +batt
engine oil renewal solenoid is connected to the
solenoid return. • 274-04 Atmospheric Pressure short to ground
Results: • 1589-03 Turbo Inlet Air Pressure Sensor
open/short to +batt
• OK – The ECM is operating properly. The problem
is in the wiring between the ECM and the connector • 1589-04 Turbo Inlet Air Pressure Sensor short to
for the engine oil renewal solenoid. ground
Repair: Repair the connectors or wiring and/or • 1785-03 Intake Manifold Pressure Sensor voltage
replace the connectors or wiring. high
g01259598
Illustration 63
Schematic for the engine pressure sensors
RENR9346-06 147
Troubleshooting Section
g01270567
Illustration 64
Air cleaner assembly
(1) Turbocharger inlet pressure sensor
g01270590
Illustration 65
(2) J2/P2 ECM connector
(3) J1/P1 ECM connector
g01270593
Illustration 66
Left side engine view
(4) Turbocharger outlet pressure (No. 2) (6) Atmospheric pressure sensor (8) Engine oil pressure sensor
(5) Intake manifold pressure sensor (7) Fuel pressure sensor
g01212799
Illustration 68
P1 ECM connector
(P1-2) +5 V sensor supply
(P1-3) Sensor return
(P1-15) Auxiliary pressure
g01259697
Illustration 67
P2 terminal locations
(P2-15) Intake manifold pressure
(P2-41) Turbocharger outlet pressure (No. 2)
(P2-17) Sensor return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-57) Atmospheric pressure
(P2-72) +5 V supply
g01159881
Illustration 69
Sensor connector
(Terminal A) +5 V sensor supply
(Terminal B) Sensor return
(Terminal C) Signal
D. Check the allen head screw for each ECM D. Measure the voltage between terminals A and B
connector and the customer connector for at each sensor connector on the engine harness.
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct E. Remove electrical power from the ECM.
torque values.
F. Connect all of the sensors.
E. Check the harness and wiring for abrasion and
for pinch points from the pressure sensors back Expected Result:
to the ECM.
Each voltage measurement is 5.0 ± 0.2 VDC.
Expected Result:
Results:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are • OK – Each voltage measurement is 5.0 ± 0.2 VDC.
free of corrosion, of abrasion, and of pinch points. The voltage is correct at the sensor connectors.
Proceed to Test Step 3.
Results:
• Not OK – At least one voltage measurement is not
• OK – The harness and wiring appear to be OK. 5.0 ± 0.2 VDC.
Proceed to Test Step 2.
Repair: Refer to Troubleshooting, “5 Volt Engine
• Not OK – There is a problem in the connectors Pressure Sensor Supply Circuit - Test”.
and/or wiring.
STOP.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of Test Step 3. Check for Active Diagnostic
the seals are properly in place and ensure that the Codes
connectors are completely coupled.
A. Connect Caterpillar Electronic Technician (ET) to
Verify that the repair eliminates the problem. the service tool connector.
Test Step 2. Check the Supply Voltage at C. Monitor the active diagnostic code screen on Cat
the Sensor Connector ET. Look for an active diagnostic code for an
engine pressure sensor.
A. Remove electrical power from the ECM.
Note: Wait at least 30 seconds so that any codes
B. Disconnect the harness connectors for the may become active.
following sensors:
D. Determine if the problem is related to an open
• Atmospheric pressure sensor circuit diagnostic code (03) or a short circuit
diagnostic code (04).
• Auxiliary pressure sensor
Expected Result:
• Boost pressure sensor
No diagnostic codes are active.
• Engine oil pressure sensor
Results:
• Fuel pressure sensor
• OK – No diagnostic codes are active for the engine
C. Restore electrical power to the ECM. pressure sensors.
Note: The original diagnostic code may not stay Repair: The original problem seems to be resolved.
active. An open circuit diagnostic code for the sensor The problem may have been related to a faulty
supply may become active when all of the sensors connection in the harness. Carefully reinspect the
are disconnected. Ignore the active codes at this time connectors and wiring. If an intermittent electrical
and continue with this test step. problem is suspected, refer to Troubleshooting,
“Electrical Connectors - Inspect”.
Note: Be sure to wiggle the harness during the
following measurements in order to reveal an STOP.
intermittent condition.
RENR9346-06 151
Troubleshooting Section
• Not OK – A 03 diagnostic code is active at C. Install the jumper wire between terminal B (sensor
this time. The ECM is detecting an open circuit return) and terminal C (sensor signal) on the
condition. Proceed to Test Step 5. harness side of the suspect sensor's connector.
• Not OK – A 04 diagnostic code is active at this D. Restore electrical power to the ECM.
time. The ECM is detecting a short circuit condition.
Proceed to Test Step 4. E. Monitor the “Active Diagnostic Codes” screen on
Cat ET. Check for an active short circuit diagnostic
Test Step 4. Disconnect the Suspect code (04) while the jumper wire is installed.
Sensor in Order to Create an Open Circuit
Note: Wait at least 30 seconds for activation of the
A. Remove electrical power from the ECM. diagnostic code.
B. Disconnect the sensor connector of the sensor F. Remove electrical power from the ECM.
with the short circuit diagnostic code (04).
G. Remove the jumper wire.
C. Restore electrical power to the ECM.
Expected Result:
D. Access the “Active Diagnostic Code” screen on
Cat ET. Check for an active open circuit diagnostic A 04 diagnostic code was active when the jumper
code (03) while the sensor is disconnected. wire was installed.
• Not OK – When the sensor is disconnected, a 04 B. Fabricate a jumper wire that is long enough to
diagnostic code remains active for the suspect create a test circuit from the ECM connector to the
sensor. There is a problem in the circuit between engine ground stud. Crimp a connector socket to
the sensor harness connector and the ECM. The one end of the jumper wire.
problem may be in the ECM. Leave the sensor
disconnected. Proceed to Test Step 6. C. Disconnect the appropriate ECM connector.
Test Step 5. Create a Short at the Suspect D. Remove the suspect sensor's signal wire from the
Sensor Connector ECM connector. Install the jumper wire into this
terminal location at the ECM connector.
A. Remove electrical power from the ECM.
E. Connect the ECM connectors.
B. Fabricate a jumper wire that is long enough to
short the terminals at the sensor connector. Crimp F. Check the operation of the ECM by creating
connector sockets to each end of the jumper wire. an open at the ECM:
152 RENR9346-06
Troubleshooting Section
a. Hold the loose end of the jumper wire away • Not OK – One of the following conditions exists:
from any ground source in order to create an The 03 diagnostic code is not active when the
open circuit condition. loose end of the jumper wire is open. The 04
diagnostic code is not active when the loose end
b. Restore electrical power to the ECM. of the jumper wire is grounded.
c. Monitor the “Active Diagnostic Code” screen Repair: There is a problem with the ECM. Replace
on Cat ET. Check the suspect sensor for an the ECM. Refer to Troubleshooting, “Replacing
active 03 diagnostic code. the ECM”.
Results:
STOP.
RENR9346-06 153
Troubleshooting Section
g01258891
Illustration 70
Schematic
g01258956
Illustration 71
(1) J1/P1
Expected Result:
g01159881
Results:
Illustration 73
Harness connector for the engine shutdown switch • OK – The status of the shutdown switch reads
(Terminal A) Engine shutdown switch (N/C) “ON” with the shutdown switch in the STOP
(Terminal B) Digital return position. The status of the shutdown switch
(Terminal C) Engine shutdown switch (N/O) reads “OFF” when the shutdown switch is in the
RUN position. The shutdown switch is operating
C. Perform a 45 N (10 lb) pull test on each of the normally.
wires for the engine shutdown switch.
Repair: The circuit for the shutdown switch
D. Check the torque of the allen head screw on appears to be operating correctly. There may be
the ECM connectors. Refer to Troubleshooting, an intermittent problem in the harness or in a
“Electrical Connectors - Inspect” for the correct connector. If an intermittent problem is suspected,
torque values. refer to Troubleshooting, “Inspecting Electrical
Connectors”.
E. Check the harness and the wiring for abrasion and
for pinch points from the switch back to the ECM. STOP.
