P-314: Poor Fuel Consumption P-318: Engine Stalls at Low RPM

Troubleshooting Without A Diagnostic Code
P-314: Poor Fuel Consumption P-318: Engine Stalls At Low RPM

NOTE: This is NOT an electronic system problem. Probable root causes:
Refer to The Systems Operation, Testing &
NOTE: This is NOT an electronic system problem.
Adjusting Manual for additional information on the
Refer to the Systems Operation, Testing &
following tests.
Probable root causes: following tests.
« Improper vessel operation * Faulty Rack Solenoid
« Speed Signal; injection timing or calibration, + Fuel Pressure is low
incorrect Speed wheel orientation, Speed Sensor
+ Faulty Engine Accessories
calibration error after replacement
Perform the following tests in order:
» Faulty Rack Solenoid
1. Check for a fuel supply problem. Refer to P-339:
+ Fuel supply
Engine Has A Fuel Supply Problem.
« Airinlet or exhaust restrictions or air system leaks 2. Check all accessory equipment. Remove and
+ Accessory equipment inspect engine accessories that may create
excessive load on the engine. Repair or replace as
required. If problem is not resolved, Refer to P-303:
1. Use the monitoring system such as VIMS (if Engine Misfires, Runs Rough Or Is Unstable.
equipped) to inspect the Trip or Job Totals for idie
time and the Histograms for excessive idle time,
poor operating habits or high load factor. Consider
environmental conditions such as wind, snow, etc.
2. Check timing calibration of 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.
3. Inspect ECM connector J14/P14 and Unit Rack
connector J6/P6 for proper connection. Check for a
fuel supply problem. Refer to P-339: Engine Has A
Fuel Supply Problem.
4. Check air inlet and exhaust systems for restrictions
and leaks. Refer to Systems Operation, Testing
& Adjusting Manual. Look for a Check Engine
Lamp indication, or tripped restriction indicators (if
equipped) associated with plugged air filters.
Replace plugged air filters, or clean filters as per
operation and maintenance guidelines, and repair
any leaks found.Refer to P-521: Analog Sensor
Supply.
5. Check all accessory equipment. Remove and
inspect engine accessories that may create
excessive load on the engine). Repair or replace as
required. Refer to the Systems Operation,
Testing & Adjusting Manual.
3408 & 3412 High Performance Marine Engines 3-15 Troubleshooting

P-319: Too Much Vibration

Refer to the Systems Operation, Testing &
following tests.
Probable Root Causes:
+ Loose or faulty vibration damper
« Engine supports are loose, wrong or are improperly
torqued
» Equipment may not be in alignment or is out of
balance
+ Engine misfiring or running rough
Perform the following tests in order.
1. Check vibration damper for damage. Tighten bolts.
If vibration damper bolt holes have damage or wear,
replace with new parts. Install a new vibration
damper if necessary.
2. Run engine through speed range while looking for
loose or broken mounts or brackets. Tighten all
mounting bolts. Install new components if
necessary.
3. Check alignment and balance, correct if required.
4. Refer to P-303: Engine Misfires, Runs Rough Or
Is Unstable.

P-320: Noise Coming From Cylinder 3. Install new parts where necessary. Broken locks
. . can cause the valve to fall into the cylinder. This will
NOTE: This is NOT an electronic system problem. cause severe damage.
Refer to the Systems Operation, Testing & o
Adjusting Manual for additional information on the 4. Check lubrication in valve compartment. There
following tests. must be a strong flow of oil at high engine idle rpm,
. but only a small flow of oil at low rpm. Oil passages
Probable Root Causes: must be clean, especially those that send oil to the
* Low quality fuel cylinder head.
+ Incorrect fuel injection timing calibration 5. Refer to P-321: To Much Valve Lash. Adjust
) according to the topic, Valve Lash in the Systems
* Faulty Rack Solenoid Operation, Testing & Adjusting Manual.
* Improper valve train operation or valve train noise 6. Replace the valve(s) and adjust according to the
(clicking) topic, Valve Lash in the Systems Operation, Testing
« Damage to valve spring(s) or locks & Adjusting Manual.
+ Not enough lubrication 7. Plunger may be stuck, repair as required.
T h vale lash Refer to the Systems Operation, Testing &
¢ Toomuchvalve las Adjusting Manual.
+ Damage to valve(s) 8. Reconditioning of cylinder head is required. Adjust
« Damaged camshaft lobe according to the topic, Valve Lash in the Systems
« Little or no valve lash, worn valve seat or face of Operation, Testing & Adjusting Manual.
valve
1. Check for a fuel supply problem. Refer to P-339:
Engine Has A Fuel Supply Problem.
2. Damage to valve spring(s). Replace damaged
parts. Damage to camshaft. Replace damaged
parts. Clean engine valve train thoroughly. Replace
damaged valve lifters. Inspect camshaft lobes for
damage. Look for valves that do not move freely.
Adjust according to the topic, Valve Lash in the
Systems Operation, Testing & Adjusting Manual.
Refer to P-322: Valve Rotocoil Or Spring Lock Is
Free.

P-321: Too Much Valve Lash P-322: Valve Rotocoil Or Spring Lock Is
NOTE: This is NOT an electronic system problem. Free
Refer to the Systems Operation, Testing & NOTE: This is NOT an electronic system problem.
Adjusting Manual for additional information on the Refer to Systems Operation, Testing & Adjusting
following tests.
Manual for additional information on the following tests.
« Not enough lubrication
« Cracked inlet valve Rotocoil
+ Rocker arm worn at face that contacts bridge
+ Broken spring locks
« Bridges for valves worn/incorrect adjustment
+ Broken valve spring(s)
« End of valve stem worn
+ Broken valve
* Worn cams on camshaft
« Loose or broken rocker shaft retaining bolt
1. Determine cause of engine overspeed that would
Perform the following tests in order: crack Rotocoil.
1. Check lubrication in valve compartment. There 2. Install new parts where necessary. Broken locks
must be a strong flow of oil at high engine idle rpm, can cause the valve to fall into the cylinder, and will
but only a small flow at low rpm. Oil passages must cause severe damage.
be clean.
3. Install new valve spring(s).
2. If there is too much wear, install new parts or rocker
4. Replace valve and other damaged parts.
arms. Adjust valve lash according to topic, Valve
Lash in the Systems Operation, Testing & Adjusting
Manual.
3. Adjust or replace bridges as necessary.
4. If there is too much wear, install new parts. Adjust
valve lash according to topic, Valve Lash in the
5. If there is too much wear, adjust valve lash
according to topic, Valve Lash in the Systems
Operation, Testing & Adjusting Manual.
6. Clean engine valve train thoroughly. Check
camshaft for wear. Check for free movement of
valves or bent valve stem. Adjust according to the
topic, Valve Lash in the Systems Operation, Testing
& Adjusting Manual.
7. Check valve lash. Check for free movement of
valves or bent valve stems. Install a new camshaft.
8. Repair or replace rocker shaft retaining bolt as
required.

P-323: Mechanical Noise (Knock) In P-324: Oil In Cooling System

Engine NOTE: This is NOT an electronic system problem.
NOTE: This is NOT an electronic system problem. Refer to Systems Operation, Testing & Adjusting
Refer to Systems Operation, Testing & Adjusting Manual for additional information on the following tests.
Manual for additional information on the following tests. Probable Root Causes:
Probable Root Causes: « Faulty engine oil cooler core or driven equipment oil
« Faulty accessory or driven equipment cooler (if equipped)
« Damaged camshaft lobe « Failure of cylinder head gasket or water seals
+ Damaged gears Perform the following tests in order:
+ Failure of bearing for connecting rod or damaged 1. Inspect each cooler and replace or repair faulty oil
crankshaft cooler.
Perform the following tests in order: 2. Check cylinder liner projection. Install a new
cylinder head gasket and new water seals in the
1. Attempt to isolate the source of the noise. If spacer plate. Tighten the cylinder head bolts
suspected, remove and inspect engine accessories. according to the Specifications Manual.
Repair or replace as necessary. Refer to the
Engine System Operation Testing & Adjusting
Manual.
2. If noise may be coming out of cylinder head, check
for damage to camshaft or valve train components.
Replace damaged parts. Clean engine valve train
thoroughly.Check for valves that do not move freely.
Refer to P-320: Noise Coming From Cylinder.
3. Install new parts where necessary.
4. Inspect the connecting rod bearings and the
bearing surfaces (journals) on the crankshaft. Install
new parts where necessary.

P-325: Fuel In Cooling System P-326: Coolant In Lubrication Oil

NOTE: This is NOT an electronic system problem. NOTE: This is NOT an electronic system problem.
Refer to Systems Operation, Testing & Adjusting Refer to Systems Operation, Testing & Adjusting
Manual for additional information on the following tests. Manual for additional information on the following
Probable Root Causes: tests.
« Internal cylinder head problem
Perform the following tests in order: « Failure of any of the oil cooler cores
« Failure of cylinder head gasket or water seals
1. Remove the valve cover. Remove the fuel supply
and fuel return line from cylinder head. Cap fuel « Crack in cylinder head
return connector and apply 700 kPa (100 psi)
* Cracked or broken cylinder liner
maximum air pressure to fuel supply connector.
Check for fuel leakage. If leakage is present, it will « Crack in cylinder block
be necessary to remove unit Install new O-Ring Perform the following tests in order:
seal.
1. Install a new oil cooler core. Drain crankcase and
refill with clean lubricant. Install new oil filters.
2. Check cylinder liner projection. Install a new
cylinder head gasket and new liner water seals in
the spacer plate. Tighten the bolts that hold the
cylinder head according to the Specifications
Manual.
3. Check for cracks in cylinder head. Repair or replace
as required.
4. Check for cracked liners. Replace cracked cylinder
liners.
5. Repair or replace cylinder block.

P-327: Fuel Dilution Of Lubrication Oil P-328: Engine Has Early Wear
Manual for additional information on the following Manual for additional information on the following
tests. tests.
Probable Root Causes: Probable Root Causes:
+ Leaking fuel seals « Dirt in lubrication oil
« Leaking fuel seals on cylinder head adapters * Airinlet leaks
+ Gross unit nozzle tip leakage or breakage + Fuel leakage into lubrication oil
« Cracked fuel supply manifold * Low Oil Pressure
« Fuel transfer pump seal leaking with plugged weep Perform the following tests in order:
hole
1. Remove dirty lubrication oil. Install new filters. Put
Perform the following tests in order. clean oil in the engine. Check oil filter bypass valve
for a weak or broken spring.
1. Inspect for signs of damage to fuel seals, replace if
required. 2. Inspect all gaskets and connections. Repair if leaks
2. Inspect for signs of damage to cylinder head fuel
are found.
seals, replace if required. 3. This will cause high fuel consumption and low
engine oil pressure. This condition may also
3. Inspect for signs of unit damage, replace as
increase the oil level in the crankcase.
required.
Refer to P-327: Fuel Dilution Of Lubrication Oil.
4. Inspect for signs of fuel supply manifold damage,
4. Refer to P-329: Engine Has Low Oil Pressure.
replace if required.
5. Repair or replace fuel transfer pump.

