Professional Documents
Culture Documents
Senr6447-01-00 - Manuals-Service-Modules - Troubleshooting (1) - 1-1
Senr6447-01-00 - Manuals-Service-Modules - Troubleshooting (1) - 1-1
Senr6447-01-00 - Manuals-Service-Modules - Troubleshooting (1) - 1-1
A ®
November 1997
Electronic
Troulbleshoofting]
3408 & 3412 High Performance
Marine Engines
8RG116-UP
3JK172-UP
Important Safety Information
Most accidents involving product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“WARNING” as shown below.
WARNING
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operation that may cause product damage are identified by NOTICE labels on the product and in this
publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warning in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting any job. Caterpillar
dealers have the most current information available. For a list of the most current publication form
numbers available, see the Service Manual Contents Microfiche, REG1139F.
How To Use This Manual
GATHER « Talk to the operator directly, if possible.
INFORMATION « What exactly are the symptoms?
» When did the symptoms begin?
« Under what conditions does the problem
occur?
« Check the machines repair history.
« What happened, and in what order (be
specific)?
Tests.
CAUSES « What subsystem could cause the problem?
« What subsystem does the manual suggest?
P-301: Engine Will Not Crank P-331: Engine Coolant Is Too Hot e
P-302: Engine Cranks But Will Not Start . P-332: Exhaust Temperature Is Too High ...........
P-318: Engine Stalls At Low RPM . 3-15 P-375: Engine Speed Switch Overspeed Test ....3-
P-319: Too Much Vibration.. 3-16 P-376: Engine Overspeed Switch Calibration...... -
P-320: Noise Coming From Cyllnder .37 P-377: Engine Speed Switch Crank
Terminate Calibration
P-321: Too Much Valve Lash .3-18
P-378: Rack Position Sensor Calibration
P-322: Valve Rotocoil Or Spring Lock Is Free . 3-18
P-379: Dynamic Rack Controls..............c.cccceueueae
P-323: Mechanical Noise (Knock) In Engine ...... 3-19
P-380: Speed Switch Calibration...............coccc....
P-324: Qil In Cooling System... .3-19
P-325: Fuel In Cooling System .3-20
09 Abnormal Update
The ECM reads the rack movements from the rack Figure 1.4 - PWM Definition
position sensor. The ECM increases or decreases the
voltage to the rack solenoid until the desired position is PWM Input Requirements
reached.
* Open collector sinking Pulse Width Modulated (PWM)
Throttle Position Sensor output with pull up resistor.
The Throttle Position Sensor is used to provide a * Low sensor stop 7.5 + 2.5% and High sensor stop
throttle signal to the ECM. Sensor output is a constant 92.5 + 2.5%.
frequency signal with a pulse width that varies with * Output frequency of 300 Hz minimum, 500 Hz
throttle position. This output signal is referred to as nominal, 700 Hz maximum.
either Duty Cycle or a Pulse Width Modulated (PWM)
* Output voltage high minimum 4.0 VDC, nominal 5.0
signal and is expressed as a percentage between 0
and 100 percent. vDC.
* Ouput voltage LOW nominal 0.23 VDC, maximum
Throttle Position vs. PWM Input 0.25 VDC and 1.0mA sink current and nominal.65
VDC, maximum 0.7 VDC and 10.0 mA sink current.
100%
(Programmed » Output linearity +2.5 % (+ duty vs. throttle lever
High Idie) 7 position.
Throttle
Position %
PWM Generator ECM
0% (Throttle Position Sensor)
(Programmed
Low Idle) é. +VDC Sensor +VDC Control
0 5 10 90 95 100
VERFY SPEED
Minimum Maximum Default
900 rpm 1200 rpm 900 rpm
Crank Termination
This is an adjustable engine speed setting that signals
the starter motor that the engine is firing and cranking
must be terminated. When the speed setting is
reached, a switch will close to start the engine
hourmeter.
Engine Synchronization
The purpose of engine synchronization is to link
multiple engine ECM's to a single throttle. This feature
adds operator convenience and is a standard practice
in marine applications to provide for either throttle to be
used in a backup situation. Engine synchronization can
be transferred to either throttle. The following code
determines throttle synchronization.
Run/Stop Lamp
To -Battery Bus Bar
The Run/Stop Lamp is used to indicate engine status.
Figure 1.7 - Lamps When the Lamp is on the engine is off.
