SENR9515-05

May 2007

Troubleshooting
3176C and 3196 Engines for Caterpillar
Built Machines
1261-Up (Machine)
CCA1-Up (Machine)
ASD1-Up (Machine)
ASE1-Up (Machine)
ARL1-Up (Machine)
APM1-Up (Machine)
APN1-Up (Machine)
CCP1-Up (Machine)
ATS1-Up (Machine)
3PD1-Up (Engine)
5ED1-Up (Engine)

For use with 14H, 16H, 140H, 143H, 160H, and 163H Motor Graders
 i01658146

Important Safety Information

Most accidents that involve 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 to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations 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 warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR9515-05 3
Table of Contents

Table of Contents CID 0001 FMI 11 Injector Cylinder #1 fault ........... 47

CID 0002 FMI 11 Injector Cylinder #2 fault ........... 47
CID 0003 FMI 11 Injector Cylinder #3 fault ........... 47
CID 0004 FMI 11 Injector Cylinder #4 fault ........... 48
Troubleshooting Section CID 0005 FMI 11 Injector Cylinder #5 fault ........... 48
CID 0006 FMI 11 Injector Cylinder #6 fault ........... 48
Electronic Troubleshooting
CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 49
System Overview .................................................... 5
CID 0041 FMI 04 8 Volt DC Supply short to
Electronic Service Tools .......................................... 6
ground ................................................................. 49
Electronic Display Module (If Equipped) ................. 8
CID 0091 FMI 08 Throttle Position signal
Replacing the ECM ................................................. 9
abnormal ............................................................. 49
Self-Diagnostics .................................................... 10
CID 0094 FMI 03 Fuel Pressure open/short to
Sensors and Electrical Connectors ........................ 11
+batt .................................................................... 50
Engine Wiring Information .................................... 15
CID 0094 FMI 04 Fuel Pressure short to ground .. 50
CID 0100 FMI 03 Engine Oil Pressure open/short to
Programming Parameters
+batt .................................................................... 50
Programming Parameters ..................................... 17
CID 0100 FMI 04 Engine Oil Pressure short to
Factory Passwords ............................................... 17
ground ................................................................. 50
Factory Passwords Worksheet ............................. 17
CID 0110 FMI 03 Engine Coolant Temperature
Flash Programming .............................................. 17
open/short to +batt .............................................. 51
CID 0110 FMI 04 Engine Coolant Temperature short
System Configuration Parameters
to ground ............................................................. 51
System Configuration Parameters ........................ 19
CID 0168 FMI 00 System Voltage High ................ 51
CID 0168 FMI 01 System Voltage Low ................. 51
Troubleshooting without a Diagnostic Code
CID 0168 FMI 02 System Voltage intermittent/
Alternator (Charging Problem) .............................. 22
erratic .................................................................. 52
Alternator (Noisy Operation) ................................. 22
CID 0172 FMI 03 Intake Manifold Air Temp open/short
Can Not Reach Top Engine RPM ......................... 23
to +batt ................................................................ 52
Coolant in Engine Oil ............................................ 24
CID 0172 FMI 04 Intake Manifold Air Temp short to
Coolant Temperature Is Too High ......................... 24
ground ................................................................. 52
ECM Will Not Accept Factory Passwords ............. 25
CID 0174 FMI 03 Fuel Temperature open/short to
ECM Will Not Communicate with Other Systems or
+batt .................................................................... 53
Display Modules .................................................. 25
CID 0174 FMI 04 Fuel Temperature short to
Electronic Service Tool Will Not Communicate with
ground ................................................................. 53
ECM .................................................................... 25
CID 0190 FMI 02 Loss of Engine Speed Signal ... 53
Elevated Idle ......................................................... 26
CID 0190 FMI 11 Engine Speed Sensor mechanical
Engine Cranks but Will Not Start .......................... 27
failure .................................................................. 54
Engine Has Early Wear ........................................ 28
CID 0248 FMI 09 CAT Data Link
Engine Misfires, Runs Rough or Is Unstable ........ 29
communications .................................................. 54
Engine Oil in Cooling System ............................... 30
CID 0253 FMI 02 Personality Module mismatch .. 54
Engine Oil Temperature Is Too High ..................... 30
CID 0254 FMI 12 Electronic Control Module
Engine Stalls at Low RPM .................................... 31
Error .................................................................... 55
Engine Vibration ................................................... 31
CID 0261 FMI 13 Engine Timing Calibration
Engine Will Not Crank ........................................... 32
required ............................................................... 55
Excessive Black Smoke ........................................ 33
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
Excessive Engine Oil Consumption ...................... 34
short to +batt ....................................................... 55
Excessive Fuel Consumption ............................... 34
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
Excessive Valve Lash ........................................... 35
short to ground .................................................... 56
Excessive White Smoke ....................................... 35
CID 0267 FMI 02 Incorrect Engine Shutdown Switch
Exhaust Temperature Is Too High ......................... 36
inputs .................................................................. 56
Fuel in Cooling System ......................................... 37
CID 0268 FMI 02 Check Programmable
Fuel Dilution of Engine Oil .................................... 37
Parameters ......................................................... 56
Intermittent Engine Shutdown ............................... 38
CID 0273 FMI 03 Turbo Outlet Pressure open/short
Intermittent Low Power or Power Cutout .............. 38
to +batt ................................................................ 57
Low Engine Oil Pressure ...................................... 40
CID 0273 FMI 04 Turbo Outlet Pressure short to
Low Power/Poor or No Response to Throttle ....... 40
ground ................................................................. 57
Mechanical Noise (Knock) in Engine .................... 42
CID 0274 FMI 03 Atmospheric Pressure open/short
Noise Coming from Cylinder ................................. 42
to +batt ................................................................ 57
Poor Acceleration or Response ............................ 43
CID 0274 FMI 04 Atmospheric Pressure short to
Valve Rotator or Spring Lock Is Free .................... 44
ground ................................................................. 58
CID 0290 FMI 03 Engine Fan Pump Pressure
Troubleshooting with a Diagnostic Code
open/short to +batt .............................................. 58
Diagnostic Codes .................................................. 46
4 SENR9515-05
Table of Contents

CID 0290 FMI 04 Engine Fan Pump Pressure short Throttle Position Sensor Circuit - Test ................ 142
to ground ............................................................. 58
CID 0291 FMI 05 Engine Cooling Fan Solenoid open Calibration Procedures
circuit ................................................................... 58 Engine Speed/Timing Sensor - Calibrate ............ 147
CID 0291 FMI 06 Engine Cooling Fan Solenoid short Injector Code - Calibrate ..................................... 150
to ground ............................................................. 59
CID 0296 FMI 09 Unable to communicate with Index Section
Transmission ECM .............................................. 59
CID 0297 FMI 09 Unable to communicate with Index ................................................................... 152
All-Wheel Drive ECM .......................................... 60
CID 0342 FMI 02 Loss of Secondary Engine Speed
signal ................................................................... 60
CID 0342 FMI 11 Secondary Engine Speed Sensor
mechanical failure ............................................... 60
CID 0545 FMI 05 Ether Start Relay open/short to
+batt .................................................................... 61
CID 0545 FMI 06 Ether Start Relay short to
ground ................................................................. 61
CID 0548 FMI 05 Throttle Lock Lamp open
circuit ................................................................... 61
CID 0548 FMI 06 Throttle Lock Lamp short .......... 62
CID 0549 FMI 02 Incorrect Throttle Lock Switch
inputs .................................................................. 62
CID 0562 FMI 09 Unable to Communicate with Cat
Monitoring System .............................................. 62
CID 0600 FMI 03 Hydraulic Oil Temperature
open/short to +batt .............................................. 63
CID 0600 FMI 04 Hydraulic Oil Temperature short to
ground ................................................................. 63

Troubleshooting with an Event Code

Event Codes ........................................................ 64
E015 High Engine Coolant Temperature Derate .. 64
E017 High Engine Coolant Temperature
Warning ............................................................... 65
E025 High Inlet Air Temperature Derate ............... 66
E027 High Inlet Air Temperature Warning ............ 67
E039 Low Engine Oil Pressure Derate ................. 68
E053 Low Fuel Pressure Warning ........................ 69
E096 High Fuel Pressure ...................................... 70
E100 Low Engine Oil Pressure Warning ............... 71
E190 Engine Overspeed Warning ........................ 72

Diagnostic Functional Tests

5 Volt Engine Pressure Sensor Supply Circuit -
Test ..................................................................... 73
Cat Data Link Circuit - Test ................................... 77
Digital Sensor Supply Circuit - Test ...................... 80
Electrical Connectors - Inspect ............................. 84
Electrical Power Supply Circuit - Test ................... 89
Engine Fan Control Solenoid Circuit - Test ........... 95
Engine Pressure Sensor Open or Short Circuit -
Test ..................................................................... 98
Engine Shutdown Switch Circuit - Test ............... 103
Engine Speed/Timing Sensor Circuit - Test ........ 106
Engine Temperature Sensor Open or Short Circuit -
Test .................................................................... 112
Ether Injection System - Test ............................... 117
Injector Solenoid Circuit - Test ............................ 124
Throttle Lock Lamp Circuit - Test ........................ 133
Throttle Lock Switch Circuit - Test ...................... 136
SENR9515-05
Troubleshooting Section
Electronic Troubleshooting
i02397878
System Overview
SMCS Code: 1900
System Operation
This engine is electronically controlled. Each cylinder
has an electronic unit injector. The Electronic Control
Module (ECM) sends a signal to each injector
solenoid in order to control the operation of the fuel
injection system.
Electronic Controls
The electronic system consists of the following
components: the ECM, the Mechanically Actuated
Electronically Controlled Unit Injectors (MEUI), the
wiring harness, the switches, and the sensors. The
ECM is the computer. The flash file is the software
for the computer. The flash file contains the operating
maps. The operating maps define the following
characteristics of the engine:
• Horsepower
• Torque curves
The ECM determines the timing and the amount of
fuel that is delivered to the cylinders. These decisions
are based on the actual conditions and/or on the
desired conditions at any given time.
The ECM compares the desired engine speed to
the actual engine speed. The actual engine speed
is determined through a signal from the engine
speed/timing sensor. The desired engine speed is
determined with the following factors:
• Throttle signal
• Other input signals from sensors
• Certain diagnostic codes
If the desired engine speed is greater than the actual
engine speed, the ECM injects more fuel in order to
increase the actual engine speed.
5
Troubleshooting Section
Cold Mode
The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
during cold mode operation. Cold mode operation
provides the following benefits:
• Increased cold weather starting capability
• Reduced warm-up time
• Reduced white smoke
Cold mode is activated whenever the engine
temperature falls below a predetermined value. Cold
mode remains active until the engine temperature
rises above a predetermined value or until a time
limit is exceeded.
Fuel Injection
The ECM controls the amount of fuel that is injected
by varying the signals to the injectors. The injector will
pump fuel only if the injector solenoid is energized.
The ECM sends a high voltage signal to the solenoid.
This high voltage signal energizes the solenoid. By
controlling the timing and the duration of the high
voltage signal, the ECM can control injection timing
and the engine RPM.
The flash file inside the ECM sets certain limits on
the amount of fuel that can be injected. The “FRC
Fuel Limit” is used to control the air/fuel ratio for
control of emissions. The “FRC Fuel Limit” is a limit
that is based on the turbocharger outlet pressure.
A higher turbocharger outlet pressure indicates that
there is more air in the cylinder. When the ECM
senses a higher turbocharger outlet pressure, the
ECM increases the “FRC Fuel Limit”. When the ECM
increases the “FRC Fuel Limit”, the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
programmed into the ECM at the factory. The “FRC
Fuel Limit” cannot be changed.
The “Rated Fuel Limit” is a limit that is based on the
power rating of the engine and on engine rpm. The
“Rated Fuel Limit” is similar to the rack stops and to
the torque spring on a mechanically governed engine.
The “Rated Fuel Limit” provides the power curves
and the torque curves for a specific engine family and
for a specific engine rating. The “Rated Fuel Limit” is
programmed into the ECM at the factory. The “Rated
Fuel Limit” cannot be changed.
6 SENR9515-05
Troubleshooting Section

Once the ECM determines the amount of fuel that Table 1

is required, the ECM must determine the timing Required Service Tools
of the fuel injection. The ECM calculates the top
center position of each cylinder from the engine Part Description
speed/timing sensor’s signal. The ECM decides when Number
fuel injection should occur relative to the top center N/A 4 mm Allen Wrench
position and the ECM provides the signal to the
injector at the desired time. The ECM adjusts timing 6V-2197 Transducer
for optimum engine performance, for optimum fuel 7X-1171 Transducer Adapter
economy, and for optimum control of white smoke.
7X-1695 Cable As
Programmable Parameters 146-4080 Digital Multimeter Gp (RS232)
7X-1710 Multimeter Probes
Certain parameters that affect the engine operation
may be changed with Caterpillar Electronic 7X-6370 Adapter Cable As (3-PIN BREAKOUT)
Technician (ET). The parameters are stored in 208-0059 Adapter Cable As (70-PIN BREAKOUT)
the ECM, and some parameters are protected
from unauthorized changes by passwords. These 257-8718 Adapter Cable As (120-PIN BREAKOUT)
passwords are called factory passwords. 167-9225 Harness (SERVICE TOOL ADAPTER)
1U-5804 Crimp Tool (12−AWG TO 18−AWG)
Passwords
175-3700 Connector Repair Kit (DEUTSCH DT)
Several system configuration parameters and most
logged events are protected by factory passwords. Two short jumper wires are needed to check the
Factory passwords are available only to Caterpillar continuity of some wiring harness circuits by shorting
dealers. Refer to Troubleshooting, “Factory two adjacent terminals together in a connector. A
Passwords” for additional information. long extension wire may also be needed to check the
continuity of some wiring harness circuits.
i02728769

Electronic Service Tools Optional Service Tools

Table 2 lists the optional service tools that may be
SMCS Code: 1900
needed during testing or repair.
Caterpillar electronic service tools are designed to Table 2
help the service technician perform the following
tasks: Optional Service Tools
Part Number Description
• Information access
198-4240 Digital Pressure Indicator
or
• System diagnostics 1U-5470 Engine Pressure Group
• System calibrations 4C-4075 Crimp Tool (4−AWG TO 10−AWG)
4C-4911(1) Battery Load Tester
• System configurations
5P-7277 Voltage Tester
• Data link communications 6V-9130(2) Temperature Adapter (MULTIMETER)

Required Service Tools 8T-5319 Connector Tool Group

155-5176 AC/DC Current Probe
The tools that are listed in Table 1 are required in
order to enable a service technician to perform the 285-0910 Multi-Tool Gp
test procedures that are found in this manual. (1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries”
and Special Instructions, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
Temperature Adapter Group”.
SENR9515-05 7
Troubleshooting Section

Caterpillar Electronic Technician Table 4

(ET) Standard Hardware for the Use of Cat ET

Part Number Description
Cat ET can display the following information:
N/A Personal Computer (PC)
• Parameters
Communication Adapter
• Event codes 275-5120 Gp (CAT ET TO ECM
INTERFACE)
• Diagnostic codes 237-7547(2) Adapter Cable As

• Engine configuration Parallel Port Cable

225-5985(3) (COMMUNICATION
Cat ET can be used by the technician to perform the ADAPTER)
following functions: (2) The 237-7547 Adapter Cable As is required to connect to the
Universal Serial Bus (USB) on computers that are not equipped
with a RS232 serial port.
• Diagnostic tests (3) The 225-5985 Parallel Port Cable is required to connect to
the parallel port.
• Calibrations
• Flash programming
• Configuration of the Electronic Control Module
(ECM)

Table 3 lists the software that is required in order to

use Cat ET. Always use the latest version of Cat ET
that is available.

Table 3

Software Requirements for Cat ET

Part Description
Number

JERD2124 Single user license for Cat ET

Data subscription for all engines and

JERD2129
machines

Note: For more information regarding the use of Illustration 1

Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
software.
Connecting Cat ET
Connecting with the Communication Adapter II
Table 4 lists the standard hardware that is required in
order to connect Cat ET.
g01255306
Connecting the Communication Adapter II
(1) Personal Computer (PC)
(2) 237-7547 Adapter Cable As
(3) 196-0055 Adapter Cable As
(4) 225-5985 Parallel Port Cable (COMMUNICATION ADAPTER)
(5) 275-5121 Communication Adapter As
(6) 207-6845 Adapter Cable As
Note: Items (3), (5), and (6) are part of the 275-5120
Communication Adapter Gp.
Use the following procedure in order to connect Cat
ET and the Communication Adapter II.

1. Remove the electrical power from the ECM.

2. Connect communications adapter (5) to a

communications port on the PC by using one of
the following methods:
8 SENR9515-05
Troubleshooting Section

a. Connect cable (4) between the “COMPUTER”

end of communications adapter (5) and the
parallel port of PC (1). Be sure to configure
Cat ET for the parallel port. This configuration
provides the fastest connection.

b. Connect cable (3) between the “COMPUTER”

end of communication adapter (5) and the
RS232 serial port of PC (1).

c. Connect cables (2) and (3) between the

“COMPUTER” end of communication adapter
(5) and the USB port of PC (1).

3. Connect cable (6) to communication adapter (5).

4. Connect cable (6) to a service tool connector.

5. Verify that the “POWER” indicator on the

communication adapter is illuminated.

6. Establish communication between Cat ET and the Illustration 2

g01297379
ECM. (1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
7. If Cat ET and the communication adapter (8) 239-9955 Communication Radio Gp
do not communicate with the ECM, refer to (9) 259-3183 Data Link Cable As
troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will Not Note: Items (7), (8), and (9) are part of the 261-3363
Communicate with ECM”. Wireless Communication Adapter Gp.

Communicating with the Wireless Communication Use the following procedure in order to connect the
Adapter wireless communication adapter for use with Cat ET.

Table 5 lists the optional hardware that is needed
in order to connect Cat ET by using a wireless
connection.
Table 5
Optional Hardware for the Use of Cat ET
1. Remove the electrical power from the ECM.
2. Ensure that the computer has been correctly
configured for the 261-4867 Card (PCMCIA).
Verify that the PC card is installed in the
computer’s PCI expansion slot.

Part Number Description 3. Connect cable (9) between communication radio

(8) and the service tool connector.
N/A Personal Computer (PC)

Wireless Communication 4. Restore the electrical power to the ECM. If Cat ET

261-3363(1) and the communication radio do not communicate
Adapter Gp
with the ECM, refer to troubleshooting without
(1) Refer to Tool Operating Manual, “Using the 261-3363 a diagnostic code Troubleshooting, “Electronic
Wireless Communication Adapter Gp” for information that is
related to the installation and the configuration. Service Tool Will Not Communicate with ECM”.

i02139021

Electronic Display Module

(If Equipped)
SMCS Code: 1901-038

An electronic display module may be used to

display CID-FMI information from the electronic
control system. Refer to the service manual for your
electronic display module for more information.
SENR9515-05
i01818651
Replacing the ECM
SMCS Code: 1901-510
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
The Electronic Control Module (ECM) contains no
moving parts. Replacement of the ECM can be
costly. Replacement can also be a time consuming
task. Follow the troubleshooting procedures in this
manual in order to be sure that replacing the ECM
will correct the problem. Verify that the suspect ECM
is the cause of the problem.
Note: Ensure that the ECM is receiving power and
that the ECM is properly wired to the negative battery
circuit before a replacement of the ECM is attempted.
Refer to Troubleshooting, “Electrical Power Supply
Circuit - Test”.
A test ECM can be used to determine if the ECM
is faulty. Install a test ECM in place of the suspect
ECM. Flash program the correct personality module
(flash file) into the test ECM. Program the parameters
for normal operation. The parameters must match
the parameters in the suspect ECM. Refer to the
following test steps for details. If the test ECM
resolves the problem, reconnect the suspect ECM.
Verify that the problem returns. If the problem returns,
replace the ECM.
Note: When a new ECM is not available, you may
need to remove an ECM from an engine that is not
in service. Ensure that the replacement ECM and
the Personality Module Interlock match the suspect
ECM. Be sure to record the parameters from the
replacement ECM on the “Parameters Worksheet”.
Use the “Copy Configuration/ECM Replacement”
feature that is found under the “Service” menu on
the electronic service tool.
9
Troubleshooting Section
NOTICE
If the personality module and engine application are
not matched, engine damage may result.
Perform the following procedure in order to replace
the ECM.
1. Connect the electronic service tool to the service
tool connector.
2. Print the parameters from the “Configuration”
screen on the electronic service tool. If a printer is
unavailable, record all of the parameters. Record
any logged diagnostic codes and logged event
codes for your records. Record the injector codes
from the “Calibrations” screen in the “Service”
menu on the electronic service tool.
Note: The injector code is a number that is found on
each of the unit injectors. The ECM uses this number
to compensate for manufacturing variations between
individual injectors. If you replace any of the unit
injectors, you must reprogram the injector codes for
the new injectors. Also, if you replace the ECM, you
must reprogram all of the injector codes.
3. Use the “Copy Configuration/ECM Replacement”
feature that is found under the “Service” menu
on the electronic service tool. Select “Load from
ECM” in order to copy the configuration from the
suspect ECM.
Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 11.a, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
4. Remove the ECM.
a. Turn the keyswitch to the OFF/RESET position.
b. Disconnect the ECM connectors J1/P1 and
J2/P2.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
c. Remove the fuel lines from the ECM (if
equipped).
d. Remove the mounting bolts from the ECM.
10
Troubleshooting Section
e. Disconnect the ECM ground strap from the
engine.
5. Install the replacement ECM.
a. Use the old mounting hardware to install the
replacement ECM. The mounting hardware
should be free of damage.
b. Reconnect the fuel lines (if equipped).
c. Ensure that the ECM mounting hardware is
installed correctly. The fuel lines should not
be putting tension on the ECM. The rubber
grommets are used to protect the ECM from
excessive vibration. The ECM should be able to
drift in the rubber grommets. If the ECM cannot
be moved slightly in the grommets, check that
the fuel lines are not pulling the ECM against
one side of the grommets.
d. Install the ECM ground strap on the engine.
e. Reconnect ECM connectors J1/P1 and
J2/P2. Tighten the allen head screws on the
connectors to the proper torque:
• 40-pin connector 2.25 N·m (20 lb in)
• 70-pin connector 6.0 N·m (53 lb in)
6. Flash program the personality module into
the ECM. Refer to Troubleshooting, “Flash
Programming” for the correct procedure.
7. Use the electronic service tool to match the engine
application and the Personality Module Interlock
if the replacement ECM was used for a different
application.
8. Configure the ECM.
a. If the “Copy Configuration” process from
Step 3 was successful, return to the “Copy
Configuration/ECM Replacement” screen on
the electronic service tool and select “Program
ECM”. Proceed to Step 10.
b. If the “Copy Configuration” process was
unsuccessful, program the ECM parameters.
The parameters should match the parameters
from Step 11.a.
Note: If the “Copy Configuration” process fails and
the parameters were not obtained in Step 11.a, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
SENR9515-05
c. If necessary, program the Engine Monitoring
System.
9. Calibrate the fuel injectors. Refer to
Troubleshooting, “Injector Codes - Calibrate”.
10. Calibrate the injection timing. Refer to
Troubleshooting, “Engine Speed/Timing Sensor -
Calibrate”.
11. Set the service hour meter for the engine ECM.
This application is equipped with a synchronized
system clock. The engine ECM acts as the
master for the system clock (service hours).
The other control modules on the machine are
synchronized against the master. When the
engine ECM is replaced, the service hours need
to be adjusted before the other control modules
can be synchronized.
a. In order to adjust the service hours on the
new engine ECM, select “Synchronize Service
Hour Meters” from the “Service” menu on the
electronic service tool and then select “Set
Master Hours”. Program the service hours for
the engine ECM (master) to correlate with the
service hours of the other control modules on
the machine. This process requires factory
passwords.
b. After the service hours have been adjusted on
the new engine ECM, synchronize the other
control modules on the machine by selecting
“Synchronize” on the electronic service tool.
12. Check for diagnostic codes and event codes.
i02378227
Self-Diagnostics
SMCS Code: 1901-038
The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
There are two types of codes:
• Diagnostic
• Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.
Diagnostic codes can have two different states:
SENR9515-05 11
Troubleshooting Section

• Active i01818880

• Logged Sensors and Electrical

Connectors
Active Code
SMCS Code: 1900-035
An active diagnostic code indicates that an active
problem has been detected. Active codes require Table 6
immediate attention. Always service active codes
Connector Function
prior to servicing logged codes.
J1/P1 ECM Connector (70 Pin)
Logged Code
J2/P2 ECM Connector (70 Pin)
Every generated code is stored in the permanent J62 Service Tool connector (9 Pin)
memory of the ECM. The codes are logged.
J100/P100 Coolant Temperature Sensor (2 Pin)
Logged codes may not indicate that a repair is Intake Manifold Air Temperature Sensor (2
J103/P103
needed. The problem may have been temporary. The Pin)
problem may have been resolved since the logging J105/P105 Fuel Temperature Sensor (2 Pin)
of the code. If the system is powered, it is possible
to generate an active diagnostic code whenever a J136/P136 Hydraulic Oil Temperature Sensor (2 Pin) (1)
component is disconnected. When the component is
Turbocharger Outlet Pressure Sensor (3
reconnected, the code is no longer active. Logged J200/P200
Pin)
codes may be useful to help troubleshoot intermittent
problems. Logged codes can also be used to review J201/P201 Engine Oil Pressure Sensor (3 Pin)
the performance of the engine and of the electronic J203/P203 Atmospheric Pressure Sensor (3 Pin)
system.
J209/P209 Fuel Pressure Sensor (3 Pin)
Event Code J211/P211 Fan Drive Pressure Sensor (3 Pin)
An event code is generated by the detection of an J300/P300 Injector Solenoid Harness (12 Pin)
abnormal engine operating condition. For example, J301/P301 Injector Solenoid 1 (2 Pin)
an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the J302/P302 Injector Solenoid 2 (2 Pin)
symptom of a problem. J303/P303 Injector Solenoid 3 (2 Pin)
J304/P304 Injector Solenoid 4 (2 Pin)
J305/P305 Injector Solenoid 5 (2 Pin)
J306/P306 Injector Solenoid 6 (2 Pin)
J400/P400 Engine Timing Calibration Probe (2 Pin)
Primary Engine Speed/Timing (Crankshaft
J401/P401
Position) Sensor (2 Pin)
Secondary Engine Speed/Timing
J402/P402
(Camshaft Position) Sensor (2 Pin)
J403/P403 Throttle Position Sensor (3 Pin)
J508/P508 Fan Control Solenoid (2 Pin)
J705/P705 Throttle Lock Switch (10 Pin)
J707/P707 Throttle Switch (10 Pin)
(1) This sensor is only applicable to 143H and 163H Motor
Graders.
12 SENR9515-05
Troubleshooting Section

g00693506
Illustration 3
ECM and harness connectors
SENR9515-05 13
Troubleshooting Section

g00928469
Illustration 4
Block diagram
14 SENR9515-05
Troubleshooting Section

g00805876
Illustration 5
Left side engine view
SENR9515-05 15
Troubleshooting Section

g00805877
Illustration 6
Top engine view

i02433503 Table 7

Engine Wiring Information Color Codes for the Harness Wire

Color Code Color Color Code Color
SMCS Code: 1408
BK Black GN Green
The wiring schematics are revised periodically. BR Brown BU Blue
The wiring schematics will change as updates are
made to the engine’s harness. For the most current RD Red PU Purple
information, always check the revision number of the OR Orange GY Gray
schematic. Use the schematic with the latest revision
number. YL Yellow WH White
PK Pink
Harness Wire Identification
For example, a wire identification of A701-GY on the
Caterpillar identifies all wires with eleven solid colors. schematic would signify a gray wire with the circuit
The circuit number is stamped on the wire at a 25 mm number A701. A701-GY identifies the power circuit
(1 inch) spacing. Table 7 lists the wire colors and the for the No. 1 Injector solenoid.
color codes.
Another wire identification on the schematic is the
size of the wire. The size of the wire will follow the
wire color. Wire size or gauge is referred to as AWG
(American Wire Gauge). AWG is a description of the
diameter of the wire.
16 SENR9515-05
Troubleshooting Section

For example, a code of 150-OR-14 on the schematic

would indicate that the orange wire in circuit 150 is a
14 AWG wire.

If the gauge of the wire is not listed, the wire is 16

AWG.

Conversion of AWG Numbers to Metric

Measurements
Table 8 shows the various AWG numbers that are
used for the wires. The metric equivalent for the
diameter of each AWG number are also shown.

Table 8
Metric Equivalents for AWG Numbers
AWG Diameter AWG Diameter
Number (mm) Number (mm)
20 0.8 14 1.6
18 1.0 12 2.0 g01143634
Illustration 7

16 1.3 4 3.2 Service welding guide (typical diagram)

3. Connect the welding ground cable as close

Welding on Applications that are as possible to the area that will be welded.
Equipped with an Electronic Control Components which may be damaged by welding
include bearings, hydraulic components, and
Module (ECM) electrical/electronic components.
Proper welding procedures are necessary in order
4. Protect the wiring harness from welding debris
to avoid damage to the engine’s electronic control
and spatter.
module, sensors, and associated components.
Remove the component that requires welding. When
5. Weld the materials by using standard welding
welding on an application that is equipped with an
methods.
ECM and removal of the component is not possible,
the following procedure must be followed. This
procedure provides the minimum amount of risk to
the electronic components.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

1. Stop the engine. Remove the electrical power

from the ECM.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,
open the switch.
SENR9515-05 17
Troubleshooting Section

Programming Parameters Since factory passwords contain alphabetic

i02253984
Programming Parameters
SMCS Code: 1900
The Caterpillar Electronic Technician (ET) can be
used to view certain parameters that can affect the
operation of the engine. Cat ET can also be used
to change certain parameters. The parameters are
stored in the Electronic Control Module (ECM). Some
of the parameters are protected from unauthorized
changes by passwords. Parameters that can be
changed have a tattletale number. The tattletale
number shows if a parameter has been changed.
characters, the Caterpillar Electronic Technician (ET)
must be used to perform these functions. In order to
obtain factory passwords, proceed as if you already
have the password. If factory passwords are needed,
Cat ET will request the factory passwords and Cat ET
will display the information that is required to obtain
the passwords. For the worksheet that is used for
acquiring factory passwords, refer to programming
parameters Troubleshooting, “Factory Passwords
Worksheet”.
i02193979
Factory Passwords Worksheet
SMCS Code: 1901

Note: A mistake in recording this information will

i02433393 result in incorrect passwords.

Factory Passwords Table 9

Factory Passwords Worksheet
SMCS Code: 1901
Dealer Code
NOTICE Customer’s Name
Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash Address
file is correct for your engine.