Expected Result: • Not OK – The status of the switch does not
read “ON” with the shutdown switch in the STOP
All of the connectors, pins and sockets are completely position. The status of the shutdown switch does
coupled and/or inserted and the harness and wiring not read “OFF” when the shutdown switch is in the
are free of corrosion, of abrasion and of pinch points. RUN position. There is a problem with the circuit
for the shutdown switch. There may be a problem
Results: with the ECM. Proceed to Test Step 3.
• OK – The harness and the connectors appear to Test Step 3. Short the Terminals at the
be OK. Proceed to Test Step 2. Harness Connector for the Shutdown
Switch
• Not OK – The connectors and/or wiring need
repair. A. Remove electrical power from the ECM.
Repair: Repair the wiring and/or the connectors. B. Fabricate a jumper wire that is long enough to
Replace parts, if necessary. Ensure that all of the short circuit two terminals at the harness connector
seals are properly in place and ensure that the for the shutdown switch. Crimp connector pins to
connectors are completely coupled. Verify that the each end of the jumper wire.
repair eliminates the problem.
C. Disconnect the harness connector for the
STOP. shutdown switch.
Test Step 2. Check the Status of the D. Check the status of the shutdown switch while
Shutdown Switch on Cat ET the circuit is shorted to the RUN position.
A. Connect Cat ET to the service tool connector. a. Install the jumper wire between terminals B
(digital return) and A (engine shutdown switch
B. Restore electrical power to the ECM. (N/C)) at the harness connector for the switch.
c. Observe the status of the shutdown switch on B. Fabricate three jumper wires that are long enough
Cat ET. to short circuit terminals at the P1 ECM connector.
Crimp connector sockets to one end of each of
Note: Wait at least 30 seconds for the status of the the jumper wires.
switch to change.
C. Remove the wires from terminal locations P1-5,
The correct status for the shutdown switch is P1-23, and P1-40 at the ECM connector. Install a
“OFF”. jumper wire into each of these terminal locations.
d. Remove electrical power from the ECM. D. Check the status of the shutdown switch while
the circuit is shorted to the RUN position.
E. Check the status of the shutdown switch while
the circuit is shorted to the STOP position. a. Short circuit the ends of the jumper wires that
are in terminal locations P1-5 (digital return)
a. Install the jumper wire between terminals C and P1-40 (engine shutdown switch (N/C)) at
(engine shutdown switch (N/O)) and B (digital the ECM connector.
return) at the harness connector for the switch.
Note: Ensure that the jumper wire that is in terminal
b. Restore electrical power to the ECM. location P1-23 is not in contact with any ground
source. The circuit for this terminal must be open.
c. Observe the status of the shutdown switch on
Cat ET. b. Restore electrical power to the ECM.
Note: Wait at least 30 seconds for the status of the c. Observe the status of the shutdown switch on
switch to change. Cat ET.
The correct status for the shutdown switch is Note: Wait at least 30 seconds for the status of the
“ON”. switch to change.
F. Remove electrical power from the ECM. The correct status for the shutdown switch is
“OFF”.
G. Remove the jumper wire from the harness
connector. d. Remove electrical power from the ECM.
Test Step 4. Short the Terminals for the F. Remove electrical power from the ECM.
Shutdown Switch at the ECM
G. Restore the wiring to the original configuration.
A. Disconnect the J1/P1 ECM connectors.
156 RENR9346-06
Troubleshooting Section
Circuit - Test The engine will start when only one sensor signal is
present. The engine will not start if the signals from
SMCS Code: 1439-038-VF; 1912-038 both sensors are lost.
System Operation Description: Both sensors are magnetic sensors. The two sensors
are not interchangeable. If a sensor is replaced, a
Use this procedure to troubleshoot any suspect timing calibration is not necessary.
problems with the following sensors:
If a replacement of the ECM is required, the ECM
• Primary engine speed/timing sensor parameters and the timing calibration can be
transferred from the suspect ECM to the replacement
• Secondary engine speed/timing sensor ECM. Timing calibration will not be necessary. This
feature requires the Caterpillar Electronic Technician
This procedure covers the following diagnostic codes: (ET) and this feature is only possible if the existing
ECM can communicate with Cat ET. Use the “Copy
• 190-08 Engine Speed Signal abnormal Configuration - ECM Replacement” feature on Cat
ET.
• 342-08 Secondary Engine Speed signal abnormal
A timing calibration is necessary after the
The engine uses two engine speed/timing sensors. ECM software has been updated. Refer to
The primary engine speed/timing sensor detects the Troubleshooting, “Engine Speed/Timing Sensor -
reference for engine speed and timing from a timing Calibrate” for information that is related to timing
ring with a notched pattern that has been machined calibration.
onto a portion of the crankshaft gear. The signal from
the primary engine speed/timing sensor is also used Complete all of the following tasks when you
by the ECM as a control reference during a timing install a speed/timing sensor:
calibration.
• Ensure that an O-ring is installed on the sensor.
If the O-ring is damaged or missing, replace the
O-ring.
RENR9346-06 157
Troubleshooting Section
g01212495
Illustration 74
Schematic for the engine speed/timing sensors
Test Step 1. Check for Diagnostic Codes • 190-08 or 342-08 code – There is an active
diagnostic code or a logged diagnostic code for
A. Connect Cat ET to the service tool connector. an engine speed/timing sensor. Proceed to Test
Refer to Troubleshooting, “Electronic Service Step 4.
Tools”.
• No codes – Neither code is active or logged.
B. Restore electrical power to the ECM.
Repair: Refer to the appropriate symptoms in
C. Start the engine and run the engine until the Troubleshooting, “Troubleshooting Without a
engine is at the normal operating temperature. Diagnostic Code”.
Note: If the engine will not start, monitor the engine STOP.
rpm on Cat ET while the engine is being cranked. Cat
ET may need to be powered from another battery Test Step 2. Check the Installation of the
while the engine is being cranked. Sensor Assembly
D. Look for these codes on Cat ET: A. Remove electrical power from the ECM.
• 190-08
• 342-08
Expected Result:
Results:
STOP.
g01167704
Illustration 76
Typical engine speed/timing sensor
(3) O-ring
Results:
g01167708
Illustration 77
Location of the engine speed/timing sensors (typical front engine
view)
(4) Harness connectors for the secondary engine speed/timing
sensor
(5) Harness connectors for the primary engine speed/timing sensor
g01212538
Illustration 79
P2 terminals that are associated with the engine speed/timing
sensors
(P2-25) Primary engine speed/timing −
(P2-35) Primary engine speed/timing +
(P2-46) Secondary engine speed/timing +
(P2-47) Secondary engine speed/timing −
(P2-92) Speed/timing shield
All of the connectors, pins and sockets are completely The resistance measurement is within the
coupled and/or inserted and the harness and wiring specifications.
are free of corrosion, of abrasion, and of pinch points.
Results:
Results:
• OK – The resistance measurement is within the
• OK – The harness and connectors appear to be specifications.
OK. Proceed to Test Step 4.
Repair: Neither a short circuit nor an open circuit
• Not OK – The connectors and/or wiring are not is indicated in the circuit. Replace the ECM. Refer
OK. to Troubleshooting, “Replacing the ECM”.
Test Step 4. Measure the Sensor Test Step 5. Measure the Resistance of
Resistance through the Engine Harness the Sensor
A. Disconnect the J2/P2 ECM connectors. A. Disconnect the harness connector for the suspect
sensor.
B. If you are troubleshooting a problem with the
primary engine speed/timing sensor, perform the B. Thoroughly inspect the sensor's connectors.
following procedure: Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
a. Measure the sensor's resistance between
P2-25 (primary engine speed/timing +) and C. Measure the sensor's resistance between
P2-35 (primary engine speed/timing -). terminals 1 and 2.
b. Check for an intermittent open circuit or for Resistance for primary engine speed/timing
a short circuit by moving the harness while sensor at 25 °C (77 °F) ............... 75 to 230 Ohms
you take the resistance measurement. Pull
the wires that are directly behind the sensor Resistance for secondary engine speed/timing
or shake the wires that are directly behind the sensor at 25 °C (77 °F) ........... 600 to 1800 Ohms
sensor.