P-329: Engine Has Low Oil Pressure Perform the following tests in order.
NOTE: This is NOT an electronic system problem. 1. Add oil if required.

Refer to Systems Operation, Testing & Adjusting 2. Check the operation of bypass valve for the filter.
Manual for additional information on the following tests Install new oil filters if required. Clean or install new
NOTICE oil cooler core(s). Remove dirty oil from engine. Put
clean oil in engine.
Do not operate engine with low oil pressure, engine
damage will result. If measured oil pressure is low,
3. Check for presence of fuel in lubricating oil. Refer
to P-327: Fuel Dilution Of Lubrication Oil.
discontinue engine operation until the problem is
corrected. 4. Make sure gauge is accurate. Test on another
engine, if possible.
5. Clean bypass valve and housing. Install new parts
Low Engine Oil Pressure Warning (CID-FMI) as necessary.
100-01 Oil pressure data is below normal operating
range for two seconds. The fault and event will be 6. Check Oil Pump Inlet Screen for obstructions.
active, and logged only if the engine has been Check for air leakage into the supply to the oil
running for at least 15 seconds. The warning lamp pump. Examine oil pump for excessive wear. Repair
is also illuminated. The fault will not appear if or replace as needed.
Caterpillar Engine Monitoring is programmed to the 7. Install new camshaft and camshaft bearings if
OFF mode. necessary.
Very Low Engine Oil Pressure (CID-FMI) 100-10 Oil 8. Inspect the main bearings and replace as
pressure data is below normal operating range for necessary.
two seconds. The fault and event will be logged. If
Derate is selected the warning lamp will begin to
flash, engine power is derated, engine rpm limited
to 1350 rpm. Fault will not appear if Caterpillar
Engine Monitoring is programmed to the OFF
mode.
Oil level may be too low
Dirty oil filters or restriction in oil cooler(s)
Diesel fuel in lubrication oil
Faulty oil pressure gauge
Oil pressure relief valve does not close
Oil pump suction pipe problem, faulty oil pump or
scavenge oil pump
Too much clearance between rocker arm shaft and
rocker arms too much clearance between camshaft
and camshaft bearings
Too much clearance between crankshaft and
crankshaft bearings

P-330: Engine Uses Too Much Lubrication

Qil
Refer to Systems Operation, Testing & Adjusting
Manual for additional information on the following
tests.
QOil leaks
Too much lubrication oil in engine
Oil temperature is too high
Too much oil in the valve compartment
Turbocharger seal ring failure
Worn valve guides
Worn piston rings
1. Find all oil leaks. Repair as required. Check for dirty
crankcase breather(s).
2. Remove extra oil. Find where extra fluid comes
from. Repair as required. Put correct amount of oil
in engine.
. Check for restrictions in the oil cooler or an oil
cooler bypass valve stuck in the open position.
Check for high coolant temperature.
Refer to P-331: Engine Coolant Is Too Hot.
. Verify the dowel is installed in the left bolt hole of
the rocker shaft. This dowel is located between the
rocker shaft and valve cover base. Check shaft and
valve cover base. Check for dirty breather element.
. Check inlet manifold for oil and repair the
turbocharger if necessary.
6. Reconditioning of the cylinder head is required.
7. Inspect and install new parts as required.

P-331: Engine Coolant Is Too Hot P-332: Exhaust Temperature Is Too High
tests. tests.
« High Coolant Temperature Warning (CID-FMI) * Incorrect fuel injection timing calibration
110-00 The engine is running, the Coolant
« Low air inlet system pressure
Temperature Sensor reading is greater than or
equal to 103°C (217°F) for two seconds, the Engine « Exhaust system has a restriction
Monitoring mode is not Off, Code 232-03 (+5V Perform the following tests in order:
Supply Above Normal) or Code 232-04 (+5V Supply
Below Normal) is not active and Codes 110-03 or 1. Connect an Electronic Service Tool and check for
110-04 are not active. If Caterpillar Engine Speed timing error.
Monitoring is programmed to WARNING: Warning 2. Check pressure in the air inlet manifold. Check for
Lamp comes on. airinlet leaks. Look for restrictions at the air cleaner.
* Heat Exchanger Check for leaks between exhaust manifold and
turbocharger. Repair or replace as necessary.
* Low coolant level in system
3. Check for exhaust restrictions. Repair as
« Combustion gases in coolant necessary.
« Incorrect fuel injection timing calibration
« Faulty water temperature regulators (thermostats)
or temperature gauge
« Faulty jacket water coolant pump or seawater pump
+ Too much load on the system
1. Clean obstructions in the heat exchanger plates.
2. Add coolant to cooling system. Check for leaks.
3. Inspect coolant for presence of bubbles. Use an
Electronic Service Tool and check for Speed timing
error.
4. Check water temperature regulators for correct
operation. Check temperature gauge operation.
Inspect jacket water or sea water pump impeller
vanes for damage or erosion. Repair as necessary.
5. Reduce the load.

P-333: Oil At The Exhaust P-339: Engine Has A Fuel Supply Problem
tests. tests.
« Turbocharger seal ring failure Low Fuel Level
« Too much oil in the valve compartment Poor Fuel Quality
* Worn valve guides Unit Priming Problem
+ Worn piston rings Low Supply Pressure
Perform the following tests in order: Fuel Supply Circuit
1. Check inlet manifold for oil and repair the Perform the following tests in order:
turbocharger if necessary.
1. Visually check fuel level (do not rely on fuel gauge
2. Verify the dowel is installed in the left bolt hole of only).
the rocker shaft. 2. In temperatures below 0°C (32°F), check for
3. Reconditioning of the cylinder head is required. congealed fuel (wax). Refer to SEBD0717, Diesel
Fuels And Your Engine. Check fuel tank for
4. Inspect and install new parts as required. foreign objects which may block the fuel supply.
. Check for fuel line restrictions and repair or replace
as required. Refer to the Systems Operation,
Testing & Adjusting Manual.
. Monitor exhaust for smoke while cranking. If smoke
is not present there may be a fuel supply problem.
. Check for air in the low pressure fuel supply system.
Purge air from the low pressure fuel supply circuit
with the hand priming pump and cranking the
engine in 30 second cycles, pausing at least 2
minutes between cranking cycles to allow the
starting motor to cool. Loosen low pressure fuel line
fitting on inlet to pressure regulating valve and hand
prime again if air in fuel continues. Also, use of a
sight glass in the low pressure supply line can be
helpful in diagnosing air in the fuel.
. Check fuel pressure after the filter in the supply
circuit during cranking. Refer to the Specifications
manual for correct pressure values. If pressure is
low, check for plugged fuel filters. If pressure still
low, repair or replace fuel transfer pump, fuel
transfer pump coupling, and fuel pressure
regulating valve as needed.
. Check for air in the low pressure fuel supply system
after replacing filters, working on the low pressure
fuel supply circuit or replacing unit Racks. Check
fuel pressure after the filter in the supply circuit
during cranking. Refer to the Specifications
manual for correct pressure values. If pressure is
low, check for plugged fuel filters. If pressure still
low, repair or replace fuel transfer pump, fuel
transfer pump coupling, and fuel pressure
regulating valve as needed.

P-341: Indicator Lamp Not Functioning

Properly To Switched +Battery
Probable Root Causes: é31 Cu;(omer f
onnector i
NOTE: For details regarding wiring harness Refer to e Low Oil Pressure _j '
Engine Electrical Schematic.
+ Fadly Bu!b. High Coolant Temperature L—j—

« Vessel Wiring 4 4|
'w
« Battery Voltage
Perform the following tests in order: Low Boost '—j—‘
e
1. Turn keyswitch OFF and check ECM Connector 5
J14/P14, and associated wiring for damage,
abrasion, corrosion or incorrect attachment. Refer Transmission Warning
to P-501: Inspecting Electrical Connectors for 5| T _‘_‘j
v
details.
2. Turn keyswitch ON, engine OFF. If the indicator
lamp does not illuminate for five seconds measure Diagnostic Lamp
e
the voltage at the lamp socket when power is first 10 -._j
applied. The voltage should be between 22.0 and
27.0 VDC for a 24 Volt system. If the voltage is in Run Stop Lamp
range replace the bulb.
17|
3. Measure the voltage between pin-1 (+Battery) and
pin-21 (-Battery) at ECM Connector J14/P14. The
voltage should be between 11 and 13 VDC for a 12 Low Coolant Level _j—
Volt system and between 22.0 and 27.0 VDC for a 12| |
24 Valt system. If the voltage is out of range Refer L v
to P-346: Electrical Power Supply to the ECM. To -Battery Bus Bar
4. Connect a jumper wire between the suspect lamp
driver of ECM Connector J14/P14 and -Battery or
+ Battery. If the lamp illuminates the circuit is "
functioning normally but the ECM is not grounding Indicator 3111’ 531’ Jumper
the lamp. Refer to P-346: Electrical Power Supply
to the ECM. Low Oil Pressure Pin-4 Pin-11 -Batt
High Coolant Pin-15 Pin-4 -Batt
Temp
Low Boost Pin-13 | Pin-5 -Batt

Transmission Pin-5 Pin-6 -Batt
Warning
Diagnostic Lamp Pin-4 Pin-10 -Batt
Low Coolant Pin-14 | Pin-12 +Batt