Note: Factory passwords are provided only to Telephone Number

Caterpillar dealers.
Information from the “Enter Factory Passwords”
Factory passwords are required to perform each of Screen on the Caterpillar Electronic Technician (ET)
the following functions: Serial Number for Cat ET

• Program a new Electronic Control Module (ECM). Engine Serial Number

ECM Serial Number
When an ECM is replaced, the system
configuration parameters must be programmed Total Tattletale
into the new ECM. A new ECM will allow these Reason Code
parameters to be programmed once without factory
passwords. After the initial programming, some Factory Passwords
parameters are protected by factory passwords. Factory Password (No. 1)

• Clear event codes. Factory Password (No. 2)

Most event codes require the use of factory

passwords to clear the code once the code has
been logged. Clear these codes only when you are
certain that the problem has been corrected.
• Unlock parameters.
Factory passwords are required in order to unlock
certain system configuration parameters. Refer
to Troubleshooting, “System Configuration
Parameters”.
i02419726
Flash Programming
SMCS Code: 1901
Flash Programming – This is a method of
programming or updating the flash file in an engine’s
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engine’s ECM.
18 SENR9515-05
Troubleshooting Section

If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference.

Programming a Flash File

1. Establish communication between Cat ET and the
engine’s ECM.

2. Select “WinFlash” from the “Utilities” menu on Cat

ET.

Note: If “WinFlash” will not communicate with the

ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM”.

3. Program the flash file into the ECM.

a. Select the engine ECM under the “Detected

ECMs”.

b. Press the “Browse” button in order to select the

name of the flash file that will be programmed
into the ECM.

c. When the correct flash file is selected, press

the “Open” button.

d. Verify that the “File Values” match the

application. If the “File Values” do not match
the application, obtain the correct flash file.

e. When the correct flash file is selected, press

the “Begin Flash” button.

f. Cat ET will indicate when flash programming

has been successfully completed.

4. Start the engine and check for proper operation.

Repair any active diagnostic or event codes.

“WinFlash” Error Messages

If you receive any error messages during flash
programming, click on the “Cancel” button in order
to stop the process. Access the information about
the “ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for
your engine.
SENR9515-05
System Configuration
Parameters
i01808896
System Configuration
Parameters
SMCS Code: 1901
System configuration parameters are parameters that
affect emissions, power of the engine, and machine
applications. Default values for the parameters
are programmed at the factory. Some parameters
may be changed by the customer in order to suit
the needs of the specific application. You must
reprogram the system configuration parameters
if the ECM is replaced and/or you reprogram the
engine rating. Proper values for these parameters
are available on the electronic service tool. Certain
configuration parameters are also stamped on the
engine information plate.
Parameter Descriptions
Injector Codes
Note: The injector codes are not part of the
“Configuration” screen on the electronic service tool.
“Injector Codes Calibration” can be found under
“Calibrations” in the “Service” menu on the electronic
service tool.
The injector code is a number that is found on each
of the unit injectors. The ECM uses this number to
compensate for manufacturing variations between
individual injectors. If you replace any of the unit
injectors, you must reprogram the code for the new
injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes.
“Rating Number”
“Rating Number” is a reference number that
corresponds to the rating map that is resident in
the personality module (flash file). Flash files may
contain more that one rating.
“Equipment ID”
The “Equipment ID” parameter allows the customer
to enter a description into the ECM in order to identify
the machine. A maximum of 17 characters can be
entered in the field.
19
Troubleshooting Section
“Engine Serial Number”
The “Engine Serial Number” should be programmed
to match the engine serial number that is stamped
on the engine information plate. The engine serial
number is not preprogrammed on a replacement
ECM.
“FLS” (Full Load Setting)
“FLS” is a number that represents the adjustment to
the fuel system that was made at the factory in order
to fine tune the fuel system. The correct value for
this parameter is stamped on the engine information
ratings plate. This value should only be changed
if the engine is rerated or a new ECM is installed.
Factory passwords are required.
“FTS” (Full Torque Setting)
“FTS” is similar to “FLS”. This value should only be
changed if the engine is rerated or a new ECM is
installed. Factory passwords are required.
“Fuel Air Ratio Control Adjust” (FARC)
FARC is a fuel system adjustment that has been
performed at the factory in order to fine tune the fuel
system. The value that is assigned to the parameter
is stamped on the Engine Information plate for each
engine.
“Ether Control”
The “Ether Control” parameter allows the operation
of this feature to be enabled or disabled.
“Number of Available Engine Power
Levels”
The “Number of Available Engine Power Levels”
parameter is programmed at the factory to enable
the use of variable power levels. Factory passwords
are required.
“High Ambient Fan”
The “High Ambient Fan” parameter can be
programmed to enable the use of different maps in
the software for the cooling fan that will provide extra
cooling for high ambient temperatures.
“Battery Elevated Idle”
The “Battery Elevated Idle” parameter allows the
operation of this feature to be enabled or disabled.
Refer to Troubleshooting, “Elevated Idle” for more
information.
20 SENR9515-05
Troubleshooting Section

Parameter Table
Table 10

Customer Specified Parameters

Parameter Available Range or Options Default Required Password
“Rating Number” Application Dependent none
“Equipment ID” 17 characters blank none
“Engine Serial Number” 8 characters blank none
“FLS” -128 to +127 0 Factory
“FTS” -128 to +127 0 Factory
“Fuel Air Ratio Control Adjust” 0 to 255 0 none
“Ether Control” “Enable” or “Disable” “Disable” none
Application
“Number of Availabe Engine Power Levels” 1 to 3 (1) Factory
Dependent
“High Ambient Fan” “On” or “Off” “Off” none
“Battery Elevated Idle” “On” or “Off” “On” none
(1) Machines that are not equipped with an electronically controlled transmission are only programmable up to “2”.

(Table 11, contd)

Parameter Worksheet
Parameter Worksheet
Record the following information before you change
any programmable parameter. “Total Tattletale”

Table 11 “High Ambient Fan”

Parameter Worksheet
“Battery Elevated Idle”
Information from ECM
Information From Engine Information Plate
“Equipment ID”
Engine Serial Number
“Engine Serial Number”
Fuel Air Ratio
(for new ECM)
“ECM Serial Number”
Full Load Setting
“Personality Module (for new ECM)
Part Number”
Full Torque Setting
“Personality Module (for new ECM)
Release Date”
Injector Codes
“Personality Module
Description” Injector Code (1)

“FLS”
Injector Code (2)

“FTS”
Injector Code (3)
“Fuel Air Ratio Control
Adjust” Injector Code (4)

“Ether Control” Injector Code (5)

“Number of Available
Engine Power Levels” Injector Code (6)
(continued)
SENR9515-05 21
Troubleshooting Section

Note: Compare the FLS and the FTS from the

ECM with the values that are listed on the Engine
Information Plate. The FLS and the FTS should only
be changed because of a mechanical change in
the engine. The use of the wrong parameters could
cause damage to the engine. The use of the wrong
parameters may also void the Caterpillar warranty.
22 SENR9515-05
Troubleshooting Section

Troubleshooting without a Alternator or Regulator

Diagnostic Code Verify that the alternator or the regulator is operating
correctly. Refer to Special Instruction, REHS0354,
“Charging System Troubleshooting” for the proper
i02121176 testing procedures. Repair the alternator or replace
the alternator, as needed.
Alternator
(Charging Problem) i02398533

SMCS Code: 1405-038; 1901-038 Alternator

(Noisy Operation)
SMCS Code: 1405-038; 1901-038
The connection of any electrical equipment and
the disconnection of any electrical equipment may
cause an explosion hazard which may result in in- Probable Causes
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an • Alternator drive belts
explosive atmosphere.
• Alternator drive pulley
Refer to Special Instruction, REHS0354, “Charging • Alternator bearings
System Troubleshooting” for the proper testing
procedures.
Recommended Actions
Probable Causes Alternator Drive Belts
• Alternator drive belts 1. Inspect the condition of the alternator drive belts. If
the belts are worn or damaged, replace the belts.
• Charging circuit
2. Check the tension on the belts. Adjust the tension,
• Regulator if necessary.
• Alternator 3. Ensure that the belts are in proper alignment.
Inspect the alternator mounting bracket for cracks
Recommended Actions and wear. Repair the mounting bracket or replace
the mounting bracket in order to ensure that the
Alternator Drive Belts belts and the alternator drive pulley are aligned.

1. Inspect the condition of the alternator drive belts.
If the alternator drive belts are worn or damaged,
replace the belts.
2. Check the tension on the alternator drive belts.
Adjust the tension, if necessary.
Charging Circuit
Inspect the battery cables, wiring, and connections in
the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts.
Alternator Drive Pulley
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the
pulley by the belt. If there is excessive wear, replace
the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
Alternator Bearings
Check the alternator bearings for signs of wear.
Repair the alternator or replace the alternator, as
needed.
SENR9515-05
i02433834
Can Not Reach Top Engine
RPM
SMCS Code: 7569
Note: If this problem occurs only under load, refer to
Troubleshooting, “Low Power/Poor or No Response
to Throttle”.
Probable Causes
• Diagnostic codes and event codes
• Cold mode operation
• Throttle signal
• Intake manifold pressure sensor and atmospheric
pressure sensor
• Fuel supply
• Air inlet and exhaust system
• Accessory equipment
Recommended Actions
Diagnostic Codes and Event Codes
Use Caterpillar Electronic Technician (ET) to check
for logged derates. The engine speed or the engine
power may be limited due to one of the following
conditions: high altitude, high intake manifold air
temperature, low oil pressure, air filter restriction,
and other factors. Refer to Troubleshooting,
“Troubleshooting with an Event Code” for the specific
events that are applicable to this application.
Cold Mode Operation
Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may cause a slow
throttle response. Engine speed may also be limited
during cold mode operation.
Throttle Signal
Use Cat ET in order to monitor the throttle position
while you operate the throttle pedal. Ensure that the
throttle position sensor is operating correctly. Refer
to Troubleshooting, “Throttle Position Sensor Circuit -
Test”.
23
Troubleshooting Section
Intake Manifold Pressure Sensor and
Atmospheric Pressure Sensor
1. Monitor the status of “Fuel Position”, of “Rated
Fuel Limit”, and of “FRC Fuel Limit” on Cat ET
while the engine is operating under full load. These
parameters must reflect the information below.
Table 12
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Use Cat ET in order to monitor the status of the
“Boost Pressure”. With the engine stopped, the
correct “Boost Pressure” is 0 kPa (0 psi).
3. Start the engine and monitor the status of “Boost
Pressure” while you vary the engine speed.
Ensure that the pressure reading is fluctuating
with the engine speed.
4. Use Cat ET in order to check the status of the
“Atmospheric Pressure”. Verify that the pressure
reading is reasonable for the current conditions.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects or debris
which may block the fuel supply.
3. Prime the fuel system if any of the following items
have been serviced recently:
• Fuel filters
• Low pressure fuel supply circuit
• Unit injectors
Note: A sight glass in the low pressure supply line
is helpful in diagnosing air in the fuel. Refer to
Testing and Adjusting, “Air in Fuel - Test” for more
information.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
24 SENR9515-05
Troubleshooting Section

4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure during engine cranking.
Refer to Systems Operation/Testing and Adjusting,
“Fuel System” for the correct procedure. If the fuel
pressure is below specifications, replace the fuel
filters. If this does not correct the problem, check
for the proper operation of the following items: fuel
transfer pump, fuel pressure relief valve, and fuel
pressure regulator valve.
Air Inlet and Exhaust System
1. Check for an air filter restriction indicator. Clean
plugged air filters or replace plugged air filters.
Refer to the Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
Accessory Equipment
Check all accessory equipment for problems that
may create excessive load on the engine. Make the
necessary repairs to damaged components. Replace
parts, if necessary.
i02381103
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual.
Cylinder Head Gasket
1. Remove the cylinder head. Refer to the
Disassembly and Assembly manual.
2. Check the cylinder liner projection. Refer to the
Systems Operation/Testing and Adjusting manual.
3. Install a new cylinder head gasket and new water
seals in the spacer plate. Refer to the Disassembly
and Assembly manual.
Cylinder Head
Check for cracks in the cylinder head. If a crack
is found, repair the cylinder head and/or replace
the cylinder head. Refer to the Disassembly and
Assembly manual.
Cylinder Liner
Check for cracked cylinder liners. Replace any
cracked cylinder liners. Refer to the Disassembly and
Assembly manual.
Cylinder Block
Inspect the cylinder block for cracks. If a crack is
found, repair the cylinder block or replace the cylinder
block.

Coolant in Engine Oil

i02194394
SMCS Code: 1300; 7569
Coolant Temperature Is Too
Probable Causes High
SMCS Code: 1350; 7569
• Engine oil cooler core
Refer to Systems Operation/Testing and Adjusting,
• Cylinder head gasket “Cooling System - Check” for information on
determining the cause of this condition.
• Cylinder head
• Cylinder liner
• Cylinder block

Recommended Actions
Engine Oil Cooler Core
1. Check for leaks in the oil cooler core. If a leak is
found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
SENR9515-05 25
Troubleshooting Section

i02419115 Recommended Actions

ECM Will Not Accept Factory 1. Connect the Caterpillar Electronic Technician (ET)
Passwords to the service tool connector. If the ECM does not
communicate with Cat ET, refer to troubleshooting
SMCS Code: 7569 without a diagnostic code Troubleshooting,
“Electronic Service Tool Will Not Communicate
with ECM”.
Probable Causes
2. Ensure that the following items are correctly
One of the following items may not be recorded installed and undamaged. Refer to the diagnostic
correctly on the Caterpillar Electronic Technician functional test Troubleshooting, “Electrical
(ET): Connectors - Inspect”.

• Passwords • ECM connector J1/P1

• Serial numbers • Machine connector
• Total tattletale • Wiring to display modules
• Reason code • Wiring to other control modules
Recommended Actions 3. Troubleshoot the Cat Data Link for possible
problems. Refer to the diagnostic functional test
1. Verify that the correct passwords were entered. Troubleshooting, “Cat Data Link Circuit - Test”.
Check every character in each password. Remove
the electrical power from the engine for 30
i02429900
seconds and then retry.
Electronic Service Tool Will
2. Verify that Cat ET is on the “Factory Password”
screen. Not Communicate with ECM
3. Use Cat ET to verify that the following information SMCS Code: 7569
has been entered correctly:
Probable Causes
• Engine serial number
• Configuration for the communications adapter
• Serial number for the electronic control module
• Electrical connectors
• Serial number for Cat ET
• Communication adapter and/or cables
• Total tattletale
• Electrical power supply to the service tool
• Reason code connector

i02471377
• Caterpillar Electronic Technician (ET) and related
hardware
ECM Will Not Communicate
• Electrical power supply to the Electronic Control
with Other Systems or Display Module (ECM)
Modules
• Flash file
SMCS Code: 7569
• Cat Data Link
Probable Causes
• Electronic Control Module (ECM)
• Electrical connectors
• Cat Data Link
26 SENR9515-05
Troubleshooting Section

Recommended Actions Electrical Power Supply to the Service

Tool Connector
Start the engine. If the engine starts, but the ECM
will not communicate with Cat ET, continue with Verify that battery voltage is present between
this procedure. If the engine will not start, refer terminals A and B of the service tool connector. If the
to the troubleshooting without a diagnostic code communication adapter is not receiving power, the
procedure Troubleshooting, “Engine Cranks but Will display on the communication adapter will be blank.
Not Start”. If the engine will not crank, refer to the
troubleshooting without a diagnostic code procedure
Troubleshooting, “Engine Will Not Crank”.
Cat ET and Related Hardware
In order to eliminate Cat ET and the related hardware
Configuration for the Communications as the problem, connect Cat ET to a different engine.
Adapter If the same problem occurs on a different engine,
check Cat ET and the related hardware in order to
1. Access “Preferences” under the “Utilities” menu determine the cause of the problem.
on Cat ET.
Electrical Power Supply to the Electronic
2. Verify that the correct “Communications Interface
Device” is selected.
Control Module (ECM)
Check power to the ECM. Refer to the diagnostic
3. Verify that the correct port is selected for use by
functional test Troubleshooting, “Electrical Power
the communication adapter.
Supply Circuit - Test”.
Note: The most commonly used port is “COM 1”.
Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
devices are configured to use the same port, exit Flash File
or close the software programs for that device.
Ensure that the correct flash file is properly installed
in the ECM.
Electrical Connectors
Note: A new ECM is not programmed to any specific
Check for correct installation of the J1/P1 and
engine until a flash file has been installed. The engine
J2/P2 ECM connectors and of the service tool
will not start and the engine will not communicate
connector. Refer to the diagnostic functional test
with Cat ET until the flash file has been downloaded.
Troubleshooting, “Electrical Connectors - Inspect”.
Refer to programming parameters Troubleshooting,
“Flash Programming”.
Communication Adapter and/or Cables
1. If you are using a “Communication Adapter II”,
Cat Data Link
ensure that the firmware and driver files for the
Troubleshoot the Cat Data Link for possible
communication adapter are the most current files
problems. Refer to the diagnostic functional test
that are available. If the firmware and driver files
Troubleshooting, “Cat Data Link Circuit - Test”.
do not match, the communication adapter will not
communicate with Cat ET.
i01941237
2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect Elevated Idle
the communication adapter to the service tool
connector. SMCS Code: 1000; 7569

3. Verify that the correct cable is being used between Probable Causes
the communication adapter and the service tool
connector. Refer to electronic troubleshooting The low idle speed may be elevated due to one of
Troubleshooting, “Electronic Service Tools”. the following conditions:

• Low battery
• Cold mode
SENR9515-05 27
Troubleshooting Section

Note: The “Elevated Idle” status flag will be activated Recommended Actions
if one of the above conditions is met.
Diagnostic Codes, Event Codes, and
Conditions Electrical Power Supply to the ECM

Low Battery Certain diagnostic codes and/or event codes may

The engine idle speed will be elevated to 1000 rpm
when all of the following conditions occur:
• System battery voltage is less than 24.5 VDC for
five minutes.
• The throttle pedal position is below 25 percent for
five minutes.
• The machine is not in gear.
• The parking brake is set.
Cold Mode
The engine idle speed will be elevated to 1000 rpm
when all of the following conditions occur:
• Cold mode is active.
• The throttle pedal position has not exceeded 25
percent for ten minutes.
prevent the engine from starting. Connect the
Caterpillar Electronic Technician (ET) and check for
active codes and/or for logged codes. Troubleshoot
any codes that are present before continuing with
this procedure.
Note: If Cat ET will not communicate with the
ECM, the problem is most likely with the electrical
power supply to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test”.
Starting Aids
1. If cold ambient conditions exist, check operation
of starting aids. Verify that the ether system is
operating correctly. Refer to Troubleshooting,
“Ether Injection System - Test”.
2. Ensure the proper operation of the jacket water
heater. Repair the jacket water heater and/or
replace the jacket water heater, if necessary.
3. Check for presence of solidified fuel (wax).

• The machine is not in gear. Engine Shutdown Switches (If Equipped)

• The parking brake is set. The engine shutdown switches should be in the
OFF position. Use Cat ET to verify the status of the
shutdown switches. When a shutdown occurs, the
i02487752
keyswitch must be turned to the OFF position for at
Engine Cranks but Will Not least 15 seconds before restarting the engine.

Start Note: If Cat ET will not communicate with the

ECM, the problem is most likely with the electrical
SMCS Code: 7569 power supply to the ECM. Refer to Troubleshooting,
“Electrical Power Supply Circuit - Test”.
Probable Causes
Engine Speed/Timing
• Diagnostic codes
1. Crank the engine and observe the engine speed
• Event codes on the Cat ET status screen. If Cat ET indicates
zero rpm, refer to Troubleshooting, “Engine
• Electrical power supply to the Electronic Control Speed/Timing Sensor Circuit - Test”.
Module (ECM)
Note: Upon initial cranking, the status for engine
• Starting aids (if applicable) speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an
• Engine shutdown switches engine speed once the ECM is able to calculate a
speed from the signal.
• Engine speed/timing
• Unit injectors
• Fuel supply
• Combustion
28
Troubleshooting Section
2. Ensure that the timing reference gear is installed
correctly. The engine will not start if the gear was
installed backward. Check for proper orientation
between the crankshaft and camshaft drive gears.
Correct the orientation and/or replace the drive
gear, if necessary. Refer to the Disassembly and
Assembly manual for information that is related to
timing the engine’s front gear train.
Unit Injectors
Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM. Refer to
Troubleshooting, “Injector Solenoid Circuit - Test” for
additional information.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary
to purge the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for the correct procedure.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may
block the fuel supply.
4. Check for air in the low pressure fuel supply
system if any of the following procedures have
been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line
is helpful in diagnosing air in the fuel. Refer to the
Systems Operation/Testing and Adjusting manual for
more information.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
5. Purge air from the low pressure fuel supply circuit.
Refer to Operation and Maintenance Manual,
“Fuel System - Prime” for the correct procedure.
SENR9515-05
6. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
7. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, “Fuel
System” for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Combustion
Check for combustion problems.
i02549485
Engine Has Early Wear
SMCS Code: 7569
Probable Causes
• Incorrect engine oil
• Contaminated engine oil
• Contaminated air
• Contaminated fuel
• Low oil pressure
Recommended Actions
Incorrect Engine Oil
Use engine oil that is recommended and change the
engine oil at the interval that is recommended by the
engine’s Operation and Maintenance Manual.
Contaminated Engine Oil
Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Refer to
the engine’s Operation and Maintenance Manual.
If the oil filter bypass valve is open, the oil will not be
filtered. Check the oil filter bypass valve for a weak
spring or for a broken spring. If the spring is broken,
replace the spring. Refer to the engine’s Disassembly
and Assembly manual. Make sure that the oil bypass
valve is operating correctly.
SENR9515-05 29
Troubleshooting Section

Contaminated Air Recommended Actions

Inspect the air inlet system for leaks. Inspect all of
the gaskets and the connections. Repair any leaks.
Inspect the air filter. Replace the air filter, if necessary.
Contaminated Fuel
Inspect the fuel filter. Replace the fuel filter, if
necessary.
Contaminants in the fuel such as hydrogen sulfide
and sulfur can lead to the formation of acids in the
crankcase. Obtain a fuel analysis.
Low Oil Pressure
When some components of the engine show bearing
wear in a short time, the cause can be a restriction in
a passage for engine oil.
Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under
those conditions. Troubleshooting the symptom
under other conditions can give misleading results.
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
Electrical Connectors
Check for correct installation of the J1/P1 and
J2/P2 Electronic Control Module (ECM) connectors
and the unit injector connectors. Refer to the
diagnostic functional test Troubleshooting, “Electrical
Connectors - Inspect”.

An indicator for the engine oil pressure may indicate
sufficient pressure, but a component is worn due to a
lack of lubrication. In such a case, look at the passage
for the engine oil supply to the component. Refer
to the Systems Operation/Testing and Adjusting
manual.
i02513923
Engine Misfires, Runs Rough
or Is Unstable
Cold Mode
Use Cat ET to verify that the engine has exited cold
mode. Cold mode operation may cause the engine to
run rough and the engine power may be limited.
Throttle Signal
Monitor throttle signal on Cat ET. Verify that the
throttle signal is stable from the low idle position to
the high idle position.

SMCS Code: 1000; 7569 Unit Injectors

Note: If the symptom is intermittent and the symptom
cannot be repeated, refer to troubleshooting without
a diagnostic code Troubleshooting, “Intermittent Low
Power or Power Cutout”. If the symptom is consistent
and the symptom can be repeated, continue with this
procedure.
1. Use Cat ET to determine if there are any active
diagnostic codes for the unit injectors.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.

3. Perform the “Cylinder Cutout Test” on Cat ET in

Probable Causes order to identify any misfiring cylinder(s). Refer
to the diagnostic functional test Troubleshooting,
• Diagnostic codes “Injector Solenoid Circuit - Test”.
• Electrical connectors
Fuel Supply
• Cold mode
1. Check the fuel lines for the following problems:
• Throttle signal restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
• Unit injectors lines and/or replace the lines.

• Fuel supply 2. Check the fuel tank for foreign objects which may
block the fuel supply.
• Air inlet and exhaust system
3. Prime the fuel system if any of the following
procedures have been performed:
30
Troubleshooting Section
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting, “Fuel
System” for the correct pressure values. If the fuel
pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Air Inlet and Exhaust System
1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
i02173692
Engine Oil in Cooling System
SMCS Code: 1350; 7569
Probable Causes
• Engine oil cooler core
• Cylinder head gasket
Recommended Actions
Engine Oil Cooler Core
1. Inspect the engine oil cooler core for leaks. If a
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly, “Engine Oil Cooler
- Remove”.
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual
for more information.
SENR9515-05
Cylinder Head Gasket
1. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the
correct procedure.
2. Check the cylinder liner projection. Refer to
Systems Operation/Testing and Adjusting for the
correct procedure.
3. Install a new cylinder head gasket and new water
seals in the spacer plate. Refer to Disassembly
and Assembly, “Cylinder Head - Install” for the
correct procedure.
i02421677
Engine Oil Temperature Is Too
High
SMCS Code: 7569
Probable Causes
• Engine oil level
• Engine oil cooler bypass valve
• Engine oil cooler core
• Engine coolant temperature
Recommended Actions
Engine Oil Level
Use the engine oil dipstick to check for the correct oil
level. If necessary, add engine oil to the crankcase.
Engine Oil Cooler Bypass Valve
Inspect the components of the engine oil cooler
bypass valve for damage. Clean the engine oil
cooler bypass valve and clean the bore for the
valve. Ensure that the bypass valve is not stuck
in the open position. Replace the components of
the bypass valve, if necessary. Refer to Systems
Operation/Testing and Adjusting for information that
is related to troubleshooting an increased engine oil
temperature.
Engine Oil Cooler Core
Check the engine oil cooler core for damage and for
plugging. Clean the engine oil cooler core or replace
the engine oil cooler core, if necessary.
SENR9515-05
Engine Coolant Temperature
If a high coolant temperature condition is also
occurring, refer to troubleshooting without a
diagnostic code Troubleshooting, “Coolant
Temperature Is Too High”.
i02455784
Engine Stalls at Low RPM
SMCS Code: 7569
Probable Causes
• Unit injectors
• Fuel supply
• Air supply
• Engine idle
• Accessory equipment
Recommended Actions
Unit Injectors
1. Check for correct installation of the J1/P1 and
J2/P2 connectors for the Electronic Control
Module (ECM). Check for correct installation of the
J300/P300 connectors for the unit injectors. Refer
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
2. Perform the “Injector Solenoid Test” with the
Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being
energized by the ECM.
3. Perform the “Cylinder Cutout Test” with Cat ET
in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Fuel Supply
1. Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for foreign objects which may
block the fuel supply.
31
Troubleshooting Section
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting.
5. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual.
6. Check the fuel pressure after the fuel filter
while the engine is being cranked. For the
correct pressure values, refer to the Systems
Operation/Testing and Adjusting manual. If the
fuel pressure is low, replace the fuel filters. If the
fuel pressure is still low, check the following items:
fuel transfer pump, fuel transfer pump coupling,
and fuel pressure regulating valve.
Air Supply
Check for restrictions in the air inlet system. Refer to
Systems Operation/Testing and Adjusting.
Engine Idle
Check the parameter for the low engine idle (if
applicable). Refer to Troubleshooting, “System
Configuration Parameters”.
Accessory Equipment
Check all accessory equipment for problems that
may create excessive load on the engine. Repair
any damaged components or replace any damaged
components.
i02419766
Engine Vibration
SMCS Code: 7569
Probable Causes
• Vibration damper
• Engine supports
32 SENR9515-05
Troubleshooting Section

• Driven equipment • Internal engine problem

• Engine misfiring or running rough
Recommended Actions
Vibration Damper
Check the vibration damper for damage. Install a
new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace
any damaged bolts. Refer to the Disassembly and
Assembly manual.
Recommended Actions
Batteries and/or Battery Cables
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
for corrosion. If the battery cables are corroded,
remove the battery cables and clean the battery
cables. Tighten any loose connections.
2. Inspect the batteries.

Engine Supports a. Charge the batteries. Refer to Special

Inspect the mounts and the brackets while you run
the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten
all of the mounting bolts. Install new components, if
necessary.
Driven Equipment
Check the alignment and the balance of the driven
equipment.
Engine Misfiring or Running Rough
Refer to troubleshooting without a diagnostic code
Troubleshooting, “Engine Misfires, Runs Rough or
Is Unstable”.
i02214238
Engine Will Not Crank
Instruction, SEHS7633, “Battery Test
Procedure”.
b. Load test the batteries. Refer to Special
Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
Starting Motor Solenoid or Starting
Circuit
1. Test the operation of the starting motor solenoid.
2. Check the wiring to the starting motor solenoid.
Starting Motor or Flywheel Ring Gear
1. Test the operation of the starting motor.
2. Inspect the starter motor pinion and the flywheel
ring gear for damage.

SMCS Code: 7569 Transmission or Engine Accessories

1. Ensure free movement of the driveline.
Probable Causes
2. Ensure that the timing pin was not left in the
• Batteries flywheel housing.
• Battery cables 3. Remove any engine accessories that may lock up
the engine and inspect any engine accessories
• Starting circuit that may lock up the engine.
• Starting motor solenoid The following list illustrates examples of engine
accessories that may lock up the engine:
• Starting motor
• Hydraulic pump that is driven from the rear gear
• Flywheel ring gear group
• Transmission • Air compressor
• Engine accessories • Engine oil pump
• Hydraulic cylinder lock • Other components that are driven by the engine
SENR9515-05 33
Troubleshooting Section

Hydraulic Cylinder Lock 4. Repair any leaks that were found. Remove
any restrictions that were found. Replace any
Check for fluid in the cylinders (hydraulic cylinder damaged components that were found.
lock) by removing the individual unit injectors.
Engine Speed/Timing
Note: Drain the fuel from the cylinder head. Fuel will
flow from the cylinder head into the cylinders when 1. Check the calibration of the engine speed/timing
the unit injector is removed. sensor. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Internal Engine Problem
2. Verify that the crankshaft and the camshaft drive
Disassemble the engine. Refer to the Disassembly gears are set with the proper orientation. Refer to
and Assembly manual. Inspect the internal the Disassembly and Assembly manual.
components for the following conditions:
Atmospheric Pressure Sensor
• Seizure
1. Remove the sensor.
• Broken components
2. Remove debris, moisture, or ice from the sensor.
• Bent components
3. Install the sensor.
i02432467
4. Check the Caterpillar Electronic Technician (ET)
Excessive Black Smoke for active diagnostic codes on the sensor. If no
active diagnostic code exists, the sensor may be
SMCS Code: 1088-035; 7569 used. The correct reading for the atmospheric
pressure is between 50 kPa (7.25 psi) and
100 kPa (14.5 psi).
Probable Causes
• Air inlet or exhaust system Boost Pressure Sensor, “Fuel Position”,
and/or “FRC Fuel Limit”
• Engine speed/timing sensor
1. Monitor the status of “Fuel Position” and “Rated
• Atmospheric pressure sensor Fuel Limit” while the engine is operating under full
load. If “Fuel Position” equals “Rated Fuel Limit”
• Boost pressure sensor and “Fuel Position” is less than “FRC Fuel Limit”,
the Electronic Control Module (ECM) is providing
• “Fuel Position” and/or “FRC Fuel Limit” the correct control. Otherwise, proceed to the next
Step.
• Flash file
2. Verify that there are no active diagnostic codes for
• Fuel quality the boost pressure sensor.