Expected Result:
Resistance at 25 °C (77 °F) ... 75 to 230 Ohms
The resistance measurement is within specifications.
C. If you are troubleshooting a problem with the
secondary engine speed/timing sensor, perform Results:
the following procedure:
• OK – The reading is within the specification. There
a. Measure the sensor's resistance between is a problem with the wiring between the engine
P2-47 (secondary engine speed/timing +) and speed/timing sensor and the ECM. There may be
P2-46 (secondary engine speed/timing -). a problem with a connector.
b. Check for an intermittent open circuit or for Repair: Repair the wiring and/or the connector.
a short circuit by moving the harness while Replace parts, if necessary. Verify that the problem
you take the resistance measurement. Pull is resolved.
the wires that are directly behind the sensor
or shake the wires that are directly behind the STOP.
sensor.
• Not OK – The reading is not within the
Resistance at 25 °C specification. There is an electrical problem with
(77 °F) ................................ 600 to 1800 Ohms the engine speed/timing sensor.
RENR9346-06 161
Troubleshooting Section
Repair: Perform the following procedure in order • 172-04 Intake Manifold Air Temp short to ground
to check and install the new sensor assembly:
• 174-03 Fuel Temperature open/short to +batt
1. Before you install the new sensor assembly,
measure the resistance of the new sensors. • 174-04 Fuel Temperature short to ground
If the resistance measurements of the new • 1796-03 Intake Manifold #2 Air Temperature
sensors are within the specifications, install the Sensor voltage above normal
new sensor assembly in the engine according
to the following procedure: • 1796-04 Intake Manifold #2 Air Temperature
Sensor voltage below normal
a. Loosen the bolt and remove the bolt that
holds the sensor to the engine. The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical.
b. Ensure that an O-ring is installed on the new The temperature sensors are passive sensors that
sensor assembly. Verify that the O-ring is have two terminals. The temperature sensors do not
free of damage. require supply voltage from the Electronic Control
Module (ECM).
c. Prior to installation, lubricate the O-ring with
clean engine oil. Pull-up Voltage
d. Seat the sensor and tighten the bolt. The ECM continuously outputs a pull-up voltage
on the circuit for the sensor signal wire. The ECM
If the sensor will not seat, replace the sensor. uses this pull-up voltage in order to detect a problem
in the signal circuit. When the ECM detects the
e. Ensure that the harness is secured in the presence of a voltage that is above a threshold on the
proper location. signal circuit, the ECM will generate an open circuit
diagnostic code 03 for the sensor.
2. Verify that the repair eliminates the problem.
If the sensor is disconnected at the sensor connector,
STOP. the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are OK. If the sensor is
i02517861
disconnected at the sensor connector, the absence
Engine Temperature Sensor of pull-up voltage at the sensor connector indicates
a problem in the signal wire. If the sensor is
Open or Short Circuit - Test disconnected at the sensor connector and the voltage
at the sensor connector is different from pull-up
SMCS Code: 1439-038-TA; 1906-038 voltage, the signal wire is shorted to another wire in
the harness.
System Operation Description:
g01259793
Illustration 80
Schematic for the engine temperature sensors
RENR9346-06 163
Troubleshooting Section
g01270819
Illustration 81
Locations of the engine temperature sensors (typical engine view)
(1) Intake manifold (No.2) air temperature (2) Intake manifold air temperature sensor (4) Fuel temperature sensor
sensor (3) Engine coolant temperature sensor
Test Step 1. Inspect the Electrical B. Thoroughly inspect all electrical connectors.
Connectors and the Wiring Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
A. Remove electrical power from the ECM.
164 RENR9346-06
Troubleshooting Section
g01270820
Illustration 82
(5) J2/P2ECM connector
g01270822
Illustration 83
P2 terminals that are associated with the engine temperature
sensors
(P2-13) Engine coolant temperature
(P2-30) Sensor return
(P2-56) Intake manifold air temperature
(P2-62) Fuel temperature
(P2-91) Intake manifold (No.2) air temperature sensor
g01155187
Illustration 84
Harness connector for the temperature sensors
(1) Sensor signal
(2) Sensor return
RENR9346-06 165
Troubleshooting Section
C. Perform a 45 N (10 lb) pull test on each of the Repair: The problem appears to be resolved.
wires at the connectors for the temperature The problem may have been related to a faulty
sensors. connection in the harness. Carefully reinspect the
connectors and wiring. Refer to Troubleshooting,
D. Check the allen head screw on each ECM “Electrical Connectors - Inspect” for additional
connector and the customer connector for information.
the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct STOP.
torque values.
• Not OK – A 03 diagnostic code is active at this
E. Check the harness and wiring for abrasions and time. The ECM detects an open circuit condition.
for pinch points from each sensor to the ECM. Proceed to Test Step 4.
Repair: Repair the connectors or wiring and/or D. Access the “Active Diagnostic Codes” screen on
replace the connectors or wiring. Ensure that all of Cat ET. Check for an active 03 diagnostic code
the seals are properly in place and ensure that the for the suspect sensor.
connectors are completely coupled.
Note: Wait at least 30 seconds for activation of the
Verify that the repair eliminates the problem. diagnostic codes.
Test Step 4. Short at the Suspect Sensor b. Fabricate a jumper wire that is long enough
at the Harness Connector to create a test circuit between the ECM
connector and the engine ground stud. Crimp a
A. Remove electrical power from the ECM. connector socket to one end of the jumper wire.
B. Disconnect the suspect sensor at the harness c. Remove the signal wire for the suspect sensor
connector. from the appropriate ECM connector. Install the
jumper wire into this terminal location.
C. Fabricate a jumper wire that is long enough to
short circuit the two terminals at the connector for d. Connect the ECM connectors.
the suspect sensor. Crimp connector pins to each
end of the jumper wire. Hold the loose end of the jumper wire away
from any ground source in order to create an
D. Install the jumper wire between terminal 1 (sensor open circuit condition.
signal) and terminal 2 (sensor return) on the
harness side of the suspect sensor's connector. e. Restore electrical power to the ECM.
E. Restore electrical power to the ECM. f. Monitor the “Active Diagnostic Code” screen
on Cat ET. A 03 diagnostic code will become
F. Monitor the “Active Diagnostic Codes” screen on active for the suspect sensor.
Cat ET after installing the jumper wire. Check for
an active 04 diagnostic code. Note: Wait at least 30 seconds for activation of the
code.
Note: Wait at least 30 seconds for activation of the
04 diagnostic code. g. Remove electrical power from the ECM.
G. Remove electrical power from the ECM. C. Check the operation of the ECM by creating a
short at the ECM.
Expected Result:
a. Connect the loose end of the jumper wire to the
A 04 diagnostic code is now active for the suspect engine ground stud in order to create a short
sensor. circuit condition.
• OK – A 04 diagnostic code is active when the c. Monitor the “Active Diagnostic Code” screen
jumper wire is installed. on Cat ET. A 04 diagnostic code will become
active when the jumper wire is grounded.
Repair: There may be a problem with the sensor.
Temporarily connect a new sensor to the harness, Note: Wait at least 30 seconds for activation of the
but do not install the new sensor in the engine. code.
Verify that there are no active diagnostic codes for
the sensor. If there are no active diagnostic codes d. Remove electrical power from the ECM.
for the sensor, permanently install the new sensor.
Clear any logged diagnostic codes. D. Restore all wiring to the original configuration.
• Not OK – The 03 diagnostic code remains active A 03 diagnostic code is active when the jumper wire
with the jumper in place. There is an open circuit is open. A 04 diagnostic code becomes active when
between the ECM and the sensor connector. There the jumper wire is shorted to the engine ground stud.
may be a problem with the ECM. Proceed to Test
Step 5. Results:
Test Step 5. Check the Operation of the • OK – A 03 diagnostic code is active when the
ECM jumper wire is open. A 04 diagnostic code becomes
active when the jumper wire is shorted to the
A. Remove electrical power from the ECM. engine ground stud.
STOP.