Level

P-342: Switch Fault . Use a Digital Volt Meter and measure the
resistance between the -Battery Connection at the
Probable Root Causes: switch and a known good -Battery Connection in the
NOTE: For details regarding wiring harness Refer to same location (another switch -Battery Connection).
Engine Electrical Schematic. The resistance should be less than 10 Ohms. If the
resistance is greater than 10 Ohms there is an open
Wiring circuit in the -Battery connection to the switch.
Faulty Switch . Make a jumper 4 inches long (100 mm) and short
across the switch contacts so the wire is connected
Electronic Control Module
to he -Battery Bus Bar. Monitor the switch status on
Perform the following tests in order: an electronic Service Tool. If the switch status
changes with the short installed replace the switch.
1. Turn keyswitch OFF and check ECM Connector
If the status does not change measure the voltage
J14/P14, and associated wiring for damage,
at the J31 Customer Connector. Use signal reading
abrasion, corrosion or incorrect attachment. Refer
probes to monitor the voltage. Connect the positive
to P-501: Inspecting Electrical Connectors for
probe to the suspect J31 input and the negative
details.
probe to the -Battery Bus Bar. The voltage should
. Make a jumper long enough to reach from the be less than 0.9 VDC. If the voltage is not less than
-Battery Bus Bar to the J31 Customer Connector. 0.9 VDC ensure the -Battery connection to the
Strip the insulation from both ends and put a switch is a direct connection to the -Battery Bus Bar
Deutsch socket on one end and a terminal that will in the engine room. If the voltage reading is
connect to the -Battery Bus Bar on the other end. fluctuating the wire form the switch to the J31
Connect the wire form the Engine Room -Battery Customer Connector has an open circuit. Replace
Bus Bar to the suspect pin on the J31 connector. the wire.
Connect an Electronic Service Tool to the Service . Use a Digital Volt Meter and measure the
Tool Connector and go to the Display Status
resistance between the suspect J31 input and
Screen. Remove and insert the jumper wire while
-Battery J14 pin-21, the resistance should be
monitoring the Electronic Service Tool. The
greater than 10 Ohms. Wiggle the harness during
Electronic Service Tool should indicate a change in
measurement to reveal an intermittent condition. If
the switch status. the resistance is less than 10 Ohms there is a short
To monitor the Trolling Input:
to -Battery. Repair as required. Measure the
Turn the Keyswitch to the ON position Engine OFF.
resistance between the suspect J31 Customer
Monitor the Desired Engine Speed on the Display Connector and the ECM connector J14. The
Status Screen. Connect the -Battery Bus Bar to the
resistance should be less than 10 Ohms. If the
J31 Customer Connector pin-20, ensure the
throttles are at Low Idle. Move the Throttles, the circuit in the wire. Repair as required.
Desired Engine Speed should change from the
programmed low idle to the maximum trolling . Make a jumper long enough to reach from the
speed. The Desired Engine Speed must be within -Battery Bus Bar to the J14 ECM Connector. Strip
30 rpm of low idle to go in or out of trolling. the insulation from both ends and put a Deutsch
To monitor Slow Vessel Mode: socket on one end and a terminal that will connect
Turn the Keyswitch to the ON position, Engine OFF. the -Battery Bus Bar on the other end. Connect the
Move the throttles to low idle. Connect the -Battery wire from the Engine Room -Battery Bus Bar to the
Bus Bar to the J31 Customer Connector pin-21 and suspect pin on the J14 ECM Connector. Turn the
monitor the Desired Engine Speed. The Desired Keyswitch to the ON position, engine OFF. Use
Engine Speed should change from the programmed signal reading probes to measure the voltage at the
low idle to 550 rpm. J14 ECM Connector. Connect the positive probe to
To monitor Engine Shutdown: the suspect J14 input and the negative probe to J14
Turn the Keyswitch to the ON position, Engine OFF. pin-21. The voltage should be less than 0.9 VDC. If
Observe the Run/Stop parameter on the Electronic the voltage is less than 0.9 VDC the ECM is not
Service Tool. When the J31 pin-14 is connected to reading the switch input. Refer to Section 2: ECM
the -Battery Bus Bar the Run/Stop status should Replacement Procedure.
read STOP.
If the Electronic Service Tool indicates a switch Switch J31 J14
status change there is a problem in the wiring from
Trolling Input Pin-31 Pin-6
the J31 Customer Connector to the switch. Go to
step 3. If the Electronic Service Tool does NOT Slow Vessel Pin-20 Pin-7
indicate a switch status change go to step 5.
Engine Shutdown Pin-14 Pin-21

P-343: Engine Synchronize Switch Not Operate the PORT throttle and observe the Desired
Functioning Properly Engine Speed on Both ECM's. The PORT and
STBD Desired Engine Speed should be equal and
Probable Root Causes: change equally while the PORT throttle is being
moved. If the throttles are not equal, measure the
NOTE: For details regarding wiring harness Refer to
the Engine Electrical Schematic.
Connector and ECM connector J14 pin-17. The
* Vessel Wiring resistance should be less than 10 Ohms, if the
« Faulty Switch
circuit in the wire. Repair the open circuit.
« Electronic Control Module
« Faulty Display Indicator If the throttles are not equal measure the voltage at
the ECM J14 Connector. Connect the positive
Perform the following tests in order: probe to the suspect J14 input and the negative
1. Turn keyswitch OFF and check ECM Connector probe to J14 pin-21. The voltage should be less
J14/P14, Customer Connector J31/P31 and than 0.9 VDC. If the voltage is less than 0.9 VDC
associated wiring for damage, abrasion, corrosion the ECM is not reading the switch input. Replace
or incorrect attachments. Refer to P-501: the ECM. Refer to Section 2: ECM Replacement
Inspecting Electrical Connectors for details. Procedure.
2. Remove the Engine Synchronization Inputs
If the voltage is greater than 0.9 VDC check the -
(431 pin-1and J31 pin-2) from the J31Customer
Battery connection to the -Battery Bus Bar. Refer to
Connector for the PORT and STBD ECM. Section 1: Station Grounding requirements.
3. Connect an Electronic Service Tool to the J13
Service Tool Connector. Turn the keyswitch to the . Connect the jumper wire from the Engine Room
ON position, engine OFF. Move the throttles and -Battery Bus Bar to the J31 Customer Connector
monitor the Desired Engine Speed for both engines. pin-2 on the PORT connector and connect the other
They should change independently of each other. If wire from the Engine Room -Battery Bus Bar to the
they do not change independently refer to P-504: J31 Customer Connector pin-1 on the STBD
Throttle Position Sensor. If the Desired Engine connector.
Speed for both engines changes independently
place both PORT and STBD Desired Engine Turn the keyswitch to the ON position, engine OFF.
Speeds within 50 rpm of each other. Operate the STBD throttle and observe the Desired
Engine Speed on Both ECM’s. The PORT and
4. Make two jumper wires long enough to reach from STBD Desired Engine Speed should be equal and
the -Battery Bus Bar to the J31 Customer change equally while the STBD throttle is being
Connector. moved. If the throttles are not equal, measure the
Strip the insulation from each wire and crimp a Connector and ECM connector J14 pin-36. The
Deutsch socket on one end of the wire and a resistance should be less than 10 Ohms, if the
terminal that will connect to the -Battery Bus Bar on resistance is greater than 10 Ohms there is an open
the other end. circuit in the wire. Repair the open circuit.
Connect the wire from the Engine Room -Battery If the throttles are not equal measure the voltage at
Bus Bar to the J31 Customer Connector pin-1 on the ECM J14 Connector. Connect the positive
the PORT connector and connect the other wire probe to the suspect J14 input and the negative
from the Engine Room -Battery Bus Bar to the J31 probe to J14 pin-21. The voltage should be less
Customer Connector pin-2 on the STBD connector. than 0.9 VDC. If the voltage is less than 0.9 VDC
the ECM is not reading the switch input. Replace
Turn the keyswitch to the ON position, engine OFF. the ECM. Refer to Section 2: ECM Replacement
Procedure.
If the voltage is greater than 0.9 VDC check the -

Battery connection to the
-Battery Bus Bar. Refer to Section 1: Station
Grounding requirements.

6. Use a 9U7330 Digital Multimeter and measure the 11. Make a jumper long enough to reach from the
resistance between the - Battery connection at the -Battery Bus Bar to J14 ECM Connector. Strip the
switch and a known good -Battery Bus Bar insulation from both ends and put a Deutsch socket
connection in the same location (another switch on one end and a terminal that will connect to the
-Battery connection). The resistance should be less -Battery Bus Bar on the other end.
than 10 Ohms. If the resistance is greater than 10
Ohms there is an open circuit to the -Battery Connect the wire fro the Engine Room -Battery Bus
connection to the switch. Bar to the suspect pin on the J14 ECM Connector.
7. Make a jumper 4 in long and short across the switch
contacts so the wire is connected to the -Battery Turn the keyswitch to the ON position, engine OFF.
Bus Bar. Monitor the Desired Engine Speed on an
Electronic Service Tool. If the Desired Engine Use signal reading probe to measure the voltage at
Speeds change with the short installed, replace the the J14 ECM Connector. Connect the positive
switch. If the Desired Engine Speed does not probe to the suspect J14 input and the negative
change, measure the voltage at the J31 Customer probe to J41 pin-21 (-Battery). The voltage should
Connector. be less than 0.9 VDC. If the voltage is less than 0.9
VDC the ECM is not reading the switch input.
Use signal reading probes to monitor the voltage Replace the ECM. Refer to Section 2: ECM
and connect the positive probe to the suspect J31 Replacement Procedure.
input and negative probe to the -Battery Bus Bar. Port
The voltage should be less than 0.9 VDC. If the J31 Customer
Connector
voltage is greater than 0.9 VDC be sure the
- Battery connection to the switch is a direct SynciP 1 t: 1
syneip2 |2 Syne Switch
connection to the -Battery Bus Bar in the engine
room. If the voltage is greater than 0.9 VDC check
the -Battery connection to the -Battery Bus Bar.
Refer to Section 1: Station Grounding
requirements.
Battery Bus Bar
8. If the voltage reading is fluctuating the wire from the SynciP1 > 1
switch to the J31 connector has an open circuit. SynciP2 2
Replace the wire.
9. Use a 9U7330 Digital Multimeter and measure the
resistance between the suspect J31 input and the
ECM Connector J14 pin-21 (-Battery). The
resistance should be greater than 10 Ohms. Wiggle SYNCH 1 SYNC 2 THROTTLE
the harness during measurement to reveal an P14 pin-17 | P14 pin-36
intermittent condition. If the resistance is less than
P31 pin-1 P31 pin-2
10 Ohms there is a short to the -Battery connection.
Repair as required. -Batt Open Primary
10. Measure the resistance between the suspect J31
Open -BATT Secondary
Customer Connector and the ECM Connector J14
connection. The resistance should be less than 10 Open Open Primary
Ohms. If the resistance is greater than 10 Ohms
there is an open circuit in the wire. Repair as
required.
If the voltage is greater than 0.9 VDC check the
-Battery connection to the -Battery Bus Bar. Refer
to Section 1: Station Grounding requirements.
3408 & 3412 High Performance Marine Engines Troubleshooting