• Valve adjustment 3. Monitor the status of “Boost Pressure” and

Recommended Actions
Air Inlet or Exhaust System
1. Check the air inlet system for restrictions and/or
for leaks.
a. Check for an air filter restriction.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet
piping .
2. Ensure that the turbocharger is in good repair.
“Atmospheric Pressure” on Cat ET. When the
engine is not running, “Boost Pressure” should be
0 kPa (0 psi).
Note: A problem with the “FRC Fuel Limit” will only
cause black smoke during acceleration. A problem
with the “FRC Fuel Limit” will not cause black smoke
during steady state operation.
Flash File
Verify that the correct flash file is installed. Refer
to Troubleshooting, “Flash Programming” for
information.

3. Check the exhaust system for restrictions.

34 SENR9515-05
Troubleshooting Section

Fuel Quality Internal Engine Wear

Cold weather adversely affects the characteristics of Internal engine wear can cause excessive oil leakage
the fuel. Refer to Operation and Maintenance Manual into the combustion area of the cylinders. Excessive
for information on improving the characteristics of the wear on the following components may cause oil
fuel during cold weather operation. consumption:

Valve Adjustment • Piston rings

Check the valve adjustment. Refer to Systems • Valve guides

Operation/Testing and Adjusting for information on
valve adjustments. Check for excessive crankcase blowby at the
engine crankcase breather. Refer to Systems
Operation/Testing and Adjusting.
i02410997

Excessive Engine Oil i02430014

Consumption Excessive Fuel Consumption

SMCS Code: 1300; 7569 SMCS Code: 1250-035; 7569

Probable Causes Probable Causes

• Oil leaks • Engine operation
• Oil level • Fuel leaks
• Turbocharger seal • Fuel quality
• Internal engine wear • Engine speed/timing

Recommended Actions • Unit injectors

Oil Leaks • Air inlet and exhaust system

Check the engine compartment for oil leaks. Repair
any oil leaks that are identified.
Oil Level
Check the engine oil level. Too much oil in the engine
crankcase can cause the engine to consume oil.
Remove excessive engine oil from the crankcase.
Ensure that the dipstick is properly calibrated
and/or that the dipstick is correct for the application.
Calibrate the dipstick and/or replace the dipstick.
Turbocharger
Check for turbocharger shaft seal leakage. Remove
the air inlet piping and the exhaust outlet piping from
the turbocharger. Check the compressor wheel and
the turbine for evidence of an oil leak. If necessary,
repair the turbocharger or replace the turbocharger.
Refer to Systems Operation/Testing and Adjusting.
• Accessory equipment
Recommended Actions
Engine Operation
Use the Caterpillar Electronic Technician (ET) to
check the “Current Totals” for excessive idle time
and/or for a high load factor which would be indicative
of poor operating habits.
Note: Engine operation may also be affected by
environmental conditions such as wind and snow.
Fuel Leaks
Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting for the
correct pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still low,
check the following items: fuel transfer pump, fuel
transfer pump coupling, and fuel pressure regulating
valve.
SENR9515-05 35
Troubleshooting Section

Fuel Quality Recommended Actions

Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Maintenance
Manual for information on improving the
characteristics of the fuel during cold weather
operation.
Engine Speed/Timing
Perform a speed/timing sensor calibration. Refer to
the calibration procedure Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
Unit Injectors
1. Check for correct installation of the J1/P1
and J2/P2 Electronic Control Module (ECM)
connectors and the unit injector connectors. Refer
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
3. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Air Inlet and Exhaust System
1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter
or replace the air filter.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting.
Lubrication
1. Remove the valve mechanism covers. Refer to
the engine’s Disassembly and Assembly manual.
2. Check the lubrication in the valve compartment.
Ensure that there is adequate engine oil flow in
the valve compartment. The passages for the
engine oil must be clean.
Valve Lash
Adjust the engine valve lash. Refer to the engine’s
Systems Operation/Testing and Adjusting manual.
Valve Train Components
1. Inspect the following components of the valve
train:
• Rocker arms
• Pushrods
• Valve lifters
• Camshaft
• Valve stems
• Rocker shafts
2. Check the components for the following conditions:
abnormal wear, excessive wear, straightness, and
cleanliness. Replace parts, if necessary.
Note: If you replace the camshaft, you must also
replace the valve lifters.

Accessory Equipment 3. Adjust the engine valve lash. Refer to the engine’s
Systems Operation/Testing and Adjusting manual.
Check all accessory equipment for problems that
may create excessive load on the engine. Repair i02711029
any damaged components or replace any damaged
components. Excessive White Smoke
SMCS Code: 1088-035; 7569
i02424626

Excessive Valve Lash Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
SMCS Code: 1105; 7569 normally. If the white smoke persists, there may be
a problem.
Probable Causes
Probable Causes
• Lubrication
• Starting aids (if applicable)
• Valve lash
• Coolant temperature sensor
• Valve train components
36 SENR9515-05
Troubleshooting Section

• Engine speed/timing Flash File

• Unit injectors Verify that the correct flash file is installed. Refer to
Troubleshooting, “Flash Programing”.
• Flash file
Fuel Supply
• Fuel supply
1. Inspect the fuel system components.
• Component wear
2. Check the fuel pressure during engine cranking.
• Cooling system Check the filtered fuel pressure. Refer to Systems
Operation/Testing and Adjusting for the correct
Recommended Actions pressure values. If the fuel pressure is low,
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump,
Starting Aids
fuel transfer pump coupling, and fuel pressure
1. Check for proper operation of the jacket water regulating valve.
heater. Repair the jacket water heater or replace
3. Check the fuel quality. Low cetane fuel can create
the jacket water heater.
white smoke. If necessary, replace the fuel with a
higher cetane fuel.
2. Ensure that the ether canister is not empty or low.
Replace the ether canister if the ether canister is
empty or low. Refer to Troubleshooting, “Ether 4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Injection System - Test”.
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Coolant Temperature Sensor operation.
1. Use the Caterpillar Electronic Technician (ET) to
verify that the engine has exited cold mode. Component Wear
Check the engine for the following problems:
2. Compare the coolant temperature from Cat ET to
the coolant temperature that is obtained from the Excessive valve wear, piston wear, ring wear, liner
wear, and reduced compression pressure.
6V-9130 Temperature Adapter (MULTIMETER).
Ensure that the temperature readings are
reasonable for the conditions that are present. Cooling System
Check for an internal coolant leak into the
Engine Speed/Timing
cylinder and/or the exhaust. Refer to Systems
Operation/Testing and Adjusting for information on
1. Check the calibration of the engine speed/timing
inspecting the cooling system.
sensor. Refer to Troubleshooting, “Engine
Speed/Timing Sensor - Calibrate”.
i02332993
2. Verify that the timing of the crankshaft and
camshaft drive gears are set with the proper Exhaust Temperature Is Too
orientation. Refer to Disassembly and Assembly
for information that is related to the correct gear
High
installation.
SMCS Code: 1050; 7569
Unit Injectors
Probable Causes
1. Perform the “Cylinder Cutout Test” on Cat ET in
order to try to isolate any cylinders that may be • Diagnostic codes
misfiring. A misfiring cylinder could be related to
an injector that is worn or in poor repair. Refer to • Electrical connectors
Troubleshooting, “Injector Solenoid Circuit - Test”.
• Air inlet and exhaust system
2. Cut out each individual cylinder for 30 to 60
seconds. Verify that the smoke decreases.
SENR9515-05
Recommended Actions
Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET)
and check for active diagnostic codes. Troubleshoot
any active diagnostic codes before continuing with
this procedure.
Electrical Connectors
Check for correct installation of the J2/P2 Electronic
Control Module (ECM) connector and of the
J300/P300 connector that is for the injectors. Refer
to Troubleshooting, “Electrical Connectors - Inspect”
for more information.
Air Inlet and Exhaust System
1. Check the air inlet manifold pressure. Check for
air inlet restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System” for more information.
2. Check for leaks between the exhaust manifold
and the turbocharger. Check for exhaust
restrictions. Refer to Systems Operation/Testing
and Adjusting, “Air Inlet and Exhaust System” for
more information.
i02514094
Fuel in Cooling System
SMCS Code: 1350; 7569
Probable Causes
• Damaged O-ring seal for a fuel injector
Recommended Actions
Replace Any Damaged Seals
1. Remove the valve mechanism covers.
2. Remove the fuel supply and the fuel return line
from the cylinder head.
3. Cap the fuel return connector and apply 700 kPa
(100 psi) maximum air pressure to the fuel supply
connector. Check for fuel leakage around the unit
injectors. If leakage is present, remove the leaking
fuel injector. Install a new O-ring seal onto the
injector. Install the injector. Connect the fuel return
line. Install the valve cover.
Verify that the problem is resolved.
37
Troubleshooting Section
i02119587
Fuel Dilution of Engine Oil
SMCS Code: 1300; 7569
Probable Causes
• Leaking seals on the case of the unit injector or on
the barrel of the unit injector
• Leaking seals on the fuel line adapter for the
cylinder head
• Excessive leakage from the unit injector tip or
breakage of the unit injector tip
• Cracked fuel supply manifold
• Leaking seal on the fuel transfer pump
Recommended Actions
Leaking Seals on the Case of the Unit
Injector or on the Barrel of the Unit
Injector
Look for signs of damage to the seals for the unit
injectors. Replace any seals that are leaking.
Leaking Seals on the Fuel Line Adapter
for the Cylinder Head
Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
lines or components.
Excessive Leakage from the Unit Injector
Tip or Breakage of the Unit Injector Tip
Look for signs of damage to the unit injectors. If
necessary, repair the unit injectors or replace the unit
injectors.
Cracked Fuel Supply Manifold
Look for signs of damage to the fuel supply manifold.
Leaking Fuel Transfer Pump Seal
Ensure that the weep hole is not plugged. If
necessary, repair the fuel transfer pump or replace
the fuel transfer pump.
38
Troubleshooting Section
i02520529
Intermittent Engine Shutdown
SMCS Code: 7569
Note: Use this procedure only if the engine shuts
down completely during operation.
Probable Causes
• Diagnostic codes
• Event codes
• Electrical connectors
• Circuit breakers
• Fuel supply
Recommended Actions
Diagnostic Codes and/or Event Codes
Certain diagnostic codes and/or event codes may
cause an engine shutdown. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
and for logged codes. Troubleshoot any codes that
are present prior to continuing with this procedure.
Electrical Connectors
1. Check for correct installation of the J1/P1 and
J2/P2 connectors for the Electronic Control Module
(ECM). Also, thoroughly inspect the connectors
for the engine speed/timing sensors. Refer to
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
2. Inspect the battery wires from the ECM to the
battery compartment. Refer to the Schematic for
specific wiring information. Check the unit injector
connectors and associated wiring for damage, or
for intermittent problems. Inspect the wires and
connectors to all circuit protection for the engine.
Check the power and ground connections to
the ECM. Check any engine shutdown switches
and associated wiring. Refer to the diagnostic
functional test Troubleshooting, “Electrical Power
Supply Circuit - Test”.
Circuit Breakers
Check the state of each of the circuit breakers. Reset
the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine
the condition that caused the circuit breaker to trip.
Make the necessary repairs.
SENR9515-05
Fuel Supply
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system.
Refer to the Operation and Maintenance Manual.
2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
3. Check the fuel tank for debris or foreign objects
which may block the fuel supply.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: Check the fuel system for air. Refer to the
Systems Operation/Testing and Adjusting manual.
5. Check fuel quality. Cold weather adversely
affects the characteristics of the fuel. Refer to the
Operation and Maintenance Manual.
6. Check the filtered fuel pressure while the
engine is being cranked. Refer to Systems
Operation/Testing and Adjusting.
If the fuel pressure is low, replace the fuel filters.
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual.
If the fuel pressure is still low, check the operation
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump.
Refer to Systems Operation/Testing and Adjusting.
i02520545
Intermittent Low Power or
Power Cutout
SMCS Code: 7569
Note: Use this procedure only if the engine does not
shut down completely.
SENR9515-05
Probable Causes
• Diagnostic codes
• Event codes
• Turbocharger
• Air inlet and exhaust restrictions
• Throttle signal
• Power supply for the Electronic Control Module
(ECM)
• Fuel supply
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Turbocharger
Ensure that the turbocharger is operating correctly.
Periodic inspection and cleaning is recommended for
the turbocharger compressor housing (inlet side).
Air Inlet and Exhaust Restrictions
Check the air inlet system for the following problems:
restrictions, collapse, and pinched line. Repair the
lines and/or replace the lines.
Check for an air filter restriction. Replace plugged air
filters and/or clean filters. Repair any leaks.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic test for your
application:
• Troubleshooting, “Throttle Position Sensor Circuit -
Test”
• Troubleshooting, “Throttle Switch Circuit - Test”
39
Troubleshooting Section
• Troubleshooting, “Speed Control - Test”
ECM Power Supply
1. Inspect the circuit between the ECM and
the batteries. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to
the diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information.
2. Inspect the circuit between the ECM and
the keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to
the diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test” for more
information.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line
is helpful in diagnosing air in the fuel. For more
information, refer to Systems Operation/Testing and
Adjusting, “Air in Fuel - Test”.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
40 SENR9515-05
Troubleshooting Section

5. Check the fuel pressure after the fuel filter
while the engine is being cranked. Refer to
Systems Operation/Testing and Adjusting, “Fuel
System” for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting for
more information.
i02430113
Engine Oil Pump
Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil
pump for excessive wear. If necessary, repair the oil
pump or replace the oil pump.
Oil Cooler
Check the engine’s oil cooler for plugging or
blockage. Clean the engine oil cooler core(s) and/or
install new engine oil cooler core(s).

Low Engine Oil Pressure Fuel Dilution

SMCS Code: 1300; 7569 Check for presence of fuel in lubricating oil. Refer
to the troubleshooting without a diagnostic code
NOTICE procedure Troubleshooting, “Fuel Dilution of Engine
Do not operate engine with low oil pressure. Engine Oil”.
damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is Engine Wear
corrected.
Inspect the camshaft and/or camshaft bearings
for excessive wear. Inspect the crankshaft and/or
Probable Causes crankshaft bearings. Excessive wear to discrete
components may be an indication of a blocked oil
• Engine oil level passage. Use an oil pressure gauge to check the
oil pressure at the main oil gallery. This will help
• Engine oil filters and oil filter bypass valve determine if the excessive wear is from low system
pressure or from passages that are blocked.
• Engine oil pump
• Engine oil cooler i02404207

• Fuel dilution Low Power/Poor or No

Response to Throttle
• Engine wear
SMCS Code: 7569
Recommended Actions
Probable Causes
Engine Oil Level
• Diagnostic codes
Inspect the engine oil level. If engine oil is low add
engine oil. Refer to the Operation and Maintenance • Event codes
Manual.
• Cold mode
Engine Oil Filters and Oil Filter Bypass
• Throttle signal
Valve
• Electrical connectors
Check the service records of the engine for
information that is related to the last oil change. If • Unit injectors
necessary, perform an oil change on the engine and
replace the engine oil filters. • Intake manifold pressure sensor
Check the operation of oil filter bypass valve. Clean • Air inlet and exhaust system
the bypass valve and the housing. If necessary,
install new parts. • Parameters
• Fuel supply
SENR9515-05
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may
cause poor performance. Connect Caterpillar
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Cold Mode
1. Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may cause the
engine to run rough and engine power may be
limited.
2. Observe the coolant temperature on the Cat ET
status screen. Verify that the reading is valid.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic test for your
application:
• Troubleshooting, “Throttle Position Sensor Circuit -
Test”
• Troubleshooting, “Throttle Switch Circuit - Test”
• Troubleshooting, “Speed Control - Test”
Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2
Electronic Control Module (ECM) connectors and the
unit injector connectors. Refer to Troubleshooting,
“Electrical Connectors - Inspect”.
Unit Injectors
1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
2. Perform the “Cylinder Cutout Test” on Cat ET in
order to identify any misfiring cylinder(s). Refer to
Troubleshooting, “Injector Solenoids Circuit - Test”
for more information.
41
Troubleshooting Section
Intake Manifold Pressure Sensor
1. Monitor the status of “Fuel Position”, “Rated Fuel
Limit”, and “FRC Fuel Limit” on Cat ET while
the engine is operating under full load. These
parameters should reflect the information below.
Table 13
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Monitor the status of “Boost Pressure” and
“Atmospheric Pressure” for normal operation
on Cat ET. When the engine is not running, the
correct value for “Boost Pressure” is 0 kPa (0 psi).
Air Inlet and Exhaust System
1. Observe the indicator lamps. Check for an air
filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual for additional
information.
2. Check the air inlet and exhaust system for
restrictions and/or for leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
Parameters
If the ECM has been replaced, compare the values on
the Engine Information Plate to following parameters
from Cat ET:
• FRC offset
• Full Load Setting (FLS)
• Full Torque Setting (FTS)
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
42
Troubleshooting Section
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting, “Air in Fuel - Test”
for more information.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
5. Check the fuel pressure after the fuel filter
while the engine is being cranked. Refer to
Systems Operation/Testing and Adjusting, “Fuel
System” for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve. Refer
to Systems Operation/Testing and Adjusting for
more information.
i02514294
Mechanical Noise (Knock) in
Engine
SMCS Code: 7569
Probable Causes
• Faulty accessory
• Cylinder head and related components
• Gear train
• Crankshaft and related components
• Piston
SENR9515-05
Recommended Repairs
Faulty Accessory
Isolate the source of the noise. Remove the suspect
engine accessories. Inspect the suspect engine
accessories. Repair the engine accessories and/or
replace the engine accessories.
Cylinder Head and Related Components
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear
to the valves, cylinder head gasket, springs, lifters,
pushrods, etc. Inspect the condition of the camshafts.
If a camshaft is replaced, new valve lifters must be
installed. Replace any damaged parts.
Gear Train
Inspect the condition of the gear train. Replace any
damaged parts.
Inspect the flywheel and the flywheel bolts.
Inspect the engine oil filters for nonferrous material.
Flaking of nonferrous material could indicate worn
gear train bearings.
Crankshaft
Inspect the crankshaft and the related components.
Inspect the connecting rod bearings and the bearing
surfaces on the crankshaft. Make sure that the
bearings are in the correct position. Look for worn
thrust plates and wear on the crankshaft. Check the
counterweight bolts. Replace any damaged parts.
Piston
Inspect the condition of the pistons. Make sure that
the piston pins are correctly installed. Replace any
damaged parts.
i02477338
Noise Coming from Cylinder
SMCS Code: 7569
Probable Causes
• Diagnostic codes
• Fuel quality
• Unit injectors
• Valve lash
SENR9515-05
• Cylinder head and related components
Recommended Actions
Diagnostic Codes
Check for active diagnostic codes on the Caterpillar
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure.
Fuel Quality
Refer to Operation and Maintenance Manual for
information on the characteristics of the fuel.
Unit Injectors
1. Check the connectors at the Electronic Control
Module (ECM). Check for correct installation
of the J1/P1 and J2/P2 ECM connectors. Also,
thoroughly inspect the unit injector wiring harness
from the ECM to the J300/P300 valve cover entry
connector. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
2. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
3. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that may be
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Valve Lash
Check the engine valve lash settings. Inspect the
valve train for sufficient lubrication. Check damage to
valve train components which may cause excessive
valve lash. Repair any problems that are found.
Refer to troubleshooting without a diagnostic code
Troubleshooting, “Excessive Valve Lash”.
Cylinder Head and Related Components
Check for signs of damage and/or wear to the valves,
cylinder head gasket, etc. Inspect the condition of
the camshafts.
i02520699
Poor Acceleration or Response
SMCS Code: 1000; 7569
Probable Causes
• Diagnostic codes
• Event codes
43
Troubleshooting Section
• Cold mode
• Flash file
• Throttle signal
• Electrical connectors
• Unit injectors
• Intake manifold (boost) pressure sensor
• Air inlet and exhaust system
• Fuel supply
Recommended Actions
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
Diagnostic Codes, Event Codes and
Derates
Certain diagnostic codes, event codes and/or derates
may cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
Cold Mode
Use Cat ET to verify that the engine has exited
cold mode. Cold mode operation may slow throttle
response.
Flash File
Verify that the correct flash file is installed.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic test for your
application:
• Troubleshooting, “Throttle Position Sensor Circuit -
Test”
• Troubleshooting, “Throttle Switch Circuit - Test”
• Troubleshooting, “Speed Control - Test”
44
Troubleshooting Section
Electrical Connectors
Check for correct installation of the J1/P1 and
J2/P2 Electronic Control Module (ECM) connectors
and the unit injector connectors. Refer to the
diagnostic functional test Troubleshooting, “Electrical
Connectors - Inspect”.
Unit Injectors
1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
are being energized by the ECM.
2. Perform the “Cylinder Cutout Test” on Cat ET
in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”.
Intake Manifold (Boost) Pressure Sensor
1. Monitor the status of “Fuel Position”, “Rated Fuel
Limit”, and “FRC Fuel Limit” on Cat ET while
the engine is operating under full load. These
parameters should reflect the information below.
Table 14
“Fuel Position” = “Rated Fuel Limit”
and
“Fuel Position” < “FRC Fuel Limit”
If “Fuel Position” equals “Rated Fuel Limit” and
“Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise,
proceed with the next Step.
2. Monitor the status of “Boost Pressure” and of
“Atmospheric Pressure” for normal operation
on Cat ET. When the engine is not running, the
correct value for “Boost Pressure” is 0 kPa (0 psi).
Air Inlet and Exhaust System
1. Observe the check engine lamp. Check for an
air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the
Operation and Maintenance Manual.
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
SENR9515-05
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
2. Check the fuel tank for foreign objects which may
block the fuel supply.
3. Prime the fuel system if any of the following
procedures have been performed:
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting, “Air in Fuel - Test”.
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
operation.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
5. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting, “Fuel System”
for the correct pressure values. If the fuel pressure
is low, replace the fuel filters. If the fuel pressure
is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling, and fuel
pressure regulating valve. Refer to Systems
Operation/Testing and Adjusting.
i02643299
Valve Rotator or Spring Lock
Is Free
SMCS Code: 1109; 7569
Use this procedure in order to troubleshoot a problem
with the valve rotators or spring locks.
Probable Cause
• Valve Components
SENR9515-05 45
Troubleshooting Section

Recommended Actions
Valve components
1. A valve rotator that is cracked or a valve rotator
that is broken is an indication of an engine
overspeed. Determine the cause of the engine
overspeed. Repair the condition.

2. Inspect the following components for damage:

• Valve rotators
• Spring locks
• Valve springs
• Valves
Note: Ensure that the valve has not contacted the
piston. If the valve has contacted the piston, check
the exhaust system for debris.

3. Replace any damaged components.

46 SENR9515-05
Troubleshooting Section

Troubleshooting with a Table 16

Diagnostic Code Failure Mode Identifiers

FMI Description
The data is valid, but the data is above the
i01547136 00
normal range of operation.
Diagnostic Codes 01
The data is valid, but the data is below the
normal range of operation.
SMCS Code: 1000; 1900
02 The data is erratic, intermittent, or incorrect.
Diagnostic codes alert the operator that a problem in 03 The voltage is above normal or shorted high.
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to the 04 The voltage is below normal or shorted low.
service technician. Diagnostic codes may be viewed The current is below normal or the circuit is
05
on the Caterpillar Electronic Technician (ET) or one open.
of the various electronic displays. Diagnostic codes
The current is above normal or the circuit is
consist of the module identifier (MID), the component 06
grounded.
identifier (CID), and the failure mode identifier (FMI).
The mechanical system is not responding
07
Module Identifier (MID) – The MID is a code with correctly.
two or three digits that indicates the electronic There is a frequency, a pulse width, or a period
module which generated the diagnostic code. Some 08
that is abnormal.
electronic displays do not display the MID because
the module which generates the code is obvious. 09 There has been an abnormal update.
Table 15 is a list of the module identifiers for this 10 There has been an abnormal rate of change.
application.
11 The failure mode is not identifiable.
Table 15
12 The device or the component is faulty.
Module Identifiers
The device or the component is out of
13
MID Description calibration.
30 Caterpillar Monitoring System 14-31 Reserved
36 Engine ECM
Note: Do not confuse diagnostic codes with
75 All Wheel Drive ECM event codes. For information on event codes, see
81 Transmission ECM Troubleshooting, “Event Codes”.

Component Identifier (CID) – The CID is a number Active Diagnostic Codes

with three or four digits. The CID indicates the
component that generated the code. For example,
the CID number 17 identifies the fuel shutoff valve.
Failure Mode Identifier (FMI) – The FMI is a two
digit code that indicates the type of failure. Table 16
is a list of the failure mode identifiers.
An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.
When an active diagnostic code is generated, a
warning may be displayed on an electronic display
such as the Caterpillar Monitoring System.

Logged Diagnostic Codes

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

• Hour of the first occurrence of the code

• Hour of the last occurrence of the code
• Number of occurrences of the code
SENR9515-05 47
Troubleshooting Section

This information is a valuable indicator for i02214575

troubleshooting intermittent problems. Any logged
diagnostic codes will automatically be deleted if no CID 0002 FMI 11 Injector
additional occurrences are recorded in 100 hours. Cylinder #2 fault
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that SMCS Code: 1290-038
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection Conditions Which Generate This Code:
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the The Electronic Control Module (ECM) is attempting
failure of the ECM. Diagnostic codes that are logged to operate the injector. The ECM detects an open
repeatedly may indicate a problem that needs special circuit or a short circuit in the circuit for the injector.
investigation.
If the cause of the diagnostic code is a problem in the
If the symptoms continue, use the proper procedure common wire, two cylinders will be affected because
for troubleshooting the symptoms that have been of the shared common wire for the injectors.
experienced by the operator.
System Response:
Note: Always clear logged diagnostic codes after
investigating and correcting the problem which The ECM will log the diagnostic code. The ECM will
generated the code. continue to attempt to operate the injector after the
code has been logged.
i02214566
The injector may not operate while the condition
CID 0001 FMI 11 Injector exists.
Cylinder #1 fault Possible Performance Effect:
SMCS Code: 1290-038
• Engine misfires
Conditions Which Generate This Code:
• Low power
The Electronic Control Module (ECM) is attempting Perform the following diagnostic procedure: “Injector
to operate the injector. The ECM detects an open Solenoid Circuit - Test”
circuit or a short circuit in the circuit for the injector.
Results:
If the cause of the diagnostic code is a problem in the
common wire, two cylinders will be affected because
• OK – STOP.
of the shared common wire for the injectors.

System Response: i02214584

The ECM will log the diagnostic code. The ECM will CID 0003 FMI 11 Injector
continue to attempt to operate the injector after the Cylinder #3 fault
code has been logged.
SMCS Code: 1290-038
The injector may not operate while the condition
exists. Conditions Which Generate This Code:
Possible Performance Effect: The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
• Engine misfires circuit or a short circuit in the circuit for the injector.

• Low power If the cause of the diagnostic code is a problem in the

common wire, two cylinders will be affected because
Perform the following diagnostic procedure: “Injector of the shared common wire for the injectors.
Solenoid Circuit - Test”
System Response:
Results:
The ECM will log the diagnostic code. The ECM will
• OK – STOP. continue to attempt to operate the injector after the
code has been logged.
48 SENR9515-05
Troubleshooting Section

The injector may not operate while the condition i02214590

exists.
CID 0005 FMI 11 Injector
Possible Performance Effect: Cylinder #5 fault
• Engine misfires SMCS Code: 1290-038

• Low power Conditions Which Generate This Code:

Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Results:
• OK – STOP.
i02214587
CID 0004 FMI 11 Injector
Cylinder #4 fault
SMCS Code: 1290-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
If the cause of the diagnostic code is a problem in the
common wire, two cylinders will be affected because
of the shared common wire for the injectors.
System Response:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
If the cause of the diagnostic code is a problem in the
common wire, two cylinders will be affected because
of the shared common wire for the injectors.
System Response:
The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
code has been logged.
The injector may not operate while the condition
exists.
Possible Performance Effect:
• Engine misfires
• Low power
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Results:
• OK – STOP.

The injector may not operate while the condition i02214594

exists.
CID 0006 FMI 11 Injector
Possible Performance Effect: Cylinder #6 fault
• Engine misfires SMCS Code: 1290-038

• Low power Conditions Which Generate This Code:

Perform the following diagnostic procedure: “Injector The Electronic Control Module (ECM) is attempting
Solenoid Circuit - Test” to operate the injector. The ECM detects an open
circuit or a short circuit in the circuit for the injector.
Results:
If the cause of the diagnostic code is a problem in the
• OK – STOP. common wire, two cylinders will be affected because
of the shared common wire for the injectors.
SENR9515-05 49
Troubleshooting Section

System Response: i02419278

The ECM will log the diagnostic code. The ECM will CID 0041 FMI 04 8 Volt DC
continue to attempt to operate the injector after the Supply short to ground
code has been logged.
SMCS Code: 1408-081; 1901-038
The injector may not operate while the condition
exists. Conditions Which Generate This Code:
Possible Performance Effect: The voltage level of the 8 volt supply is below normal.

• Engine misfires System Response:

• Low power The Electronic Control Module (ECM) logs the

diagnostic code. The ECM flags all digital sensors
Perform the following diagnostic procedure: “Injector as invalid data and all digital sensors are set to the
Solenoid Circuit - Test” respective default values.
Results: Possible Performance Effect:

• OK – STOP. • The engine may experience low power.

i02419277
Troubleshooting:

CID 0041 FMI 03 8 Volt DC Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test”
Supply short to +batt
Results:
SMCS Code: 1408-081; 1900-038; 1901-038

Conditions Which Generate This Code:

• OK – STOP.