STOP.
i02533981
g01267513
Illustration 85
Schematic of the ether injection system
168 RENR9346-06
Troubleshooting Section
Discard cylinders in a safe place. Do not puncture B. Thoroughly inspect connectors (1) and (2). Also,
or burn cylinders. thoroughly inspect the connectors for solenoid
(3). Refer to the diagnostic functional test
Keep ether cylinders out of the reach of unautho- Troubleshooting, “Electrical Connectors - Inspect”.
rized personnel.
g01167488
Illustration 86
Location of the J1/P1 connectors (typical engine view)
g01215917
(1) J1/P1 connectors Illustration 88
Terminal locations at the P1 connector for the ether injection
system
(P1-18) Solenoid return
(P1-20) Ether injection solenoid
RENR9346-06 169
Troubleshooting Section
Results:
C. Perform a 45 N (10 lb) pull test on each of the Test Step 3. Check for Signal Voltage
wires that are associated with the ether injection at the Harness Connector for the Ether
system. Injection Solenoid
D. Check the torque of the allen head screws for each A. Remove the electrical power from the ECM.
of the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical B. Disconnect the harness connector at the ether
Connectors - Inspect”. injection solenoid.
E. Check the harness and the wiring for abrasion and C. Restore the electrical power to the ECM.
for pinch points from the ether injection solenoid
to the ECM connector. D. Proceed to the “Diagnostic Overrides” screen on
Cat ET.
Expected Result:
E. Activate the ether injection system. The system
All connectors, pins, and sockets are completely will activate for ten seconds.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. F. Check for a signal voltage between the terminals
at the harness connector for the ether injection
Results: solenoid.
• OK – The connectors and the wiring appear to be G. Remove the electrical power from the ECM.
OK. Proceed to Test Step 2.
Expected Result:
• Not OK – The connectors and/or the wiring are
not OK. The signal voltage is 8.0 ± 0.5 VDC at the connector
for the ether injection solenoid.
Repair: Repair the connectors and/or the wiring.
Replace parts, if necessary. Verify that the problem Results:
is resolved.
• OK – The signal voltage is 8.0 ± 0.5 VDC at the
STOP. connector for the ether injection solenoid.
Test Step 2. Check the Ether Canisters Repair: Voltage is reaching the ether injection
for Fluid solenoid. There is a problem with the solenoid.
Connect a new ether solenoid to the harness.
A. Ensure that the electrical power is removed from Verify that the problem has been corrected prior to
the ECM. installing the new solenoid.
C. Determine if the canister is empty. • Not OK – The signal voltage is not 8.0 ± 0.5 VDC
at the connector for the ether injection solenoid.
Expected Result: There is a problem in the harness or in a connector
between the ECM and the connector for the ether
The ether canister is not empty. injection solenoid. There may be a problem with
the ECM. Proceed to Test Step 4.
170 RENR9346-06
Troubleshooting Section
Test Step 4. Check the Operation of the Repair: The ECM is not producing the correct
ECM signal voltage. There is a problem with the
ECM. Replace the ECM. Refer to electronic
A. Disconnect the J1/P1 ECM connectors. troubleshooting Troubleshooting, “Replacing the
ECM”.
B. Fabricate two jumper wires that are long enough to
provide a test circuit at the ECM. Crimp connector STOP.
sockets onto one end of each of the jumper wires.
i02627384
C. Remove the wires from terminal locations P1-18
(digital return) and P1-20 (ether injection solenoid)
at the ECM connector. Install a jumper wire into
Fuel Filter Differential Pressure
each of these terminal locations. Switch Circuit - Test
D. Connect the J1/P1 ECM connectors. SMCS Code: 1435-038-FI
F. Proceed to the “Diagnostic Overrides” screen on Perform this procedure if you suspect that there is
Cat ET. a problem in the circuit for the fuel filter differential
pressure switch.
G. Activate the ether injection system. The system
will activate for ten seconds. This procedure covers the following event codes:
H. Check for a signal voltage between the jumper • E390-1 Fuel Filter Restriction Warning
wires at the ECM connector for the ether injection
solenoid. • E390-2 Fuel Filter Restriction Derate
I. Remove the electrical power from the ECM. The fuel filter differential pressure switch is used
to detect excessive restriction in the fuel filter. The
J. Restore all of the wiring to the original switch is normally closed. When the fuel pressure
configuration. at the switch reaches 103 ± 14 kPa (15 ± 2 psi) the
switch will open. The switch is used in order to detect
Expected Result: a plugged fuel filter element. The Electronic Control
Module (ECM) will alert the operator of the condition.
The signal voltage is 8.0 ± 0.5 VDC at the ECM for Use this test in order to verify that the fuel filter
the ether injection solenoid. differential pressure switch is operating correctly.
Results:
STOP.
g01322152
Illustration 90
Schematic for fuel filter differential pressure switch
g01161069
Illustration 92
Fuel filter base (typical example)
(2) Fuel filter differential pressure switch
g01214446
Illustration 91 B. Thoroughly inspect connectors (1). Also,
Left side engine view (typical example) thoroughly inspect each connector for switch (2).
(1) J2/P2 ECM connectors
Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”
for details.
172 RENR9346-06
Troubleshooting Section
g01155187
Illustration 94
Connector for the fuel filter differential pressure switch
(Terminal 1) Fuel filter differential pressure switch
(Terminal 2) Signal return
Expected Result:
Results:
STOP.
g01321577
Illustration 93
P2 ECM connector
Test Step 2. Check the Switch Circuit
(P2-65) Fuel filter differential pressure switch
(P2-83) Signal return
A. Disconnect the connector for the differential
pressure switch.
Expected Result:
Results: i03793013
Repair: Replace the differential pressure switch. • A suspected problem with an injector solenoid
C. Check continuity at the ECM connector between • 1-06 Cylinder #1 Injector short
terminal P2-65 (fuel filter pressure switch) and
terminal P2-83 (switch return). • 2-05 Cylinder #2 Injector open circuit
The resistance check indicates a short circuit. • 3-05 Cylinder #3 Injector open circuit
• OK – The resistance check indicates a short • 4-05 Cylinder #4 Injector open circuit
circuit.
• 4-06 Cylinder #4 Injector short
Repair: Check all connectors and wiring. Ensure
that there are clean, solid connections at each • 5-05 Cylinder #5 Injector open circuit
connector. Return all wiring to the original
configuration and retest the circuit. The most • 5-06 Cylinder #5 Injector short
likely cause of the problem is a poor connection.
The next most likely cause of the problem is the • 6-05 Cylinder #6 Injector open circuit
differential pressure switch. The least likely cause
of the problem is the ECM. The ECM can be tested • 6-06 Cylinder #6 Injector short
by creating a short between the ECM terminals for
the differential pressure switch. Start and run the • 7-05 Cylinder #7 Injector open circuit
engine. After an hour, check for an E390 event
code. If the event code is activated with the short • 7-06 Cylinder #7 Injector short
in place at the ECM connector, replace the ECM.
Refer to Troubleshooting, “Replacing the ECM”. • 8-05 Cylinder #8 Injector open circuit
Verify that the problem is resolved.
• 8-06 Cylinder #8 Injector short
STOP.
• 9-05 Cylinder #9 Injector open circuit
• Not OK – The resistance check indicates an open
circuit. • 9-06 Cylinder #9 Injector short
Repair: Repair the connectors or wiring and/or • 10-05 Cylinder #10 Injector open circuit
replace the connectors or wiring between the ECM
and the connector for the differential pressure • 10-06 Cylinder #10 Injector short
switch.
• 11-05 Cylinder #11 Injector open circuit
STOP.
174 RENR9346-06
Troubleshooting Section
• 11-06 Cylinder #11 Injector short During the test, when a cylinder is cut out, an
increase in “Fuel Position” will be noticed for the
• 12-05 Cylinder #12 Injector open circuit remaining cylinders. This increase in “Fuel Position”
represents an increase in the amount of fuel that
• 12-06 Cylinder #12 Injector short must be delivered by the remaining cylinders in order
to maintain the desired engine speed.
Perform this procedure under conditions that are
identical to the conditions that exist when the problem When a weak cylinder (malfunctioning injector) is cut
occurs. Typically, problems with the injector solenoid out, the increase in “Fuel Position” will not be as large
occur when the engine is warmed up and/or when as the increase for a cylinder that has an acceptable
the engine is under vibration (heavy loads). level of performance.