Data Connections
Communication Data Link
The ECM provides output pins that are dedicated to the communication data link. The data link is available to
share data with other electronic display modules which allows a monitoring system display (GPS, EVIM, EMS, etc)
and the ECM to communicate when connected together.
Engine Room
(CAT DatalLik- 00 CAT Deta Link+ 9
Data Bus 7
TemminalStip #1
Tvistd Par
18 AWG
Twisted Pair
BANG
Data Bus
T s 2 0-8
CAT DataLir o o ‘CAT Data Link +
Twisted Pait
18 A\
Service Tool
U
Rack BTM 1
Trolling Mode I
I
Ll Synchronization Switch I
I
il
Rack Position Sensor Engine Shutdown Switch I
|
Primary Throttle and 1
I
090>
Throttle Position Sensor 1
I
— >
cusTouER c c
CORNECTION - =
@31 r 0
RACK_POSITION
SENSOR (P11)
ATA DATA
LiNk” (413):
S
COOLANT LEYEL
SENSOR' (P7,
&
J
PL
€ 5 o
e - — ENGINE_OIL
XUSN_ TEWP. I / F———— 5PRESSURE SENSOR
SENSOR (434)
A= = =
BACKUP SPEED
sensor (P16) |
RSTS)
ENGINE COOLANT
TEMPERATURE
sheon 1o LU ——-—
VIEW €-£ e
RlBK BRTe) e
Beloho i
Bt T \
- /
VIEW D-D
Fol¥iE" as.
ViEW B-8
VIEW A=A
E10859
Figure 1.11 - Sensor and Connector Locations
Receptacle Wedge
ECM Connector (FrontView)
= - -
Mo s 7 e 5 482 1 2
oocooco | ©0000
Deutsch DT Connector Plug lm OO O O Ol o 150 O OO O)n
Plug Wedigo - : %O O O O Ofs :500000??'
Ll O0000O Q0000 |
|p> e 1 _40 39 38 av_és 3836 33 32 31
Deutsch Pin Contact Deutsch Socket Contact Gustomer Connecto (Fron Vew) Customer Connector (Rear View)
12 AWG
Station 1 o Station 2
® -Battery Bus Bar @ @ - Battery Bus Bar
®
12 AWG Port
| P31/J31
-
19| -Battery
13| +Battery
STBD
P31/J31
= 0l |_ 13| +Battery
l_‘ J 19| -Battery
Engine Room | !
- Battery Bus Bar
Common off
— b O+Run
|_| | ,,J Start
Incorrect
Installation
u
P Wire Exiting Straight Out
Of Connector Correctly
The ECAP or ET communicates with the Electronic 7X1180% Internal Expansion Board
Control Module to read diagnostic codes, to read the
SEHS8742 Special Instruction
various sensor output signals such as engine rpm, or
boost pressure, and controls electronic calibration of SEHS9199 Tool Operating Manual
the sensors through the ECM.
The ECAP (requires PWM adapter to measure at the " Refer to Special Instruction SEHS8742, Using the
sensor) can measure Pulse Width Modulated (PWM) 8T8697 Electronic Control Analyzer Programmer
signals, such as the signal produced by the Throttle
(ECAP).
Position Sensor. 2The NEXG4516 Service Program is a subscription
which will be updated regularly to service all 3406E
There are several adapter cables, breakout T cables, Marine engines.
probes, etc, that are used with the Electronic Service
Tools in order to access measurements of signals. 3 Refer to Operating Manual SEHS9199 to use the
NEXG4516 Marine/Industrial Functions Service
The Breakout T harness is inserted in series between a Program.
harness jack and plug to permit voltage measurement
“*The 139-4166 replaces the 7X1412 and the 7X1570.
on an operating system. The Bypass T harness is used
to bypass the harness signal lines for engine sensors 5 Referto Special Instruction SEHS8833 for installing
the 7X1180 Internal Expansion Board in the 8T8697
A heavy duty multimeter is suitable for making the ECAP Service Tool.
necessary measurements. Other Special Tools include
those needed to measure pressure or temperature.
Service Tools
N 7X1701
8T8697 Electronic Control P
Analyzer Program Communication
Adapter
T T
1U5804 8T5318 Pin Removal Tool ~ 1U5718 Extraction Pump
/= —c——
Electronic Technician
Recommendations
Provide a copy of the ‘Customer Questionnaire’ located
on in Section 3: Troubleshooting Without A
Diagnostic Code in this manual. Include comments for
the Customer’s Complaint section of the report
indicating if the Diagnostic/Warning Lamp was on
continuously or intermittently and if symptoms such
as low power are present.