The voltage level of the 8 volt supply is above normal. i02417388

System Response: CID 0091 FMI 08 Throttle

The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags all digital sensors
as invalid data and all digital sensors are set to the
respective default values.
Possible Performance Effect:
• The engine may experience low power.
Troubleshooting:
Perform the following diagnostic procedure: “Digital
Sensor Supply Circuit - Test”
Results:
Position signal abnormal
SMCS Code: 1915-ZS
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an
incorrect frequency on the throttle signal.
System Response:
The code is logged. The ECM flags the throttle
position as invalid data and a default value of zero
percent is used.
Possible Performance Effect:

• OK – STOP. • The engine speed is limited to low idle.

Troubleshooting:

Perform the following diagnostic procedure: “Throttle

Position Sensor Circuit - Test”

Results:

• OK – STOP.
50
Troubleshooting Section
i02424760
CID 0094 FMI 03 Fuel Pressure
open/short to +batt
SMCS Code: 1408-081; 1718-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal
voltage that is above normal.
System Response:
The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is
used.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Results:
• OK – STOP.
i02424763
CID 0094 FMI 04 Fuel Pressure
short to ground
SMCS Code: 1408-081; 1718-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) reads signal
voltage that is below normal.
System Response:
The ECM will log the diagnostic code. The ECM flags
fuel pressure as invalid data and a default value is
used.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
SENR9515-05
Results:
• OK – STOP.
i02378792
CID 0100 FMI 03 Engine Oil
Pressure open/short to +batt
SMCS Code: 1924-038
Conditions Which Generate This Code:
The signal voltage from the engine oil pressure
sensor is above 4.8 VDC for at least eight seconds.
System Response:
The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags oil pressure as
invalid data and a default value of 600 kPa (87 psi)
is used.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Results:
• OK – STOP.
i02424648
CID 0100 FMI 04 Engine Oil
Pressure short to ground
SMCS Code: 1924-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a
signal voltage that is below normal.
System Response:
The code is logged. The ECM flags oil pressure as
invalid data and a default value is used.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
SENR9515-05 51
Troubleshooting Section

Results: Possible Performance Effect:

• OK – STOP. • The engine may misfire.

i02427669
• The engine may experience reduced speed (rpm)
and/or low power.
CID 0110 FMI 03 Engine Troubleshooting:
Coolant Temperature
open/short to +batt Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
SMCS Code: 1906-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The signal voltage from the engine coolant
temperature sensor is above normal. i02378796

System Response: CID 0168 FMI 00 System

The Electronic Control Module (ECM) will log the
Voltage High
diagnostic code. The ECM flags coolant temperature SMCS Code: 1900-038
as invalid data and a default value is used. The
engine will not go into cold mode.
Conditions Which Generate This Code:
Possible Performance Effect:
Battery voltage exceeds 32 VDC for two seconds.
• The engine may misfire. System Response:
• The engine may experience reduced speed (rpm) The Electronic Control Module (ECM) will log the
and/or low power. diagnostic code.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure:
Temperature Sensor Open or Short Circuit - Test”
“Electrical Power Supply Circuit - Test”
Results:
Results:
• OK – STOP. • OK – STOP.
i02427678
i02378802

CID 0110 FMI 04 Engine CID 0168 FMI 01 System

Coolant Temperature short to
ground
SMCS Code: 1906-038
Conditions Which Generate This Code:
The signal voltage from the engine coolant
temperature sensor is below normal.
Voltage Low
SMCS Code: 1900-038
Conditions Which Generate This Code:
Battery voltage drops below 6 VDC for two seconds
for 12 volt systems, or the battery voltage drops
below 9 VDC for two seconds for 24 volt systems.

System Response: System Response:

The Electronic Control Module (ECM) will log the The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags coolant temperature diagnostic code.
as invalid data and a default value is used. The
engine will not go into cold mode.
52 SENR9515-05
Troubleshooting Section

Possible Performance Effect: i02378820

• Engine misfire CID 0172 FMI 03 Intake

Manifold Air Temp open/short
• Engine shutdown
to +batt
Troubleshooting:
SMCS Code: 1921-038
Perform the following diagnostic procedure:
“Electrical Power Supply Circuit - Test” Conditions Which Generate This Code:

Results: The signal voltage from the inlet air temperature

sensor exceeds 4.9 VDC for eight seconds.
• OK – STOP.
System Response:

i02458713 The Electronic Control Module (ECM) logs the

diagnostic code. The ECM flags Inlet air temperature
CID 0168 FMI 02 System as invalid data and a default temperature of 85 °C
Voltage intermittent/erratic (185 °F) is used.

SMCS Code: 1900-038 Possible Performance Effect:

Conditions Which Generate This Code: • Low power

While the engine is running, the battery voltage drops Troubleshooting:
below 9 VDC intermittently, or the battery voltage
drops below 9 VDC three times in a seven second Perform the following diagnostic procedure: “Engine
period. Temperature Sensor Open or Short Circuit - Test”

System Response: Results:

The Electronic Control Module (ECM) will log the • OK – STOP.

diagnostic code.
i02378836
Possible Performance Effect:
CID 0172 FMI 04 Intake
• The engine may misfire and/or shutdown
Manifold Air Temp short to
Troubleshooting: ground
Perform the following diagnostic procedure: SMCS Code: 1921-038
“Electrical Power Supply Circuit - Test”
Conditions Which Generate This Code:
Results:
The signal voltage from the inlet air temperature
• OK – STOP. sensor dropped below 0.2 VDC for eight seconds.

System Response:

The Electronic Control Module (ECM) will log the

diagnostic code. The ECM flags Inlet air temperature
as invalid data and a default value of 85 °C (185 °F)
is used.

Possible Performance Effect:

• Low power
SENR9515-05 53
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Results:
• OK – STOP.
• There are no performance effects.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”

Results:
i02385225

CID 0174 FMI 03 Fuel • OK – STOP.

Temperature open/short to
i02397885
+batt
CID 0190 FMI 02 Loss of Engine
SMCS Code: 1922-038
Speed Signal
Conditions Which Generate This Code: SMCS Code: 1907-038
The Electronic Control Module (ECM) detects signal
Conditions Which Generate This Code:
voltage that is above normal.
The Electronic Control Module (ECM) detects the
System Response:
following conditions:
The ECM will log the diagnostic code. The ECM flags
fuel temperature as invalid data and a default value • The engine has been running for three seconds,
and the engine is not cranking.
is used.

Possible Performance Effect: • The pattern of the timing ring from the primary
engine speed/timing sensor (crankshaft position) is
lost without a ramp down in engine speed (rpm).
• Low power
Troubleshooting: • The pattern of the timing ring returns within one
second of being lost.
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” • Battery voltage is greater than 9 VDC for the last
two seconds.
Results:
System Response:
• OK – STOP. The ECM will log the diagnostic code. The diagnostic
code may be viewed on a display module or on
i02424798 the electronic service tool. If a valid signal is not
received from the primary engine speed/timing
CID 0174 FMI 04 Fuel sensor, the ECM will default to the secondary engine
Temperature short to ground speed/timing sensor.

SMCS Code: 1922-038 Possible Performance Effect:

Conditions Which Generate This Code: • Engine misfires

The Electronic Control Module (ECM) detects signal • Engine shutdown

voltage that is below normal.
Note: The engine will shut down only if the primary
engine speed/timing sensor and the secondary
System Response:
engine speed/timing sensor fail.
The ECM will log the diagnostic code. The ECM flags
Troubleshooting:
fuel temperature as invalid data and a default value
is used.
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test”
54 SENR9515-05
Troubleshooting Section

Results: • The engine is not cranking.

• OK – STOP. • Communication was lost for two or more seconds.
System Response:
i02460929

CID 0190 FMI 11 Engine Speed The ECM will log the diagnostic code.

Sensor mechanical failure Possible Performance Effect:

SMCS Code: 1408-081; 1907-038 All features that depend on the CAT Data Link will
be disabled.
Conditions Which Generate This Code:
Troubleshooting:
The Electronic Control Module (ECM) detects the
following conditions: Perform the following diagnostic procedure: “CAT
Data Link Circuit - Test”
• The pattern of the timing ring from the primary
engine speed/timing sensor is lost for more than Results:
one second.
• OK – STOP.
• The signal from the secondary engine speed/timing
sensor is good.
i02428636

System Response: CID 0253 FMI 02 Personality

The ECM will log the diagnostic code. The ECM will Module mismatch
use the secondary engine speed/timing sensor.
SMCS Code: 1902-038
Possible Performance Effect:
Conditions Which Generate This Code:
• The engine may misfire and/or shutdown
The flash file that is used for replacement is for
Note: The engine will shut down only if the primary a different engine family or for a different engine
engine speed/timing sensor and the secondary application.
engine speed/timing sensor fail.
System Response:
Troubleshooting:
Caterpillar Electronic Technician (ET) will not be able
Perform the following diagnostic procedure: “Engine to clear the code.
Speed/Timing Sensor Circuit - Test”
Possible Performance Effect:
Results:
• The fuel injection system is disabled and the
• OK – STOP. engine will not start.

Troubleshooting:
i02125649

CID 0248 FMI 09 CAT Data Link
communications
SMCS Code: 1408-081; 1900-038; 1901-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects all of
the following conditions:
Check the Part Number of the Flash File
A. Restore the electrical power to the Electronic
Control Module (ECM).
B. Verify that the part number for the flash file agrees
with the latest update that is available on Service
Technician Workbench (STW), or on SIS Web.
Expected Result:

• The battery voltage to the ECM has been above 9 The correct flash file is installed in the ECM.
VDC for the last two seconds.
SENR9515-05 55
Troubleshooting Section

Results: i02348802

• OK – The correct flash file is installed in the ECM.
Repair: The engine will not start until the 253-02
diagnostic code is cleared. Clearing this code
requires factory passwords.
Acquire factory passwords. Clear the 253-02
diagnostic code. Return the engine to service.
STOP.
CID 0261 FMI 13 Engine Timing
Calibration required
SMCS Code: 1912-524
Conditions Which Generate This Code:
The timing has not been calibrated since the
Electronic Control Module (ECM) was installed or the
calibration is incorrect.

• Not OK – The correct flash file is not installed in System Response:

the ECM.
The ECM will log the diagnostic code.
Repair: Flash program the ECM with the correct
flash file. Refer to programming parameters The ECM uses default timing.
Troubleshooting, “Flash Programming”. Verify that
the problem is resolved. Possible Performance Effect:
STOP. • Engine misfires

i02125661 • Low power

CID 0254 FMI 12 Electronic • Reduced engine speed
Control Module Error • White exhaust smoke
SMCS Code: 1901-038
• Increased exhaust emissions
Conditions Which Generate This Code: Troubleshooting:
The Electronic Control Module (ECM) has detected Perform the following diagnostic procedure: “Engine
an internal fault. Speed/Timing Sensor - Calibrate”
System Response: Results:
The ECM will log the diagnostic code.
• OK – STOP.
Possible Performance Effect:
i02445665
• Engine power and engine performance may be
affected. CID 0262 FMI 03 5 Volt Sensor
DC Power Supply short to
• Any normal ECM function may be affected.
+batt
• Engine shutdown
SMCS Code: 1408-081; 1900-038
Troubleshooting:
Conditions Which Generate This Code:
Replace the ECM. Ensure that the new ECM serial
number ends with the same two characters as the The voltage level of the 5 volt supply is above normal.
old ECM serial number. Refer to Troubleshooting,
“Replacing the ECM” before replacing the ECM. System Response:

Results: The Electronic Control Module (ECM) will log the

diagnostic code. The ECM flags all 5 volt sensors
• OK – STOP. as invalid data and the respective default values are
used.
56 SENR9515-05
Troubleshooting Section

Possible Performance Effect: • Both of the switch inputs from the engine shutdown
switch are in the open state.
• The engine may experience low power.
• Both of the switch inputs from the engine shutdown
Troubleshooting: switch are in the closed state.

Perform the following diagnostic procedure: “5 Volt System Response:

Engine Pressure Sensor Supply Circuit - Test”
The ECM will log the diagnostic code. The engine
Results: shutdown switch will not function.

• OK – STOP. Possible Performance Effect:

i02445677
• The engine will shut down.

CID 0262 FMI 04 5 Volt Sensor Troubleshooting:

DC Power Supply short to Perform the following diagnostic procedure: “Engine

ground Shutdown Switch Circuit - Test”

Results:
SMCS Code: 1408-081; 1900-038

Conditions Which Generate This Code: • OK – STOP.

The 5 volt sensor supply voltage drops below normal. i02713570

System Response: CID 0268 FMI 02 Check

The Electronic Control Module (ECM) logs the
diagnostic code. The ECM flags all 5 volt sensors
as invalid data and the respective default values are
used.
Possible Performance Effect:
• The engine may experience low power.
Troubleshooting:
Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test”
Results:
• OK – STOP.
Programmable Parameters
SMCS Code: 1900-038; 1901-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects that
one or more of the programmable parameters have
not been programmed.
System Response:
The diagnostic code is not logged. Any
unprogrammed parameters are set to the default
value. Engine performance may be affected. This is
dependent on the unprogrammed parameters.
Possible Performance Effect:

i02538396 • Low power

CID 0267 FMI 02 Incorrect Troubleshooting:
Engine Shutdown Switch Use Caterpillar Electronic Technician (ET) to
inputs reprogram the system configuration parameters.
Refer to Troubleshooting, “System Configuration
SMCS Code: 1900-038 Parameters” for additional information.

Conditions Which Generate This Code: Results:

The Electronic Control Module (ECM) detects one of • A 0268-2 code is active
the following conditions:
SENR9515-05 57
Troubleshooting Section

Repair: Identify the condition that is displayed System Response:

beneath the code:
If a programmable parameter is displayed, program
that parameter with the correct value.
If “Injector Code” is displayed, load the missing
injector trim file into the ECM.
The Electronic Control Module (ECM) logs the
diagnostic code. The ECM flags turbocharger outlet
pressure as invalid data. A default value of 100 kPa
(14.5 psi) is used.
Possible Performance Effect:

STOP. • Low power

Troubleshooting:
i02378875

CID 0273 FMI 03 Turbo Outlet Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Pressure open/short to +batt
Results:
SMCS Code: 1917-038
• OK – STOP.
Conditions Which Generate This Code:

With an engine speed of zero rpm, the signal voltage i02281091

for the turbocharger outlet pressure sensor exceeds

4.95 VDC for at least two seconds.
CID 0274 FMI 03 Atmospheric
Pressure open/short to +batt
System Response:
SMCS Code: 1923-038
The Electronic Control Module (ECM) logs the
diagnostic code. The ECM flags the turbocharger Conditions Which Generate This Code:
outlet pressure as invalid data. A default value of
100 kPa (14.5 psi) is used. The signal voltage from the atmospheric pressure
sensor is above 4.8 VDC for at least eight seconds.
Possible Performance Effect:
System Response:
• Low power
The Electronic Control Module (ECM) will log
Troubleshooting: the diagnostic code. The ECM flags atmospheric
pressure as invalid data and a default value of
Perform the following diagnostic procedure: “Engine 100 kPa (15 psi) is used.
Pressure Sensor Open or Short Circuit - Test”
Possible Performance Effect:
Results:
Low power
• OK – STOP.
Troubleshooting:
i02378876
Perform the following diagnostic procedure: “Engine
CID 0273 FMI 04 Turbo Outlet Pressure Sensor Open or Short Circuit - Test”

Pressure short to ground Results:

SMCS Code: 1917-038 • OK – STOP.

Conditions Which Generate This Code:

The signal voltage for the turbocharger outlet

pressure sensor falls below 0.5 VDC for two seconds.
58 SENR9515-05
Troubleshooting Section

i02473210 Results:
CID 0274 FMI 04 Atmospheric • OK – STOP.
Pressure short to ground
i02499105
SMCS Code: 1923-038
CID 0290 FMI 04 Engine
Conditions Which Generate This Code:
Fan Pump Pressure short to
The signal voltage from the atmospheric pressure ground
sensor is below normal.
SMCS Code: 1387-038; 1408-081
System Response:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) will log
the diagnostic code. The ECM flags atmospheric The Electronic Control Module (ECM) detects a
pressure as invalid data and a default value is used. signal voltage from the fan pump pressure sensor
that is below normal.
Possible Performance Effect:
System Response:
• The engine may experience low power.
The ECM logs the diagnostic code. The ECM uses
Troubleshooting: a predefined cooling map to determine the speed of
the cooling fan.
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” Possible Performance Effect:

Results: • There are no performance effects.

• OK – STOP. Troubleshooting:

Perform the following diagnostic procedure: “Engine

i02499095
Pressure Sensor Open or Short Circuit - Test”
CID 0290 FMI 03 Engine Fan
Results:
Pump Pressure open/short to
+batt • OK – STOP.

SMCS Code: 1387-038; 1408-081 i02390257

Conditions Which Generate This Code: CID 0291 FMI 05 Engine

The Electronic Control Module (ECM) detects a
signal voltage from the fan pump pressure sensor
that is above normal.
System Response:
The ECM logs the diagnostic code. The ECM uses
a predefined cooling map to determine the speed of
the cooling fan.
Possible Performance Effect:
• There are no performance effects.
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Cooling Fan Solenoid open
circuit
SMCS Code: 1359-OD
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an
open circuit or a short to +Battery condition in the
circuit for the engine cooling fan solenoid.
System Response:
The ECM logs the diagnostic code. While the
condition is present, the ECM loses the ability to
control the engine cooling fan.
SENR9515-05 59
Troubleshooting Section

Possible Performance Effect: i02197964

• Overheating of the engine CID 0296 FMI 09 Unable

to communicate with
• Overcooling of the engine
Transmission ECM
Troubleshooting:
SMCS Code: 1901; 4801
Perform the following diagnostic procedure: “Engine
Fan Control Solenoid Circuit - Test” Conditions Which Generate This Code:

Results: The Electronic Control Module (ECM) detects one of

the following conditions:
• OK – STOP.
• Communication with the transmission cannot
be established within three seconds after ECM
i02390261 powerup.
CID 0291 FMI 06 Engine • After communication with the transmission has
Cooling Fan Solenoid short to been established, communication stops for one
second.
ground
The ECM detects all of the following conditions:
SMCS Code: 1359-OD

Conditions Which Generate This Code:

• If the transmission ECM is being flashed, the
transmission ECM is not in sleep mode.
The Electronic Control Module (ECM) detects a
short to ground condition in the circuit for the engine
• Battery voltage is greater than 19 VDC for five
seconds.
cooling fan solenoid.

System Response:
• The engine is not cranking.
System Response:
The ECM logs the diagnostic code. While the
condition is present, the ECM loses the ability to The ECM will log the diagnostic code. All transmission
control the engine cooling fan. features that rely on the data link are disabled.
Possible Performance Effect: Possible Performance Effect:
• Overheating of the engine • Transmission features that rely on the data link are
disabled.
• Overcooling of the engine
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Cat
Perform the following diagnostic procedure: “Engine Data Link Circuit - Test”
Fan Control Solenoid Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
60 SENR9515-05
Troubleshooting Section

i01895292 i02571960

CID 0297 FMI 09 Unable to CID 0342 FMI 02 Loss of

communicate with All-Wheel Secondary Engine Speed
Drive ECM signal
SMCS Code: 1901; 4801 SMCS Code: 1907-038

Conditions Which Generate This Code: Conditions Which Generate This Code:

A diagnostic code will be generated if the ECM The signal from the secondary engine speed/timing
detects one of the following conditions: sensor is intermittent or lost for less than one second.

• Communication with the all wheel drive ECM can
not be established within 3 seconds after ECM
powerup.
• After communication with the all wheel drive ECM
has been established, communication stops for 1
second.
A diagnostic code will be generated if the ECM
detects all of the following conditions:
• If the all wheel drive ECM is being flashed, the all
wheel drive ECM is not in sleep mode.
• Battery voltage is greater than 19 VDC for 5
seconds.
System Response:
The Electronic Control Module (ECM) will log the
diagnostic code.
There should not be a noticeable change in engine
response unless the signal for the primary engine
speed/timing sensor is lost. The loss of signals from
both speed/timing sensors will shut down the engine.
Possible Performance Effect:
The engine may misfire or the engine may run rough
during starting.
Troubleshooting:

• The engine is not cranking. Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test”
System Response:
Results:
The ECM will log the diagnostic code. The diagnostic
code may be viewed on a display module or on the • OK – STOP.
electronic service tool. Any features of the all wheel
drive system that rely on the data link are disabled.
i02120367

Possible Performance Effect: CID 0342 FMI 11 Secondary

• Any features of the all wheel drive system that rely Engine Speed Sensor
on the data link are disabled.
mechanical failure
Troubleshooting:
SMCS Code: 1907-038
Perform the following diagnostic procedure: “CAT Conditions Which Generate This Code:
Data Link Circuit - Test”
The signal for the secondary speed/timing sensor is
Results: intermittent or lost.
• OK – STOP. System Response:

The Electronic Control Module (ECM) will log the

diagnostic code.
SENR9515-05 61
Troubleshooting Section

Possible Performance Effect: i01942702

There should not be a noticeable change in engine CID 0545 FMI 06 Ether Start
response unless the signal for the primary sensor Relay short to ground
is also lost. The loss of both sensors will shut down
the engine. SMCS Code: 1456-038-R7
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Engine The Electronic Control Module (ECM) detects all of
Speed/Timing Sensor Circuit - Test” the following conditions:
Results: • The ECM has detected an open or a short to
ground at the output for the ether relay for at least
• OK – STOP. two seconds.

i01939089 • The driver output is on.

CID 0545 FMI 05 Ether Start • Battery voltage is greater than 9 VDC for the last
two seconds.
Relay open/short to +batt
SMCS Code: 1456-038-R7
• The ECM has been powered for at least three
seconds.
Conditions Which Generate This Code: System Response:
The Electronic Control Module (ECM) detects all of The ECM will log the diagnostic code. Ether injection
the following conditions: is disabled.
• An open circuit or a short to +Battery condition is Possible Performance Effect:
detected at the ether relay output for at least two
seconds.
• Hard starting
• The driver output is off. Troubleshooting:
• Battery voltage is greater than 9 VDC for the last Perform the following diagnostic procedure: “Ether
two seconds. Injection System - Test”
• The ECM has been powered for at least three Results:
seconds.

System Response:
• OK – STOP.

The ECM will log the diagnostic code. Ether injection i02241435
is disabled.
CID 0548 FMI 05 Throttle Lock
Possible Performance Effect: Lamp open circuit
• Hard starting SMCS Code: 1408-081; 7431-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ether The Electronic Control Module (ECM) detects all of
Injection System - Test” the following conditions:
Results: • An open circuit or a short to +Battery condition is
detected.
• OK – STOP.
• The ECM has been powered for at least two
seconds.
62 SENR9515-05
Troubleshooting Section

System Response: • There is an erroneous signal from the throttle lock

mode switch.
The ECM will log the diagnostic code. The diagnostic
code may be viewed on a display module or on the • There is an erroneous signal from the throttle
Caterpillar Electronic Technician (ET). speed set switch.

Troubleshooting: System Response:

Perform the following diagnostic procedure: “Throttle The ECM will log the diagnostic code. The diagnostic
Lock Lamp Circuit - Test” code may be viewed on a display module or on
the Caterpillar Electronic Technician (Cat ET). The
Results: throttle lock feature is disabled.

• OK – STOP. Possible Performance Effect:

i02241443
• The throttle lock feature will not be available.

CID 0548 FMI 06 Throttle Lock Troubleshooting:

Lamp short Perform the following diagnostic procedure: “Throttle

Lock Switch Circuit - Test”
SMCS Code: 1408-081; 7431-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects all of
the following conditions:
i02495060

• The ECM has detected a short to ground condition. CID 0562 FMI 09 Unable
• The ECM has been powered for at least two to Communicate with Cat
seconds.
Monitoring System
System Response:
SMCS Code: 1900-038
The ECM will log the diagnostic code. The diagnostic
Conditions Which Generate This Code:
code may be viewed on a display module or on the
Caterpillar Electronic Technician (ET).
The Electronic Control Module (ECM) has lost
communications with the Caterpillar Monitoring
Troubleshooting:
System.
Perform the following diagnostic procedure: “Throttle
System Response:
Lock Lamp Circuit - Test”
The diagnostic code is logged.
Results:
Possible Performance Effect:
• OK – STOP.
• All features that depend on communications with
i01860686 the Caterpillar Monitoring System are disabled.

CID 0549 FMI 02 Incorrect Troubleshooting:

Throttle Lock Switch inputs Perform the following diagnostic procedure: “Cat
SMCS Code: 1900-038 Data Link Circuit - Test”

Conditions Which Generate This Code: Results:

The ECM detects one of the following conditions: • OK – STOP.

SENR9515-05 63
Troubleshooting Section

i01545579 Possible Performance Effect:

CID 0600 FMI 03 Hydraulic Oil • Low power
Temperature open/short to
Troubleshooting:
+batt
Perform the following diagnostic procedure: “Engine
SMCS Code: 509T-038 Temperature Sensor Open or Short Circuit - Test”
Conditions Which Generate This Code: Results:

The ECM detects all of the following conditions: • OK – STOP.

• The ECM reads signal voltage that is above 4.8
VDC for eight seconds.

• The ECM has been powered for at least two

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic

code may be viewed on a display module or on ET.
The ECM flags hydraulic oil temperature as invalid
data.

Possible Performance Effect:

• Low power
Troubleshooting:

Perform the following diagnostic procedure: “Engine

Temperature Sensor Open or Short Circuit - Test”

Results:

• OK – STOP.

i01545617

CID 0600 FMI 04 Hydraulic Oil

Temperature short to ground
SMCS Code: 509T-038

Conditions Which Generate This Code:

The ECM detects all of the following conditions:

• The ECM reads signal voltage that is below 0.2

VDC for eight seconds.

• The ECM has been powered for at least two

seconds.

System Response:

The ECM will log the diagnostic code. The diagnostic

code may be viewed on a display module or on ET.
The ECM flags hydraulic oil temperature as invalid
data.
64
Troubleshooting Section
Troubleshooting with an
Event Code
i02378925
Event Codes
SMCS Code: 1900
The Electronic Control Module (ECM) monitors
engine operating conditions such as low oil pressure
or high coolant temperature. If an operating condition
exceeds the normal condition, an event code is
generated. The event code will be active until the
condition returns to normal. The ECM also logs the
event. Events usually indicate a mechanical problem
instead of an electronic system problem.
Events can be in the form of a warning, a derate
or a shutdown. The events that are available for
this application can be found in this section of the
document.
g01040769
Illustration 8
Output voltage from a typical analog temperature sensor
SENR9515-05
Illustration 8 shows the typical output voltage from an
analog sensor. If the output signal voltage is between
4.2 VDC and 4.8 VDC, the ECM will generate an
event code.
Monitoring System
The Caterpillar Electronic Technician (ET) can
be used to program certain monitoring system
parameters. Certain features can be enabled or
disabled and some of the trip points can be set.
Refer to the table for monitoring system parameters in
Troubleshooting, “System Configuration Parameters”
for the various features that can be programmed.
One of the following actions will be taken if an event
occurs:
“Warning” – The warning lamp will illuminate
continuously while the event is occurring.
“Derate” – The warning lamp will flash while the
event is occurring and engine power will be derated.
“Shutdown” – The warning lamp will flash while the
event is occurring and the engine will be shutdown.
If multiple derates are active, the derate that limits
the most power will be the derate that is shown.
When a selected monitoring system parameter is
programmed to “Off”, the ECM will not take any
action on the event. For example, the warning lamp
will not illuminate.
i01450805
E015 High Engine Coolant
Temperature Derate
SMCS Code: 1900
Conditions Which Generate This Code:
The ECM detects all of the following conditions:
• The engine has been running more than three
minutes. This three minute delay begins once the
engine speed is above 0 rpm.
• Engine coolant temperature is equal to 106 °C
(223 °F) or greater than 106 °C (223 °F) for more
than four seconds.
• 110-03 Engine Coolant Temperature open/short to
+batt is not active.
SENR9515-05 65
Troubleshooting Section

• 110-04 Engine Coolant Temperature short to Results:

ground is not active.
• OK – There may be an intermittent problem.
System Response:
Repair: Monitor the operation of the engine.
The ECM will log the diagnostic event. The ECM will
derate the engine power. The maximum derate is 25 Repair the problem.
percent of full power. The ECM will restore full engine
power when the engine coolant temperature falls to Ensure that the repair eliminates the problem.
104 °C (219 °F) for 20 seconds.
STOP.
Possible Performance Effect:
• Not OK
• Low power
Repair: Repair the problem.
Troubleshooting:
Ensure that the repair eliminates the problem.
• There may be a problem with the cooling system.
STOP.
• There may be a problem with the coolant
temperature sensor.
i01436529

Test Step 1. Check for Diagnostic Codes. E017 High Engine Coolant
A. Connect ET to the service tool connector. Temperature Warning
B. Turn the keyswitch to the ON position. The engine SMCS Code: 1900
should be OFF.
Conditions Which Generate This Code:
C. Check for any active diagnostic codes or logged
diagnostic codes. The ECM detects all of the following conditions:

Expected Result: • The engine has been running more than three
minutes. This three minute delay begins once the
There should be no diagnostic codes that are present. engine speed is above 0 rpm.

Results: • Engine coolant temperature is equal to 105 °C

(221 °F)or greater than 105 °C (221 °F) for more
• OK – Proceed to Test Step 2. than four seconds.