These engines have Electronic Unit Injectors (EUI) Note: Prior to running the “Cylinder Cutout Test”, all
that are mechanically actuated and electronically active diagnostic codes must be repaired.
controlled. The Engine Control Module (ECM) sends
a high voltage signal to each injector solenoid. The “Injector Solenoid Test”
signal is sent with the proper injection duration and
injection timing for the current engine load and Use the “Injector Solenoid Test” to diagnose an open
speed. The injector solenoid is mounted on top of circuit or a short circuit in the wiring for the injector
the fuel injector body. solenoids. With the engine stopped, the “Injector
Solenoid Test” will briefly activate each injector
If an open circuit condition is detected in the solenoid solenoid. An audible click can be heard as each
circuit, a diagnostic code is generated. The ECM will solenoid is activated. After performing the test, Cat
continue to try to fire the injector. If a short circuit ET will indicate the status of the solenoid as “OK”,
condition is detected, a diagnostic code is generated. “Open”, or “Short”.
The ECM will disable the solenoid circuit. The ECM
will periodically try to fire the injector. If the short
circuit condition remains, this sequence of events will
be repeated until the problem is corrected.
g02050353
Illustration 95
Schematic for the injector solenoids
176 RENR9346-06
Troubleshooting Section
g01166729
Illustration 96
Left side engine view (typical example)
(1) J2/P2 ECM connectors Illustration 97
g01202827
(2) R1/P3 Injector valve cover entry connectors (right bank)
(3) R1/P4 Injector valve cover entry connectors (left bank) P2 terminals that are associated with the injector solenoids
(P2-18) Injector 8 return
B. Thoroughly inspect connectors (1), (2), and (3). (P2-21) Injector 10 return
Refer to Troubleshooting, “Electrical Connectors (P2-22) Injector 4 return
(P2-31) Injector 6 return
- Inspect”. (P2-42) Injector 12 return
(P2-50) Injector 2 return
(P2-58) Injectors 10 & 12 supply
(P2-67) Injectors 6 & 8 supply
(P2-68) Injectors 2 & 4 supply
(P2-99) Injectors 9 & 11 supply
(P2-104) Injectors 1 & 3 supply
(P2-105) Injector 11 return
(P2-106) Injector 5 return
(P2-107) Injector 9 return
(P2-108) Injector 7 return
(P2-115) Injectors 5 & 7 supply
(P2-116) Injector 1 return
(P2-118) Injector 3 return
RENR9346-06 177
Troubleshooting Section
Expected Result:
Results:
g01161232
Repair: Repair the connectors or wiring and/or
Illustration 98 replace the connectors or wiring. Ensure that all of
P3 terminals that are associated with the injector solenoids the seals are properly in place and ensure that the
(P3-1) Injector 12 return connectors are completely coupled.
(P3-2) Injector 10 return
(P3-3) Injector 8 return Verify that the repair eliminates the problem.
(P3-4) Injector 6 return
(P3-5) Injector 4 return
(P3-6) Injector 2 return STOP.
(P3-7) Injectors 10 & 12 supply
(P3-8) Injectors 6 & 8 supply Test Step 2. Check for Logged Diagnostic
(P3-9) Injectors 2 & 4 supply
Codes for the Injector Solenoids
A. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service
Tools”.
Expected Result:
D. Shut off all parasitic loads such as air compressors G. As each solenoid is energized by the ECM, an
which could affect the results of the test. audible click can be heard at the valve cover.
Allow the “Injector Solenoid Test” to continue until
E. Follow the instructions that are given on the each cylinder is activated at least two times.
screen.
Expected Result:
F. To start the test, select the start button at the
bottom of the screen. All cylinders indicate “OK” on Cat ET.
Repair: If a problem with the fuel system is • Not OK - “Open” – Note the cylinder that indicates
suspected and diagnostic codes are not active or “Open”. Proceed to Test Step 5.
logged, refer to Systems Operation/Testing and
Adjusting for information that is related to the low • Not OK - “Short” – Note the cylinder that indicates
pressure fuel system. “Short”. Proceed to Test Step 6.
Expected Result:
Results:
Illustration 101
g01161304 D. Perform the “Injector Solenoid Test” at least two
times.
P4 terminals that are associated with the injector solenoids
(harness side of connector)
Expected Result:
(P4-1) Injector 1 return
(P4-2) Injector 3 return
(P4-3) Injector 5 return All of the cylinders in the appropriate bank indicate
(P4-4) Injector 7 return “Open” on Cat ET.
(P4-5) Injector 9 return
(P4-6) Injector 11 return
(P4-7) Injectors 1 & 3 supply
Results:
(P4-8) Injectors 5 & 7 supply
(P4-9) Injectors 9 & 11 supply • OK – All cylinders indicate “Open” on Cat ET. The
ECM and the engine harness are OK. Proceed to
E. Insert one end of the jumper wire into the P300 Test Step 7.
connector socket for the suspect injector's supply
wire. Insert the other end of the jumper wire • Not OK – One or more cylinders indicate “Short”
into the P300 connector socket for the suspect on Cat ET. Note the cylinders that indicate “Short”.
injector's return wire. This will replace the injector Proceed to Test Step 8.
solenoid with a short circuit.
Test Step 7. Check the Injector Harness L. Remove the electrical power from the ECM.
Under the Valve Cover for an Open
Circuit or a Short Circuit Expected Result:
A. Remove the electrical power from the ECM. • OK – Cat ET displays the correct status during
the test.
B. Remove the valve cover in order to gain access
to the suspect injector. Repair: The harness wiring is OK. There may be a
problem with the injector. Use a multimeter to check
C. Disconnect the harness connector from the the resistance of the suspect injector solenoid.
suspect injector.
The correct resistance of each injector solenoid is
1.06 ± 0.05 Ohms at 25 °C (77 °F).
STOP.
g01147088
Illustration 102 • Not OK – Cat ET did not display the correct status
Connector terminals for the injector solenoid during the test.
D. Thoroughly clean the terminals on the injector Repair: There is a problem with the injector
solenoid and on the harness connector. harness under the valve cover. There may be a
problem with a connector. Repair the wiring and/or
E. Use a jumper wire to short circuit the connector the connector, when possible. Replace parts, if
terminals for the suspect injector. This will necessary.
effectively replace the injector solenoid with a
short circuit. STOP.
F. Restore the electrical power to the ECM. Test Step 8. Check the ECM for Proper
Operation
G. Perform the “Injector Solenoid Test” at least two
times.
H. Remove the electrical power from the ECM. A. Remove the electrical power from the ECM.
I. Remove the jumper wire from the injector B. Fabricate a jumper that is long enough to reach
connector. This will effectively replace the injector from the P2 ECM connector to the engine ground
solenoid with an open circuit. stud. Crimp a connector socket to one end of the
jumper wire.
J. Restore the electrical power to the ECM.
C. Disconnect the P2 connector.
K. Perform the “Injector Solenoid Test” at least two
times.
RENR9346-06 181
Troubleshooting Section
D. Remove the supply wire from the terminal location Repair: There is a problem with the ECM. Replace
for the suspect injector at the ECM connector. the ECM. Refer to Troubleshooting, “Replacing the
Install the jumper wire into this socket. ECM”. Verify that the problem is resolved.
Expected Result:
Results:
STOP.
Table 15
Diagnostic Codes Table
Code and Description Conditions which Generate System Response Label on Sensor
this Code
827-3 Left Exhaust The Electronic Control The code is logged. “FRONT LEFT EXHAUST
Temperature Sensor voltage Module (ECM) detects a The ECM flags the exhaust TC”
above normal signal voltage that is above temperature as invalid data. Located in the exhaust
normal. manifold below the
turbocharger
827-4 Left Exhaust The Electronic Control
Temperature Sensor voltage Module (ECM) detects a
below normal signal voltage that is below
normal.
827-8 Left Exhaust The Electronic Control
Temperature Sensor Module (ECM) detects a
abnormal frequency, pulse sensor frequency that is
width, or period greater than 600 Hz or less
than 400 Hz.
The ECM detects a duty
cycle that is greater than 88
percent or a duty cycle that is
less than 22 percent.