Failure Cause
Comments on Failure cause should include the
number of diagnostic codes that were logged and if
the code was Active. Indicate the source of the
problem and how it was discovered, such as followed
procedure P-514, or a visual inspection revealed
wire abrasion on the engine harness.
Vessel ID
Identification number (or name) of the vessel assigned
by the customer and used only for customer reference.
Not required by the ECM.
Engine Location
Identifies PORT, CENTER and STARBOARD
locations for multiple engine installations. This feature
must be programmed for Engine Vision and the EMS
Display to work properly.
ECM Replacement Procedure (c) Remove the fuel lines, ECM mounting bolts and
disconnect the ECM ground strap.
Replacing The Electronic Control Module
With A New ECM
The Electronic Control Module (ECM) is the heart of
the electronic control system used on the 3408 and Use caution when removing fuel lines. The
3412 High Performance Marine Engine. The ECM fuel may be under pressure and can
contains no moving parts, has a very high reliability penetrate body tissue.
rating and replacement can be time consuming. Most
problems occur in the connectors, wiring, or sensors.
Follow the troubleshooting procedures outlined in this d) DO NOT lose any of the ECM mounting
guide. DO NOT replace an ECM on speculation! hardware (i.e. rubber grommets, spacers and
washers).
To ensure the suspect ECM is the cause of the
problem, temporarily connect a new or test (known e) Ensure the old ECM’s mounting hardware is free
good) ECM, before replacing the old ECM. To of damage and use it to install the new ECM.
temporarily connect a test ECM you must transfer the Reconnect the fuel lines. Ensure the ECM
Personality Model data from the old ECM to the test mounting hardware is installed correctly. Verify
ECM and program any necessary parameters required the fuel lines are not tugging or pulling on the
for testing (the parameters must be programmed ECM. The rubber grommets are used to protect
exactly as they were in the old ECM.) Refer to the the ECM from excessive vibration. When
following test steps for details. If the test ECM resolves installed correctly, the ECM can drift in the
the problem, reconnect the old ECM and verify the rubber grommets. If the ECM cannot be moved
problem returns. If the problem returns, replace the old slightly in the grommets, check that the fuel
ECM. lines are not pulling the ECM against one side
of the grommets.
The parameters stored in the ECM to be replaced,
must be read with an Electronic Service Tool and (f) Reconnect the 40-Pin Deutsch connector and
recorded. The Personality Module from the old ECM the ground strap to the ECM.
must be installed in the new ECM. After the new ECM Step 3: Calibrate the Rack Position Sensor.
is installed on the engine, the parameters recorded Use the Electronic Service Tool to select
from the old ECM must be programmed into the new
Monitor/Calibrate option to calibrate the sensor.
ECM and the Boost Pressure and Rack Position
(Refer To P-378: Rack Position Sensor
Sensor must be recalibrated.
Calibration).
NOTE: If the parameters cannot be read they must be
obtained elsewhere. Some parameters are stamped on Step 4: Calibrate the Boost Pressure Sensor. (Refer to
the Engine Information Plate, but most parameters P-602: Boost Pressure Sensor Calibration.)
must be obtained from the user or dealer that installed
the engine.
The following procedure is a summary of the basic
steps necessary to program a replacement ECM.
Step 1: Use a copy of the Read/Change Parameters
Worksheet in this manual to record the Parameters
from the ECM being replaced.
NOTE: It is recommended to record any Logged
Events also.
(a) Use an Electronic Service Tool to access
Parameters from the ECM being replaced.
(b) Record the Parameters listed on the worksheet.
Step 2: Replace the faulty ECM.
(a) Turn the keyswitch to the OFF position.
(b) Use a 4 mm Allen wrench to disconnect the
40-Pin Deutsch connector.
Personality/
Module
Access Cover
L o)
Personality Module
1. Gather Operator Information. Verify complaint is not + Do they correlate to probable causes?
due to normal engine operation. « Did they occur at the same time as the symptoms?
2. Perform a visual inspection of the engine. Check « Are some codes Logged repeatedly?
fuel and oil level, supply and/or condition. Check for
visible wiring and connector problems or damaged Other Symptoms
components.
* Are they related to this symptom?
. Check and repair all ACTIVE/LOGGED Diagnostic
Codes using the troubleshooting procedures in « Do they have common probable causes?