• Not OK • 110-03 Engine Coolant Temperature open/short to

Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
Ensure that the repair eliminates the problem.
STOP.
Test Step 2. Perform a Check of the
Cooling System.
A. Perform a check of the cooling system. Refer to
Troubleshooting, “Coolant Temperature is Too
High” for possible causes.
Expected Result:
There are no problems with the cooling system.
+batt is not active.
• 110-04 Engine Coolant Temperature short to
ground is not active.
System Response:
The ECM will log the warning. The ECM will transmit
a warning to the display in the cab. The ECM will
reset the warning when the coolant temperature falls
below 103 °C (217 °F) for more than four seconds.
Possible Performance Effect:
• Low power
Troubleshooting:
• There may be a problem with the cooling system.
• There may be a problem with the coolant
temperature sensor.
66
Troubleshooting Section
Test Step 1. Check for Diagnostic Codes.
A. Connect ET to the service tool connector.
B. Turn the keyswitch to the ON position. The engine
should be OFF.
C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
There should be no diagnostic codes that are present.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
Ensure that the repair eliminates the problem.
STOP.
Test Step 2. Perform a Check of the
Cooling System.
A. Perform a check of the cooling system. Refer to
Troubleshooting, “Coolant Temperature is Too
High” for possible causes.
Expected Result:
There are no problems with the cooling system.
Results:
• OK – There may be an intermittent problem.
Repair: Monitor the operation of the engine.
Repair the problem.
Ensure that the repair eliminates the problem.
STOP.
• Not OK
Repair: Repair the problem.
Ensure that the repair eliminates the problem.
STOP.
SENR9515-05
i01939099
E025 High Inlet Air
Temperature Derate
SMCS Code: 1900
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects all of
the following conditions:
• Air inlet temperature is equal to 79 °C (174 °F)
or greater than 79 °C (174 °F) for more than four
seconds.
• The engine has been running more than three
minutes. This three minute delay begins once the
engine speed is above zero rpm.
System Response:
The ECM will log the diagnostic event. The ECM
will derate engine power by three percent for each
degree celsius above 79 °C (174 °F). The maximum
derate is 80 percent of full power. The ECM will
restore full power when the air inlet temperature falls
to 77 °C (171 °F) for 20 seconds.
Possible Performance Effect:
• Low power
Troubleshooting:
• There may be a problem with the aftercooler.
• There may be a problem with the air inlet
temperature sensor.
Test Step 1. Check for Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (Cat
ET) to the service tool connector.
B. Turn the keyswitch to the ON position. The engine
should be off.
C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
No diagnostic codes are present.
Results:
• OK – Proceed to Test Step 2.
• Not OK
SENR9515-05
Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
Ensure that the repair eliminates the problem.
STOP.
Test Step 2. Perform a Check of the
Aftercooler
A. Perform a check of the aftercooler. Refer to the
appropriate topic in Testing and Adjusting for
possible causes.
Expected Result:
There are no problems with the aftercooler.
Results:
• OK – There may be an intermittent problem.
Repair: Monitor the operation of the engine.
Repair the problem.
Ensure that the repair eliminates the problem.
STOP.
• Not OK
Repair: Repair the problem.
Ensure that the repair eliminates the problem.
STOP.
i01939101
E027 High Inlet Air
Temperature Warning
SMCS Code: 1900
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects all of
the following conditions:
• Air inlet temperature is equal to 75 °C (167 °F)
or greater than 75 °C (167 °F) for more than four
seconds.
• The engine has been running more than three
minutes. This three minute delay begins once the
engine speed is above zero rpm.
67
Troubleshooting Section
System Response:
The ECM will log the warning. The ECM will transmit
a warning to the display in the cab. The ECM will
reset the warning when the air inlet temperature is
less than 73 °C (163 °F) for more than four seconds.
Possible Performance Effect:
• Low power
Troubleshooting:
• There may be a problem with the aftercooler.
• There may be a problem with the air inlet
temperature sensor.
Test Step 1. Check for Diagnostic Codes
A. Connect the Caterpillar Electronic Technician (Cat
ET) to the service tool connector.
B. Turn the keyswitch to the ON position. The engine
should be off.
C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
No diagnostic codes are present.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
Ensure that the repair eliminates the problem.
STOP.
Test Step 2. Perform a Check of the
Aftercooler
A. Perform a check of the aftercooler. Refer to the
appropriate topic in Testing and Adjusting for
possible causes.
Expected Result:
There are no problems with the aftercooler.
Results:
• OK – There may be an intermittent problem.
68 SENR9515-05
Troubleshooting Section

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

• Not OK
Repair: Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

i01449403

E039 Low Engine Oil Pressure

Derate
SMCS Code: 1900
Conditions Which Generate This Code:
The ECM detects all of the following conditions:
• The engine has been running for at least 10
seconds. This 10 second delay begins once the
engine speed is greater than 0 rpm.
• Engine oil pressure is below the trip line in
Illustration 9 for two seconds.
• 100-03 Engine Oil Pressure open/short to +batt is
not active.
• 100-04 Engine Oil Pressure short to ground is not
active.
• 100-13 Engine Oil Pressure calibration required is
not active.
g00758873
Illustration 9
System Response:
The ECM will log the derate. The ECM derates the
engine power by a maximum of 35 percent. The ECM
will restore full power when the engine oil pressure
rises above the reset line for two seconds.
Possible Performance Effect:
• Low power
Troubleshooting:
• There may be a problem with the engine lubrication
system.
• There may be a problem with the engine oil
pressure sensor.
Test Step 1. Check for Diagnostic Codes.
A. Connect ET to the service tool connector.

B. Turn the keyswitch to the ON position. The engine

should be off.

C. Check for any active diagnostic codes or logged

diagnostic codes.

Expected Result:

There should be no diagnostic codes that are present.

Results:

• OK – Proceed to Test Step 2.

• Not OK
SENR9515-05 69
Troubleshooting Section

Repair: Repair the diagnostic codes that are
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section
of this manual.
Ensure that the repair eliminates the problem.
STOP.
• 94-13 Fuel Pressure calibration required is not
active.
• 274-03 Atmospheric Pressure open/short to +batt
is not active.
• 274-04 Atmospheric Pressure short to ground is
not active.

Test Step 2. Perform a Check of the • 274-13 Atmospheric Pressure calibration required
Engine Lubrication System. is not active.

A. Perform a check of the engine lubrication system.

Refer to Troubleshooting, “Low Engine Oil
Pressure”.

Expected Result:

There are no problems with engine oil pressure.

Results:

• OK – There may be an intermittent problem.

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

• Not OK Illustration 10
g00759024

Repair: Repair the problem. System Response:

Ensure that the repair eliminates the problem. The ECM will log the warning. The ECM will transmit
a warning to the display in the cab. The ECM will
STOP. clear the warning when the fuel pressure increases
above the reset line for four seconds.
i01545623
Troubleshooting:
E053 Low Fuel Pressure
Warning • There may be a problem with the fuel system.

SMCS Code: 1900

Conditions Which Generate This Code:
The ECM detects all of the following conditions:
• The engine has been running more than 60
seconds. This 60 second delay begins once the
engine speed is above 0 rpm.
• Fuel pressure is below the trip line in Illustration
10 for ten seconds.
• 94-03 Fuel Pressure open/short to +batt is not
active.
• 94-04 Fuel Pressure short to ground is not active.
• There may be a problem with the fuel pressure
sensor.
Test Step 1. Check for Diagnostic Codes.
A. Connect ET to the service tool connector.
B. Turn the keyswitch to the ON position. The engine
should be off.
C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
There should be no diagnostic codes that are present.
70 SENR9515-05
Troubleshooting Section

Results: • Fuel pressure is above the trip line in Illustration

11 for two seconds.
• OK – Proceed to Test Step 2.
• 94-03 Fuel Pressure open/short to +batt is not
• Not OK active.

Repair: Repair the diagnostic codes that are • 94-04 Fuel Pressure short to ground is not active.
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section • 94-13 Fuel Pressure calibration required is not
of this manual. active.

Ensure that the repair eliminates the problem.

STOP.

Test Step 2. Perform a Check of the Fuel

System.
A. Perform a check of the fuel system. Refer to the
appropriate topic in Testing and Adjusting for
possible causes.

Expected Result:

There are no problems with the fuel system.

Results:

• OK – There may be an intermittent problem.

Repair: Monitor the operation of the engine.
g00759310
Illustration 11
Repair the problem.
System Response:
Ensure that the repair eliminates the problem.
The ECM will log the warning. The ECM will transmit
STOP. a warning to the display in the cab. The ECM will
clear the warning when the fuel pressure decreases
• Not OK below the reset line for ten seconds.
Repair: Repair the problem. Troubleshooting:
Ensure that the repair eliminates the problem. • There may be a problem with the fuel system.
STOP. • There may be a problem with the fuel pressure
sensor.
i01545649
Test Step 1. Check for Diagnostic Codes.
E096 High Fuel Pressure
A. Connect ET to the service tool connector.
SMCS Code: 1900
B. Turn the keyswitch to the ON position. The engine
Conditions Which Generate This Code: should be off.

The ECM detects all of the following conditions:
• The engine has been running more than 60
seconds. This 60 second delay begins once the
engine speed is above 0 rpm.
C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
There should be no diagnostic codes that are present.
SENR9515-05 71
Troubleshooting Section

Results: • Engine oil pressure is below the trip line in

Illustration 12 for two seconds.
• OK – Proceed to Test Step 2.
• 100-03 Engine Oil Pressure open/short to +batt is
• Not OK not active.

Repair: Repair the diagnostic codes that are • 100-04 Engine Oil Pressure short to ground is not
present. Refer to the appropriate topic in the active.
“Troubleshooting With a Diagnostic Code” section
of this manual.

Ensure that the repair eliminates the problem.

STOP.

Test Step 2. Perform a Check of the Fuel

System.
A. Perform a check of the fuel system. Refer to the
appropriate topic in Testing and Adjusting for
possible causes.

Expected Result:

There are no problems with the fuel system.

Results:

• OK – There may be an intermittent problem.

Repair: Monitor the operation of the engine.
Repair the problem.
Ensure that the repair eliminates the problem.
STOP.
g00752455
Illustration 12
System Response:
The ECM will log the warning. The ECM will transmit
a warning to the display in the cab. The ECM will
reset the warning when the oil pressure is above the
reset line in Illustration 12 for 20 seconds.

• Not OK Possible Performance Effect:

Repair: Repair the problem. • Low power
Ensure that the repair eliminates the problem. Troubleshooting:
STOP. • There may be a problem with the engine lubrication
system.
i01436875
• There may be a problem with the engine oil
E100 Low Engine Oil Pressure pressure sensor.
Warning Test Step 1. Check for Diagnostic Codes.
SMCS Code: 1900 A. Connect ET to the service tool connector.
Conditions Which Generate This Code: B. Turn the keyswitch to the ON position. The engine
should be off.
The ECM detects all of the following conditions:
C. Check for any active diagnostic codes or logged
• The engine has been running for at least 10 diagnostic codes.
seconds. This 10 second delay begins once the
engine speed is above 0 rpm. Expected Result:

There should be no diagnostic codes that are present.

72 SENR9515-05
Troubleshooting Section

Results: Troubleshooting:

• OK – Proceed to Test Step 2. Question the Operator

• Not OK Determine the events that caused the overspeed
of the engine. The operator may be operating the
Repair: Repair the diagnostic codes that are machine incorrectly.
present. Refer to the appropriate topic in the
“Troubleshooting With a Diagnostic Code” section Results:
of this manual.
• OK – STOP.
Ensure that the repair eliminates the problem.

STOP.

Test Step 2. Perform a Check of the

Engine Lubrication System.
A. Perform a check of the engine lubrication system.
Refer to Troubleshooting, “Low Engine Oil
Pressure”.

Expected Result:

There are no problems with engine oil pressure.

Results:

• OK – There may be an intermittent problem.

Repair: Monitor the operation of the engine.

Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

• Not OK
Repair: Repair the problem.

Ensure that the repair eliminates the problem.

STOP.

i02379465

E190 Engine Overspeed

Warning
SMCS Code: 1900

Conditions Which Generate This Code:

The engine speed has exceeded 2800 rpm.

System Response:

The Electronic Control Module (ECM) logs the event.

SENR9515-05 73
Troubleshooting Section

Diagnostic Functional
Tests
i01894349

5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1408-081; 1901-081

System Operation Description:

The Electronic Control Module (ECM) supplies a

regulated voltage of 5.0 ± 0.16 VDC to the following
sensors:

• Atmospheric pressure sensor

• Engine oil pressure sensor
• Fan drive pressure sensor
• Fuel pressure sensor
• Turbocharger outlet pressure sensor
The supply for the +5 V engine pressure sensor is
routed from the ECM to terminal A of each pressure
sensor connector. The supply voltage is 5.0 ± 0.16
VDC.

The +5 V diagnostic code is probably caused by a

short circuit to ground or a short circuit to another
voltage source in the harness.
74 SENR9515-05
Troubleshooting Section

g00806781
Illustration 13
Schematic

g00807176
Illustration 14
ECM connectors (wire side)
SENR9515-05
Illustration 15
g00810608
Sensor connector
Test Step 1. Disconnect the ECM
Connectors
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the service
tool connector.
C. Disconnect the P1 ECM connector and the P2
ECM connector from the ECM.
D. Check the connectors for corrosion and moisture.
E. Connect a 140-2266 Cable (Seventy-Pin
Breakout) at the J1/P1 ECM connector.
F. Turn the keyswitch to the ON position.
G. Check for active diagnostic codes on the electronic
service tool.
Note: An open circuit diagnostic code should be
active for all of the engine pressure sensors.
Expected Result:
The 5 volt diagnostic codes are not active. An open
circuit diagnostic code should be active for all of the
engine pressure sensors.
Results:
• OK – The 5 volt diagnostic codes are not active.
75
Troubleshooting Section
Repair: Reconnect the P2 ECM connector.
Remove the breakout T. Reconnect the P1 ECM
connector.
Proceed to Test Step 2.
• Not OK – The 5 volt diagnostic codes are still
active.
Repair: Connect a test ECM.
If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently install the new
ECM.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Disconnect the Sensors
A. Turn the keyswitch to the ON position.
B. Monitor the active diagnostic code screen on the
electronic service tool.
C. Disconnect the pressure sensors one at a time.
Wait for 30 seconds after each pressure sensor is
disconnected.
Note: The 5 volt diagnostic code will become inactive
if a pressure sensor is the cause of the 5 volt
diagnostic code.
D. Ensure that all of the pressure sensors are
disconnected.
Expected Result:
The 5 volt diagnostic code is still active when all of
the pressure sensors are disconnected.
Results:
• OK – The 5 volt diagnostic code is still active.
Repair: Leave all of the pressure sensors
disconnected.
Proceed to Test Step 4.
• Not OK – The 5 volt diagnostic code disappears
when the pressure sensors are disconnected.
Repair: Reconnect all of the pressure sensors
except the suspect sensor.
Proceed to Test Step 3.
76
Troubleshooting Section
Test Step 3. Check the Signal Wire
A. Turn the keyswitch to the ON position.
Note: The suspect sensor should be disconnected.
B. Measure the voltage between terminal C
(Signal) and terminal B (Engine Pressure Sensor
Common) of the connector for the suspect sensor
on the engine harness.
Expected Result:
The voltage should be less than 7.0 VDC.
Results:
• OK – The voltage is within the range.
Repair: Reconnect all of the pressure sensors.
Disconnect the sensor that is causing the 5 volt
diagnostic code.
Temporarily connect a new sensor.
If the problem is resolved with the new sensor,
reconnect the suspect sensor.
If the problem returns, replace the suspect sensor.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The voltage is greater than 7.0 VDC.
Repair: Inspect the signal wire for a short circuit to
a voltage source.
Repair the signal wire or replace the signal wire.
Verify that the repair eliminates the problem.
STOP.
Test Step 4. Determine the Condition that
is Present
A. Turn the keyswitch to the ON position.
B. Access the active diagnostic code screen on the
electronic service tool.
Expected Result:
262-03 or 262-04 is active.
Results:
• 262-03 – Proceed to Test Step 5.
SENR9515-05
• 262-04 – Proceed to Test Step 7.
Test Step 5. Measure the 5 Volt Supply to
the Sensor
A. Turn the keyswitch to the ON position.
Note: All of the pressure sensors should be
disconnected.
B. Measure the voltage between terminal A (Engine
Pressure Sensor +5V) and chassis ground for
each pressure sensor.
Expected Result:
The voltage should be 5.0 ± 0.16 VDC.
Results:
• OK – The 5 volt supply is within the range.
Proceed to Test Step 6.
• Not OK – The voltage is greater than 5.16 volts.
Repair: Check the 5 volt supply wire for a short to
a higher voltage source.
Repair the 5 volt supply wire or replace the 5 volt
supply wire.
Verify that the repair eliminates the problem.
STOP.
Test Step 6. Check the Common Wire
A. Turn the keyswitch to the ON position.
B. Measure the voltage between terminal A (Engine
Pressure Sensor +5V) and terminal B (Engine
Pressure Sensor Common) on all of the pressure
sensors.
C. While the voltage is monitored, perform a 45 N
(10 lb) pull test on the common wires for the 5
volt supply.
• P2:3 (Engine Pressure Sensor Common)
• P1:3 (Engine Pressure Sensor Common)
Expected Result:
The voltage should be 5.0 ± 0.16 VDC.
Results:
• OK – The voltage is within the range.
SENR9515-05 77
Troubleshooting Section

Repair: If the problem is intermittent, refer to i02182948

Troubleshooting, “Electrical Connectors - Inspect”.
STOP.
• Not OK – The voltage is not within the range.
Repair: Inspect the common wire for an open
circuit.
Repair the common wire or replace the common
wire.
Verify that the repair eliminates the problem.
Cat Data Link Circuit - Test
SMCS Code: 1408-081; 1900-081
System Operation Description:
The Cat Data Link is a two wire electrical connection
that is used for communication between electronic
modules such as the engine Electronic Control
Module (ECM), the machine control module,
electronic transmission controls, electronic dash
displays, and Caterpillar Electronic Technician (ET).

STOP.

Test Step 7. Check the Resistance of the

Harness
A. Turn the keyswitch to the OFF position.

B. Verify that all of the sensors are disconnected.

C. Measure the resistance between terminal A

(Engine Pressure Sensor +5V) and terminal B
(Engine Pressure Sensor Common) of each
pressure sensor connector.

Expected Result:

The resistance should be greater than 20,000 ohms,

or “OL” is displayed on the multimeter.

Results:

• OK – The 5 volt supply and the pressure sensor

common are not shorted.

Repair: Check the 5 volt supply for a short to

ground.

Repair the 5 volt supply wire or replace the 5 volt

supply wire.

Verify that the repair eliminates the problem.

STOP.

• Not OK – There is a short between the 5 volt

supply and the pressure sensor common.

Repair: Locate the short between the 5 volt supply

and the pressure sensor common.

Repair the faulty wiring or replace the faulty wiring.

Verify that the repair eliminates the problem.

STOP.
78 SENR9515-05
Troubleshooting Section

g00813521
Illustration 16
Schematic

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Turn the keyswitch to the OFF/RESET position.

B. Thoroughly inspect the J1/P1 ECM connector and

all other connectors in the wiring harness. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for details.

Note: Refer to the Electrical System Schematic for

further information about the machine wiring.

Expected Result:

All connectors, pins, and sockets are completely

inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK – Proceed to Test Step 2.

• Not OK
Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.
SENR9515-05 79
Troubleshooting Section

Test Step 2. Check for Shorts in the • Not OK – There is a short circuit in the harness
Harness or in a connector.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

Test Step 3. Check Resistance through

the Harness

g00699950
Illustration 17
ECM connector P1

A. Disconnect the J1/P1 ECM connector.

B. Disconnect all modules from the Cat Data Link.

C. Disconnect Cat ET from the service tool connector.

g00699950
D. Measure the resistance between P1:8 (Cat Data Illustration 18
Link +) and P1:9 (Cat Data Link −). ECM connector P1

E. Measure the resistance between P1:8 (Cat Data A. Use a suitable piece of wire to short J62:D (Cat
Link +) and chassis ground. Data Link +) and J62:E (Cat Data Link −) at the
service tool connector.
F. Measure the resistance between P1:9 (Cat Data
Link −) and chassis ground. B. Measure the resistance between P1:8 (Cat Data
Link +) and P1:9 (Cat Data Link −).
Expected Result:
C. Measure the resistance across the Cat Data Link
The resistance is greater than 20,000 Ohms for each at the other modules.
measurement.
Expected Result:
Results:
The resistance ia less than 10 Ohms for each
• OK – Proceed to Test Step 3. measurement.
80 SENR9515-05
Troubleshooting Section

Results:

• OK – The Cat Data Link is OK.

Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the problem is intermittent.

STOP.

• Not OK – There is an open circuit or excessive

resistance in the harness or in a connector.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

i01554118

Digital Sensor Supply Circuit

- Test
SMCS Code: 1408-081; 1900-081-NS

System Operation Description:

The digital sensor supply provides power to the

throttle position sensor. The ECM supplies the digital
sensor with 8.0 ± 0.5 VDC.

The digital sensor supply is output short circuit

protected. The ECM is protected from a short to
ground and a short to + battery condition. The digital
sensor is NOT protected.

g00807537
Illustration 19
Schematic

Test Step 1. Inspect Electrical Connectors B. Thoroughly inspect the J1/P1 ECM connector,
and Wiring the J61/P61 machine connector, and all other
connectors in the circuit. Refer to Troubleshooting,
A. Turn the keyswitch to the OFF/RESET position. “Electrical Connectors - Inspect” for details.
SENR9515-05 81
Troubleshooting Section

Expected Result:

All connectors, pins, and sockets should be

completely inserted and coupled. The harness and
wiring should be free of corrosion, abrasion, and
pinch points. All connections and grounds should be
tight and free of corrosion.

Results:

• OK – Proceed to Test Step 2.

• Not OK
Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check for Shorts in the

Harness from the ECM to the Digital
Sensor

g00807533
Illustration 20
ECM connector P1

A. Disconnect ECM connector J1/P1 and the digital • Not OK – There is a short between the ECM and
sensor. the sensor.

B. Measure the resistance between P1:4 (Digital Repair: Repair the circuit.
Sensor +8 VDC) and engine ground.
STOP.
C. Measure the resistance between P1:4 (Digital
Sensor +8 VDC) and P1:5 (Digital Sensor Return).

D. Leave the J1/P1 ECM connector and the digital

sensor disconnected.

Expected Result:

The resistance should be greater than 20,000 Ohms

for each measurement.

Results:

• OK – Proceed to Test Step 3.

82
Troubleshooting Section
Test Step 3. Check for Open Circuits in
the Harness Between the ECM and the
Digital Sensor
Illustration 21
Note: The J1/P1 ECM connector and the digital
sensor should still be disconnected.
A. Install a jumper wire between P1:4 (Digital Sensor
+8 VDC) and P1:5 (Digital Sensor Return).
B. Measure the resistance between terminal A (+8
VDC) and terminal B (Return) of the connector for
the digital sensor.
Expected Result:
The resistance should be less than 10 Ohms for each
measurement.
Results:
• OK – Proceed to Test Step 4.
• Not OK – There is an open circuit in the wiring
harness between the sensor and the ECM.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 4. Check the Digital Sensor
Supply Voltage at the Sensor Connector
A. Disconnect the digital sensor.
B. Turn the keyswitch to the ON position.
C. Measure the voltage across terminal A (+8 VDC)
and terminal B (Return) of the connector for the
digital sensor.
SENR9515-05
g00807533
Expected Result:
The digital sensor supply voltage should be 8.0 ± 0.5
VDC.
Results:
• OK – The supply voltage is reaching the sensor.
Proceed to Test Step 5.
• Not OK – The supply voltage is not reaching the
sensor. Proceed to Test Step 7.
Test Step 5. Check the Digital Sensor for
an Internal Short
A. Install a 7X-6370 Adapter Cable (3 Pin DT
Breakout) at the sensor connector, but do not
connect the sensor to the breakout at this time.
B. Turn the keyswitch to the ON position.
C. Reconnect the digital sensor while you observe
the voltage across terminals A (Digital Sensor +8
VDC) and B (Return) at the breakout.
Expected Result:
The supply voltage should be 8.0 ± 0.5 VDC.
The voltage should not drop when the sensor is
connected.
Results:
• OK – The sensor does not have an internal short.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the problem is intermittent.
STOP.
SENR9515-05 83
Troubleshooting Section

• Not OK – The sensor may have an internal short.

Proceed to Test Step 6.

Test Step 6. Temporarily Install a New

Sensor
A. Disconnect the suspect sensor and remove the
suspect sensor.

B. Turn the keyswitch to the ON position.

C. Temporarily connect a new sensor to the breakout

while you observe the voltage across terminals
A (Digital Sensor +8 VDC) and B (Return) at the
breakout.

Expected Result:

The supply voltage should be 8.0 ± 0.5 VDC.

The voltage should not drop when the sensor is
connected.

Results:

• OK – The suspect sensor was faulty.

Repair: Permanently install the new sensor.

STOP.

• Not OK – The sensor and the circuit appear to be

OK at this time.

Repair: Refer to Troubleshooting, “Electrical

Connectors - Inspect” if the problem is intermittent.

STOP.

Test Step 7. Check the Digital Sensor

Supply Voltage at the ECM

g00807533
Illustration 22
J1/P1 breakout

A. Install a 140-2266 Adapter Cable (70 Pin C. Measure the voltage across P1:4 (Digital Sensor
Breakout) at the J1/P1 ECM connector. +8 VDC) and P1:5 (Digital Sensor Return) at the
breakout.
B. Turn the keyswitch to the ON position.
84 SENR9515-05
Troubleshooting Section

Expected Result: • Always use a 147-6456 Wedge Removal Tool to

remove wedges from DT connectors. Never use a
The supply voltage should be 8.0 ± 0.5 VDC. screwdriver to pry a wedge from a connector.

Results: • Always use a breakout harness for a voltmeter

• OK – The ECM is supplying the correct voltage.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the problem is intermittent.
STOP.
probe or a test light. Never break the insulation
of a wire in order to access to a circuit for
measurements.
• If a wire is cut, always install a new terminal for
the repair.

• Not OK – The ECM is not supplying the correct

voltage.
Repair: Verify your results.
Replace the ECM. Refer to Troubleshooting,
“Replacing the ECM” before replacing the ECM.
Verify that the repair eliminates the problem.
STOP.
The connection of any electrical equipment and
the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
explosive atmosphere.
Test Step 1. Check Connectors for
Moisture and Corrosion

i02378207

Electrical Connectors - Inspect

SMCS Code: 1408-040-CY

System Operation Description:

Most electrical problems are caused by poor

connections. The following procedure will assist in
detecting problems with connectors and with wiring.
If a problem is found correct the condition and verify
that the problem is resolved.

Intermittent electrical problems are sometimes

resolved by disconnecting and reconnecting
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a g01131211
Illustration 23
connector, there are several possible reasons. The Leaky seal at the connector (typical example)
likely reasons are loose terminals, improperly crimped
terminals, moisture, corrosion, and inadequate A. Inspect all wiring harnesses. Ensure that the
mating of a connection. routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
Follow these guidelines: angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 23. This will create a
• Always use a 1U-5804 Crimp Tool to service path for the entrance of moisture. Verify that the
Deutsch HD and DT connectors. Never solder the seals for the wires are sealing correctly.
terminals onto the wires. Refer to “SEHS9615,
Servicing Deutsch HD and DT Style Connectors”.
SENR9515-05
g01131276
Illustration 24
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
B. Ensure that the sealing plugs are in place. If
any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 24.
Illustration 25
g01131019
Seal for a three-pin connector (typical example)
85
Troubleshooting Section
g01131165
Illustration 26
Seal for ECM connector (typical example)
C. Disconnect the suspect connector and inspect the
connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.
D. Thoroughly inspect the connectors for evidence
of moisture entry.
Note: It is normal to see some minor seal abrasion
on connector seals. Minor seal abrasion will not allow
the entry of moisture.
If moisture or corrosion is evident in the connector,
the source of the moisture entry must be found and
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired,
the problem will recur. Simply drying the connector
will not fix the problem. Check the following items
for the possible moisture entry path:
• Missing seals
• Improperly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
connector, thoroughly check the connector’s
harness for damage. Also check other connectors
that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.
86 SENR9515-05
Troubleshooting Section

Expected Result: Expected Result:

The harness wiring, connectors, and seals are in
good condition. There is no evidence of moisture in
the connectors.
Results:
• OK – The harness wiring, connectors, and seals
are in good condition. Proceed to Test Step 2.
• Not OK – A problem has been found with the
harness or the connectors.
Repair: Repair the connectors or the wiring, as
required. Ensure that all of the seals are properly
in place. Ensure that the connectors have been
reattached.
If corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion.
If moisture was found in the connectors, run the
engine for several minutes and check again for
moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to
replace the wires.
The wires are free of abrasion, of nicks, and of cuts
and the harness is properly clamped.
Results:
• OK – The harness is OK. Proceed to Test Step 3.
• Not OK – There is damage to the harness.
Repair: Repair the wires or replace the wires,
as required. Verify that the repair eliminates the
problem.
STOP.
Test Step 3. Inspect the Connector
Terminals
A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
Verify that the terminals are properly aligned in
the connector and verify that the terminals are
properly located in the connector.
Expected Result:
The terminals are properly aligned and the terminals
appear undamaged.

Verify that the repair eliminates the problem. Results:

STOP. • OK – The terminals are OK. Proceed to Test Step

4.
Test Step 2. Check the Wires for Damage
to the Insulation • Not OK – The terminals of the connector are
damaged.
A. Carefully inspect each wire for signs of abrasion,
of nicks, and of cuts. Repair: Repair the terminals and/or replace the
terminals, as required.
Inspect the wires for the following conditions:
Verify that the repair eliminates the problem.
• Exposed insulation
STOP.
• Rubbing of a wire against the engine
• Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion
of wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
SENR9515-05
Test Step 4. Perform a Pull Test on Each
Wire Terminal Connection
g01131435
Illustration 27
Receptacle lock wedge (typical example)
A. Ensure that the locking wedge for the connector
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
installed properly.
B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test
checks whether the wire was properly crimped
in the terminal and whether the terminal was
properly inserted into the connector.
Expected Result:
Each terminal and each connector easily withstands
45 N (10 lb) of pull and each wire remains in the
connector body.
Results:
• OK – All terminals pass the pull test. Proceed to
Test Step 5.
• Not OK – A wire has been pulled from a terminal
or a terminal has been pulled from the connector.
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as
required. Verify that the repair eliminates the
problem.
STOP.
87
Troubleshooting Section
Test Step 5. Check Individual Pin
Retention into the Socket
g01131604
Illustration 28
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for
the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
pin by the socket.
Expected Result:
The sockets provide good retention for the new pin.
Results:
• OK – The terminals are OK. Proceed to Test Step
6.
• Not OK – Terminals are damaged.
Repair: Use the 1U-5804 Crimp Tool to replace
the damaged terminals. Verify that the repair
eliminates the problem.
STOP.
Test Step 6. Check the Locking
Mechanism of the Connectors
A. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.
B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
the connector returns to the locked position.
Expected Result:
The connector will securely lock. The connector and
the locking mechanism are without cracks or breaks.
Results:
• OK – The connectors are in good repair. Proceed
to Test Step 7.
88 SENR9515-05
Troubleshooting Section

• Not OK – The connector’s locking mechanism is

damaged or missing.

Repair: Repair the connector or replace the

connector, as required. Verify that the repair
eliminates the problem.

STOP.

Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged. g01132863
Illustration 31
A. Connect the ECM connectors. Allen head screw for the 40 pin ECM connector (typical example)

c. Torque the allen head screw for the 40 pin ECM

connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

g01132827
Illustration 29
Allen head screw for the 120 pin ECM connector (typical example)

g01133047
a. Torque the allen head bolt for the 120 pin ECM Illustration 32
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)

B. Connect the customer connector.

Torque the allen head screw for the 40 pin

customer connector and the 70 pin customer
connector to 2.25 ± 0.25 N·m (20 ± 2 lb in).