828-3 Right Exhaust The Electronic Control The code is logged. “FRONT RIGHT EXHAUST
Temperature Sensor voltage Module (ECM) detects a The ECM flags the exhaust TC”
above normal signal voltage that is above temperature as invalid data. Located in the exhaust
normal. manifold below the
turbocharger
828-4 Right Exhaust The Electronic Control
Temperature Sensor voltage Module (ECM) detects a
below normal signal voltage that is below
normal.
828-8 Right Exhaust The Electronic Control
Temperature Sensor Module (ECM) detects a
abnormal frequency, pulse sensor frequency that is
width, or period greater than 600 Hz or less
than 400 Hz.
The ECM detects a duty
cycle that is greater than 88
percent or a duty cycle that is
less than 22 percent.
2350-3 Left Exhaust #2 The Electronic Control The code is logged. “REAR LEFT EXHAUST TC”
Temperature Sensor voltage Module (ECM) detects a The ECM flags the exhaust Located in the exhaust
above normal signal voltage that is above temperature as invalid data. manifold below the
normal. turbocharger
2350-4 Left Exhaust #2 The Electronic Control
Temperature Sensor voltage Module (ECM) detects a
below normal signal voltage that is below
normal.
2350-8 Left Exhaust The Electronic Control
#2 Temperature Sensor Module (ECM) detects a
abnormal frequency, pulse sensor frequency that is
width, or period greater than 600 Hz or less
than 400 Hz.
The ECM detects a duty
cycle that is greater than 88
percent or a duty cycle that is
less than 22 percent.
(continued)
RENR9346-06 183
Troubleshooting Section
System Operation
g01405556
Illustration 103
Schematic of the sensor circuit for the PWM sensors
g01406331
Illustration 104
Locations of the left side exhaust temperature sensors
(1) “FRONT LEFT EXHAUST TC” (2) “REAR LEFT EXHAUST TC”
RENR9346-06 185
Troubleshooting Section
g01406077
Illustration 105
Location of the ECM connector that is for the exhaust temperature
sensors
(3) J2/P2 ECM connectors
g01406078
Illustration 106
Terminal locations at the P2 ECM connector that are for the
exhaust temperature sensor
(P2-29) Digital sensor supply
(P2-39) Front left exhaust temperature
(P2-49) Front right exhaust temperature
(P2-65) Rear left exhaust temperature
(P2-73) Rear right exhaust temperature
(P2-93) Digital return
186 RENR9346-06
Troubleshooting Section
Expected Result:
g01159881
Results:
Illustration 107
Terminal locations at the connectors for the exhaust temperature • OK – The correct supply voltage is measured at
sensor the sensor connector. The sensor is receiving the
(Terminal A) Digital sensor supply correct supply voltage. Proceed to Test Step 3.
(Terminal B) Digital return
(Terminal C) Exhaust temperature
• Not OK – The voltage is not correct at the sensor
connector.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and the customer
Repair: There is a problem in the circuit for the
connector that are associated with the circuit.
digital sensor supply that is between the ECM and
the exhaust temperature sensor. Repair the circuit.
C. Check the allen head screw on each ECM
Refer to Troubleshooting, “Sensor Supply - Test”
connector for the proper torque. refer to
for details that are related to troubleshooting a
Troubleshooting, “Electrical Connectors - Inspect”
problem with the circuit.
for the correct torque values.
STOP.
D. Check the harness and the wiring for abrasion
and for pinch points.
Test Step 3. Check the Signal Frequency
Expected Result:
and the Duty Cycle at the Sensor
A. Disconnect the sensor connector from the exhaust
All connectors, pins, and sockets are completely
temperature sensor.
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
B. Remove the signal wire from terminal C of the
harness side of the connector for the exhaust
Results:
temperature sensor.
• OK – The connectors and wiring appear to be OK. C. Install a 7X-6370 Adapter Cable As (3-PIN
Proceed to Test Step 2.
BREAKOUT) at the sensor connector.
• Not OK – The connectors and/or wiring are not D. Connect the sensor to the breakout harness.
OK.
E. Restore electrical power to the ECM. Turn the
Repair: Repair the connectors or wiring and/or
keyswitch to the ON position.
replace the connectors or wiring.
F. Measure the frequency and the duty cycle
STOP.
between terminal B (digital return) and terminal C
(exhaust temperature) at the 7X-6370 Adapter
Test Step 2. Check the Supply Voltage at Cable As (3-PIN BREAKOUT).
the Sensor
G. Remove electrical power from the ECM. Turn the
A. Disconnect the exhaust temperature sensor at the
keyswitch to the OFF position.
harness connector.
H. Remove the breakout harness. Restore the wiring
B. Restore electrical power to the ECM. Turn the
to the original configuration.
keyswitch to the ON position.
RENR9346-06 187
Troubleshooting Section
The frequency is between 400 and 600 Hz. The duty • OK – The frequency and the duty cycle are within
cycle is between 22 and 88 percent. specifications.
Note: When the temperature of the sensor probe is Repair: A valid signal appears at the ECM, but the
50 °C (122 °F) the duty cycle output of the sensor ECM is not detecting the signal properly. There is a
is 22 percent. When the temperature of the sensor problem with the ECM. Replace the ECM. Refer to
probe is 850 °C (1550 °F) the duty cycle output of Troubleshooting, “ECM - Replace” for details.
the sensor is 88 percent.
STOP.
Results:
• Not OK – The frequency and the duty cycle are
• OK – The frequency and the duty cycle are within not within specifications.
specifications. The sensor is producing a valid
signal. Proceed to Test Step 4. Repair: There is not a valid signal at the ECM
connector. Repair the signal wire in the harness
• Not OK – The frequency and the duty cycle are that is between the ECM connector and the harness
not within specifications. connector for the suspect exhaust temperature
sensor. Verify that the repair eliminates the
Repair: The sensor is not producing a valid signal. problem.
Replace the exhaust temperature sensor. Verify
that the repair eliminates the problem. STOP.
STOP.
i02517370
B. Restore electrical power to the ECM. Turn the Use this procedure to troubleshoot the system when
keyswitch to the ON position. a 91-08 Throttle Position Signal abnormal is active.
C. Install a 7X-1709 Multimeter Probe (BLACK) into The throttle position sensor provides the throttle
terminal location P2-14 (digital return) at the ECM signal to the Electronic Control Module (ECM).
connector.
Expected Result:
g01193730
The frequency is between 400 and 600 Hz. The duty Illustration 108
cycle is between 22 and 88 percent. Mounting location of the throttle position sensor on the throttle
pedal (typical example)
Note: When the temperature of the sensor probe is
50 °C (122 °F) the duty cycle output of the sensor
is 22 percent. When the temperature of the sensor
probe is 850 °C (1550 °F) the duty cycle output of
the sensor is 88 percent.
188 RENR9346-06
Troubleshooting Section
g01259511
Illustration 109
Schematic for throttle position sensor
g01258956
Illustration 110
Location of the J1/P1 ECM connectors
g01214474
Illustration 111
P1 ECM connector
(P1-4) 8 VDC supply
(P1-5) Digital return
(P1-66) Throttle position
g01159881
Illustration 112
Terminal locations for the throttle position sensor
(Terminal A) 8 V supply
(Terminal B) Digital return
(Terminal C) Throttle position
D. Check the allen head screw from each ECM Test Step 3. Check the Status for
connector for the proper torque. Refer to “Throttle Position” on Cat ET
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque value. A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
E. Check the harness and the wiring for abrasion
and for pinch points. B. Restore electrical power to the ECM.
STOP. STOP.
Test Step 2. Inspect the Throttle Pedal • Not OK – The throttle position that is displayed on
Assembly Cat ET is questionable. There may be a problem
with the sensor. Proceed to Test Step 4.
A. Inspect the throttle pedal assembly for components
that are loose, bent, missing, or worn. Test Step 4. Check the Supply Voltage at
the Sensor
B. Slowly depress the pedal and release the pedal.
A. Remove electrical power from the ECM.
Expected Result:
B. Disconnect the harness connector for the throttle
The throttle pedal assembly operates smoothly position sensor.
without excessive drag. The pedal springs back
smoothly to the low idle position without assistance. C. Restore electrical power to the ECM.