Section 4: Troubleshooting With A Diagnostic Finally, test each probable cause using the tests
Code. suggested by the procedure. Be sure to check
If ALL three of these inspections reveal no problems, connectors, especially on intermittent problems!
identify probable causes using the procedure or Refer to Section 5: P-501: Inspecting Electrical
procedures in this section that best describes the Connectors for details.
symptoms. Narrow the probable causes given in the
procedure by considering operator information,
operating conditions, and repair history of the vessel.
Operator Questionnaire
Ask the operator to answer the following question before attempting to repair an intermittent problem, or a problem
with symptoms but no diagnostic codes. Use this and the response guidelines to these questions on the next
page.Questionnaire Response
Response
1. If the Diagnostic/Warning Lamp illuminated there will be a logged diagnostic code. If the operators
symptoms do not match the symptoms for the diagnostic code, troubleshooting the diagnostic code will not
correct the problem.
2. If the problem is easily repeatable, take the vessel for a test run with an Electronic Service Tool and not the
conditions when the problem occurs.
3. If the vessel has been to other shops for the same problem, call the other shop and find out what has been
done. Avoid replacing the same components again unless absolutely sure they are the problem. It is unlikely
a component will fail again after a recent replacement.
4. If the engine shuts down completely, check the ECM battery connections, -Battery Bus Bar connections, fuel
system, fuel and engine Speed Sensors. Refer to P-305: Intermittent Engine Shutdowns.
5. If the engine will not restart. Repair as required. If the engine shuts down completely, check the ECM battery
connections, -Battery Bus Bar connections, fuel system, fuel, and engine Speed Sensors. If the engine will
not restart, refer to P-302: Engine Cranks, But Will Not Start.
6. Check for Cold Mode operation. The engine will operate in Cold Mode when the coolant temperature is
below 60 °C. During cold Mode the start rack is limited to 10 mm during engine start-up to 500 rpm. The
engine will remain in Cold Mode for a maximum of 5 minutes or when the engine speed is above 1200 rpm
the Cold Mode will deactivate. If the engine is not operating in Cold Mode, check the ECM battery
connections,
-Battery Bus Bar connections, fuel system, fuel and engine Speed Sensors. Refer to P-303: Engine
Misfires Runs Rough Or Is Unstable.
7. If one set of gages tuned off, after the power up sequence, check the battery connection to the display. If one
set of gauges displayed an ERROR message, check the battery connection to the ECM. If one set of gauges
turned off, after the power up sequence and the engine burped when the display turned off, check the
-Battery Bus Bar connections for that engine. Refer to P-346: Electrical Power Supply To The ECM.
8. If both sets of gauges turned off after the power up sequence, check the battery connection to the display. If
both sets of gauges turned off after the power up sequence, and the engine burped when the display turned
off, check the -Battery Bus Bar connections to the engines. Refer to P-346: Electrical Power Supply To
The ECM. If both sets of gauges displayed and ERROR message, check the -Battery bus Bar connections
to the ECM. Refer to P-346: Electrical Power Supply To The ECM. If the battery connections to the ECM
and displays are OK, then refer to P-344: Cannont Communicate Over The CAT Data Link.
9. If the problem occurs at a specific engine speed, check the Top Engine Limit and set it to the maximum value
and verify the problem is corrected.
10. Operate the engine under similar load conditions. Check the low pressure fuel lines for restriction, fuel/water
separator, and fuel tanks/lines for foreign objects blocking the fuel supply.
Response
11. Check for Cold Mode operation. The engine will operate in Cold Mode when the coolant temperature is
below 60 °C. During cold Mode the start rack is limited to 10 mm during engine start-up to 500 rpm. The
engine will remain in Cold Mode for a maximum of 5 minutes or when the engine speed is above 1200 rpm
the Cold Mode will deactivate.
12. Check for Cold Mode operation. The engine will operate in Cold Mode when the coolant temperature is
below 60 °C. During cold Mode the start rack is limited to 10 mm during engine start-up to 500 rpm. The
engine will remain in Cold Mode for a maximum of 5 minutes or when the engine speed is above 1200 rpm
the Cold Mode will deactivate.
13. If the problem occurs after the vessel has been subject to rain/spray washing, thoroughly inspect the
connector for moisture entry. Refer to P-501: Inspecting Electrical Connectors.
14. If the problem occurs when the engines are synchronized check the -Battery Bus Bar connections to both
ECM's ensure that both ECM's and the Throttle Position Sensors are connected directly to the -Battery Bus
Bar. Refer to P-346: Electrical Power Supply To The ECM.