Expected Result:

The ECM connector is secure and the allen head

screws are properly torqued.

Results:

Illustration 30
g01132849
• OK – The ECM connectors and the customer
Allen head screw for the 70 pin ECM connector (typical example) connector is properly connected. Proceed to Test
Step 8.
b. Torque the allen head screw for the 70
pin ECM connector to 6.0 + 1.5 - 0.5 N·m • Not OK – The allen head screws for the ECM
(55 + 13 - 4 lb in). connector or the customer connector is damaged.
SENR9515-05 89
Troubleshooting Section

Repair: Repair the connector or replace the
connector, as required. Verify that the repair
eliminates the problem.
STOP.
Test Step 8. Perform the “Wiggle Test” on
the Caterpillar Electronic Technician (ET)
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET.
The cause of an intermittent power supply to the ECM
can occur on either the positive side (unswitched +
battery) or the negative side. Both sides are routed
from the ECM to the battery.
Usually, battery power to the service tool connector
is independent of the keyswitch. Therefore, you will
be able to power up ET, but you may not be able to
communicate with the engine ECM. The engine ECM
requires the keyswitch to be in the ON position in
order to establish communications.

B. Choose the appropriate group of parameters to
monitor.
C. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent problems.
If an intermittent problem exists, the status will be
highlighted and an audible beep will be heard.
For intermittent problems such as intermittent
shutdowns that could be caused by machine wiring,
temporarily bypassing the machine wiring may be
an effective means of determining the root cause. If
the symptoms disappear with the bypass wiring, the
machine wiring is the cause of the problem. A means
of bypassing machine wiring is explained in this test
procedure.

Expected Result:

No intermittent problems were indicated during the

“Wiggle Test”.

Results:

• OK – No intermittent problems were found. The

harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.

• Not OK – At least one intermittent problem was

indicated.

Repair: Repair the harness or the connector. Verify

that the repair eliminates the problem.

STOP.

i01556179

Electrical Power Supply Circuit

- Test
SMCS Code: 1408-081; 1900-081

System Operation Description:

Engine shutdowns that are accompanied by a loss of

other electrical accessories indicate a problem in the
keyswitch or the relay circuit. This does not indicate a
problem in the wiring at the ECM. Verify that there are
no problems with the starting system or the charging
system before you use this test.
90 SENR9515-05
Troubleshooting Section

g00809336
Illustration 33
Schematic

Note: The 307-OR wire that is connected to P1:64

(Keyswitch (Start)) is not currently utilized by the
ECM.

Test Step 1. Inspect Electrical Connectors

and Wiring

g00809337
Illustration 34
ECM connector P1 (wire side)

A. Thoroughly inspect the J1/P1 ECM connector, the
battery connections, and the connections to the
keyswitch. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
B. Perform a 45 N (10 lb) pull test on each of the wires
in the ECM connector that are associated with the
electrical power supply. Refer to Illustration 34.
C. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
SENR9515-05 91
Troubleshooting Section

D. Check the harness and wiring for abrasions and

for pinch points from the battery to the ECM. Also,
check the harness and wiring for abrasions and
for pinch points from the keyswitch to the ECM.

Expected Result:

All connectors, pins, and sockets should be

completely coupled and/or inserted. The harness and
wiring should be free of corrosion, abrasion, and/or
pinch points.

Results:

• OK – Proceed to Test Step 2.

• Not OK – There is a problem with the connectors
or wiring.

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

STOP.

Test Step 2. Check the Battery Voltage at

the Batteries
A. Measure the no-load battery voltage and load
test the batteries. Use the 4C-4911 Battery Load
Tester. Refer to Special Instruction, SEHS9249,
“Use of 4C-4911 Battery Load Tester for 6, 8
and 12 Volt Lead Acid Batteries” and Special
Instruction, SEHS7633, “Battery Test Procedure”.

Expected Result:

The battery voltage is OK and the batteries pass the

load test.

Results:

• OK – Proceed to Test Step 3.

• Not OK
Repair: Recharge or replace the faulty batteries.
Verify that the repair eliminates the problem.

STOP.
92 SENR9515-05
Troubleshooting Section

Test Step 3. Check the Unswitched

Battery Voltage at the ECM

g00809340
Illustration 35
ECM connector P1 (ECM side)

A. Ensure that the keyswitch is in the OFF position.

B. Disconnect the J1/P1 ECM connector.

C. Measure the voltage between all of the +Battery

terminals and all of the −Battery terminals in the
P1 ECM connector. Refer to Illustration 35.

Expected Result:

The measured voltage is a constant voltage that is

within ± 1 VDC of battery voltage.

Results:

• OK – The ECM is receiving the correct unswitched

battery voltage. Proceed to Test Step 4.

• Not OK
Repair: If an intermittent condition is suspected,
refer to Troubleshooting, “Electrical Connectors -
Inspect”.

Isolate the circuit that is not providing the correct

voltage. Repair the circuit. Verify that the repair
eliminates the problem.

STOP.
SENR9515-05 93
Troubleshooting Section

Test Step 4. Check the Keyswitch Voltage

at the ECM

g00809340
Illustration 36
ECM connector P1 (ECM side)

A. Ensure that the J1/P1 ECM connector is

disconnected.
B. Turn the keyswitch to the ON position.
C. Measure the voltage between P1:70 (Keyswitch
(Run)) and P1:63 (−Battery).
NOTICE
Do Not connect the bypass harness to the battery un-
til the 20 Amp in-line fuse has been removed from the
+Battery line. If the fuse is not removed before con-
nection to the battery, a spark may result.

D. Turn the keyswitch to the OFF position and

reconnect the J1/P1 ECM connector.

Expected Result:

The measured voltage is a constant voltage that is

within ± 1 VDC of battery voltage.

Results:

• OK – The ECM is receiving the correct voltage at

this time. Proceed to Test Step 5.

• Not OK
Repair: Repair the keyswitch circuit. Verify that the
repair eliminates the problem.

STOP.

Test Step 5. Bypass the Machine Wiring

Batteries give off flammable fumes which can ex-

plode.

To avoid injury or death, do not strike a match,

cause a spark, or smoke in the vicinity of a battery.
94
Troubleshooting Section
Illustration 37
Bypass harness
Note: This bypass harness is only for test
applications. This bypass harness may be left only
temporarily on the vehicle. The bypass harness can
be used in order to determine if the cause of the
intermittent problem is interruptions in battery power
to the ECM or the keyswitch circuit.
A. Turn the keyswitch to the OFF position.
B. Disconnect the J1/P1 ECM connector.
C. Connect a bypass harness to the J1/P1 ECM
connector.
D. Remove the 20 Amp in-line fuse from the positive
battery circuit of the bypass harness and connect
the alligator clamps directly to the battery posts.
Note: This bypass directly connects the circuit for the
keyswitch to the ECM. The ECM will remain powered
until the positive battery circuit is interrupted. Remove
the 20 Amp fuse from the in-line fuse holder in order
to power down the ECM. Do not connect the bypass
to the battery posts without first removing the 20
Amp in-line fuse. Do not remove the bypass from
the battery posts without first removing the 20 Amp
in-line fuse.
E. Connect an ET to the service tool connector of
the bypass harness and verify that communication
is established.
F. Restore all wiring to the original condition after
testing.
SENR9515-05
g00781203
Expected Result:
Installing the bypass eliminates the problem.
Note: The status of the keyswitch will always indicate
“On” while the bypass harness is installed.
Results:
• OK – The symptoms disappear when the bypass
harness is installed. Also, the symptoms return
when the bypass harness is removed. The problem
is in the machine wiring that supplies power to the
ECM. Repair the wiring that supplies power to the
ECM. STOP.
• Not OK
Repair: Connect the bypass to another battery and
verify if the problem is resolved. If the problem is
resolved, the problem is with the machine batteries.
If the problem still exists, temporarily connect
a test ECM. Remove all jumpers and replace
all connectors. Recheck the system for active
diagnostic codes and repeat the Test Step. If the
problem is resolved with the test ECM, reconnect
the suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05 95
Troubleshooting Section

i01565793

Engine Fan Control Solenoid

Circuit - Test
SMCS Code: 1359-081-OD

System Operation Description:

The ECM controls the speed of the fan by controlling

the current to the fan control solenoid. The fan
control solenoid controls the displacement of the
hydraulic pump that supplies pressurized oil to the
fan motor. The fan control solenoid is controlled by
a signal between 0.65 and 1.8 Amp. The fan pump
defaults to maximum pressure and a diagnostic code
is generated if no signal is sent to the solenoid.

g00813712
Illustration 38
Schematic

Test Step 1. Inspect Electrical Connectors Verify that the repair eliminates the problem.
and Wiring
STOP.
A. Turn the keyswitch to the OFF/RESET position.
Test Step 2. Check the Resistance
B. Thoroughly inspect the J1/P1 ECM connector through the Solenoid
and all other connectors in the circuit. Refer to
Troubleshooting, “Electrical Connectors - Inspect” A. Disconnect the J508/P508 fan control solenoid
for details. connector.

Expected Result: B. Measure the resistance of the sensor between

All connectors, pins, and sockets should be
completely inserted and coupled. The harness and
wiring should be free of corrosion, abrasion, and
pinch points. All connections and grounds should be
tight and free of corrosion.
J508:1 (Fan Control Solenoid) and J508:2
(Solenoid Return).
Expected Result:
Resistance should be between 4.5 and 5.5 Ohms.

Results: Results:

• OK – Proceed to Test Step 2. • OK – Proceed to Test Step 4.

• Not OK • Not OK – There may be a problem with the fan
control solenoid. Proceed to Test Step 3.
Repair: Repair the circuit.
96 SENR9515-05
Troubleshooting Section

Test Step 3. Temporarily Install a New

Fan Control Solenoid
A. Remove the fan control solenoid.

B. Temporarily install a new fan control solenoid.

C. Start the engine. Ensure that the keyswitch is in

the ON position.

D. Compare the status for “Fan Pump Pressure” to

the status for “Desired Fan Pump Pressure” on ET.

E. Turn the keyswitch to the OFF/RESET position.

Expected Result:

The status for “Fan Pump Pressure” should closely

correlate with the status for “Desired Fan Pump
Pressure”.

Results:

• OK – The fan control solenoid was faulty.

Repair: Permanently install the new fan control
solenoid.

Verify that the repair eliminates the problem.

STOP.

• Not OK – There may be a problem with the

harness. Proceed to Test Step 4.

Test Step 4. Check for Shorts in the

Harness

g00815132
Illustration 39
ECM connector P1

A. Disconnect the J1/P1 ECM connector and the C. Measure the resistance between P1:51 (Solenoid
J508/P508 fan control solenoid connector. Return) and chassis ground.

B. Measure the resistance between P1:43 (Fan D. Measure the resistance between P1:43 (Fan
Control Solenoid) and chassis ground. Control Solenoid) and P1:51 (Solenoid Return).
SENR9515-05 97
Troubleshooting Section

Expected Result:

The resistance for each measurement should be

greater than 20,000 Ohms.

Results:

• OK – Proceed to Test Step 5.

• Not OK – There is a short between the ECM and
the fan control solenoid.

Repair: Repair the circuit.

STOP.

Test Step 5. Check for Open Circuits in

the Harness

g00815132
Illustration 40
ECM connector P1

A. Ensure that the keyswitch is in the OFF/RESET Verify that the repair eliminates the problem.
position and that the J1/P1 ECM connector is
disconnected. STOP.

B. Use a suitable piece of wire to short P1:43 (Fan Test Step 6. Compare “Fan Pump
Control Solenoid) and P1:51 (Solenoid Return). Pressure” to “Desired Fan Pump
Pressure”
C. Disconnect the J508/P508 fan ontrol solenoid
connector. A. Start the engine.

D. Measure the resistance between P508:1 (Fan B. Compare the status for “Fan Pump Pressure” to
Control Solenoid) and P508:2 (Solenoid Return). the status for “Desired Fan Pump Pressure” on ET.

Expected Result: C. Turn the keyswitch to the OFF/RESET position.

The resistance should be less than 10 Ohms. Expected Result:

Results: The status for “Fan Pump Pressure” should closely

correlate with the status for “Desired Fan Pump
• OK – Proceed to Test Step 6. Pressure”.

• Not OK – There is an open circuit in the wiring Results:

harness between the fan control solenoid and the
ECM. • OK – The system is functioning correctly.
Repair: Repair the circuit.
98 SENR9515-05
Troubleshooting Section

Repair: Refer to Troubleshooting, “Electrical i01894351

Connectors - Inspect” if the problem is intermittent.
STOP.
• Not OK – Proceed to Test Step 7.
Test Step 7. Measure the Current to the
Fan Control Solenoid
A. Reconnect the J1/P1 ECM connector.
B. The J508/P508 fan control solenoid connector
should still be disconnected. Install a jumper wire
between J508:2 and P508:2.
C. Connect an ammeter that is capable of
withstanding a 5 Amp current between J508:1 and
P508:1.
D. Start the engine and observe the reading on the
ammeter that is installed in the circuit.
E. Turn the keyswitch to the OFF/RESET position.
F. Remove the ammeter and the jumper wire from
the circuit.
G. Reconnect the J508/P508 fan control solenoid
connector.
Expected Result:
The ECM should be supplying between 0.65 and 1.8
Amp to the fan control solenoid.
Results:
Engine Pressure Sensor Open
or Short Circuit - Test
SMCS Code: 1408-081; 1917-081; 1923-081;
1924-081
System Operation Description:
Use this procedure to troubleshoot the system only
when there is an active diagnostic code or when
a diagnostic code can easily be activated. This
procedure covers open circuit diagnostic codes and
short circuit diagnostic codes that are associated with
the following sensors:
• Atmospheric pressure sensor
• Engine oil pressure sensor
• Fan drive pressure sensor
• Fuel pressure sensor
• Turbocharger outlet pressure sensor
The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Electronic Control Module (ECM) sends a 5 Volt
supply to terminal A of each sensor. The sensor
common connection is connected to terminal B of
each sensor. The signal voltage from terminal C of
each sensor is sent to the appropriate terminal on
the ECM.

• OK – The ECM appears to be supplying the

correct current to the solenoid. Either the pump or
the motor may not be responding correctly.

Repair: Troubleshoot the hydraulic system. Refer

to Testing and Adjusting, “Hydraulic and Steering
System”.

STOP.

• Not OK – The ECM may not be producing a valid

supply.

Repair: Verify your results.

Replace the ECM. Refer to Troubleshooting,

“Replacing the ECM” before replacing the ECM.

Verify that the repair eliminates the problem.

STOP.
SENR9515-05 99
Troubleshooting Section

g00806781
Illustration 41
Schematic

g00807176
Illustration 42
ECM connectors (wire side)
100 SENR9515-05
Troubleshooting Section

Test Step 2. Inspect Electrical Connectors

And Wiring
A. Thoroughly inspect the J1/P1 ECM connector, the
J2/P2 ECM connector, and any connectors that
are associated with the suspect pressure sensor.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.

B. Perform a 45 N (10 lb) pull test on each of the

wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.

C. Check the ECM connector (Allen Head Screw) for

the proper torque of 6.0 N·m (55 lb in).

D. Check the harness and wiring for abrasion and

pinch points from the sensors back to the ECM.

Expected Result:
g00810608
Illustration 43
Sensor connector
All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring
Test Step 1. Check for Active +5 V Sensor should be free of corrosion, abrasion or pinch points.
Supply Diagnostic Codes
Results:
A. Connect the electronic service tool to the service
tool connector. • OK – Proceed to Test Step 3.

B. Turn the keyswitch to the ON position. Wait at • Not OK

least 15 seconds for activation of the diagnostic
codes.
C. Verify that neither of the following diagnostic
codes are active:
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the repair eliminates the problem.

• 262-03 5 Volt Sensor Supply short to +batt
Clear all logged diagnostic codes.
• 262-04 5 Volt Sensor Supply short to ground
Expected Result: STOP.

Neither of the preceding diagnostic codes are active.
Results:
• OK – The diagnostic codes are not active. Proceed
to Test Step 2.
• Not OK – At least one of the diagnostic codes is
active.
Test Step 3. Determine the Condition that
is Present
A. Turn the key switch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
B. Monitor the active diagnostic code screen on the
electronic service tool.

Repair: Perform the following diagnostic C. Determine if the problem is related to an open
procedure: Troubleshooting, “5 Volt Engine circuit diagnostic code or a short circuit diagnostic
Pressure Sensor Supply Circuit - Test”. code.

STOP. Expected Result:

Either an open circuit diagnostic code or a short

circuit diagnostic code is active.
SENR9515-05
Results:
• Short Circuit – A short circuit diagnostic code is
active at this time. Proceed to Test Step 4.
• Open Circuit – An open circuit diagnostic code is
active at this time. Proceed to Test Step 7.
Test Step 4. Disconnect the Suspect
Sensor
A. Turn the keyswitch to the OFF position.
B. Disconnect the sensor with the short circuit
diagnostic code.
C. Turn the keyswitch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
D. Check for an active open circuit diagnostic code
for the disconnected sensor.
Expected Result:
An open circuit diagnostic code is now active for the
disconnected sensor.
Results:
• OK – A short circuit diagnostic code was active
before disconnecting the sensor. An open circuit
diagnostic code became active after disconnecting
the sensor.
Repair: Temporarily connect a new sensor.
Check for active diagnostic codes.
If the new sensor fixes the problem, reconnect the
suspect sensor.
If the problem returns, permanently install the new
sensor.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is a short circuit between the
sensor and the ECM.
Repair: Leave the suspect sensor disconnected.
Proceed to Test Step 5.
Test Step 5. Create an Open Circuit at the
ECM
A. Turn the keyswitch to the OFF position.
B. Remove the signal wire of the suspect sensor
from the appropriate ECM connector.
101
Troubleshooting Section
C. Turn the keyswitch to the ON position.
D. Check for active diagnostic codes.
Expected Result:
An open circuit diagnostic code became active after
removing the signal wire.
Results:
• OK – A short circuit diagnostic code was active
before removing the signal wire. An open circuit
diagnostic code became active after removing the
signal wire. Proceed to Test Step 6.
• Not OK – There is still a short circuit diagnostic
code.
Repair: Connect a test ECM.
If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
suspect ECM.
Verify that the repair eliminates the problem.
STOP.
Test Step 6. Check the Resistance of the
Harness
A. Turn the keyswitch to the OFF position.
B. Verify that the suspect sensor is disconnected.
C. Measure the resistance between terminal B
(Engine Pressure Sensor Common) and terminal
C (Signal) of the connector for the suspect sensor
on the engine harness.
Expected Result:
The resistance is greater than 20,000 ohms, or “OL”
is displayed on the multimeter.
Results:
• OK – The resistance is greater than 20,000 ohms,
or “OL” is displayed on the multimeter.
Repair: Check the signal wire for a short to ground.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is a short between the pressure
sensor common and the signal wire.
102
Troubleshooting Section
Repair: Locate the short between the pressure
sensor common and the signal wire.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.
Test Step 7. Measure the Sensor Supply
Voltage
A. Turn the key switch to the OFF position.
B. Disconnect the suspect sensor.
C. Turn the keyswitch to the ON position.
D. Measure the voltage from terminal A (Engine
Pressure Sensor +5V) to terminal B (Engine
Pressure Sensor Common).
Expected Result:
The voltage is 5.0 ± 0.16 VDC.
Results:
• OK – The sensor supply voltage is correct.
Repair: Leave the sensor disconnected.
Proceed to Test Step 8.
• Not OK – The sensor supply voltage is out of the
range.
Repair: Check the 5 volt supply wire for an open
circuit.
Repair the faulty wiring or replace the faulty wiring.
Verify that the repair eliminates the problem.
STOP.
Test Step 8. Create a Short Circuit at the
Sensor
A. Turn the keyswitch to the ON position.
B. Monitor the active diagnostic code screen.
C. Install a jumper wire between terminal C
(Signal) and terminal B (Engine Pressure Sensor
Common) of the connector for the suspect sensor
on the engine harness. Wait at least 15 seconds
for activation of the short circuit diagnostic code.
SENR9515-05
Expected Result:
A short circuit diagnostic code is active when the
jumper wire is installed. An open circuit diagnostic
code is active when the jumper wire is removed.
Results:
• OK – The engine harness and the ECM are OK.
Repair: Temporarily connect a new sensor.
If the new sensor fixes the problem, reconnect the
suspect sensor.
If the problem returns, permanently replace the
suspect sensor.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The open circuit diagnostic code remains
active when the jumper wire is installed.
Repair: Remove the jumper wire.
Proceed to Test Step 9.
Test Step 9. Create a Short Circuit at the
ECM
A. Turn the keyswitch to the OFF position.
B. Disconnect the ECM connector that is associated
with the suspect sensor.
Note: If the suspect sensor is connected to the
J1/P1 ECM connector, connect a 140-2266 Cable
(Seventy-Pin Breakout) at the J1/P1 ECM connector.
C. Turn the keyswitch to the ON position.
D. Monitor the active diagnostic code screen. Wait at
least 15 seconds for activation of the code.
Note: When the ECM connector is disconnected, all
of the open circuit diagnostic codes for the pressure
sensors that are wired to that ECM connector will be
active. This is normal.
E. Install a jumper wire between the terminal for the
signal of the suspect sensor and the pressure
sensor common on the ECM. If the suspect
sensor is connected to the J1/P1 ECM connector,
install the jumper at the breakout T. Wait at least
15 seconds for activation of the short circuit
diagnostic code.
SENR9515-05
Expected Result:
A short circuit diagnostic code is active for the
suspect sensor.
Results:
• OK – The ECM is operating properly.
Repair: Leave the ECM connector disconnected
and/or leave the breakout in place.
Proceed to Test Step 10.
• Not OK – The open circuit diagnostic code is still
active when the jumper wire is installed.
Repair: Temporarily connect a test ECM.
If the test ECM fixes the problem, reconnect the
suspect ECM.
If the problem returns, permanently replace the
ECM.
Verify that the repair eliminates the problem.
STOP.
Test Step 10. Check the Resistance of
the Harness
A. Turn the keyswitch to the OFF position.
B. Verify that the suspect sensor is disconnected.
C. Check the resistance between terminal A (Engine
Pressure Sensor +5V) and terminal C (Signal)
of the connector for the suspect sensor on the
engine harness.
Expected Result:
The resistance is greater than 20,000 ohms or “OL”
is displayed on the multimeter.
Results:
• OK – There is an open circuit in the signal wire.
Repair: Locate the open in the signal wire.
Repair the faulty wiring or replace the faulty wiring.
Reconnect the ECM connector.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is a short between the 5 volt
supply and the signal wire.
103
Troubleshooting Section
Repair: Locate the short between the 5 volt supply
and the signal wire.
Repair the faulty wiring or replace the faulty wiring.
Reconnect the ECM connector.
Verify that the repair eliminates the problem.
STOP.
i01660741
Engine Shutdown Switch
Circuit - Test
SMCS Code: 7418-081-ZS
System Operation Description:
The ground level shutdown switch provides the ability
to shut down the engine. The ECM remains active.
ET can be used to communicate with the ECM. The
ground level shutdown switch must be returned to
the RUN position and the keyswitch must be cycled
to the OFF/RESET position before the ECM will allow
the engine to start.
To shut down the engine, lift the red cover guard
and toggle the switch to the SHUTDOWN position.
The ECM reads the switch position. If the engine is
running, the ECM disables the fuel injection. The
ECM will not allow the engine to start if the engine
is not running.
The voltage at the ground level shutdown input of the
ECM P1:54 should be 11.5 ± 0.5 VDC with the switch
in the RUN position. The voltage at the ground level
shutdown input of the ECM P1:56 should be less
than 0.5 VDC with the switch in the RUN position.
104
Troubleshooting Section
Illustration 44
Schematic
Test Step 1. Check for Connector Damage
A. Turn the keyswitch to the OFF/RESET position.
B. Check the connectors and wiring for the following
problems: damage, corrosion, abrasion, and
incorrect attachment.
Expected Result:
The connectors and wiring should be free of the
following problems: damage, corrosion, abrasion,
and incorrect attachment.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check the Switch Status on
ET
A. Connect ET to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Operate the ground level shutdown switch.
Observe the status for the ground level shutdown
switch on ET.
Expected Result:
The status of the switch should be “ON” with the
switch in the SHUTDOWN position. The status should
be “OFF” when the switch is in the RUN position.
SENR9515-05
g00857198
Results:
• OK – The switch is operating normally.
Repair: If an intermittent problem is suspected,
refer to Troubleshooting, “Electrical Connectors -
Inspect”.
STOP.
• Not OK – Proceed to Test Step 3.
Test Step 3. Short the Wires at the Switch
A. Disconnect the J700/P700 ground level shutdown
switch.
B. Use a suitable piece of wire to short P700:B
(Switch Return) and P700:C (Ground Level
Shutdown (NC)).
C. Turn the keyswitch to the OFF/RESET position.
D. Turn the keyswitch to the ON position.
E. Observe the status of the ground level shutdown
switch on ET.
Note: The status should be “ON”.
F. Remove the jumper wire from the connector.
G. Install the jumper wire between P700:B (Switch
Return) and P700:A (Ground Level Shutdown
(NO)).
H. Turn the keyswitch to the OFF/RESET position.
I. Turn the keyswitch to the ON position.
J. Observe the status of the ground level shutdown
switch on ET.
SENR9515-05
Note: The status should be “OFF”.
K. Remove the jumper wire.
Expected Result:
The status should be “OFF” when P700:B (Switch
Return) is shorted to P700:C (Ground Level
Shutdown (NC)). The status should be “ON” when
P700:A (Ground Level Shutdown (NO)) is shorted to
P700:B (Switch Return).
Results:
• OK – The problem is not with the harness and/or
the ECM.
Repair: Temporarily connect a new switch. Verify
that the new switch solves the problem before you
permanently install the new switch.
STOP.
• Not OK – There is a problem in the harness and/or
the ECM. Proceed to Test Step 4.
Test Step 4. Check for a Short Circuit in
the Wiring Harness
A. Turn the keyswitch to the OFF/RESET position.
B. Disconnect the J1/P1 ECM connector and
the J700/P700 ground level shutdown switch
connector.
C. Measure the resistance between P1:54 (Ground
Level Shutdown (NO)) and P1:18 (Switch Return).
D. Measure the resistance between P1:56 (Ground
Level Shutdown (NC)) and P1:18 (Switch Return).
E. Measure the resistance between P1:54 (Ground
Level Shutdown (NO)) and P1:56 (Ground Level
Shutdown (NC)).
F. Measure the resistance between P1:56 (Ground
Level Shutdown (NC)) and engine ground.
G. Measure the resistance between P1:54 (Ground
Level Shutdown (NO)) and engine ground.
Expected Result:
The resistance should be greater than 20,000 Ohms
for each measurement.
Results:
• OK – The wiring harness is not shorted. Proceed
to Test Step 5.
• Not OK – There is a short in the harness between
the switch and the ECM.
105
Troubleshooting Section
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 5. Check the Resistance
through the Harness
A. Install a jumper wire between P700:A (Ground
Level Shutdown (NO)) and P700:B (Switch
Return).
B. Measure the resistance between P1:54 (Ground
Level Shutdown (NO)) and P1:18 (Switch Return).
C. Remove the jumper wire.
D. Install the jumper wire between P700:C (Ground
Level Shutdown (NC)) and P700:B (Switch
Return).
E. Measure the resistance between P1:56 (Ground
Level Shutdown (NC)) and P1:18 (Switch Return).
F. Remove the jumper wire.
Expected Result:
The resistance should be less than 10 Ohms for each
measurement.
Results:
• OK – The resistance is within acceptable limits.
Proceed to Test Step 6.
• Not OK – There is an open or excessive resistance
in the harness.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 6. Short the Switch Inputs at
the ECM
A. Remove the F715-PU wire from P1:54. Remove
the F716-WH wire from P1:56. Remove the
J766-PU wire from P1:18. Use a 121-9587 Wire
Removal Tool.
B. Insert a jumper wire with Deutsch sockets on each
end between P1:56 and P1:18.
C. Reconnect all connectors.
D. Turn the keyswitch to the ON position.
106
Troubleshooting Section
Additional diagnostic codes may be generated
because the switch return will no longer be
connected to the other sensors and/or switches.
Clear the codes after you complete this test.
E. Observe the status of the ground level shutdown
switch on ET.
Note: The status should be “OFF”.
F. Turn the keyswitch to the OFF/RESET position.
G. Disconnect the J1/P1 ECM connector.
H. Remove the jumper wire.
I. Insert the jumper wire between P1:54 and P1:18.
J. Reconnect all of the connectors.
K. Turn the keyswitch to the ON position.
L. Observe the status of the ground level shutdown
switch on ET.
Note: The status should be “ON”.
M. Turn the keyswitch to the OFF/RESET position.
N. Remove the jumper wire.
Expected Result:
The status should be “OFF” when the wire is inserted
between P1:56 and P1:18. The status should be “ON”
when the wire is inserted between P1:54 and P1:18.
Results:
• OK – The harness is faulty.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The switch and the wiring appear to be
working properly, but the ECM is not reading the
switch inputs properly.
Repair: Verify your results before you replace the
ECM. Refer to Troubleshooting, “Replacing the
ECM”.
STOP.
SENR9515-05
i01893597
Engine Speed/Timing Sensor
Circuit - Test
SMCS Code: 1912-081
System Operation Description:
Use this procedure to troubleshoot the system only
under the following conditions:
• There is an active diagnostic code or an easily
repeated diagnostic code that is associated with
the engine speed/timing sensors.
• You have been referred to this test from
Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
The engine uses two engine speed/timing sensors.
The secondary engine speed/timing sensor picks
up the camshaft gear and the primary engine
speed/timing sensor picks up the crankshaft gear.
Both of the engine speed/timing sensors detect the
reference for engine speed and timing from a unique
pattern on the respective gear. The ECM counts the
time between pulses that is created by the sensor as
the gear rotates in order to determine rpm.
Under normal operation, the camshaft position sensor
is used to determine timing for starting purposes.
The camshaft position sensor is used to determine
when the piston in the No. 1 cylinder is at the top of
the compression stroke. When the timing has been
established, the crankshaft position sensor is then
used to determine engine speed and the signal from
the camshaft sensor is ignored.
After locating the No. 1 cylinder, the ECM triggers
each injector in the correct firing order and at the
correct unit injector timing. The actual timing and
duration of each injection is based on engine rpm
and load. If the engine is running and the signal from
the crankshaft position sensor is lost, a slight change
in engine performance will be noticed when the ECM
performs the changeover to the camshaft position
sensor. Loss of the signal from the camshaft position
sensor during engine operation will not result in any
noticeable change in engine performance. However,
if the signal from the camshaft position sensor is not
present during start-up the following conditions may
exist:
• The engine may require a slightly longer period of
time to start-up.
• The engine may run rough for a few seconds until
the ECM determines the proper firing order by
using the crankshaft position sensor only.
SENR9515-05 107
Troubleshooting Section

The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. The loss of the signal from both of the
sensors during engine operation will result in the
termination of injection and the shutting down the
engine by the ECM. The loss of the signal from both
of the sensors during start-up will prevent the engine
from starting.