• Not OK – The voltage is not correct at the sensor Test Step 6. Check the Signal Frequency
connector. and the Duty Cycle at the ECM
Repair: The sensor is not receiving the correct A. Disconnect the J1/P1 ECM connectors.
supply voltage. There may be a problem
in the circuit for the digital supply. Refer to B. Remove the wire from terminal location P1-66
Troubleshooting, “Digital Sensor Supply Circuit (throttle position) at the ECM connector.
- Test” for details.
C. Install a 208-0059 Adapter Cable As (70-PIN
STOP. BREAKOUT) between the J1 and the P1 ECM
connectors.
Test Step 5. Check the Signal Frequency
and the Duty Cycle at the Sensor D. Connect the J1/P1 ECM connectors.
A. Remove the wire from terminal location C (throttle E. Restore electrical power to the ECM.
position) on the harness side of the connector for
the throttle position sensor. F. Measure the frequency between the loose signal
wire (throttle position) and P1-5 (digital return)
B. Install a 7X-6370 Adapter Cable As (3-PIN on the breakout harness while you operate the
BREAKOUT) at the connector for the throttle throttle pedal.
position sensor.
G. Set the multimeter to read the duty cycle of the
C. Connect the connector for the throttle position sensor. Measure the duty cycle between the loose
sensor. signal wire (throttle position) and P1-5 (digital
return) on the breakout harness while you operate
D. Restore electrical power to the ECM. the throttle pedal.
E. Measure the frequency and the duty cycle H. Remove electrical power from the ECM.
between terminal B (digital return) and terminal C
(throttle position) at the 7X-6370 Adapter Cable Expected Result:
As (3-PIN BREAKOUT) while you operate the
throttle pedal. The frequency is between 150 and 1000 Hz. The
duty cycle is between 5 percent and 95 percent.
F. Remove electrical power from the ECM.
Results:
G. Remove the breakout harness. Restore the
wiring for the harness connector to the original • OK – The frequency and the duty cycle are within
configuration. specifications for the entire range of the pedal.
Expected Result: Repair: A valid signal appears at the ECM, but the
ECM is not reading the signal properly. Replace
The frequency is between 150 and 1000 Hz. The the ECM. Refer to Troubleshooting, “Replacing
duty cycle is between 5 and 95 percent. the ECM” for complete instructions. Verify that the
repair eliminates the problem.
Results:
STOP.
• OK – The frequency and the duty cycle are within
specifications for the entire range of the pedal. The • Not OK – The frequency and the duty cycle are
sensor is producing a valid signal. Proceed to Test not within specifications.
Step 6.
Repair: There is a valid signal in the isolated circuit
• Not OK – The frequency and the duty cycle are between the sensor and the sensor connector, but
not within specifications. there is not a valid signal at the ECM connector.
The problem is in the harness wiring or in a
Repair: The sensor is not producing a valid signal. connector between the ECM and the harness
Replace the throttle position sensor. Verify that the connector for the throttle position sensor. Repair
repair eliminates the problem. the harness and/or the connectors. Replace parts,
if necessary. Verify that the repair eliminates the
STOP. problem.
STOP.
192 RENR9346-06
Troubleshooting Section
The two signals are then used by the ECM to B. After the engine has warmed up, access the
calculate a timing offset. The offset is used by the “Timing Calibration” screen on Cat ET. Access the
ECM to calibrate the signal from the secondary following display screens in order:
engine speed/timing sensor.
• “Service”
Note: A timing calibration will not increase the
available engine power. • “Calibrations”
Test Step 1. Check for Active Diagnostic • “Timing Calibration”
Codes
C. To calibrate the timing to the correct setting, set
A. Turn the keyswitch to the OFF position. the engine speed to 1100 ± 50 rpm and select
“Continue” on Cat ET. Wait until Cat ET indicates
B. Connect the Caterpillar Electronic Technician that the timing is calibrated.
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. D. Press the “Continue” button on Cat ET. Wait until
Cat ET indicates that the ECM has calculated the
C. Turn the keyswitch to the ON position. timing reference.
D. Check for any active diagnostic codes. Note: If Cat ET displays “Calibration Unsuccessful”,
the electronic injection timing has not been calibrated.
Expected Result:
Expected Result:
No active diagnostic codes are present.
The timing calibration was successful.
RENR9346-06 193
Troubleshooting Section
Results:
STOP.
STOP.
194 RENR9346-06
Index Section
Index
Numerics CID 0091 FMI 08 Throttle Position signal
abnormal.............................................................. 57
5 Volt Engine Pressure Sensor Supply Circuit - CID 0094 FMI 03 Fuel Pressure open/short to
Test .................................................................... 100 +batt..................................................................... 58
CID 0094 FMI 04 Fuel Pressure short to ground... 58
CID 0100 FMI 03 Engine Oil Pressure open/short to
A +batt..................................................................... 58
CID 0100 FMI 04 Engine Oil Pressure short to
Alternator (Noisy Operation).................................. 26 ground.................................................................. 58
Probable Causes ............................................... 26 CID 0100 FMI 10 Engine Oil Pressure Sensor
Recommended Actions...................................... 26 abnormal rate of change...................................... 59
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt............................................... 59
C CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 59
Calibration Procedures ........................................ 192 CID 0168 FMI 00 System Voltage High................. 60
Can Not Reach Top Engine RPM .......................... 26 CID 0168 FMI 01 System Voltage Low.................. 60
Probable Causes ............................................... 26 CID 0168 FMI 02 System Voltage intermittent/
Recommended Actions...................................... 26 erratic................................................................... 60
Cat Data Link Circuit - Test.................................. 105 CID 0172 FMI 03 Intake Manifold Air Temp open/short
CID 0001 FMI 05 Cylinder #1 Injector open to +batt................................................................. 61
circuit ................................................................... 50 CID 0172 FMI 04 Intake Manifold Air Temp short to
CID 0001 FMI 06 Cylinder #1 Injector short .......... 50 ground.................................................................. 61
CID 0002 FMI 05 Cylinder #2 Injector open CID 0174 FMI 03 Fuel Temperature open/short to
circuit ................................................................... 50 +batt..................................................................... 61
CID 0002 FMI 06 Cylinder #2 Injector short .......... 51 CID 0174 FMI 04 Fuel Temperature short to
CID 0003 FMI 05 Cylinder #3 Injector open ground.................................................................. 62
circuit ................................................................... 51 CID 0190 FMI 08 Engine Speed signal abnormal.. 62
CID 0003 FMI 06 Cylinder #3 Injector short .......... 51 CID 0253 FMI 02 Personality Module mismatch ... 62
CID 0004 FMI 05 Cylinder #4 Injector open CID 0261 FMI 11 Engine Timing Offset fault ......... 63
circuit ................................................................... 52 CID 0261 FMI 13 Engine Timing Calibration
CID 0004 FMI 06 Cylinder #4 Injector short .......... 52 required................................................................ 64
CID 0005 FMI 05 Cylinder #5 Injector open CID 0262 FMI 03 5 Volt Sensor DC Power Supply
circuit ................................................................... 52 short to +batt........................................................ 64
CID 0005 FMI 06 Cylinder #5 Injector short .......... 52 CID 0262 FMI 04 5 Volt Sensor DC Power Supply
CID 0006 FMI 05 Cylinder #6 Injector open short to ground..................................................... 64
circuit ................................................................... 53 CID 0267 FMI 02 Incorrect Engine Shutdown Switch
CID 0006 FMI 06 Cylinder #6 Injector short .......... 53 inputs ................................................................... 65
CID 0007 FMI 05 Cylinder #7 Injector open CID 0268 FMI 02 Check Programmable
circuit ................................................................... 53 Parameters .......................................................... 65
CID 0007 FMI 06 Cylinder #7 Injector short .......... 54 CID 0274 FMI 03 Atmospheric Pressure open/short
CID 0008 FMI 05 Cylinder #8 Injector open to +batt................................................................. 65
circuit ................................................................... 54 CID 0274 FMI 04 Atmospheric Pressure short to
CID 0008 FMI 06 Cylinder #8 Injector short .......... 54 ground.................................................................. 66
CID 0009 FMI 05 Cylinder #9 Injector open CID 0291 FMI 05 Engine Cooling Fan Solenoid open
circuit ................................................................... 54 circuit ................................................................... 66
CID 0009 FMI 06 Cylinder #9 Injector short .......... 55 CID 0291 FMI 06 Engine Cooling Fan Solenoid short