15. If the engines kick out of a switch feature while the switch is supposed to be engaged, check the -Battery
Circuit to the switches. Refer to P-342: Switch Fault or P-343: Engine Synchronize Switch Not
Functioning Properly.
P-301: Engine Will Not Crank . Verify timing pin was not left in the flywheel housing
after setting valve lash. Visually inspect timing hole
NOTE: This is NOT an electronic system problem. to verify pin is not present. Use the 959082 Engine
Refer to the Systems Operation, Testing & Turning Tool and attempt to manually turn the
Adjusting Manual for additional information on the engine. If unable to turn the engine, remove and
following tests. inspect engine accessories that can lock up the
engine (air compressor, oil pump, seawater pump,
Probable root causes: etc). Repair or replace as necessary. Refer to the
engine System Operation Testing & Adjusting
« Battery Cables/Batteries Manual.
« Starting motor solenoid or circuit problem (in system 6. Check for fluid in the cylinders.
wiring)
. Disassemble engine to inspect for internal
« Starting motor/flywheel ring gear components that may be seized, broken, bent, out
of alignment, etc. Refer to the Disassembly &
« Engine accessory
Assembly Manual.
* Hydraulic cylinder lock
« Internal engine problem
+ OEM Neutral Safety Switch
Perform the following tests in order:
1. Check shutdown switch, battery posts and battery
starter cables for loose connections and corrosion.
Remove and clean cables and connections if
corroded. Load test batteries, Refer to Special
Instruction, SEHS9249 Use Of 4C4911 Battery
Load Tester. If necessary, charge the batteries.
Refer to Special Instruction, SEHS7633 Battery
Test Procedure.
2. Test starting motor solenoid operation. Check
system wiring to starting motor solenoid. Ensure the
Starting Motor Mag Solenoid is receiving the correct
voltage. Turn the keyswitch to the ON position,
Engine OFF. With the Start switch in the start
position measure the voltage between TS1 pin-1
and TS1 pin-5, the voltage should be between 11
VDC and 25 VDC. Measure the voltage at C1 pin-2
(+Battery) to C1 pin-1 (-Battery). If the +Battery
voltage is not present check the wiring. If the
+Battery is present and the engine will not crank,
replace the Starting Motor Mag Solenoid.
3. Test starting motor operation. Refer to Systems
Operation, Testing & Adjusting Manual. Inspect
starting motor pinion and ring gear for damage.
4. Ensure free movement of driveline. If not free,
Refer to the Unit Systems Operation, Testing &
Adjusting Manual. Check transmission neutral
gear indicator for proper operation and adjustment,
repair or replace as required.
P-302: Engine Cranks But Will Not Start 6. Observe the engine rpm on an Electronic Service
Tool Status screen while cranking the engine. If the
Probable root causes: Electronic Service Tool displays 0 rpm while
« Overspeed Switch cranking the engine, there is a problem in the
Speed Sensor circuit. Refer to P-514: Engine
« Starting aids/fuel gel (cold temperature operation) Speed Sensor.
» Engine Shutdown Switch Setting . Check for a fuel supply problem. Refer to P-339:
* Vessel/Engine wiring Engine Has A Fuel Supply Problem.
+ Personality Module or ECM . If an overspeed condition is detected by the
Overspeed switch, the relay in the overspeed switch
« Speed Signal box will open causing the shutoff solenoid to
« Fuel supply release and the engine to shut down. Cycle the
power to the ECM ro reset the overspeed switch
« Combustion problem
and verify the problem is present. If the problem still
« Shutoff Solenoid exsits refer to P-375: Engine Speed Switch
Overspeed Test.
Perform the following tests in order:
1. Reset the Overspeed Switch if applicable. If the
condition is a result of a an engine overspeed and
the resetting the Overspeed Switch does not
eliminate the problem refer to P-375: Engine
Speed Switch Overspeed Test.
. If cold ambient conditions exist, check operation of
starting aids. Check cylinder block jacket water
heater for malfunction and replace if required.
Check for presence of congealed fuel (wax).
. Make sure the Engine Shutdown Switch is in the
RUN position. Connect an Electronic Service Tool
and verify Shutdown Switch position status. If
Electronic Service Tool does not operate, Refer to
P-307: Electronic Service Tool Will Not
Communicate With ECM. If a shutdown occurs,
the keyswitch must be turned to the OFF position,
then to the ON position before the engine will start.
NOTE: Aftermarket engine protection devices
usually interrupt power to the ECM and prevent
communications with the Electronic Service Tool.