Both sensors are magnetic sensors with an integral

connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.

Note: When the sensors are being installed,

complete all of the following tasks:

• Lubricate the O-ring with oil.

• Ensure that the sensor is fully seated into the
engine before tightening the bracket bolt.

• Ensure that the connector is properly latched.

• Ensure that the harness is properly secured, and
ensure that the tie-wraps are placed in the correct
location.

g00985645
Illustration 45

Note: Do not attempt to disconnect the pigtail from

the sensor. The pigtail is sealed in the connector.
108
Troubleshooting Section
Illustration 46
P2 ECM connector
Test Step 1. Check for Diagnostic Codes
A. Connect the electronic service tool to the service
tool connector.
B. Turn the keyswitch to the ON position.
C. Verify whether any of the following diagnostic
codes are active or logged:
• 190-02 Loss of Engine Speed signal
• 190-11 Engine Speed Sensor mechanical failure
• 342-02 Loss of Secondary Engine Speed signal
• 342-11 Secondary Engine Speed Sensor
mechanical failure
D. If the diagnostic code is logged but not active, run
the engine until the engine is at normal operating
temperature. The problem may only occur when
the engine is at the normal operating temperature.
SENR9515-05
g00944371
E. If the engine will not start, monitor the engine
speed on the electronic service tool while the
engine is being cranked. The electronic service
tool may need to be powered from another battery
while the engine is being cranked in order to
ensure that the electronic service tool does not
reset.
Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
abnormal. This message will be replaced with an
engine speed once the ECM is able to calculate a
speed from the signal.
Expected Result:
One or more of the diagnostic codes that are listed
above are logged or active.
Results:
• Diagnostic Codes – There is a logged diagnostic
code or an active diagnostic code for the engine
speed/timing sensors. Proceed to Test Step 3.
• No Diagnostic Codes – There are no diagnostic
codes for the engine speed/timing sensors, but the
engine is not running properly.
SENR9515-05
Repair: Proceed to the appropriate topic in
Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
STOP.
• No Engine rpm – Engine rpm is not indicated on
the electronic service tool. Proceed to Test Step 2.
Test Step 2. Check the Installation of the
Sensors and the Brackets
g00810795
Illustration 47
Sensors and mounting brackets (typical example)
A. The flange of the sensor should be flush against
the engine in order to ensure proper operation.
B. Inspect the bracket in order to ensure that the
installation allows the flange of the sensor to be
flush against the engine.
Verify that the bracket is not bent.
Note: The bracket cannot be replaced separately.
C. Ensure that the O-ring has been installed on
the sensor, and ensure that the O-ring is free of
damage.
109
Troubleshooting Section
D. If either of the following diagnostic codes is active,
there may be a problem with the assembly of the
engine:
• 190-11 Engine Speed Sensor mechanical failure
• 342-11 Secondary Engine Speed Sensor
mechanical failure
Expected Result:
The sensors and the bracket are properly installed.
Results:
• OK – The sensors and the bracket are properly
installed. Proceed to Test Step 3.
• Not OK
Repair: Perform the following procedure in order
to properly install the sensors and the bracket:
1. Loosen the bolt that holds the sensor mounting
bracket to the engine.
2. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor or
replace the sensor, as required.
Note: The sensor must not be removed from the
bracket.
3. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
location.
4. Verify that the repair eliminates the problem.
STOP.
Test Step 3. Inspect Electrical Connectors
and Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect the J2/P2 ECM connector.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.
C. Perform a 45 N (10 lb) pull test on the following
wires in the P2 ECM connector that are associated
with the engine speed/timing sensors:
• P2:48 (Primary Engine Speed/Timing +)
• P2:49 (Primary Engine Speed/Timing -)
• P2:58 (Secondary Engine Speed/Timing +)
• P2:59 (Secondary Engine Speed/Timing −)
110
Troubleshooting Section
D. Ensure that the latch tab on the connector is
properly latched and ensure that the latch tab is
fully latched.
E. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
F. Ensure that the harness wiring is not pulled
too tightly. When the harness wiring is pulled
too tightly, vibrations or movement can cause
intermittent connections.
G. Inspect the harness wiring for nicks and abrasions.
H. Ensure that the wiring harness is correctly routed
and secured at the proper locations.
Expected Result:
All connectors, pins, and sockets should be
completely coupled and/or inserted. The harness
and wiring should be free of corrosion, abrasion, and
pinch points.
Results:
• OK – The connectors and the wiring are OK.
Proceed to Test Step 4.
• Not OK – There is a problem with the connectors
and/or the wiring.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 4. Measure the Circuit
Resistance at the ECM Connector
A. Disconnect the J2/P2 ECM connector.
B. Use the following procedure to measure the circuit
resistance for the crankshaft position sensor:
a. Measure the resistance between P2:48
(Primary Engine Speed/Timing +) and P2:49
(Primary Engine Speed/Timing -).
Note: Check for an intermittent problem (open or
short) by moving the harness while you measure the
resistance. Pull the wires that are directly behind the
sensors and shake the wires that are directly behind
the sensors.
Resistance ....................... 75.0 to 230.0 Ohms
SENR9515-05
C. Use the following procedure to measure the circuit
resistance for the camshaft position sensor:
a. Measure the resistance between P2:58
(Secondary Engine Speed/Timing +) and P2:59
(Secondary Engine Speed/Timing −).
Note: Check for an intermittent problem (open or
short) by moving the harness while you measure the
resistance. Pull the wires that are directly behind the
sensors and shake the wires that are directly behind
the sensors.
Resistance ........................ 600 to 1800 Ohms
Expected Result:
The readings agree with the values that are listed
above.
Results:
• OK – Neither a short circuit nor an open circuit is
indicated. Proceed to Test Step 6.
• Not OK – The resistance is not within the
acceptable range when the circuit resistance is
measured through the engine harness. Proceed
to Test Step 5.
Test Step 5. Measure the Resistance of
the Sensor
A. Turn the keyswitch to the OFF position.
B. Check the harness and the wiring for abrasion and
pinch points from the sensor back to the ECM.
C. Disconnect the suspect sensor from the engine
harness.
D. Thoroughly inspect the J401/P401 primary
engine speed/timing sensor (crankshaft position)
connector and the J402/P402 secondary
engine speed/timing sensor (camshaft position)
connector. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
E. Use the following procedure to measure the
resistance of the crankshaft position sensor:
a. Disconnect the J401/P401 primary engine
speed/timing sensor (crankshaft position)
connector.
b. Measure the resistance between terminal 1
and terminal 2 of the sensor.
Resistance ....................... 75.0 to 230.0 Ohms
SENR9515-05
F. Use the following procedure to measure the
resistance of the camshaft position sensor:
a. Disconnect the J402/P402 secondary engine
speed/timing sensor (camshaft position)
connector.
b. Measure the resistance between terminal 1
and terminal 2 of the sensor.
Resistance ........................ 600 to 1800 Ohms
Expected Result:
The readings agree with the values that are listed
above.
Results:
• OK – The sensor resistance is within tolerance.
Proceed to Test Step 6.
• Not OK – The sensor resistance is out of the
specified range.
Repair: Perform the following procedure in order
to check and install the new sensor:
Note: Timing calibration is not necessary following
replacement of either of the speed/timing sensors.
Refer to the information in the System Operation
Section regarding the installation of sensors.
1. Before installing the new sensor, measure the
resistance of the new sensor.
If the new sensor resistance is in the correct
range, install the new sensor in the engine, as
follows:
a. Loosen the bolt that holds the sensor
mounting bracket to the engine.
b. Ensure that the O-ring is installed and free
of damage.
c. Seat the sensor and tighten the bolt.
If the sensor will not seat, repair the sensor
or replace the sensor, as required.
Note: The sensor must not be removed from the
bracket.
d. Ensure that the sensor is properly oriented
and that the harness is secured in the proper
location.
2. Verify that the repair eliminates the problem.
STOP.
111
Troubleshooting Section
Test Step 6. Install a Bypass Harness for
the Engine Speed/Timing Sensors
A. Turn the keyswitch to the OFF position.
B. Use the following procedure to bypass the circuit
for the crankshaft position sensor:
a. Remove the E964-WH wire from P2:48
(Primary Engine Speed/Timing +).
b. Remove the E963-BK wire from P2:49 (Primary
Engine Speed/Timing -).
c. Install a 16 AWG wire with Deutsch sockets
on both ends between P2:48 (Primary Engine
Speed/Timing +) and P401:2.
d. Install a 16 AWG wire with Deutsch sockets
on both ends between P2:49 (Primary Engine
Speed/Timing -) and P401:1.
Note: Twisted pair wiring is required. Ensure that the
wires have at least one twist per inch.
C. Use the following procedure to bypass the circuit
for the camshaft position sensor:
a. Remove the E966-YL from P2:58 (Secondary
Engine Speed/Timing +).
b. Remove the E965-BU from P2:59 (Secondary
Engine Speed/Timing −).
c. Install a 16 AWG wire with Deutsch sockets on
both ends between P2:58 (Secondary Engine
Speed/Timing +) and P402:2.
d. Install a 16 AWG wire with Deutsch sockets on
both ends between P2:59 (Secondary Engine
Speed/Timing −) and P401:1.
Note: Twisted pair wiring is required. Ensure that the
wires have at least one twist per inch.
D. Reconnect the J2/P2 engine harness connector .
E. Start the engine in order to determine if the bypass
harness repairs the problem.
F. Turn the keyswitch to the OFF/RESET position.
Expected Result:
The problem is corrected with the installation of the
bypass harness.
Results:
• OK – The bypass harness eliminated the problem.
112 SENR9515-05
Troubleshooting Section

Repair: Permanently install a new section of i01589940

harness.
STOP.
• Not OK – The problem remains with the bypass
installed.
Repair: Verify that the correct terminals have been
installed in the correct location in the P2 ECM
connector. If the temporary harness was installed
correctly, install the original wiring.
Proceed to Test Step 7.
Test Step 7. Check the ECM
A. Turn the keyswitch to the OFF position.
B. Temporarily connect a test ECM.
C. Start the engine. Run the engine in order to repeat
the conditions when the problem occurs.
D. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
E. If the problem returns with the suspect ECM,
replace the ECM.
Verify that the repair eliminates the problem.
Engine Temperature Sensor
Open or Short Circuit - Test
SMCS Code: 1906-081; 1917-081; 1922-081;
1928-081
System Operation Description:
Use this procedure to troubleshoot the system only
when there is an active diagnostic code or when
a diagnostic code can easily be activated. This
procedure covers open circuit diagnostic codes and
short circuit diagnostic codes that are associated with
the following sensors:
• Coolant temperature sensor
• Inlet air temperature sensor
• Fuel temperature sensor
• Hydraulic oil temperature sensor
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical.
The temperature sensors are passive sensors that
have two terminals. The temperature sensors do not
require supply voltage from the ECM.

Expected Result:

The problem remains with the suspect ECM.

Results:

• OK – The problem is resolved with the test ECM

and the problem returns with the suspect ECM.

Repair: Replace the ECM.

Verify that the repair eliminates the problem.

STOP.

• Not OK – The test ECM did not eliminate the

problem.

Repair: Replace the sensor.

Verify that the repair eliminates the problem.

STOP.
SENR9515-05 113
Troubleshooting Section

g00824325
Illustration 48
Schematic

Test Step 1. Verify all Active Diagnostic
Codes
A. Connect ET to the service tool connector.
B. Turn the keyswitch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
Repair: If there are logged diagnostic codes for one
or more of the temperature sensors and the engine
is not running properly, refer to Troubleshooting,
“Troubleshooting without a Diagnostic Code”. If
the engine is running properly at this time, an
intermittent condition may be causing the logged
codes. Refer to Troubleshooting, “Electrical
Connectors - Inspect”.

C. Monitor the “Active Diagnostic Codes” screen on STOP.

ET.

Expected Result:

There is an active diagnostic code for one or more of

the temperature sensors.

Results:

• Yes – There is an active diagnostic code for one

or more of the temperature sensors. Proceed to
Test Step 2.

• No – There are no active diagnostic codes for the

temperature sensors.
114
Troubleshooting Section
Test Step 2. Inspect Electrical Connectors
and Wiring
Illustration 49
ECM connectors
A. Thoroughly inspect the J1/P1 ECM connector,
the J2/P2 ECM connector, the suspect sensor
connector, and any other connectors in the circuit.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details.
B. Perform a 45 N (10 lb) pull test on each of the
wires in the sensor connector and the ECM
connector that are associated with the active
diagnostic code. Refer to Illustration 49.
C. Verify that the latch tab of the connector is properly
latched.
D. Check the ECM connector (allen head screw) for
the proper torque of 6.0 N·m (55 lb in).
E. Check the harness and wiring for abrasions and
for pinch points from the sensor to the ECM.
Expected Result:
All connectors, pins, and sockets should be
completely coupled and/or inserted. The harness
and wiring should be free of corrosion, abrasion, and
pinch points.
SENR9515-05
g00824457
Results:
• OK – Proceed to Test Step 3.
• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
Test Step 3. Verify that the Diagnostic
Code is Still Active
A. Turn the keyswitch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
B. Access the “Active Diagnostic Codes” screen on
ET and check for active diagnostic codes.
C. Determine if the problem is related to an open
circuit diagnostic code or a short circuit diagnostic
code.
SENR9515-05
Expected Result:
A short circuit diagnostic code or an open circuit
diagnostic code is active.
Results:
• Short Circuit – A short circuit diagnostic code is
active at this time. Proceed to Test Step 4.
• Open Circuit – An open circuit diagnostic code is
active at this time. Proceed to Test Step 6.
• No Active Diagnostic Codes – There is a problem
in the connectors and/or the wiring.
Repair: Carefully reinspect the connectors and
wiring. The diagnostic code will probably reoccur.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for additional information.
STOP.
Test Step 4. Disconnect the Sensor in
Order to Create an Open Circuit
A. Turn the keyswitch to the OFF/RESET position.
B. Disconnect the connector to the sensor with the
short circuit diagnostic code.
C. Turn the keyswitch to the ON position. Wait at
least 15 seconds for activation of the diagnostic
codes.
D. Access the “Active Diagnostic Codes” screen on
ET and check for an active open circuit diagnostic
code for the suspect sensor.
Expected Result:
An open circuit diagnostic code is now active for the
disconnected sensor.
Results:
• OK – A short circuit diagnostic code was active
before disconnecting the sensor. An open circuit
diagnostic code became active after disconnecting
the sensor. Proceed to Test Step 5.
• Not OK – There is a short circuit between the
sensor harness connector and the ECM. Leave the
sensor disconnected. Proceed to Test Step 7.
Test Step 5. Determine if the Short Circuit
is in the Connector or in the Sensor
A. Thoroughly inspect the connector for moisture.
B. Inspect the seals and reconnect the sensor.
115
Troubleshooting Section
C. If the short circuit diagnostic code reappears, the
sensor is the problem.
a. Temporarily connect a new sensor to the
harness, but do not install the new sensor in
the engine.
D. Check for a short circuit diagnostic code while the
new sensor is connected.
Expected Result:
The short circuit diagnostic code is not present when
a new sensor is connected.
Results:
• OK – The suspect sensor had an internal short.
Repair: Permanently install the new sensor and
clear any logged diagnostic codes.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The connector is shorted.
Repair: Repair the connector.
STOP.
Test Step 6. Short the Sensor Connector
A. Turn the keyswitch to the ON position.
B. Unplug the suspect sensor.
Note: Monitor the “Active Diagnostic Codes” screen
on ET before installing the jumper wire and after
installing the jumper wire.
C. Install a jumper wire with Deutsch sockets on
each end between the terminals on the plug for
the suspect sensor. Wait at least 15 seconds for
activation of the short circuit diagnostic code.
D. Remove the jumper wire.
Expected Result:
A short circuit diagnostic code is active when the
jumper wire is installed. An open circuit diagnostic
code is active when the jumper wire is removed.
Results:
• OK – The engine harness and the ECM are OK.
Repair: Perform the following repair:
1. Temporarily reconnect the suspect sensor.
116 SENR9515-05
Troubleshooting Section

2. If the diagnostic code remains active, replace

the sensor.

3. Verify that the repair eliminates the problem.

4. Clear all logged diagnostic codes.

STOP.

• Not OK – The open circuit diagnostic code remains

active with the jumper in place. There appears
to be an open circuit between the ECM and the
sensor. Proceed to Test Step 7.

Test Step 7. Check the Operation of

the ECM by Creating Open And Short
Circuits at the ECM Connector

g00825608
Illustration 50
ECM connectors (wire side)

A. Turn the keyswitch to the OFF/RESET position.
B. Disconnect the appropriate ECM connector for the
suspect sensor. Thoroughly inspect both halves
of the connector for signs of corrosion and/or
moisture.
C. Reconnect the ECM connector.
D. Turn the keyswitch to the ON position. Monitor the
“Active Diagnostic Code” screen on ET. Wait at
least 15 seconds for activation of the code.
An open circuit diagnostic code should be active
for the suspect sensor. Note the sensor that has
the open circuit diagnostic code.
E. Remove the signal wire and the return wire for
the suspect sensor from the appropriate ECM
connector. Refer to Illustration 50.
Note: Active open circuit diagnostic codes will be
generated for any other temperature sensors that
share the return for the suspect sensor.
SENR9515-05
F. Install a jumper wire with Deutsch sockets on each
end between the terminal for the suspect sensor
signal and the return for the suspect sensor.
Note: A short circuit diagnostic code should be active
when the jumper wire is installed.
G. Monitor the “Active Diagnostic Code” screen on
ET. Wait at least 15 seconds for activation of the
code.
Expected Result:
An open circuit diagnostic code is active when the
wires are removed from the ECM connector. A short
circuit diagnostic code is active when the jumper wire
is installed.
Results:
• OK – The ECM is working properly. Proceed to
Test Step 8.
• Not OK – One of the following conditions exists:
The open circuit diagnostic code is not active when
the harness is disconnected. The short circuit
diagnostic code is not active when the jumper wire
is installed.
Repair: Perform the following repair:
1. Temporarily connect a test ECM.
2. Remove all jumper wires and reconnect all
connectors and wires.
3. Recheck the system for active diagnostic codes.
4. Repeat this test step.
5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
6. If the problem returns with the suspect ECM,
replace the ECM.
7. Verify that the repair eliminates the problem.
STOP.
Test Step 8. Bypass the Wiring Harness
between the ECM and the Sensor
Connector
A. Turn the keyswitch to the OFF/RESET position.
B. Remove the sensor signal wire from the ECM
connector.
C. Disconnect the sensor connector.
D. Remove the signal wire (terminal 1) from the
sensor connector on the engine harness.
117
Troubleshooting Section
E. Fabricate a jumper wire that is long enough to
reach from the ECM to the sensor connector with
Deutsch sockets on both ends.
F. Insert one end of the jumper wire into the signal
terminal of the ECM connector. Insert the other
end of the jumper wire into terminal 1 of the sensor
connector on the engine harness.
G. Reconnect the sensor connector.
H. Turn the keyswitch to the ON position.
I. Monitor the “Active Diagnostic Codes” screen on
ET for either the open circuit diagnostic code for
the sensor or the short circuit diagnostic code for
the sensor.
Expected Result:
No diagnostic codes are present for the suspect
sensor when the jumper wire is installed.
Results:
• OK – There is a problem in the wiring harness
between the ECM and the sensor connector.
Repair: Repair the circuit and clear all diagnostic
codes.
Verify that the repair eliminates the problem.
STOP.
• Not OK – Restart this procedure and carefully
perform each step. STOP.
i01584647
Ether Injection System - Test
SMCS Code: 1456-081
System Operation Description:
The ether injection system will improve cold weather
starting of the engine. The ECM controls the ether
injection system. The ether injection system can
operate in automatic mode and in manual mode. The
ether injection system is disabled if there is an active
engine shutdown.
Automatic Mode
In automatic mode, the ECM energizes the relay for
the ether in cycles of six seconds. The ether is turned
ON for three seconds and the ether is then turned
OFF for three seconds.
In the automatic mode, the ether injection system is
enabled when all of the following conditions occur:
118 SENR9515-05
Troubleshooting Section

• Engine speed is between 35 and 500 rpm.

• Coolant temperature or inlet air temperature is less
than 0 °C (32 °F).

Note: Less than 30 °C (86 °F) in high altitude

conditions

Manual Mode

Manual mode is activated by pressing the start aid

switch. In manual mode, a 6 cc (0.4 in3) shot of ether
is injected when the start aid switch is depressed.

In manual mode, the ether injection system is

enabled when all of the following conditions are met:

• The start aid switch is placed in the MANUAL

position.

• Engine speed is between 35 and 1200 rpm.

• Coolant temperature or inlet air temperature is less
than 10 °C (50 °F).

Note: Less than 40 °C (104 °F) in high altitude

conditions

g00822142
Illustration 51
Schematic
SENR9515-05 119
Troubleshooting Section

Test Step 2. Check the Status of the Ether

Switch on ET
Breathing ether vapors or repeated contact of
A. Remove the ether canister from the ether solenoid.
ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
B. Connect ET to the service tool connector.
following procedures.
C. Turn the keyswitch to the ON position.
Use ether only in well ventilated areas.
D. Press the start aid switch to “MANUAL”. Observe
Do not smoke while changing ether cylinders.
the status of “Ether Switch” on ET.
Use ether with care to avoid fires.
Expected Result:
Do not store replacement ether cylinders in living
When the start aid switch is pressed, ET should
areas or in the operator’s compartment.
display the status of the switch as “On”.
Do not store ether cylinders in direct sunlight or
When the start aid switch is not pressed, ET should
at temperatures above 49 °C (120 °F).
display the status of the switch as “Off”.
Discard cylinders in a safe place. Do not puncture
Results:
or burn cylinders.

Keep ether cylinders out of the reach of unautho- • OK – The start aid switch is operating correctly.
Proceed to Test Step 6.
rized personnel.

To avoid possible injury, be sure the brakes are ap- • Not OK – The ECM is not seeing the signal from
the start aid switch. Proceed to Test Step 8.
plied and all controls are in Hold or Neutral when
starting the engine.
Test Step 3. Short the Switch Wires
Test Step 1. Inspect Electrical Connectors A. Turn the keyswitch to the ON position.
and Wiring
B. Disconnect the start aid switch.
A. Turn the keyswitch to the OFF/RESET position.
C. Observe the status of “Ether Switch” on ET.
B. Thoroughly inspect the J1/P1 ECM connector
and all other connectors in the circuit. Refer to Note: The status should be “Off”.
Troubleshooting, “Electrical Connectors - Inspect”
for details. D. Install a jumper wire between terminal 2 and
terminal 3 in the plug for the start aid switch.
Expected Result:
E. Observe the status of “Ether Switch” on ET.
All connectors, pins, and sockets should be
completely inserted and coupled. The harness and Note: The status should be “On”.
wiring should be free of corrosion, abrasion, and
pinch points. All connections and grounds should be Expected Result:
tight and free of corrosion.
When the terminals are shorted, ET should display
Results: the status of the start aid switch as “On”.

• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
When the terminals are not shorted, ET should
display the status of the start aid switch as “Off”.
Results:
• OK – The start aid switch is not operating correctly.
Repair: Replace the start aid switch.
Verify that the repair eliminates the problem.

STOP.
120 SENR9515-05
Troubleshooting Section

• Not OK – The start aid switch is operating Results:

correctly. Proceed to Test Step 4.
• OK – There is a problem in the wiring between the
Test Step 4. Short the Switch Inputs at switch and the ECM.
the ECM
Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

• Not OK – The ECM is not reading the switch input

properly.

Repair: Verify your results. Replace the ECM.

Refer to Troubleshooting, “Replacing the ECM”
before replacing the ECM.

Verify that the repair eliminates the problem.

STOP.

Test Step 5. Check for Correct Operation

of the Solenoid
Note: The ether canister must be removed prior to
Illustration 52
g00823121 activating this test.
P1 ECM connector (wire side)
A. Turn the keyswitch to the ON position.
A. Turn the keyswitch to the OFF/RESET position.
B. Proceed to the “Diagnostic Overrides” screen on
ET.
B. Remove the wires from P1:22 (Start Aid Switch)
and P1:18 (Switch Return).
C. Activate the ether injection system.
C. Turn the keyswitch to the ON position.
Note: The diagnostic override will only activate the
relay for 3 seconds.
D. Observe the status of “Ether Switch” on ET.
D. Listen for an audible click as the start aid solenoid
Note: The status should be “Off”.
is activated. Listen for an audible click as the start
aid solenoid is deactivated.
E. Install a jumper wire with Deutsch sockets on each
end between P1:22 (Start Aid Switch) and P1:18
Expected Result:
(Switch Return).
A click should be heard when the solenoid is
F. Turn the keyswitch to the ON position.
activated.
G. Observe the status of “Ether Switch” on ET.
Results:
Note: The status should be “On”.
• OK – The ether injection system is operating
correctly. STOP.
H. Remove the jumper wire and reinstall the wires in
the P1 connector.
• Not OK – The solenoid is not being energized or
the solenoid is bad. Proceed to Test Step 6.
Expected Result:

When the jumper wire is installed, ET should display

Test Step 6. Check the Resistance of the
the status of the switch as “On”.
Solenoid
A. Disconnect the J504/P504 start aid solenoid
When the jumper wire is not installed, ET should
connector.
display the status of the start aid switch as “Off”.
SENR9515-05 121
Troubleshooting Section

B. Measure the resistance of the solenoid between
J504:1 (Solenoid Power) and J504:2 (Solenoid
Return).
C. Reconnect J504/P504 Start Aid Solenoid
connector.
• Not OK – The start aid solenoid is not receiving
the correct signal. Proceed to Test Step 8.
Test Step 8. Check the Resistance of the
Relay

Expected Result:

Resistance should be less than 10 Ohms.

Results:

• OK – The resistance of the solenoid is OK.

Proceed to Test Step 7.

• Not OK – The resistance of the solenoid is out of

specification.

Repair: Replace the solenoid.

g00823118
Illustration 53
Verify that the repair eliminates the problem. Relay terminals

STOP. A. Turn the keyswitch to the OFF/RESET position.

Test Step 7. Check the Supply Voltage to
the Solenoid
Note: The ether canister must be removed prior to
activating this test.
A. Disconnect the J504/P504 start aid solenoid
connector.
B. Turn the keyswitch to the ON position.
C. Proceed to the “Diagnostic Overrides” screen on
ET.
D. Activate the ether injection system.
Note: The diagnostic override will only activate the
relay for 3 seconds.
E. Measure the voltage between P504:1 (Solenoid
Power) and P504:2 (Solenoid Return) when the
ether injection system is activated.
B. Unplug the start aid relay.
C. Measure the resistance between terminal 85 and
terminal 86 of the relay.
Expected Result:
The resistance should be between 250 Ohms and
500 Ohms.
Results:
• OK – Proceed to Test Step 9.
• Not OK – The relay is faulty.
Repair: Replace the relay.
Verify that the repair eliminates the problem.
STOP.

Expected Result:

The supply voltage should be greater than 22.0 VDC.

Results:

• OK – The ECM is properly controlling the ether

injection system, but the solenoid is not working.

Repair: Replace the solenoid.

Verify that the repair eliminates the problem.

STOP.
122
Troubleshooting Section
Test Step 9. Check the Signal Voltage to
the Relay
g00823292
Illustration 54
Relay connector (terminal side)
Note: The ether canister must be removed prior to
activating this test.
A. Unplug the start aid relay.
B. Turn the keyswitch to the ON position.
C. Proceed to the “Diagnostic Overrides” screen on
ET.
D. Activate the ether injection system.
Note: The diagnostic override will only activate the
relay for 3 seconds.
E. Measure the voltage between terminal 85
(Solenoid Return) and terminal 86 (Ether ON) of
the plug for the relay.
Expected Result:
The voltage should be 24.0 ± 8.0 VDC.
Results:
• OK – The relay is receiving the signal from the
ECM. Proceed to Test Step 10.
• Not OK – The relay is not receiving the signal from
the ECM. Proceed to Test Step 12.
SENR9515-05
Test Step 10. Check the Output Voltage
of the Relay
g00822999
Illustration 55
Relay connector (wire side)
Note: The ether canister must be removed prior to
activating this test.
A. Ensure that all connectors are connected to the
wiring harness.
B. Turn the keyswitch to the ON position.
C. Proceed to the “Diagnostic Overrides” screen on
ET.
D. Activate the ether injection system.
Note: The diagnostic override will only activate the
relay for 3 seconds.
E. Use signal reading probes to measure the voltage
across terminal 85 (Solenoid Return) and terminal
87 (Solenoid Power) of the relay.
Expected Result:
The voltage should be 24.0 ± 8.0 VDC.
Results:
• OK – There is a problem in the wiring between the
relay and the start aid solenoid.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The relay is not sending power to the
solenoid. Proceed to Test Step 11.
SENR9515-05 123
Troubleshooting Section

Test Step 11. Check the Power Supply to Test Step 12. Check for Shorts in the
the Relay Wiring Harness between the Relay and
the ECM

g00823292
Illustration 56
g00823185
Illustration 57
Relay connector (terminal side)
ECM connector P1 (ECM side)
A. Unplug the start aid relay.
A. Ensure that the keyswitch is in the OFF/RESET
B. Measure the voltage between terminal 30 position.
(+Battery) of the connector for the relay and
chassis ground. B. Disconnect the J1/P1 ECM connector.

Expected Result: C. Unplug the start aid relay.