P-344: Cannot Communicate Over The 4. Turn the keyswitch to the ON position, engine OFF.
CAT DATA Link Use signal reading probes to verify the display
modules are receiving the correct voltage
EMS |CMS |GPS [EVIM
NOTE: For details regarding wiring harness Refer to
+Battery| Pin 1| Pin1 B+ B+
Engine Electrical Schematic.
« Faulty Electrical Connectors -Battery| Pin2 | Pin2 B- B-
* Incorrect Wiring EMS, CMS, GPSIM, EVIM, and the Engine Vision
« Battery Voltage Display should be receiving 24 VDC (+/-3 VDC). Verify
proper installation of the CAT Data Link wires on
* Open/Short in wiring harness
BOTH ECM's.
Faulty Modules
EMS | CMS |GPS | EVIM
CDL Data+ |Pin5 | Pin23 | D+ D+
J14/P14, Customer Connector J31/P31, Service CDL Data- | Pin 14| Pin24 | D- D-
Tool Connector J13 and associated displays and
The CAT Data Link wires should be installed properly.
wiring for damage, abrasion, corrosion or incorrect
attachment. Ensure the Battery connections at the If the Data Link wires are properly installed proceed to
Battery posts are firmly connected and free of next step. If the Data Link Wires are improperly
corrosion. Refer to P-501: Inspecting Electrical installed repair as required.
Connectors for details. 5. Turn the keyswitch to the OFF position. Disconnect
. Verify that an error message is being displayed. the ECM connector Disconnect the EMS Main
The Main EMS unit or CMS Display displays an Module connector and CMS Connector, if installed.
error message randomly, OR the EMS tachometer Disconnect the EIVM and GPSIM, if installed. Set
displays an EE message randomly (the unit may an ohmmeter on the 20k Ohm scale and measure
operate properly for some period of time), OR the resistance between the CAT Data Link terminals
The Engine Vision Display displays an ERROR at the ECM connector. Wiggle the harness during
message under all gauges (the unit may operate measurements to reveal an intermittent short.
properly for some period of time), or the Engine
Vision Diagnostic and/or maintenance screens are ECM CAT CAT
not functioning properly and WAITING FOR ECM CONNECTORS DATA+ DATA-
RESPONSE is displayed. If any of these symptoms, P31 Pin9 Pin 19
are present the problem is NOT in the ECM or P2 Pin9 Pin 3
display modules. The problem is likely in the vessel P2 Pin9 Pin3
wiring. Proceed to the next step. If any of the
symptoms are not present proceed to step 4. Continue checking the following pin combinations:
. Turn the keyswitch to the OFF position. Install a CAT DATA+ to -Battery
140-2588 Data Booster on each engine ECM if not CAT DATA- to -Battery
already done. CAT DATA+ to +Battery
NOTE: If Engine Vision is installed on the vessel, CAT DATA- to +Battery
the 140-2588 Data Booster may need to be should CAT DATA+ to Analog Ground (Sensor Common)
be installed on both ECM's. CAT DATA- to Analog Ground (Sensor Common)
Check for shorts on both the PORT and STBD
The display modules should be working properly displays. Wiggle the harness during measurements
with the 140-2588 Data Booster installed. If NOT to reveal an intermittent short. The resistance
Verify that there are good connections on the CAT should be more than 20k Ohms for each
Data Link wires. If OK, temporarily install another measurement. If the resistance measures greater
data cable run using 143-5018 cable. The than 20k Ohms proceed to next step. If the
combined length should not exceed 30 m (100 ft) resistance measures less than 20k Ohms there is a
STOP. short in the harness or connectors. Repair as
required.

Bypass Harness Wiring Diagram

Engine Monitoring System Bypass
Parts Required __ Quantity _Description

40-Pin
EMS Socket 9-Pin Socke
8T8730 9 16/18 AWG Socket Plug Plug
878735 1 9-Pin Plug Connector
8T9834 1 40-Pin Plug Connector +Battery| 1 A
-Battery| 2 B
Harness Code 3)—] L C
CDL Data+| § ID <E 3

CDL Data - 14>—J_ F
G
H
J
Computerized Monitoring System Bypass
Parts Required _ Quantity

878730 12 16/18 AWG Socket 40-Pin
878735 1 9-Pin Plug Connector EMS Socket 9-Pin Socke
8T9834 1 40-Pin Plug Connector Plug Plug
+Battery| 1 A
-Battery| 2 I B
b c
CDL Data +| 23 |—-< D
CDL Data - 24>_|—-——< E
Harness Code| 25} F
Harness Code| 26 G
Harness Code| 28 H
Harness Code| 29 J
Engine Vision Bypass
To EVIM
Parts Required Quantity Description 9-Pin Socke
5P2321 4 Spade Terminal Plug
878735 1 9-Pin Plug Connector +Battery }—* A
:-— B
-Battery < c
+Dat 3-—I__< P
-Data L Sm [ F
G
H
J

6. Turn the keyswitch to the OFF position. Disconnect

the ECM connector Disconnect the EMS Main
Module connector and CMS Connector, if installed.
Disconnect the EIVM and GPSIM, if installed. Use a S | cwS | eS| Ewm) v®
jumper wire to short the CAT Data+ and CAT Data- +Batt Pin-1 Pin-1 B+ B+ Pin-A
terminals at the ECM connector. ot 2 2 o o o
-fl):_cfl: +D Pin-5 Pin-23 D+ D+ pin-D

D Pin-6 Pin-24 D- D- pin-e
ECM CAT CAT PORT Pin-31 Pin-29 NA NA NA

CONNECTORS DATA+ DATA-
- . sTBD Pin3 Pin-27 NA NA NA
P14 Pin 9 Pin 19
P14 Pin9 Pin 3 H: Pin26
P14 Pin 9 Pin 3 Cooe. | M| | M| M| m
Set an ohmmeter on the 200 Ohm scale and
measure the resistance between the CAT Data+
and CAT Data- terminals at all display and display
interface module connectors. Wiggle the harness
during measurements to reveal an intermittent open
condition. Check for opens on both the PORT and
STBD displays. The resistance should be less than
10 Ohms for each measurement. If the resistance
measures less than 10 Ohms proceed to next
step. If the resistance is greater than 10 Ohms
there is an open in the harness, repair as required.
7. Turn the keyswitch to the OFF position. Make a
Bypass Harness as indicated in the Bypass Wiring
Harness Diagram. Connect the display system
directly to the Service Tool Connector on the engine
harness using the Bypass Harness. Reconnect all
display connectors.
NOTE: The length of the bypass harness should not
exceed 1m (3 ft). Refer to the Bypass Harness
Wiring Diagram. The display module should work
properly with the bypass harness installed.
If the ECM and display systems are OK. The
problem is due to the wiring. Proceed to step 3.
If the ECM and display systems are NOT OK,
connect the display on another engine. If the
problem returns on the other engine, replace the
display. If the problem does not return, replace the
engine ECM. Refer to Section 2:
ECM Replacement replacement procedure.
STOP.

P-346: Electrical Power Supply to The ECM 2. Use a 9U7330 Digital Multimeter and insert Signal
Reading Probes to measure the voltage between
Probable Root Causes: P14 pin-1 (+Battery) and P14 pin-21 (-Battery).
Crank the engine. The voltage should be between
NOTE: For details regarding wiring harness Refer to 22.0 and 27.0 VDC with the keyswitch ON and
Engine Electrical Schematic. above 6 VDC while cranking. If the voltage is in
range STOP. If the voltage is out of range proceed
« Faulty Electrical Connectors
to next step.
< Incorrect Vessel Wiring . Measure no-load battery voltage at the battery
« Open/Short in wiring harness posts. Load test the batteries using the 4C4911
Battery Load Tester. Refer to the Special
« Battery Voltage Instruction SEHS9249, and Special Instruction
« Battery To ECM Below Normal (CID-FMI) 168-01 SEHS7633 for further assistance. The no-load
The Battery Voltage is below 10 VDC for a 12 VDC voltage at the batteries should be at least 22.0 VDC
system for 60 seconds or below 20 VDC for a 24 and the batteries should pass the load test. If the
VDC system for 60 seconds.|f the voltage voltage is in range the wiring or components
disappears the engine will shut down. between the batteries and the ECM are preventing
voltage from reaching the ECM. Refer to the Vessel
« Intermittent or Low Battery (CID-FMI) 168-02 Service manual for instruction on how to
Indicates the battery circuit to the ECM has either
troubleshoot the vessel wiring harness.If the voltage
an intermittent or low battery condition while the
is out of range replace the batteries STOP.
engine is running. If Battery voltage disappears
without returning, the ECM will not log this . Turn keyswitch OFF. Build a bypass circuit using a
diagnostic code and the engine will shut down.The 14 AWG wire. Connect the battery end of the
engine may experience engine rpm burps, bypass DIRECTLY to the battery post. Remove
intermittent and/or complete shu downs while the pin-1 (+Battery) and pin-21 (-Battery) from P14
conditions causing this diagnostic code are present. (ECM connector). Insert the other end of the bypass
The CID-FMI may be viewed on the display into P14 pin-1 (+Battery) and pin-21 (-Battery).
modules or an Electronic Service Tool. It is logged Install the temporary switch in the operator
only if the engine is running. compartment. It will take place of the normal ignition
switch during testing. After the tests are complete,
Perform the following tests in order: restore all wiring to the original condition. If the
1. Turn keyswitch OFF and check ECM Connector symptoms disappear with the bypass installed, but
J14/P14, Customer Connector J31/P31, Service reappear when it is removed, the problem is in the
Tool Connector J13 and associated wiring for vessel wiring supplying power to the ECM.
damage, abrasion, corrosion or incorrect Unit Wiring Bypass Diagram
attachment. Refer to P-501: Inspecting Electrical
Connectors for details. ONIOFF
(20) Amp Rating
15 AMP FUSE
(+ Battery
To P14 pin-1
By E—
L. L)
Repair as required STOP.
NOTE: This bypass is for TEST PURPOSES ONLY. it

may be left on the vessel temporarily to test whether
intermittent problems are due to interruptions in battery
power to the ECM. Since this will also bypass any
engine protection devices. Obtain approval from the
owner before releasing the vessel with this bypass
installed. The added switch is installed in parallel with
the ignition switch.

P-347: Engine Has A Low Coolant Level . If the complaint is Coolant Level always reads
LOW, disconnect the Coolant Level Sensor from
Probable Root Causes: the harness. Observe the coolant level status on the
* Leak in the cooling system Electronic Service Tool Display Status screen.
Install a jumper from P7 pin-B (Sensor Common) to
« Water pump seals P7 pin-C (Coolant Level). The Coolant Level status
« High engine operating temperature should change from LOW to OK with the jumper
installed and change from OK to LOW with the
« Improper sensor installation jumper removed. If the status changes from LOW to
« Electrical Connectors and Wiring OK, replace the Coolant Level Sensor.
« Wiring Harness OPEN/SHORT . Turn keyswitch OFF. Disconnect the Sensor at
connector P7. Set an ohmmeter on the 200 Ohm
« Electronic Control Module scale and measure the resistance from P14 pin-26
« Low Coolant Level Warning 111-01. The engine has (Coolant Level) to P7 pin-C. Measure the resistance
been running for at least 30 seconds and the from P14 pin-30 (Digital Sensor Return) to P7 pin-B.
Coolant Level Sensor has indicated the absence of Measure the resistance from P14 pin-35 (Digital
fluid for at least ten seconds. The CID-FMI may be Sensor +8 V) to P7 pin-A. Resistance should read
viewed on the display modules or an Electronic less than 2 Ohms through the wires. If the
Service Tool. It is logged in memory except as resistance reads greater than 2 Ohms There is an
noted. The ECM will activate the warning lamp. open circuit in the harness. Repair as required.
Perform the following tests in order: . Turn keyswitch OFF, disconnect J14/P14. Set an
ohmmeter on the 20k Ohm scale and measure the
1. Perform a visual inspection of the cooling system. resistance from P14 pin-35 (+8 V) to P14 pin-26
Refer to System Operation Test and Adjustment (Coolant Level). Measure the resistance from P14
Manual for more details. pin-26 (Coolant Level) to P14 pin-30 (Sensor
2. Inspect water pump seals, a small amount of Common), and P14 pin-26 (Coolant Level) to the
coolant leakage across the surface on the “face -Battery Bus Bar. Resistance should measure more
type” seals is normal, and required to provide than 20k Ohms through the wires. If the resistance
lubrication for this type of seal. A hole is provided in measures less than 20k Ohms there is a short
the water pump housing to allow this coolant/seal circuit in the wiring harness. Repair as required.
lubricant to drain from the pump housing. 9. Turn keyswitch OFF. Turn keyswitch to the ON
Intermittent leakage of small amounts of coolant position, engine OFF. Using Signal Reading Probes
from this hole is not an indication of water pump measure the voltage at P14 pin-35 (+8 V) to P14
seal failure. Replace the water pump seals only if a pin-30 (Sensor Common). The voltage should be
large amount of leakage, or a constant flow of 8.0 £ 0.4 VDC. If the voltage is out of range refer to
coolant is observed draining from the water pump P-346: Electrical Power Supply to the ECM.
housing. Refer to Disassemble and Assemble, for a
10. Remove J14 pin-26 (Coolant Level Signal). Make a
complete description of replacement of the water
jumper wire long enough to reach from J14 pin-35
pump seals.
(Analog Sensor Common) to the J14 pin-26
3. Turn keyswitch OFF. Check ECM Connector (Coolant Level Signal). Strip the insulation from
J14/P14, Coolant Level Sensor Connector P7/J7 both ends of the wire and attach a Deutsch socket
and wiring for damage, abrasion or corrosion. Refer on one end and a terminal that will connect to the
to P-501: Inspecting Electrical Connectors for Analog Sensor Common. NOTE: Do not disconnect
additional information. All connectors, pins, sockets the Analog Sensor Common from the J14
should be completely mated and free of corrosion, Connector. Use a signal reading probe to access
abrasion or pinched points. the Analog Sensor Common. Turn the keyswitch to
4. Turn keyswitch OFF. the ON position, engine OFF. Use signal reading
Connect an Electronic Service Tool to the Service probes to measure the voltage at the J14 ECM
Tool Connector (J13). Turn keyswitch to the ON connector. Connect the positive probe to the
position, engine OFF. Monitor the Coolant Level on suspect J14 pin-26 and the negative probe to J14
the Display Status Screen. pin-21. The voltage should be less than 0.9 VDC. If
5. If the complaint is Coolant Level always read OK, the voltage is less than 0.9 VDC the ECM is not
disconnect the Coolant Level Sensor from the reading the switch input. Replace the ECM. Refer
harness. Observe the coolant level status on the to Section 2: ECM Replacement Procedure. If the
Electronic Service Tool Display Status screen. If the voltage is greater than 0.9 VDC refer to the station
status changes from OK to LOW replace the grounding requirements in Section 1: System
Coolant Level Sensor. Overview.