Check for correct installation and operation of
Aftermarket engine protection devices. Aftermarket
devices may need to be bypassed to continue.
. Check for correct installation of the ECM connector
J14/P14, Speed Sensor connector J10/P10. Refer
to P-501: Inspecting Electrical Connectors. If the
problem occurs only after the engine is warmed up,
the circuit breakers may be exceeding the trip point
because of overheating. Check the circuit breakers
on the vessel, reset if required.
. Verify there is not an Active 253-02 Diagnostic
Code. If the diagnostic code is present, Refer to
Section 2: Programming Parameters.
P-303: Engine Misfires, Runs Rough Or Is . Inspect ECM connector J14/P14 and the Rack
Unstable Solenoid connector J6/P6 for proper connection.
Repair or replace as required. Refer to P-501:
NOTE: If the problem is intermittent and cannot be Inspecting Electrical Connectors. Check for
re-created, Refer to P-306: Intermittent Low Power active or recently logged Rack Solenoid diagnostic
Or Power Cutouts. If the problem is consistent and codes.Check for a fuel supply problem.
can be re-created, continue with this procedure. Refer to P-339: Engine Has A Fuel Supply
Problem.
Probable root causes:
. Check air inlet and exhaust systems for restrictions
« Engine Overspeed Warning (CID-FMI) 190-00 and leaks. Refer to Systems Operation, Testing
Engine Overspeed Warning. The Electronic control & Adjusting Manual. Look for a Check Engine
Module (ECM) detects engine speed greater than Lamp indication, or tripped restriction indicators (if
2700 rpm for 0.6 seconds. The CID-FMI may be equipped) associated with plugged air filters.
viewed on the display modules or an Electronic Replace plugged air filters, or clean filters as per
Service Tool. It is logged in memory. The ECM will operation and maintenance guidelines, and repair
attempt to limit Top Engine Limit by not allowing the any leaks found. Also, refer to P-521: Analog
vessel BTM to open. The ECM will de energize the Sensor Supply. Refer to Systems Operation,
Shutoff Solenoid to shut off the Fuel Supply. Testing & Adjusting Manual if an internal engine
problem is suspected.
* Cold Mode Operation (Normal Operation, if the
problem occurs only after start-up)
« Throttle Input Signal
« Faulty Rack Solenoid
+ Fuel supply
* Airinlet or exhaust restrictions or air system leaks
< Internal engine problem
NOTE: If the problem only occurs under certain
conditions (high rpm, full load, engine operating
temperature, etc), test the engine under those
conditions. Troubleshooting the symptoms under other
conditions can give misleading results.
Perform the following tests in order:
1. Monitor the Electronic Service Tool Status screen to
verify the engine has exited Cold Mode Operation.
Observe the coolant temperature reading on the
Electronic Service Tool. If incorrect, Refer to P-591:
Engine Sensor Open/Short.
2. Observe the throttle position input reading on the
Electronic Service Tool Status screen. If incorrect or
erratic, refer to P-504: Throttle Position Sensor.
P-304: Low Power/Poor Or No Response 6. Monitor Actual Fuel, Max Fuel, and FRC Limit on
To Throttle the Electronic Service Tool. These parameters
should be as follows while the vessel is operating
Probable root causes: under full load.
+ Cold Mode Operation (Normal operation if the
Actual Fuel = Max Fuel
problem occurs only after start-up in cold weather)
AND
« Engine is in a derated mode Actual Fuel < FRC Limit
« Throttle input signal to the ECM
If the parameters are as indicated above, the
« Faulty electronic unit injector (individual cylinder electronics are operating correctly. If these
malfunction) parameters are not as indicated, verify proper Inlet
« Inlet Air Manifold Pressure Sensor signal Air Manifold Pressure Sensor (boost) operation.
Check inlet air and exhaust systems for restrictions
+ Airinlet or exhaust system restrictions or leaks
and leaks. Refer to Systems Operation, Testing
« Improper adjustment of FRC Offset, Full Load & Adjusting Manual. Look for a Check Engine
Setting, Full Torque Setting Lamp indication, or tripped restriction indicators
+ Fuel supply (if equipped) associated with plugged air filters.
Replace plugged air filters, or clean filters as per
Perform the following tests in order: operation and maintenance guidelines, and repair
1. If ECM has been replaced, check Read/Change any leaks found. Refer to P-591: Engine Sensor
parameters and compare to values on Engine Open/Short.
Information Plate. Make sure the correct personality 7. Check for a fuel supply problem. Refer to P-339:
module is installed. Refer to Section 2: Engine Has A Fuel Supply Problem.