CID 0010 FMI 05 Cylinder #10 Injector open to ground.............................................................. 66
circuit ................................................................... 55 CID 0342 FMI 08 Secondary Engine Speed signal
CID 0010 FMI 06 Cylinder #10 Injector short ........ 55 abnormal.............................................................. 66
CID 0011 FMI 05 Cylinder #11 Injector open CID 0533 FMI 09 Brake Control abnormal update
circuit ................................................................... 56 rate....................................................................... 67
CID 0011 FMI 06 Cylinder #11 Injector short......... 56 CID 0533 FMI 14 Brake Control special
CID 0012 FMI 05 Cylinder #12 Injector open instruction ............................................................ 67
circuit ................................................................... 56 CID 0544 FMI 02 Engine Cooling Fan Speed Sensor
CID 0012 FMI 06 Cylinder #12 Injector short ........ 56 loss of signal ........................................................ 67
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 57 CID 0544 FMI 08 Engine Cooling Fan Speed signal
CID 0041 FMI 04 8 Volt DC Supply short to abnormal.............................................................. 68
ground.................................................................. 57 CID 0569 FMI 05 Oil Injection Solenoid current below
normal.................................................................. 68
RENR9346-06 195
Index Section
CID 0569 FMI 06 Oil Renewal Solenoid short to CID 2534 FMI 05 Compression Brake Low/High
ground.................................................................. 68 Solenoid #2 current below normal ....................... 78
CID 0827 FMI 03 Left Exhaust Temperature CID 2534 FMI 06 Compression Brake Low/High
open/short to +batt............................................... 69 Solenoid #2 current above normal....................... 79
CID 0827 FMI 04 Left Exhaust Temperature short to CID 2535 FMI 05 Compression Brake Medium/High
ground.................................................................. 69 Solenoid #1 current below normal ....................... 79
CID 0827 FMI 08 Left Exhaust Temperature signal CID 2535 FMI 06 Compression Brake Medium/High
abnormal.............................................................. 69 Solenoid #1 current above normal....................... 79
CID 0828 FMI 03 Right Exhaust Temperature CID 2536 FMI 05 Compression Brake Medium/High
open/short to +batt............................................... 70 Solenoid #2 current below normal ....................... 79
CID 0828 FMI 04 Right Exhaust Temperature short CID 2536 FMI 06 Compression Brake Medium/High
to ground.............................................................. 70 Solenoid #2 current above normal....................... 80
CID 0828 FMI 08 Right Exhaust Temperature signal Compression Brake Solenoid Circuit - Test ......... 108
abnormal.............................................................. 70 Coolant in Engine Oil............................................. 27
CID 1273 FMI 09 Unable to Communicate with Probable Causes ............................................... 27
Chassis Control Module....................................... 71 Recommended Actions...................................... 27
CID 1273 FMI 14 Chassis Control Module special Coolant Temperature Is Too High .......................... 28
instruction ............................................................ 71 Probable Causes ............................................... 28
CID 1589 FMI 03 Turbo Inlet Air Pressure Sensor Recommended Repairs ..................................... 28
open/shrt to +bat.................................................. 71
CID 1589 FMI 04 Turbo Inlet Air Pressure Sensor
short to ground..................................................... 72 D
CID 1785 FMI 03 Intake Manifold Pressure Sensor
voltage high ......................................................... 72 Diagnostic Codes .................................................. 49
CID 1785 FMI 04 Intake Manifold Pressure Sensor Active Diagnostic Codes .................................... 49
voltage low........................................................... 72 Diagnostic Codes............................................... 49
CID 1785 FMI 10 Intake Manifold Pressure Signal Logged Diagnostic Codes.................................. 50
abnormal rate of change...................................... 72 Diagnostic Functional Tests................................. 100
CID 1795 FMI 03 Turbo #2 Outlet Pressure Sensor Digital Sensor Supply Circuit - Test ...................... 117
voltage above normal .......................................... 73
CID 1795 FMI 04 Turbo #2 Outlet Pressure Sensor
voltage below normal........................................... 73 E
CID 1795 FMI 10 Turbo #2 Outlet Pressure Sensor
abnormal rate of change...................................... 74 E096 High Fuel Pressure ...................................... 84
CID 1796 FMI 03 Intake Manifold #2 Air Temperature E1000 High Left Intake Manifold Air Temperature.. 98
Sensor voltage above normal .............................. 74 E171 Low Engine Oil Level ................................... 84
CID 1796 FMI 04 Intake Manifold #2 Air Temperature E172 High Air Filter Restriction ............................. 85
Sensor voltage below normal .............................. 74 E194 High Exhaust Temperature........................... 85
CID 2271 FMI 05 Engine Oil Renewal System E321 High Right Exhaust Temperature ................. 87
Actuation Solenoid current below normal ............ 75 E322 High Left Exhaust Temperature.................... 88
CID 2271 FMI 06 Engine Oil Renewal System E360 Low Engine Oil Pressure.............................. 90
Actuation Solenoid current above normal............ 75 E361 High Engine Coolant Temperature ............... 90
CID 2350 FMI 03 Left Exhaust #2 Temperature E362 Engine Overspeed ....................................... 92
voltage above normal .......................................... 75 E363 High Fuel Supply Temperature..................... 92
CID 2350 FMI 04 Left Exhaust #2 Temperature E390 Fuel Filter Restriction ................................... 93
voltage below normal........................................... 76 E539 High Intake Manifold Air Temperature.......... 93
CID 2350 FMI 08 Left Exhaust #2 Temperature E540 Low Engine Oil Refill Tank Level.................. 94
abnormal frequency, pulse width, or period ......... 76 E775 High Left Exhaust #2 Temperature............... 95
CID 2351 FMI 03 Right Exhaust #2 Temperature E776 High Right Exhaust #2 Temperature ............ 96
voltage above normal .......................................... 76 ECM Will Not Accept Factory Passwords.............. 29
CID 2351 FMI 04 Right Exhaust #2 Temperature Probable Causes ............................................... 29
voltage below normal........................................... 77 Recommended Actions...................................... 30
CID 2351 FMI 08 Right Exhaust #2 Temperature ECM Will Not Communicate with Other Systems or
abnormal frequency, pulse width, or period ......... 77 Display Modules .................................................. 30
CID 2417 FMI 05 Ether Injection Control Solenoid Probable Causes ............................................... 30
current low ........................................................... 77 Recommended Actions...................................... 30
CID 2417 FMI 06 Ether Injection Control Solenoid Electrical Connectors - Inspect............................ 121
current high.......................................................... 78 Electrical Power Supply Circuit - Test.................. 126
CID 2533 FMI 05 Compression Brake Low/High Electronic Service Tool Will Not Communicate with
Solenoid #1 current below normal ....................... 78 ECM..................................................................... 30
CID 2533 FMI 06 Compression Brake Low/High Probable Causes ............................................... 30
Solenoid #1 current above normal....................... 78 Recommended Actions...................................... 30
196 RENR9346-06
Index Section
Self-Diagnostics..................................................... 12
Sensor Signal (PWM) - Test ................................ 181
Sensors and Electrical Connectors ....................... 13
C27 and C32 Engines........................................ 15
System Configuration Parameters......................... 22
Parameter Descriptions ..................................... 22
Parameter Table................................................. 24
Parameter Worksheet ........................................ 24
System Overview..................................................... 6
Passwords ........................................................... 7
Programmable Parameters.................................. 7
System Operation ................................................ 6
Table of Contents..................................................... 3
Test ECM Mode ..................................................... 19
Throttle Position Sensor Circuit - Test ................. 187
Troubleshooting Section.......................................... 6
Troubleshooting with a Diagnostic Code ............... 49
Troubleshooting with an Event Code..................... 81
Troubleshooting without a Diagnostic Code .......... 26