P-350: Engine Has A High Transmission P-351: Engine Has A High Transmission
Oil Temperature Oil Pressure
tests. tests.
* Transmission Oil Temperature (CID-FMI) 177-00. High Transmission Oil Pressure (CID-FMI) 127-00.
The Transmission Oil Temperature Sensor reading The Transmission Oil Pressure signal voltage is
is greater than or equal to 102°C (216DEG F) for above normal operating range for five seconds and
five seconds and the engine has been running from no transmission oil pressure sensor faults are active
30 seconds and a transmission temperature sensor The fault and event is logged (if the engine has
fault is not ACTIVE.The fault and Event is logged been running for at least 30 seconds).
and the warning lamp is illuminated.
Programmable Parameters
+ Oil leaks Stuck Relief Valve
* Too much oil in the valve compartment
1. Connect an Electronic Service Tool to the Service
1. Find all oil leaks. Repair as required. Tool Connector and view the Customer Specified
2. Remove extra oil. Find where extra fluid comes Parameters screen. Transmission Qil Pressure can
from. Repair as required. be programmed TO ANY VALUE from 700 to 2716
3. Check fi ricti in the relief val kPa (100 to 338 psi). The oil pressure gauge on the
- Check for restrictions in the relief valve. CMS will flash when any of the warning segments
4. Check for high coolant temperature. are ON.
Refer to P-331: Engine Coolant Is Too Hot. 2. Make sure that the pressure level set by the
5. Inspect and install new parts as required.Refer to Electronic Service Tool for the Customer Specified
the OEM for your vessel transmission. Parameters is within a reasonable operating range.
Adjust the range measurement if applicable.
3. The relief valve is stuck open, Refer to the OEM
for your vessel transmission.

P-374: Engine Speed Switch Crank 2. Check the diode connections between terminal 8
Terminate and 10. Replace the diode as necessary. Refer to
the engine wiring schematic. If the diode is OK
NOTE: For detailed wiring information refer to the proceed to next step.
engine wiring schematic. 3. Disconnect all wires from terminal 10 and recheck
the voltage. The voltage should be 0 VDC. If the
voltage is in range (0 VDC) there is a problem with
Tools Needed the unit wiring. Refer to Q'he engine wiring
schematic for your engine. If the voltage is
6V800 Digital Multimeter greater than 0 VDC replace the Engine Speed
or Switch.
4. Slowly increase the input frequency (Adjust the
6V7070 Heavy-Duty Digital Multimeter Crank Terminate Pot slowly counterclockwise) until
- terminal 10 is at + Battery with respect to terminal 5.
875200 | Signal Generator/Counter Group This step will energizer %e hourm?eter after crank
4C6534 Harness terminate speed has been reached. The frequency
should be between 703 and 793 Hz (between 375
N and 425 rpm).If the frequency is in range, proceed
Probable Root Causes: to next step.) If the frequenc)y( is incorrgct i
« Incorrect Voltage recalibrate the ESS. Refer to P-376: Engine
F y Overspeed Switch Calibration.
+ Faulty Diode
5. Check the voltage between the hourmeter
* Hourmeter terminals. The voltage should be between 22.0 and
+ Relay 27.0 VDC. For a 24 VDC system and between 10.5
. . and 13.5 for a 12 VDC system. If the voltage is in
+ Engine Speed Switch range proceed to step 7. If the voltage is out of
range proceed to next step.
5% REWMR@OM CRANK O 6. Chec;k the continuity on the hourmgter between
0 O @ terminal A on the Hourmeter and pin-10 on the
verEY | sPEED ESS. Check the continuity on the Hourmeter
2 between terminal B and -Battery. If the continuity
%; checks OK replace the hourmeter. If the continuity
. does not check OK repair the connection
between the terminals.
7. Slowly reduce the input frequency (adjust the Crank
Terminate Pot slowly clockwise) until terminal 10 is
at 0 VDC with respect to terminal 5. The frequency
should be less than 20 Hz (11 rpm). If the frequency
is in range the crank terminate is OK. If the
frequency is out of range replace the ESS.
1. Ensure the hour meter is connected during the
crank terminate test to provide a load to the ESS.
Adijust the crank terminate pot clockwise several
turns, set the frequency of the 8T5200 Signal
Generator/Counter Group to 0 Hz and use a Digital
Volt Meter to measure the voltage on ESS terminals
10 and terminal 5, measure the voltage at terminal
11 and terminal 5. The voltage should be 0 VDC at
terminal 10 and +Battery at terminal 11. If the
voltage at terminal 11 is less than + Battery there is
a problem with the wiring harness. Repair as
required. If the voltage at terminal 10 is not 0 VDC
proceed to next step. If the voltage is in range
proceed to step 4.

P-375: Engine Speed Switch Overspeed . Slowly increase the input frequency (Adjust the
Test crank terminate pot clockwise) until terminal 7 is at
+Battery with respect to terminal 5 and terminal 8 is
at +Battery with respect to terminal 5.
Tools Needed The overspeed LED should illuminate when the
6V800 Digital Multimeter frequency is increased above the overspeed
setting. The frequency should be 4750 to 4850 Hz
or (2526 to 2574 rpm). If the frequency is incorrect of
the LED did not illuminate Recalibrate the ESS.
6V7070 Heavy-Duty Digital Multimeter
Refer to P-376: Engine Overspeed Switch
875200 Signal Generator/Counter Group Calibration.
. Set the Frequency (Adjust the crank terminate pot
4C6534 Harness
counterclockwise) to 0 Hz. The overspeed LED
should remain illuminated and terminal 7 should be
Probable Root Causes: at +Battery with respect to terminal 5 and terminal 8
should be at +Battery with respect to terminal 5. If
* Incorrect Voltage
the frequency is out of range replace the ESS. If the
* Wiring voltages check OK proceed to next step.
* Relay . Depress the reset button on the ESS.The
overspeed LED should be OFF and terminal 7
« Engine Speed Switch
should be 0 VDC with respect to terminal 5, and
Perform the following tests in order: tumoral 8 should be at +Battery with respect to
terminal 5. If the voltages are in range proceed to
1. Set the frequency of the 875200 Signal Generator/
next step. If the voltages are NOT in range replace
Counter Group to 3800 plus or minus 50 Hz.
the engine speed switch.
NOTE: The frequency may be set anywhere above
Crank Terminate (between 706 and 800 Hz) and 6. Increase the frequency (Adjust the crank terminate
below the overspeed setting (between 4850 and pot clockwise) above 4800 Hz (2548 rpm) until the
4750 Hz). Measure the voltage on terminal 7 and LED illuminates.
terminal 5. Measure the voltage on terminal 8 and NOTE: During normal operation (less than 4800 Hz)
terminal 5. The voltage at terminal 7 should be the relay should be normally closed and the LED
0VDC. The voltage at terminal 8 should be must be OFF. When an overspeed is detected
+Battery. If terminal 8 is out of range there is a (greater than 4800 Hz) and the LED illuminates, the
problem with the unit wiring. If terminal 7 is in range relay must open terminals 87A and 30.
proceed to step 3. If terminal 7 is out of range The relay should open when the overspeed LED on
proceed to next step. the front face of the ESS illuminates. If the relay
functions properly proceed to step 8. If the relay
does not function properly proceed to next step.
@ 75% RESETOVER\@/OVER
CRANK OIL
@ . Check the continuity between terminal 7 of the ESS
and terminal 85 of the relay (SR1). Check continuity
vswv sFEED
between terminal 5 of the ESS and terminal 86 of
the relay (SR1). If the continuities check OK
replace the relay. If the continuity does not check
OK inspect the relay connections and repair as
required.
”?nj]fifljnuj]wfl
7
. Check the connection to the Speed Sensor
Magnetic Pick UP. Check terminal 2, 3, and 4 of the
ESS for proper connections. If the connections are
OK, refer to Section 5:P-514 Engine Speed
2. Disconnect all wires from terminal 10 and recheck Sensor. If the connections are NOT OK repair as
the voltage. The voltage at terminal 7 should be required.
0 VDC. If the voltage at terminal 7 is 0 VDC there is
a problem with the wiring. If the voltage is out of
range, refer to P-376: Engine Overspeed Switch
Calibration.