Programming Parameters.
. Monitor the Electronic Service Tool Status screen to
verify the engine has exited Cold Mode. During
Cold Mode, engine power and response may be
limited. Observe the coolant temperature reading
on the Electronic Service Tool. If incorrect, refer to
P-591: Engine Sensor Open/Short.
. Connect an Electronic Service Tool and check for
Active engine derates.
. Monitor the Throttle Status on an Electronic Service
Tool. Observe throttle position and verify it is stable
and can reach 100 percent. Refer to P-504:
Throttle Position Sensor.
. Ensure the engine is not synchronized to another
throttle. If the Desired Engine Speed does not
change when the throttle is adjusted, move the
Secondary throttle and watch the Desired Engine
Speed. If the Desired Engine Speed does not
change refer to Section 5: P-504: Throttle
Position Sensor.
P-307: Electronic Service Tool Will Not 5. Turn keyswitch OFF. Remove pin-D and pin-E from
Communicate With ECM the J13 Service Tool connector. Attempt to
communicate with the ECM. If the Electronic
NOTE: The Remote Optional Electronic Service Tool Is Service Tool communicates with the ECM, replace
Not Recommended For The 3400 High Performance the wires from pin-D and pin-E. If the Electronic
Marine Engine. Service Tool does not communicate with the ECM,
proceed to next step.
Probable root causes:
. Turn keyswitch OFF. Disconnect the J14 ECM
« Electronic Service Tool or Communication Adapter connector and remove the service tool from the J13
Service Tool cable problem Service Tool Connector. Make a jumper and short
« Personality Module or ECM Problem J14 pin-29 to J14 pin-38. Measure the resistance
between J14 pin-29 and J14 pin-38. the resistance
+ DataLink should be less than 10 Ohms. If the resistance is in
* Electrical Power Supply to the ECM Connector or range proceed to next step. If the resistance is out
wiring problem in electronic system wiring harness of range there is a short in the harness. Repair as
required.
Perform the following tests in order:
. Set the Ohmmeter on the 20k ohms scale and
1. Turn keyswitch OFF and check ECM Connector measure the resistance at the J13 service tool
J14/P14, Customer Connector J31/P31, Service connector, between
Tool Connector J13 and associated wiring for pin-J and pin-A
damage, abrasion, corrosion or incorrect pin-J and Pin-B
attachment. Refer to P-501: Inspecting Electrical pin-H and pin-A
Connectors for details. pin-H and Pin-B.
2. Be sure the correct Personality Module is properly The resistance should measure greater than 20k
installed in the ECM. In the event that the ECM on ohms. If the resistance is less than 20k ohms there
the engine is new, the engine will not start or is a short in the wiring harness. Repair as required.
communicate until the Personality Module is If the resistance is in range and the problem is still
installed. Refer to Section 2: Programming present, refer to Section 2: ECM Replacement
Parameters. Procedure.
3. Turn keyswitch ON, engine OFF. Use signal
reading probes to measure the battery voltage at
the J13 Service Tool Connector. Connect the
positive probe to pin-A and the negative probe to
Pin-B. The voltage should be greater than 11 VDC
for a 12 volt system and greater than 22 VDC for a
24 Volt system. If the voltage is in range proceed to
next step. If the voltage is out of range refer to
P-346: Electrical Power Supply To The ECM.
. Turn keyswitch ON, engine OFF. Use signal
reading probes to measure the voltage at the J14
ECM Connector. Connect the positive probe to the
J14 pin-1 and the negative probe to J1 pin-21. The
voltage should be greater than 11 VDC for a 12 volt
system and greater than 22 VDC for a 24 Volt
system. If the voltage is in range proceed to next
step. If the voltage is out of range refer to
P-346: Electrical Power Supply To The ECM.
P-308: ECM Will Not Accept Factory P-310: Excessive Black Smoke
Passwords Probable root causes:
Probable root causes: Air inlet restriction or air system leaks
« Error entering password Speed Signal; injection timing or calibration, Speed
* Incorrect Serial Number (Engine, ECM, or Sensor calibration error after replacement
Electronic Service Tool), Total Tattletale, or Reason Faulty Inlet Air Manifold Pressure Sensor,
Code used to obtain password Atmospheric Pressure Sensor, or sensor calibration
Perform the following tests in order: Personality Module
1. Verify correct passwords were entered. Check each Fuel supply: low supply pressure, air in low
character in passwords for accuracy (for instance pressure fuel system, poor fuel quality
letter | vs. number 1, Z vs. 2, O vs. 0, etc). Turn the
Incorrect valve adjustment
keyswitch to the OFF/RESET position for 30
seconds and then retry. Perform the following tests in order:
2. Verify the Electronic Service Tool is on the Factory 1. Connect an Electronic Service Tool and compare
Passwords screen. Verify Engine serial number atmospheric and inlet pressure readings. Check for
used to calculate password is correct. Verify the filter restriction derates and alarms. Check air inlet
Total Tattletale, Reason Code, Electronic Service and exhaust systems for restrictions and leaks.
Tool Serial Number and ECM Serial Number is Check for a failed turbocharger. Refer to Systems
correct. Refer to Factory Passwords in Section 2: Operation, Testing & Adjusting Manual. Replace
Programming Parameters for more details. plugged air filters, or clean filters as per operation
and maintenance guidelines, and repair any leaks
found. Verify proper operation of the Inlet Air
Manifold Pressure and Atmospheric Pressure
Sensors. Refer to P-521: Analog Sensor Supply.
. Check calibration of the Speed Sensor, recalibrate if
required. Check for proper orientation between
crankshaft and camshaft drive gears, repair as
required. Refer to procedure in Disassembly &
Assembly Manual.
. Monitor Atmospheric Pressure with an Electronic
Service Tool. Observe Inlet Air Manifold Pressure,
Fuel Pos, Rated Fuel Pos and FRC Fuel Pos while
the vessel is operating under full load.
Fuel Pos = Rated Fuel Pos
AND
FRC Fuel Pos > Rated Fuel Pos
NOTE: A problem with the FRC will only create
black smoke problems on acceleration, not steady
state operation. Check for a restriction in the
Atmosphere path, remove dirt and debris, if
required. Atmospheric pressure should range from
50 to 100 kPa (7.5 to 15 psi) depending on your
area of operation. Refer to P-521: Analog Sensor
Supply.
. Check for a fuel supply problem. Refer to P-339:
Engine Has A Fuel Supply Problem.
. Check valve adjustment.
P-312: Can Not Reach Top Engine RPM 4. Check for a fuel supply problem. Refer to P-339:
Engine Has A Fuel Supply Problem.
NOTE: If this problem occurs only under load, Refer to
5. Check air inlet and exhaust systems for restrictions
P-304: Low Power/Poor Or No Response to
and leaks. Refer to Systems Operation, Testing
Throttle.
& Adjusting Manual. Look for a Check Engine
Probable root causes: Lamp indication, or tripped restriction indicators (if
equipped) associated with plugged air filters.
« Engine is in Cold Mode or derated
Replace plugged air filters, or clean filters as per
Personality Module operation and maintenance guidelines, and repair
Throttle Position Sensor signal any leaks found. Also, Refer to P-521: Analog
Sensor Supply.
Faulty Inlet Air Manifold Pressure Sensor or
Atmosphere signal or calibration . Check all accessory equipment. Remove and
inspect engine accessories that may create
Fuel supply excessive load on the engine (air compressor,
Air inlet or exhaust restriction or air system leaks power steering pump, oil pump, etc). Repair or
replace as required. Refer to the Systems
Air supply/low boost Operation, Testing & Adjusting Manual.
Faulty Accessory Equipment
High Engine Load
Perform the following tests:
1. Connect an Electronic Service Tool screen and
verify the engine has exited Cold Mode, check for
Active engine derates. Verify the programming
parameters are correct. Refer to Section 2:
Programming Parameters
NOTE: Engine performance may be reduced due
to, dirty air filters, high exhaust temperatures or
other factors.
. Monitor the Throttle Status on an Electronic Service
Tool. Observe throttle position and verify it can
reach 100 percent. Operate the engine at high idle
with the vessel in neutral. If the engine can not
reach programmed high idle or if the Electronic
Service Tool reading is unstable, Refer to P-504:
Throttle Position Sensor.
. Monitor Actual Fuel, Max Fuel, and FRC Limit on
the Electronic Service Tool. These parameters
should be as follows while the engine is operating
under full load.
Actual Fuel = Max Fuel
AND
Actual Fuel < FRC Limit
If the parameters are as indicated above, the
electronics are operating correctly. If these
parameters are not as indicated check the following.
Monitor boost pressure and atmospheric pressure
on the Electronic Service Tool Status screen for
normal operation. Verify proper Inlet Air Manifold
Pressure Sensor (boost) operation.