P-376: Engine Overspeed Switch 3. Run engine at 75% of overspeed setting rom. Make
Calibration reference to the Speed Specification Chart.
. With the engine at 75% of overspeed setting rpm,
Probable Root Causes: push the VERIFY button and hold in. Turn O.S
« Incorrect Voltage adjustment potentiometer in the direction of MAX
ARROW (clockwise) slowly until the LED overspeed
* Wiring light illuminates. The Engine will shut down since
* Relay the speed switch is connected to the fuel shutoff
solenoid.
« Engine Speed Switch
. To reset speed switch, push in reset button.
Perform the following tests in order: 6.
. Slowly turn O.S. Adjustment potentiometer
1. Remove lockwire and seal from seal screws. approximately one turn clockwise and repeat Steps
Remove seal screw from access hole for overspeed 3,4, and 5.
adjustment screw. NOTE: More adjustment may be needed to get the
2. Use a small screwdriver and lightly turn O.S correct setting. Turn adjustment potentiometer
adjustment potentiometer twenty turns in the clockwise to increase speed setting and
direction of the MAX ARROW (clock wise). counterclockwise to decrease speed setting. Turn
NOTE: The overspeed adjustment screw is made adjustment potentiometer very slowly only a small
so that it can not cause damage to the amount at a time until adjustment is correct.
potentiometer or be removed if the adjustment 7. When the speed setting is correct install seal screw
screw is turned too much. for overspeed adjustment hole and install lockwire
and seal.
SPEED SPECIFICATION CHART

o Cranking
Overspeed Setting (7\7 e/:lfo ;lerspeed Termination
Y Setting
Typical Mag . Mag Pickup Mag

l're|eth Rated Engine Pickup SEHS;T Frequency Engine Pickup
Model Rin Engine Speed Frequency (pm) (Hz) Speed Frequen
Geagr Speed (rpm) (Hz) ,?(’,TE a | NOTEB: (rpm) oy (Hz)
(rpm) NOTE C: } and C: NOTE C:
3408/ 2550+ 400

3412 113 2300 2% 480050 1910 3600 495 753+47
NOTE A: To verify overspeed shutdown system

operation depress the verify button on the ESS. The
engine must shut down at 75% or more of overspeed
setting.
NOTE B: Input Voltage: maximum 37 VDC Minimum 8
VDC.
NOTE C: The Magnetic Pickup Frequency (Hz) at the
overspeed or cranking termination setting is calculated
with the following formula.
MAGNETIC PICKUP FREQUENCY=
NO OF TEETH ON RING GEAR X
OVERSPEED OR CRANKING TERMINATION RPM
SETTING DIVIDED BY 60.

P-377: Engine Speed Switch Crank NOTE: The crank terminate adjustment screw is
Terminate Calibration made so that it can not cause damage to he
potentiometer or may be removed if the adjustment
Probable Root Causes: screw is turned too much.
« Incorrect Voltage 3. Turn C.T adjustment potentiometer twelve turns in
the direction of MAX ARROW (clockwise) for an
« Wiring
approximate crank terminate setting;.
* Relay 4. . Start engine and make a note of the speed at which
« Engine Speed Switch the hourmeter energizes. See the chart for the
correct crank terminate speed.
Perform the following tests in order: NOTE: If setting is not correct repeat steps 5 and 6.
1. Remove lockwire and seal from seal screws. If setting was correct go to step 7.
Remove seal screw from access hole for overspeed 5. Stop engine and turn adjustment potentiometer
adjustment screw. (clockwise to increase and counterclockwise to
2. Use a small screwdriver and lightly turn C.T decrease) crank terminate speed.
adjustment potentiometer twenty turns in the 6. Start and make a note of the speed at which the
direction of the MAX ARROW (clock wise). hourmeter energizes. If needed, make small
adjustments until the crank terminate speed is
correct.
7. Install seal screw for crank terminate adjustment
hole and install lockwire and seal.
SPEED SPECIFICATION CHART
o Cranking
Overspeed Setting (7\7 e/‘r,ifo \)lerspeed Termination
Y Setting
Typical Mag " Mag Pickup Mag
Ifieth Rated Engine Pickup SEneg;rée Frequency Engine Pickup
Model Ring Engine Speed Frequency (r‘;’)m) (Hz) Speed Frequen
Speed (rpm) (Hz) . NOTE B: (rpm) cy (Hz)
Gear (rpm) NOTE C: NOTEA: | anac: NOTE C:
3408/ 2550+ 400
3412 113 2300 2% 480050 1910 3600 +25 753+47
NOTE A: To verify overspeed shutdown system

operation depress the verify button on the ESS. The
engine must shut down at 75% or more of overspeed
setting.
NOTE B: Input Voltage: Maximum 37 VDC Minimum 8
VDC.
NOTE C: The Magnetic Pickup Frequency (Hz) at the
overspeed or cranking termination setting is calculated
with the following formula.
MAGNETIC PICKUP FREQUENCY=
NO OF TEETH ON RING GEAR X
OVERSPEED OR CRANKING TERMINATION RPM
SETTING DIVIDED BY 60.

P-378: Rack Position Sensor Calibration 4. Remove the rack solenoid (BTM) and cover.
Tools Needed 2 il \ #‘ g
9U5127 Engine Tool Group e 9 7 ‘?‘4 L8 e
Consisting of:
1 - 4C9580 Slotted Socket

2-4C9581 Rack Zero Pin
1 - 4C9582 Crowfoot Wrench
1 - 4C9583 Fuel Pump Gage
€53869P1 : ol w4
1 - 6V2112 Fuel Pump Timing Pin
1-6V3073 Plastic C Shutoff Lever (3)

Plastic Case 5. Remove the shutoff lever.
’ 3
1 - 9U5120 Spanner Wrench 8. Remove the plugs from the pump housing.
1-9U5128 Foam Insert
Perform the following procedure in order:

1. Turn keyswitch OFF.
2. Connect an Electronic Service Tool to the Service
Tool Connector J13.
3. Turn keyswitch to the ON position, engine OFF.
Select “Calibrate/Monitor” from the main menu and
then select “Rack Position Sensor Calibration” to
monitor “Rack Position”.
- . i
4C9581 Rack Zero Pins (4)
7. Install the 4C9581 Rack zero pins in the top of the
fuel injection pump housing. Move rack control bar
approximately 25 mm toward the front of the engine
and block in this position.
Rack Solenoid (BTM) (1) Cover (2)

. With the rack held back against the zero pins, read P-379: Dynamic Rack Controls
the rack position status on the Electronic Service
Tool. Probable Root Causes:
If the Rack position reading is 9.50 + 0.05 mm + Wiring
(0.37+ 0.002 in) the rack position sensor is
calibrated correctly, STOP. Rack Solenoid
If the Rack position reading is NOT 9.50 + 0.05 mm Rack Position Sensor
(0.37+ 0.002 in) the rack position sensor is NOT
calibrated correctly. Perform the following tests in order:
J14/P14, Customer Connector J31/P31, Service
Tool Connector J13 and associated wiring for
damage, abrasion, corrosion or incorrect
attachment. Refer to P-501: Inspecting Electrical
Connectors for details.
2. Start the engine and monitor the “Desired Rack”
and “Actual Rack” on the Electronic Service Tool.
The Desired engine speed should be equal to the
programmed Low Idle rpm and steady. The Actual
sl ga;g Ish)ould follow Desired Rack within + 0.5mm
poa . i A .. n).
e NOTE: The lag in the “Status Display” Screen
Rack Position Sensor Locknut (6) causes some normal differences between the two
. readings.
9 dln"'if/z t:;?;g?:f% ggflzg‘lxfimrxqfi:;fi('nCh For a typical engine idling with normal accessory,
M both readings should be between 4.50mm (0.18 In)
position sensor. to 5.25mm (0.21 In).
10. Ensure the rack position sensor wiring is connected If the Desired Engine Speed is unstable, refer to
to the engine harness connector wiring. Section 5, P-504: Throttle Position Sensor. If the
11. Ensure keyswitch is in the ON position, engine readings are not as specified refer to Section 5,
OFF. Select the Calibrate/Monitor display that has P-542: Rack Solenoid. If the ECM is able to control
Rack Position Sensor Calibration from the main the rack properly at idle proceed to the next step.
menu on the Electronic Service Tool. 3. Operate the engine under load and monitor the
12. Turn the collar on the rack position sensor in or out “Desired Rack, Rated Rack and FRC Rack” on the
as indicated by the Electronic Service Tool, until the Electronic Service Tool. The Desired Rack should
“Calibrated” is displayed. If the rack position sensor reach Rated Rack with the engine fully loaded. If
is unable to calibrate refer to Section 5: P-515 the rack is performing correctly there is not a
Rack Position Sensor. problem with the rack at this time. If the Desired
" . Rack is limited to FRC Rack, the ECM is sensin:
1. Tlgh!en the locknut to 55 7'M (411.5 b ,fl)' Low Boost Pressure. Refer to section 5, P591?
14. Verify the Rack Position Sensor Calibration. Engine Sensor Open/Short. If the Desired Rack is
15. Turn keyswitch OFF. limited to some other value below Rated Rack the
16. Install the rack solenoid. ECM is intentionally limiting power or engine speed,
17. Install the shutoff lever and cover on the governor Ireler to P-303: Engine Misfires Runs Rough Or
housing. s Unstable.
18. Remove the 4C9581 rack zero pins and install the
plugs in the top of the fuel injection pump housing.

P-380: Speed Switch Calibration . Set the frequency to the oil step set point. The LED
indicator inside the oil step adjust pot hole will be
Tools Needed ON when the oil step is energized.
NOTE: The oil step takes two seconds to energize
6V800 Digital Multimeter once the frequency is reached. The oil step LED
indicator should illuminate. Proceed to next
or step.
6V7070 Heavy-Duty Digital Multimeter . Connect 24 VDC power lead to terminal 6 and
ground lead to terminal 5. Connect the frequency
8T5200 Signal Generator/Counter Group generator's signal lead to terminal 4 and minus lead
4C6534 Harness to terminal 3. Apply power to the speed switch. Set
the frequency to the oil step set point. Measure
resistance across the oil step relay normally closed
Perform the following tests in order: contacts terminal 11 and 12. The resistance
should be 0. Adjust the oil step pot clockwise
several turns, zero the frequency and set the
frequency to the oil step set point until the relay
resistance is zero. Proceed to next step.
Ensure the Main Power Supply has been
. Set the frequency to the overspeed set point.
disconnected. Possible strong electrical shock
NOTE: The overspeed LED Indicator will illuminate
hazard if the Main Power Supply is not
when the overspeed relay is energized.Apply power
disconnected. to the speed switch. Set the frequency to the
1. Disconnect Main Power. overspeed set point. Measure resistance across the
2. Check electrical connectors and wiring for damage overspeed step relay normally closed contacts
or incorrect attachment. All connectors, pins, terminal 11 and 12.
sockets should be completely mated and should be NOTE: The overspeed reset button next to the
free of corrosion, abrasion or pinched points. overspeed indicator LED MUST be pressed to
release the overspeed relay.
3. Remove the three cover screw from the top of the
Replace the three cover screws once all the
speed switch. Connect 24 VDC power lead to
frequencies are set.
terminal 6 and ground lead to terminal 5. Connect
Write down the engine speed and three frequency
the frequency generator's signal lead to terminal 4
set points and the actual frequencies on a tag.
and minus lead to terminal 3. Apply power to the
Install a security wire through each of the three
speed switch. Set the frequency to the crank
cover screws and retainer clip on the upper right
terminate set point. Measure resistance across the
comer bolt. Place the wire through the tag and pull
crank terminate relay normally closed contacts
both tight. The resistance should be 0.
terminal 11 and 12. The resistance should be 0.
If the resistance is greater than 0. Adjust the crank
terminate pot clockwise several turns, zero the
frequency and set the frequency to the crank
terminate set point until the relay resistance is zero.
Proceed to next step.
4. Adjust the Crank Terminate Pot slowly
counterclockwise until the relay energizes.
A click will be heard when the relay energizes.
5. Zero the frequency. Set the frequency to 10 Hz
below the set point. Increment the frequency in 1 Hz
steps until the relay energizes. The relay should
energize close to the set point. The relay
energizes close to the set point. If not, adjust the pot
slightly in the direction that the frequency is off
(clockwise if too low counterclockwise if too high).
Set the frequency to zero then 10 Hz below the set
point and increase the increments in 1 Hz steps
until the relay energizes. Proceed to next step.
3408 & 3412 High Performance Marine Engines 342 Troubleshooting

SECTION 4: Troubleshooting With A Diagnostic Code
Diagnostic Codes LOGGED Diagnostic Codes

Diagnostic codes are used by the electronic system to When the ECM generates a diagnostic code, it will log
alert the operator that a problem exists and indicates to the code in permanent memory within the ECM. The
the service technician the nature of the problem. ECM has an internal diagnostic clock and will record
the hour of the first occurrence, the hour of the last
Diagnostic Codes may be viewed using Electronic
occurrence and the number of occurrences of the
Service Tools (ET or ECAP) or the various electronic
code. Knowing when and how often the code was
display modules. The CID, or Component |Dentifier,
generated can be a valuable indicator when
tells which component in the system the diagnostic
troubleshooting intermittent problems.
code is for. The FMI, or Failure Mode Identifier
indicates what the failure mode is. Logged codes can be retrieved or erased using an
Electronic Service Tool. Logged diagnostic codes will
The code number will direct you to a procedure in
automatically be deleted if no additional occurrences
Functional Test Procedures. Do not confuse diagnostic
are recorded in 100 hours. When investigating logged
codes with diagnostic events. Events can be logged in
diagnostic codes, keep in mind the following
the ECM to track information about the engine. An
information
example would be a low oil pressure event. An event is
generated when the engine oil pressure is low but not Some diagnostic codes may be sensitive, and may log
out of range for the sensor. This does not indicate a occurrences that did not result in operator or pilot
problem with the sensor, rather it indicates a problem complaints. If the time the code was logged does not
with the engine oil pressure. Refer to Logged Events correlate to a complaint, there may be nothing to fix.
later in this section for more information. The most likely cause of an intermittent problem is a
faulty connection or damaged wiring. Next likely is a
ACTIVE Diagnostic Codes component failure (sensor or switch). Least likely is
failure of the ECM itself.
An ACTIVE diagnostic code represents a problem with
the electronic control system that should be Diagnostic codes that are logged repeatedly may
investigated and corrected as soon as is practical. indicate a problem that needs special investigation.
If the condition generating the diagnostic occurs only To troubleshoot a logged diagnostic code, refer to the
for a brief moment, the message will disappear and the Diagnostic Code Cross Reference to Functional Test
diagnostic code will be LOGGED in the ECM memory. Procedures in this section under the specific code
To troubleshoot an active diagnostic code, refer to the number.
Diagnostic Code Cross Reference to Functional Test The code number will direct you to a procedure in
Procedures in this section under the specific code Functional Test Procedures. If the symptoms continue,
number. use the proper procedure for troubleshooting the
symptoms that have been experienced by the operator.
Refer to Troubleshooting Without A Diagnostic Code.
NOTE: Always clear logged diagnostic codes after
investigating and correcting the problem which
generated the code.

Troubleshooting With A Diagnostic Code
Events Event Codes

The ECM can log engine events. Events refer to Event Codes are issued by the ECM for each engine
engine operating conditions such as low fuel pressure event. They are not necessarily an indication of
or an Engine Overspeed Warning. Logged events do problems within the Electronic system. These event
not indicate an electronic system problem, but may codes are read and interpreted by the Electronic
indicate an engine system problem. Service Tool, which displays a numeric code and a
description of the LOGGED EVENT. The LOGGED
Diagnostic Codes Effect on Engine ID’s can be found under the DIAGNOSTIC window on
Performance the electronic service tool. The code is logged and
some can only be cleared by factory passwords.
When the ECM detects an engine problem, it NOTE: Events can only be viewed with a Caterpillar
generates an Active diagnostic code, and logs the code Electronic Technician service tool.
to indicate when and how many times the problem has The information displayed for a LOGGED Event is as
occurred. There are two types of diagnostic codes: follows:
Fault (or problem) Codes and Event Codes.
«+ CID- Event Identifier. The CID is a three digit number
Diagnostic Codes are provided to indicate an that corresponds to an ACTIVE or LOGGED engine
electrical or electronic problem has been detected by event.
the ECM. In some cases the engine performance can
be affected when the condition causing the code exists. + Test Description- The text which describes the
More frequently, however, the operator cannot detect event.
any difference in the engine performance. * Number Of Occurrences- The number of “good to
If the operator indicates a performance problem occurs bad” transitions that have occurred.
whenever the Diagnostic Lamp is flashing, the « Time Of First Occurrence- The time that the first
diagnostic code may indicate the cause of the problem, logged event occurred, measured in the ECM hours, by
and should be corrected. the diagnostic clock is shown on the Logged Events
If the operator does not indicate a problem with the service tool screen.
engine performance and a diagnostic code is logged by » Time Of Last Occurrence- The time that the last
the ECM, it indicates the ECM detected an abnormal logged diagnostic occurred, measured in ECM hours
condition, but it did not affect performance. by the diagnostic clock.
If this is the case, unless there are several occurrences This manual contains a table listing all of the CID-FMI
of the code in a very short period of time, or, the ECM diagnostic codes, along with the page number where
is indicating an Active Code at the present time, there details regarding the cause, performance affect, and
is most likely nothing wrong with the system. troubleshooting of the code can be located.

Using ET and ECAP to Display ACTIVE Diagnostic Codes

Connect ET or ECAP to the Communication Adapter Tool to the Service Tool Connector.
Turn the keyswitch to the ON position, engine OFF.
For ET select the Display Active Diagnostics option.
L
For ECAP select the Marine Functions and select the Diagnostic Function.
For ECAP select the Active Diagnostic Code Function.
Each Diagnostic Code CID and FMI are listed and followed by a text description.
[~=[Cat Electronic Technician - Active Diagnos

Fle Dagosics
[— 3400 MAR (0XX00000)

—J Low Oil Pressure
Code | Description
Ry \
N \
=
3400 MAR (0XX00000)
|
CID-FMI \ DIAGNOSTIC DESCRIPTION
Example ECAP Screen: Display /
ACTIVE Diagnostic Messges
ACTIVE Diagnostic Codes /

100-1 Low Oil Pressure Warning (46)
102413 Boost Pressure Sensor Calibrtion (42)
more...PressAoryto move through the list of messages.

Using ET and ECAP to Display LOGGED Diagnostic Codes

1. Connect ET or ECAP to the Communication Adapter Tool to the Service Tool Connector.
2. Turn the keyswitch to the ON position, engine OFF.
3. For ET select the Display Logged Diagnostics option.
4. For ECAP select the Marine Functions and select the Diagnostic Function.
5. For ECAP select the Logged Diagnostic Code Function.
6. Each Diagnostic Code CID and FMI are listed and followed by a text descnp(lon
%‘CatElectronic Techn an - Active Diagnostic Codes
Diagnostic
—CowolPressue Warning (48)
Oil Pressure Sensor Short Circuit (24)
Loss of Engine RPM signal #2 (34)
Atmospheric Sensor Short Circuit (26)
Engine Overspeed Warning (35)
Loss of Engino RPM Signal (34)
_clear ] ot |
— - i
Number Of Times First Time The
CID-FMI piagnostic Description The Diagnostic Diagnostic Was LaSt Time The
/ Was Logged Logged E;%“e?f‘“: Was
o Prows g/or e move throuan ine et of gasages. Return|is siear tnis megdass
/ / Looged Fauite (Glock: 1317 hours) \{i (L -~
Low Oil Pressure Warning (46) 4 9% 96
Oil Pressure Sensor Short Circuit (24) 1 9% 96
more...Press 4 or |, to move through the list of messages. Return to clear this message.

Using ET and ECAP to Display Status

Connect ET or ECAP to the Communication Adapter Tool to the Service Tool Connector.
Turn the keyswitch to the ON position, engine OFF.
N
For ET select the Display Status option.

For ECAP select the Marine Functions and select the Display Status Function.
op
Each Display Option is listed and followed by a text description.

Cat Electronic Technician -Status =
File Diagnotics _information Service Utites Uk Settings _Help.
Mkl
3400 MAR
= [ow] &l
(OXX0000)
o)==kl
[ No Engine Speed |[ Cold Mode ][ ] [
— 3400 MAR Group 1

3400 MAR (0XX0000,
¢ » Unidentified Failure PSI Engine Speed
1000 rpm Desired Engine Speed
Rack Position
0 rpm Desired Rack Position
100 Throttle Position
o Estimated Fuel Rate
187 Engine Oil Pressure
Engine Coolant Temperature
16% Boost Pressure
Atmospheric Pressure
[Groups || Zoomin || More || [ Hewa | [ |
ECAP Display Status

more...Press 4 or to move through the list of measages. Return to clear this message
Engine RPM Rack Position Throttle Position Oil Pressure Boost Pressu:
Des Engine RPM Des Rack Pos. EST Fuel Rate Coolant Temp Inlet Air Press.
more...Press 4 or | to move through the list of messages. Return to clear this message.

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

00 Data Valid, but above normal operational range
01 Data Valid, but below normal operational range
02 Data Erratic, Intermittent, or Incorrect
03 Voltage above normal or shorted high
04 Voltage below normal or shorted low
05 Current below normal or open circuit
06 Current above normal or grounded circuit
07 Mechanical System not responding properly
08 Abnormal Frequency, Pulse Width, or Period

09 Abnormal Update
10 Abnormal Rate of Change
11 Failure Mode not identifiable

12 Faulty Device or Component
13 Uncalibrated device or component
14-31 Reserved for future assignment
Active Code - The CID and FMI can be sent through the data link through the display module or through the
Communication Adapter Tool, then to the Electronic Service Tool or various electronic display modules.
Logged Code - The diagnostic will be entered into the permanent memory (Diagnostic Log) when it becomes
active. The number of occurrences will be saved in the “good to faulty counter” in the permanent memory
(Diagnostic Log). First and last occurrence time (engine hours) will also be saved in the permanent memory
(Diagnostic Log). This information is then available for display on the Electronic Service Tool.

Reference Sheet For Diagnostic Codes

CID-FMI FLASH CODES DESCRIPTION PROCEDURE NO
Shutoff Solenoid Open Circuit.............cccceevvreerirceriirinen. P-552
-Shutoff Solenoid Short Circuit. P-552
.Excessive Engine Power.
Rack BTM Open CirCUit ............cc.ruieereieeiermeneieeneeeneans
.Rack BTM Short Circuit
.Rack Sensor Open Circui
Rack Sensor Short Circuit............ccoo.cuerericiieieceeeeeeae
.Rack System Fault
.Rack Sensor Rate of Change
Secondary Speed Signal Rate of Change ...............ccc.c.... P-514
.Loss of Secondary Speed Signal......
.Secondary Speed Signal Out of Range
.Invalid Throttle Signal
.Throttle Sensor Rate of Change
.Throttle Sensor Calibration
.Low Oil Pressure Warning ..
.Oil Pressure Sensor Open
.Oil Pressure Sensor Short ..
Oil Pressure Rate of Change
.Very Low Oil Pressure
Boost Sensor Open Circuit..........ccoovveururieieviicinnieinns
Boost Sensor Short Circuit
.Boost Sensor Calibration .
High Coolant Temperature Warning
Coolant Temperature Sensor Open Circuit
Coolant Temperature Sensor Short Circuil
....Very High Coolant Temperature
Low Coolant Level Warning
Very Low Coolant Level ..
High Transmission Oil Pressure Warning
Transmission Oil Pressure Open
Transmission Oil Pressure Short

Reference Sheet For Diagnostic Codes (Continued)

168-01 ... Battery Voltage Below Normal. . P-346
168-02 Intermittent Battery . P-346
177-00 High Transmission Oil Temperature Warning . . P-350
... Transmission Oil Temperature Open . P-591
Transmission Oil Temperature Short. . P-591
... Very High Transmission Oil Temperature . P-350
... Engine Overspeed Warning .... . P-303
Loss of Primary Engine Speed Signal .P-514
... Engine Speed Out of Range........... .P-514
... Engine Speed Rate of Change .P-514
... +5 VDC Supply Above Normal . P-521
+5 VDC Supply Below Normal............ccccveevecerinreenecnninnnn. P-521
+8 VDC Supply Above Normal . P-522
+8 VDC Supply Below Normal. . P-522
... Personality Module Fault ............ccccooooiiiniicniccciccns P-513
Check Customer/System Parameters .P-513
ECMFault ......cccocoeeci P-513

P-500 P-500
P-500: HOW TO USE TESTS

System Operation
This area is used to describe subsystem component Figure P-500.1: Throttle Position Sensor Diagram
operation and other pertinent details for
troubleshooting.
Figure P-500.2: Throttle Position Sensor Schematic

Port TPS Terminal Strip Port Engine J31 Port Engine ECM
73 Customer Connector Connector J14/P14
signal | ¢ o 8 <|Primary Throtte
-Battery| B — 8 37€{ Secondary Throttle
+Batten| Aj- 1 17€{ Synch Input 1
2. 36<€] Synch Input 2
i Switch -Bat Tc I
Synchronization 7€
3¢/-+Balt To Thottle 5
g?;“;;yr O . STBD Engine J31 STBD Engine ECM

o i 4 Customer Connector Connector J14/P14
N[ 8 €{Synch Input 1
STBD TPS 2 37<]Synch Input 2
Signal | C oo o \17€{ Primary Throttle
1.2 3
Batiery
\Batery| | AB rminal Sip '_§MM ., <|-BattTo Thotle 36€1 Secondary Throttle
1 3¢ +Batt To Thottle

P-500 P-500
Figure P-500.3: How To Use Pin Connector
Sockets o be accessed in test are highlighted
J14/P 14 ECM Connector (Rear View) /

- ——
Drawing represents the rear (open socket) view of P14

and P31 as seen when disconnected from the J side (side of connector
mounted to the ECM) This view s ilstratec in the test stops
that require measurements at the P Connector (Plug) while it
is unmated (disconnected) from the J side (Jack).
P31/J31 Customer Connector (Rear View)
Diagnostic Codes
CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

0-00 ###-## Example Diagnostic Code Describes ECM diagnostic Gives directions to
Describes conditions which lead up to the logging and response to active |the next
creation of a Diagnostic Code. diagnostic codes. appropriate step
in troubleshooting
CID-FMI (Component ID-Failure Mode
the subsystem.
Identifier): SAE J1587 standard diagnostic
Follow name of
code numbers.
Subsystem
Component
Functional Test
Identified.
Functional Test
TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Procedure To Be Performed Is Named Here
Actual step by step instructions are listed here after each OK = | Gives direction to next
check. appropriate step in
« Follow each step in descending order. troubleshooting the subsystem
Expected Results are printed in bold type. foran OK result. STOP.
NOT OK = | Gives direction to next
appropriate step in
troubleshooting the subsystem
for an NOT OK result.

P-501 P-501
P-501: INSPECTING ELECTRICAL CONNECTORS

System Operation
Many of the procedures in this troubleshooting guide Simply disconnecting and then reconnecting
will direct you to check a specific electrical connector. connectors can sometimes solve a problem. If this
The 3408 & 3412 High Performance Marine Engines occurs, likely causes are loose terminals, improperly
use a variety of Deutsch connectors. Intermittent crimped terminals or corrosion. Follow this procedure
electrical problems are often caused by poor to thoroughly inspect the connectors to determine if
connections. Always check for an Active Diagnostic connectors are the cause of the problem.
Code before breaking any connection and check again
immediately after reconnecting the connector to see if
the problem goes away.
Figure P-501.1: Deutsch Pin/Socket

Correct Correct
Installation Installation
|—
= Ifl s |
—— Wire Exiting Straight Out
Harness Correctly Routed Of Connector Correctly
White Plug
Correctly Inserted
Harness Routing at ECM Connector Deutsch Sealing Plug Insertion
Incorrect
Installation
b i —
Wire Exiting Pulled
Up On Connector Harness Pulled Toward Center
Harness Pulled Up Incorrectly Too Close To Connector White Plug
too Close To Connector Over-Inserted
Figure P-501.2: Electrical Connectors
Oun oo Db ming iy

P-501 P-501
Functional Test
TEST STEP RESULT DIAGNOSIS/ACTION
Step 1: Check Deutsch “DT” Connector Locking,

Deutsch “HD” Connector Lock Ring
* Ensure the connector is properly locked (clicked) together OK = | The connector is properly
and the two halves can not be pulled apart. locked together and the two
The connector should be properly locked together and halves can not be pulled apart.
the two halves should not be able to be pulled apart. Proceed to next step.
NOT OK = | The locking mechanism is
cracked or broken on the
connector or the connector is
cracked or broken on the
connector or the connector will
not lock. Replace the
connector. Repair as
required. STOP.
Step 2: Check ECM Connector “Allen Screw”

« Ensure the connector bolt is tightened to the proper OK = | The connector bolt is tightened
torque, Do not exceed 2.25 N.m (10 Ib). to the proper torque Proceed
The connector bolt should be tightened to the proper to next step.
torque. NOT OK = | The connector bolt is not
tightened to the proper torque
or is damaged. A 6V6703
Bolt-Kit is available to repair
the ECM. Repair as required.
STOP.
Step 3: Perform 10 Lb (44.5 N.M) Pull Test
« Each pin and connector should easily withstand 10 Ib OK= | Each pin and connector
(44.5 N.m) of pull, and remain in the connector body. This withstands the pull test.
test checks whether the wire as properly crimped in the Proceed to next step.
terminal and whether the terminal was properly inserted NOT OK = | A pin or connector fails the pull
into the connector. The “DT” connectors use an orange test. Repair as required.
wedge to lock the pins in place. Check to ensure the STOP.
orange wedge is not missing and installed properly on the
“DT” connectors.
NOTE: Terminals should always be crimped onto the wires
using a Deutsch Crimp tool. Do not solder terminals. Use
the 1U5804 Deutsch Crimp Tool.
Each pin and connector withstands the pull test.

P-314: Poor Fuel Consumption P-318: Engine Stalls at Low RPM

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P-314: Poor Fuel Consumption P-318: Engine Stalls at Low RPM

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Troubleshooting Without A Diagnostic Code

P-314: Poor Fuel Consumption P-318: Engine Stalls At Low RPM

3408 & 3412 High Performance Marine Engines 3-15 Troubleshooting

P-319: Too Much Vibration

3408 & 3412 High Performance Marine Engines 3-16 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-17 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-18 Troubleshooting

P-323: Mechanical Noise (Knock) In P-324: Oil In Cooling System

« Damaged camshaft lobe « Failure of cylinder head gasket or water seals

+ Damaged gears Perform the following tests in order:

3408 & 3412 High Performance Marine Engines 3-19 Troubleshooting

P-325: Fuel In Cooling System P-326: Coolant In Lubrication Oil

3408 & 3412 High Performance Marine Engines 3-20 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-21 Troubleshooting

NOTE: This is NOT an electronic system problem. 1. Add oil if required.

3408 & 3412 High Performance Marine Engines 3-22 Troubleshooting

P-330: Engine Uses Too Much Lubrication

3408 & 3412 High Performance Marine Engines 3-23 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-24 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-25 Troubleshooting

P-341: Indicator Lamp Not Functioning

+ Fadly Bu!b. High Coolant Temperature L—j—

Low Boost Pin-13 | Pin-5 -Batt

Diagnostic Lamp Pin-4 Pin-10 -Batt

Low Coolant Pin-14 | Pin-12 +Batt

3408 & 3412 High Performance Marine Engines 3-26 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-27 Troubleshooting

If the voltage is greater than 0.9 VDC check the -

3408 & 3412 High Performance Marine Engines 3-28 Troubleshooting

3408 & 3412 High Performance Marine Engines Troubleshooting

3408 & 3412 High Performance Marine Engines 3-30 Troubleshooting

Bypass Harness Wiring Diagram

Parts Required __ Quantity _Description

CDL Data+| § ID <E 3

Parts Required _ Quantity

Engine Vision Bypass

3408 & 3412 High Performance Marine Engines 3-31 Troubleshooting

6. Turn the keyswitch to the OFF position. Disconnect

-ﬂ):_cﬂ: +D Pin-5 Pin-23 D+ D+ pin-D

ECM CAT CAT PORT Pin-31 Pin-29 NA NA NA

3408 & 3412 High Performance Marine Engines 3-32 Troubleshooting

Repair as required STOP.

NOTE: This bypass is for TEST PURPOSES ONLY. it

3408 & 3412 High Performance Marine Engines 3-33 Troubleshooting

3408 & 3412 High Performance Marine Engines Troubleshooting

3408 & 3412 High Performance Marine Engines 3-35 Troubleshooting

3408 & 3412 High Performance Marine Engines 3-36 Troubleshooting

3408 & 3412 High Performance Marine Engines Troubleshooting

SPEED SPECIFICATION CHART

Typical Mag . Mag Pickup Mag

3408/ 2550+ 400

NOTE A: To verify overspeed shutdown system

3408 & 3412 High Performance Marine Engines 3-38 Troubleshooting

SPEED SPECIFICATION CHART

NOTE A: To verify overspeed shutdown system

3408 & 3412 High Performance Marine Engines 3-39 Troubleshooting

1 - 4C9580 Slotted Socket

1-6V3073 Plastic C Shutoff Lever (3)

1-9U5128 Foam Insert

Perform the following procedure in order:

Rack Solenoid (BTM) (1) Cover (2)

3408 & 3412 High Performance Marine Engines 3-40 Troubleshooting