The voltage should be 24.0 ± 8.0 VDC. D. Measure the resistance between P1:21 (Start Aid
Relay) and P1:67 (Solenoid Return).
Results:
Expected Result:
• OK – The relay is faulty.
The resistance should be greater than 20,000 Ohms.
Repair: Replace the relay.
Results:
Verify that the repair eliminates the problem.
• OK – Proceed to Test Step 13.
STOP.
• Not OK – There is a short between the ECM and
• Not OK – There is a problem in the wiring between the relay.
the relay and the +Battery terminal.
Repair: Repair the circuit.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem.
STOP.
STOP.
124
Troubleshooting Section
Test Step 13. Check the Voltage for the
Relay at the ECM
g00823285
Illustration 58
ECM connector P1 (wire side)
Note: The ether canister must be removed prior to
activating this test.
A. Turn the keyswitch to the OFF/RESET position.
B. Remove the wire from P1:21 (Start Aid Relay) in
the P1 ECM connector.
C. Turn the keyswitch to the ON position.
D. Proceed to the “Diagnostic Overrides” screen on
ET.
E. Activate the ether injection system.
Note: The diagnostic override will only activate the
relay for 3 seconds.
F. Measure the voltage between the open terminal at
P1:21 (Start Aid Relay) and engine ground.
G. Turn the keyswitch to the OFF/RESET position.
H. Reinstall the wire to P1:21 (Start Aid Relay).
Expected Result:
The voltage should be 24.0 ± 8.0 VDC.
Results:
• OK – The ECM is supplying the correct voltage.
There may be an open circuit or a short circuit in
the harness.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05
• Not OK – The ECM is not supplying the correct
voltage.
Repair: Verify your results. Replace the ECM.
Refer to Troubleshooting, “Replacing the ECM”
before replacing the ECM.
Verify that the repair eliminates the problem.
STOP.
i02370331
Injector Solenoid Circuit - Test
SMCS Code: 1290-038
System Operation Description:
Use this procedure under the following circumstances:
• 1-11 Injector Cylinder #1 fault
• 2-11 Injector Cylinder #2 fault
• 3-11 Injector Cylinder #3 fault
• 4-11 Injector Cylinder #4 fault
• 5-11 Injector Cylinder #5 fault
• 6-11 Injector Cylinder #6 fault
• You have been directed to this procedure from
Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
Perform this procedure under conditions that are
identical to the conditions that exist when the problem
occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).
The engine has electronic unit injectors that are
mechanically actuated and electronically energized.
The Electronic Control Module (ECM) sends a 105
volt pulse to each injector solenoid. The pulse is
sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid
is mounted on top of the fuel injector body. The
105 volt pulse can be individually cut out to aid in
troubleshooting misfire problems.
If an open is detected in the solenoid circuit, a
diagnostic code is generated. The ECM continues
to try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will then enable the
solenoid. If the short circuit remains this sequence of
events will be repeated until the problem is corrected.
SENR9515-05 125
Troubleshooting Section

The injector codes must be programmed into the

ECM. The injector code is a four digit number (last
four digits of the serial number for the injector) that
is found on each of the unit injectors. The ECM
uses this number to compensate for manufacturing
variations between individual injectors. If you replace
any of the unit injectors, you must reprogram the
code for the new injectors. Also, if you replace the
ECM, you must reprogram all of the injector codes.
The ECM will generate the following diagnostic code
if the injector codes are not programmed:

• 268-02 Check Programable Parameters

For more information, refer to Troubleshooting,
“Injector Code - Calibrate”.

g00927316
Illustration 59
Schematic
126
Troubleshooting Section
Illustration 60
Pin locations for ECM
Test Step 1. Inspect Electrical Connectors
and Wiring
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if the
keyswitch is not turned to the OFF position.
B. Thoroughly inspect the J2/P2 ECM connector
and the J300/P300 injector connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for details.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and each of the wires
that are associated with injector solenoids.
Refer to Illustration 60.
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.
SENR9515-05
g01000770
E. Check the J300/P300 injector connector in order
to ensure the proper mating of the connector.
F. Check the harness and wiring for abrasions and
for pinch points from the injectors to the ECM.
Expected Result:
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – The harness and wiring are “OK”. Proceed
to Test Step 2.
• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05
Test Step 2. Check for Logged Diagnostic
Codes Regarding Injector Solenoids
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the “Logged Diagnostic Codes” screen
on Cat ET.
Expected Result:
One or more of the following diagnostic codes has
been logged:
• 1-11 Injector Cylinder #1 fault
• 2-11 Injector Cylinder #2 fault
• 3-11 Injector Cylinder #3 fault
• 4-11 Injector Cylinder #4 fault
• 5-11 Injector Cylinder #5 fault
• 6-11 Injector Cylinder #6 fault
Results:
• OK – There are logged diagnostic codes for the
injectors. Proceed to Test Step 4.
• Not OK – There are no logged diagnostic codes
for the injectors. Proceed to Test Step 3.
Test Step 3. Perform the “Cylinder Cutout
Test”
A. Start the engine.
B. Allow the engine to warm up to normal operating
temperature (approximately 77 °C (171 °F)).
C. After the engine is warmed to operating
temperature, access the “Cylinder Cutout Test” on
Cat ET by accessing the following display screens
in order:
• “Diagnostics”
• “Diagnostic Tests”
• “Cylinder Cutout Test”
D. Enable the cooling fan, if the fan is not controlled
by the ECM. If the ECM controls the cooling fan,
the cooling fan will start automatically when the
test begins.
E. Shut off all parasitic loads such as the air
conditioning and the air compressors which could
affect the results of the test.
127
Troubleshooting Section
F. Set the engine speed to 1200 ± 20 rpm.
G. Select the start button at the bottom of the screen
for the “Cylinder Cutout Test”.
H. Select the “4 Cylinder Cutout Test” which is the
default test.
I. Follow the instructions that are provided in the
“Cylinder Cutout test”. The cylinder cutout tests
are interactive so the procedure is guided to the
finish.
Note: The “Manual Cylinder Cutout Test” is also
available. Access the manual test by selecting the
“Change” button on the screen for the “Cylinder
Cutout Test”. The “4 Cylinder Cutout Test” is the
recommended starting procedure. The automated
tests run twice collecting data.
Expected Result:
All cylinders indicate “OK”.
Results:
• OK – All cylinders indicate “OK”.
Repair: If the engine is misfiring or if the
engine has low power, refer to Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”
and Troubleshooting, “Low Power/Poor or No
Response to Throttle”.
If a diagnostic code results from running the
“Cylinder Cutout Test”, proceed to Test Step 4.
• Not OK – All cylinders did not indicate “OK”.
Proceed to Test Step 4.
Test Step 4. Use the Injector Solenoid
Test to Test the Injector Solenoids
A. Start the engine.
B. Allow the engine to warm up to normal operating
temperature (approximately 77 °C (171 °F)).
C. Turn the keyswitch to the OFF/RESET position.
D. Turn the keyswitch to the ON position.
E. Access the “Injector Solenoid Test” on Cat ET by
accessing the following display screens in order:
• “Diagnostics”
• “Diagnostic Tests”
• “Injector Solenoid Test”
F. Activate the test.
128 SENR9515-05
Troubleshooting Section

Note: The test is in the “Interactive Diagnostic Tests”. Expected Result:

Do not confuse the “Injector Solenoid Test” with the
“Cylinder Cutout Test”. The “Cylinder Cutout Test” is All cylinders indicate “OPEN”.
used to shut off fuel to a specific cylinder while the
engine is running. The injector solenoid test is used Results:
in order to actuate the injector solenoids. This allows
the click of the injector solenoids to be heard when • OK – All cylinders indicate “OPEN”. Proceed to
the engine is not running in order to determine that Test Step 6.
the circuit is functioning properly.
• Not OK – All cylinders did not indicate “OK”. Note
G. As each solenoid is energized by the ECM an the cylinders that indicate a short circuit. Proceed
audible click can be heard at the valve cover. to Test Step 7.
Listen for a click at each valve cover. A black
square will appear over the cylinder number when Test Step 6. Use the Injector Solenoid
the cylinder is being fired. Test to Check for Opens in the Engine
Wiring Harness
H. Perform the injector solenoid test at least two
times.

Expected Result:

All cylinders indicate “OK”.

Results:

• OK – There is not an electronic problem with the

injectors at this time.

Repair: If the “Injector Solenoid Test” returned a

“NOT OK” for any injector, refer to Troubleshooting,
“Engine Misfires, Runs Rough or Is Unstable”.

STOP.

• Not OK – All cylinders did not indicate “OK”.

Note the cylinders that indicate “OPEN” and/or
“SHORT”. Proceed to Test Step 5.
g00706830
Illustration 61
Test Step 5. Use the Injector Solenoid
Test to Check for Shorts in the Engine Engine harness connector for the injectors
Wiring Harness

Electrical shock hazard. The electronic unit injec-

Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Disconnect the J300/P300 injector connector at
the valve cover base.
C. Turn the keyswitch to the ON position.
D. Perform the injector solenoid test at least two
times.
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Disconnect the J300/P300 injector connector at
the valve cover base.
C. Turn the keyswitch to the ON position.
D. Fabricate a jumper wire 100 mm (4 inch) long.
SENR9515-05
E. Insert one end of the jumper wire into the common
socket of the problem injector. Insert the other end
of the jumper wire into the appropriate socket for
the suspect injector in the P300 injector connector.
For example, if injector 5 is the problem injector,
insert the jumper in terminal 5 and in terminal 8 of
the P300 injector connector.
F. Perform the injector solenoid test at least two
times.
G. Repeat this test for each suspect Injector. Ensure
that the injector solenoid test is disabled before
handling the jumper wires.
Expected Result:
Cat ET displays “SHORT” for the cylinder with the
jumper wire.
Results:
• OK 1 – Test Step 4 indicated that only one injector
had an “OPEN” or “SHORT”, or that one injector
had an “OPEN” but the other injector on the injector
common line had a “SHORT”. Proceed to Test
Step 9.
• OK 2 – Test Step 4 indicated that two injectors that
share an injector common line are open. Proceed
to Test Step 10.
• OK 3 – Test Step 4 indicated that two injectors
that share an injector common line are shorted.
Proceed to Test Step 11.
• Not OK – Cat ET did not display “SHORT” for the
cylinder with the jumper wire. Proceed to Test Step
8.
Test Step 7. Use the Injector Solenoid
Test to Check the ECM for Short Circuits
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Disconnect the J2/P2 ECM connector from the
ECM and check for evidence of moisture.
C. Turn the keyswitch to the ON position.
D. Perform the injector solenoid test at least two
times.
129
Troubleshooting Section
Expected Result:
All cylinders indicate “OPEN” when the P2 ECM
connector is disconnected from the ECM.
Note: When the engine harness is disconnected
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.
Results:
• OK – The short circuit is in the engine harness.
Repair: Repair the engine harness or replace the
engine harness, as required. Clear all diagnostic
codes after completing this test step.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The engine harness is “OK”.
Repair: Perform the following repair:
1. Temporarily connect a test ECM.
2. Remove all jumpers and replace all connectors.
3. Recheck the system for active diagnostic codes.
4. Repeat the test step.
5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
6. If the problem returns with the suspect ECM,
replace the ECM.
7. Verify that the repair eliminates the problem.
STOP.
Test Step 8. Check the ECM For an Open
Circuit
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if the
keyswitch is not turned to the OFF position.
B. Disconnect the engine harness from the J2 ECM
connector. Connect a 140-2266 Cable (Breakout
T) to the ECM. Do not connect the engine harness
to the breakout t.
130
Troubleshooting Section
C. Use a jumper wire to short between the socket of
the injector and the common socket of the suspect
injector.
D. Turn the keyswitch to the ON position.
E. Perform the injector solenoid test at least two
times.
Note: When the engine harness is disconnected
all of the diagnostic codes for supply voltage to the
sensors will be active. This is normal. Clear all of
these diagnostic codes after completing this test step.
Expected Result:
Cat ET displays “SHORT” for the cylinder with the
jumper wire.
Results:
• OK – The ECM is “OK”.
Repair: Replace the engine harness or repair the
engine harness, as required.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The ECM is not “OK”.
Repair: Perform the following repair:
1. Temporarily connect a test ECM.
2. Remove all jumpers and replace all connectors.
3. Recheck the system for active diagnostic codes.
4. Repeat the test step.
5. If the problem is resolved with the test ECM,
reconnect the suspect ECM.
6. If the problem returns with the suspect ECM,
replace the ECM.
7. Verify that the repair eliminates the problem.
STOP.
Test Step 9. Check The Injector Harness
Under the Valve Cover
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
SENR9515-05
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Remove the valve cover.
C. Disconnect the harness from the problem injector.
Disconnect the harness from the other injector
that has the same injector common line.
D. Thoroughly clean the terminals of both injectors
and of the harness.
E. Exchange the harness between the two injectors
that share the common line.
F. Turn the keyswitch to the ON position.
G. Perform the injector solenoid test at least two
times.
Expected Result:
Exchanging the harness between the two injectors
caused the problem to move to the other injector
on Cat ET.
Results:
• OK – Cat ET indicates that the problem has
moved.
Repair: Replace the faulty injector. Restore the
wiring to the proper injectors.
Verify that the repair eliminates the problem.
STOP.
• Not OK – Cat ET still indicates that the problem is
with the original injector.
Repair: Replace the injector harness under the
valve cover.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05
Test Step 10. Check the Engine Harness
Under the Valve Cover for an Open
Circuit in the Common Line
Illustration 62
g00706832
Harness terminals of electronic unit injector
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Remove the valve cover.
C. Disconnect each of the injectors that indicate an
“OPEN” from the wiring harness. Ensure that each
of the connectors from the disconnected injector
harness does not touch other components and
short to ground.
D. Attach a jumper wire to both terminals of the
injector harness for the two injectors that share
an injector common line.
E. Turn the keyswitch to the ON position.
F. Perform the injector solenoid test at least two
times.
Expected Result:
The cylinders with the short in place indicate an
“OPEN”.
131
Troubleshooting Section
Results:
• OK – The problem appears to be in the engine
harness under the valve cover.
Repair: Perform the following repair:
1. Replace the engine harness under the valve
cover.
2. Run the injector solenoid test in order to check
the installation of the new harness before
installing the valve covers.
3. Verify that the repair eliminates the problem.
STOP.
• Not OK – Both injectors indicate “SHORT”.
Repair: Replace both injectors.
Verify that the repair eliminates the problem.
STOP.
Test Step 11. Check the Engine Harness
Under the Valve Cover for Short Circuits
in the Injector Wires
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Remove the valve cover.
C. Disconnect each of the injectors that indicate a
“SHORT” from the wiring harness. Ensure that
each of the connectors from the disconnected
injector harness does not touch other components
and short to ground.
D. Turn the keyswitch to the ON position.
E. Perform the injector solenoid test at least two
times.
Expected Result:
Both cylinders indicate an “OPEN”.
Results:
• OK – Neither of the injector wires are shorted to
the engine.
132
Troubleshooting Section
Repair: Leave the injector wires disconnected.
Proceed to Test Step 12.
• Not OK – There is a short in the injector harness
under the valve cover.
Repair: Replace the injector harness under the
valve cover.
Verify that the repair eliminates the problem.
STOP.
Test Step 12. Check For a Short Circuit in
the Injector Common Line to the Engine
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Disconnect the J2/P2 ECM connector.
C. Locate the common line for the problem injector
in the P2 connector. Measure the resistance from
the terminal to the engine ground stud connection.
Expected Result:
The multimeter indicates that the resistance is
greater than 10 Ohms.
Results:
• OK – The harness is not shorted to ground.
Repair: Reconnect the engine harness to the ECM.
Proceed to Test Step 13.
• Not OK – The harness is shorted to ground.
Repair: Replace the injector harness under the
valve cover.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05
Test Step 13. Check For a Short Circuit in
the Injector
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Reconnect one of the two disconnected injectors.
C. Turn the keyswitch to the ON position.
D. Perform the injector solenoid test at least two
times.
Expected Result:
The reconnected injector indicates a “SHORT”.
Results:
• OK – The injector has an internal short.
Repair: Replace the Injector.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The injector is OK. There may be a
problem with the other injector. Proceed to Test
Step 14.
Test Step 14. Check For a Short Circuit
in the Other Injector
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
A. Turn the keyswitch to the OFF/RESET position.
A strong electrical shock hazard is present if
the keyswitch is not turned to the OFF/RESET
position.
B. Reconnect the other disconnected injector.
C. Turn the keyswitch to the ON position.
D. Perform the injector solenoid test at least two
times.
SENR9515-05 133
Troubleshooting Section

Expected Result:

The reconnected injector indicates a “SHORT”.

Results:

• OK – The injector has an internal short.

Repair: Replace the faulty injector. Restore the
wiring to the proper injectors.

Verify that the repair eliminates the problem.

STOP.

• Not OK – This injector is OK.

Repair: There may be an intermittent problem.

Refer to Troubleshooting, “Electrical Connectors

- Inspect”.

STOP.

i01592513

Throttle Lock Lamp Circuit -

Test
SMCS Code: 1408-081; 7431-038

System Operation Description:

The throttle lock lamp illuminates in order to indicate

that the throttle lock feature is activated. The throttle
lock lamp will be illuminated when the engine speed
is sustained in either the manual mode or the
automatic mode.

The throttle lock lamp receives battery power from

the engine control relay. The ECM activates the lamp
by providing a path to ground.

g00827353
Illustration 63
Schematic
134
Troubleshooting Section
Test Step 1. Inspect Electrical Connectors
and Wiring
A. Thoroughly inspect the J1/P1 ECM connector,
the socket for the throttle lock lamp, any other
connectors in the circuit, and the associated
wiring. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
B. Check the harness and wiring for abrasions and
for pinch points.
Expected Result:
All connectors, pins and sockets should be completely
coupled and/or inserted and the harness and wiring
should be free of corrosion, abrasion or pinch points.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the
connectors are completely coupled.
STOP.
Test Step 2. Check for Normal Operation
of the Lamp
A. Activate the throttle lock feature in the automatic
mode:
a. Turn the keyswitch to the ON position.
b. Depress the throttle hold mode switch in the
forward direction to the AUTO position.
c. Depress the throttle speed set switch in the
forward direction to the SET position.
B. Monitor the throttle lock lamp.
Note: The lamp should be on.
C. Move the throttle hold mode switch to the OFF
position.
Note: The lamp should turn off.
Expected Result:
The lamp should turn on when the engine speed is
being sustained by the throttle lock feature. The lamp
should turn off when the throttle hold mode switch is
moved to the OFF position.
SENR9515-05
Results:
• OK – The throttle lock lamp appears to operating
correctly at this time. STOP.
• Not OK – The throttle lock lamp remains on.
Proceed to Test Step 5.
• Not OK – The throttle lock lamp does not come on.
Proceed to Test Step 3.
Test Step 3. Check for Power at the
Throttle Lock Lamp
A. Turn the keyswitch to the ON position.
B. Use a voltage test lamp to check for power
between the throttle lock lamp and chassis
ground. Check both terminals on the lamp socket.
Note: If the test lamp only lights on one side of the
socket, the bulb is bad.
Expected Result:
The test lamp should light.
Results:
• OK – The lamp is receiving power and the bulb is
good. Proceed to Test Step 4.
• Not OK - Power On One Side – The lamp is
receiving power, but the bulb is bad.
Repair: Replace the bulb.
Verify that the repair eliminates the problem.
STOP.
• Not OK - No Power – The lamp is not receiving
power.
Repair: Repair the power circuit to the lamp. The
lamp receives battery power through the engine
control breaker. Refer to the Electrical Schematic
for more details.
Verify that the repair eliminates the problem.
STOP.
SENR9515-05 135
Troubleshooting Section

Test Step 4. Check for Power at the ECM Test Step 5. Check the Harness for a
Short to Ground

g00827352
Illustration 64
g00827352
Illustration 65
ECM Connector P1 (ECM side)
ECM Connector P1 (ECM side)
A. Disconnect the J1/P1 ECM connector.
A. Disconnect the J1/P1 ECM connector.
B. Turn the keyswitch to the ON position.
B. Remove the bulb for the throttle lock lamp from
C. Use a voltage test lamp to check for power the socket.
between P1:28 (Throttle Lock Lamp) and engine
ground. C. Measure the resistance between P1:28 (Throttle
Lock Lamp) and engine ground.
D. Turn the keyswitch to the OFF/RESET position.
Expected Result:
Expected Result:
The resistance should be greater than 20,000 Ohms.
The test lamp should light.
Results:
Results:
• OK – The wire is not shorted to ground. Proceed
• OK – The circuit from the ECM to the throttle lock to Test Step 6.
lamp appears to be good. Proceed to Test Step 6.
• Not OK – The G946-OR wire is shorted to ground
• Not OK – There is an open circuit between the between the ECM and the throttle lock lamp.
throttle lock lamp and the ECM.
Repair: Repair the circuit.
Repair: Repair the open circuit.
Verify that the repair eliminates the problem.
Verify that the repair eliminates the problem.
STOP.
STOP.
136
Troubleshooting Section
Test Step 6. Check the ECM
g00828187
Illustration 66
ECM connector P1 (wire side)
A. Ensure that the J1/P1 ECM connector is
connected.
B. Remove the G946-OR wire from P1:28 (Throttle
Lock Lamp).
C. Install a voltage test lamp between the +Battery
and P1:28 (Throttle Lock Lamp).
D. Activate the throttle lock feature in the automatic
mode:
a. Turn the keyswitch to the ON position.
b. Depress the throttle hold mode switch in the
forward direction to the AUTO position.
c. Depress the throttle speed set switch in the
forward direction to the SET position.
E. Observe the test lamp.
Note: The test lamp should be on.
F. Move the throttle hold mode switch to the OFF
position.
Note: The test lamp should turn off.
Expected Result:
The test lamp should illuminate accordingly.
SENR9515-05
Results:
• OK – The ECM and the circuit appear to be
working properly at this time.
Repair: If an intermittent condition is suspected,
refer to Troubleshooting, “Electrical Connectors -
Inspect” for more details.
STOP.
• Not OK – The ECM is not functioning properly.
Repair: Verify your results. Refer to
Troubleshooting, “Replacing the ECM”
before replacing the ECM.
Verify that the repair eliminates the problem.
STOP.
i01860710
Throttle Lock Switch Circuit -
Test
SMCS Code: 1900-081-ZS
System Operation Description:
The throttle lock feature is activated through the
use of the throttle lock mode switch and the throttle
speed set switch in order to maintain a desired
engine speed. The throttle lock mode switch is a
three-position rocker switch that is used to select the
mode of operation. The throttle speed set switch is
a two-position momentary rocker switch. This switch
is for setting the engine speed and/or adjusting
the engine speed. The throttle lock feature has the
following three modes of operation:
• Automatic Mode
• Manual Mode
• OFF
Automatic Mode
Depress the throttle lock mode switch in the forward
direction to the AUTO position in order to select the
automatic mode. Use the throttle pedal to achieve
the desired engine speed and then depress the
throttle speed set switch in the forward direction
(SET/ACCEL) in order to set the desired engine
speed.
Note: The throttle lock lamp will be illuminated when
the engine speed is sustained in the automatic mode.
SENR9515-05
Moving the throttle speed set switch in the forward
direction (SET/ACCEL) will increase the desired
engine speed. Moving the throttle speed set switch
in the backward direction (RESUME/DECEL) will
decrease the desired engine speed. Bumping the
throttle speed set switch will adjust the desired
engine speed by 100 rpm. Holding the throttle speed
set switch will adjust the desired engine speed at a
rate of 700 rpm per second.
Note: Actual engine speed may ramp at a slower rate
than desired engine speed. The throttle speed set
switch controls desired engine speed. For example,
if you bump the throttle speed set switch five times,
desired engine speed will immediately increase by
500 rpm. Actual engine speed may not react quickly
if the engine is under load.
Applying the service brake will suspend the selected
engine speed and the engine will decelerate at a
rate of 700 rpm per second until the engine speed
matches the desired engine speed for the throttle
pedal position.
After the throttle pedal has been released to less
than 10 percent, depressing the throttle pedal to
more than 25 percent will suspend the selected
engine speed and the engine speed will change at a
rate of 700 rpm per second until the engine speed
matches the desired engine speed for the position
of the throttle pedal.
The suspended engine speed may be resumed
by depressing the throttle speed set switch in
the backward direction (RESUME/DECEL). The
resume feature will be disabled under the following
circumstances:
• The throttle lock mode switch is moved to the OFF
position or the MAN position.
• The keyswitch is turned to the OFF position.
• The engine stalls.
Manual Mode
Depress the throttle lock mode switch in the
backward direction to the MAN position in order to
select the manual mode. Use the throttle pedal to
achieve the desired engine speed and then depress
the throttle speed set switch in the forward direction
(SET/ACCEL) in order to set the desired engine
speed.
Note: The throttle lock lamp will be illuminated when
the engine speed is sustained in the manual mode.
137
Troubleshooting Section
Moving the throttle speed set switch in the forward
direction (SET/ACCEL) will increase the desired
engine speed. Moving the throttle speed set switch
in the backward direction (RESUME/DECEL) will
decrease the desired engine speed. Bumping the
throttle speed set switch will adjust the desired
engine speed by 100 rpm. Holding the throttle speed
set switch will adjust the desired engine speed at a
rate of 700 rpm per second.
Note: Actual engine speed may ramp at a slower rate
than desired engine speed. The throttle speed set
switch controls desired engine speed. For example,
if you bump the throttle speed set switch five times,
desired engine speed will immediately increase by
500 rpm. Actual engine speed may not react quickly
if the engine is under load.
Moving the throttle pedal past the engine speed
setpoint will increase the engine speed. Releasing
the throttle pedal will allow the engine speed to return
to the locked engine speed.
Applying the service brake will not suspend the
throttle lock feature. Therefore, the resume feature is
not available in manual mode.
Moving the throttle lock mode switch to the OFF
position or to the AUTO position will disable the
manual mode.
OFF
When the throttle lock mode switch is in the OFF
(center) position, the throttle lock feature is disabled
and the throttle pedal is the only means of controlling
engine speed.
138 SENR9515-05
Troubleshooting Section

g00948725
Illustration 67
Schematic

g00825927
Illustration 68
P1 ECM connector (throttle speed set switch)
SENR9515-05
Illustration 69
P1 ECM connector (throttle lock mode switch)
Test Step 1. Inspect Electrical Connectors
and Wiring
A. Turn the keyswitch to the OFF/RESET position.
B. Thoroughly inspect the J1/P1 ECM connector,
the J61/P61 machine connector, the throttle lock
mode switch, the throttle speed set switch, any
other connectors in the circuit, and the associated
wiring. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
Expected Result:
All connectors, pins, and sockets should be
completely inserted and coupled. The harness and
wiring should be free of corrosion, abrasion, and
pinch points.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Check the Status of the
Throttle Speed Set Switch on the
Electronic Service Tool
A. Connect the electronic service tool to the service
tool connector and turn the keyswitch to the ON
position.
B. Observe the status of “Throttle Lock Set/Accel
Switch Position” and “Throttle Lock Resume/Decel
Switch Position” on the electronic service tool.
Note: The status should be “Off”.
139
Troubleshooting Section
g00948729
C. Hold the throttle speed set switch in the
SET/ACCEL position and observe the status of
“Throttle Lock Set/Accel Switch Position” on the
electronic service tool.
Note: The status should be “On”.
D. Hold the throttle speed set switch in the
RESUME/DECEL position and observe the status
of “Throttle Lock Resume/Decel Switch Position”
on the electronic service tool.
Note: The status should be “On”.
Expected Result:
The status should change accordingly as you change
switch positions.
Results:
• OK – The throttle speed set switch is operating
correctly. Proceed to Test Step 5.
• Not OK – There is a problem in the circuit for the
throttle speed set switch. Proceed to Test Step 3.
Test Step 3. Short the Wires at the
Throttle Speed Set Switch
A. Disconnect the throttle speed set switch.
B. Turn the keyswitch to the ON position.
C. Install a jumper wire with male spade terminals
on each end between terminal 2 (Return) and
terminal 6 (Speed Set/Accel) on the wiring
harness connector for the throttle speed set switch
and observe the status of “Throttle Lock Set/Accel
Switch Position” on the electronic service tool.
The status should be “On”.
140
Troubleshooting Section
D. Move the jumper wire to terminal 2 (Return) and
terminal 1 (Speed Resume/Decel). Observe the
status of “Throttle Lock Resume/Decel Switch
Position” on the electronic service tool.
The status should be “On”.
E. Move the jumper wire to terminal 2 (Return) and
terminal 4 (Speed Center Pos). Observe the
status of “Throttle Lock Set/Accel Switch Position”
and “Throttle Lock Resume/Decel Switch Position”
on the electronic service tool.
The status should be “Off”.
F. Turn the keyswitch to the OFF/RESET position.
Expected Result:
The status should change accordingly as you short
the terminals in the wiring harness connector.
Results:
• OK – The ECM and the wiring harness are
functioning properly.
Repair: Replace the throttle speed set switch.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is a problem in the circuit between
the ECM and the throttle speed set switch.
Repair: Remove the jumper wire and reconnect
the switch.
Proceed to Test Step 4.
Test Step 4. Short the Inputs at the ECM
for the Throttle Speed Set Switch
A. Remove the following wires from the P1 ECM
connector:
• P1:18 (Switch Return)
• P1:23 (Speed Center Pos)
• P1:40 (Speed Set/Accel)
• P1:41 (Speed Resume/Decel)
B. Turn the keyswitch to the ON position.
SENR9515-05
C. Install a jumper wire with Deutsch sockets on each
end between P1:18 (Switch Return) and P1:40
(Speed Set/Accel). Observe the status of “Throttle
Lock Set/Accel Switch Position” on the electronic
service tool.
The status should be “On”.
D. Move the jumper wire to P1:18 (Switch Return)
and P1:41 (Speed Resume/Decel). Observe the
status of “Throttle Lock Resume/Decel Switch
Position” on the electronic service tool.
The status should be “On”.
E. Move the jumper wire to P1:18 (Switch Return)
and P1:23 (Speed Center Pos). Observe the
status of “Throttle Lock Set/Accel Switch Position”
and “Throttle Lock Resume/Decel Switch Position”
on the electronic service tool.
The status should be “Off”.
F. Turn the keyswitch to the OFF/RESET position.
G. Remove the jumper wire and reconnect the wires
to the P1 ECM connector.
Expected Result:
The status should change accordingly as you short
the terminals in the P1 ECM connector.
Results:
• OK – There is either an open circuit or a short
circuit in the wiring between the ECM and the
switch.
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
• Not OK – The ECM is not responding to the inputs
from the switch.
Repair: Verify your results. Refer to
Troubleshooting, “Replacing the ECM”
before replacing the ECM.
Verify that the new ECM eliminates the problem.
STOP.
Test Step 5. Check the Status of the
Throttle Lock Mode Switch on the
electronic service tool
A. Turn the keyswitch to the ON position.
SENR9515-05
B. Move the throttle lock mode switch to the AUTO
position and observe the status of “Throttle Lock
Switch” on the electronic service tool.
The status should be “On”.
C. Move the throttle lock mode switch to the MAN
position and depress the throttle speed set switch
forward to the SET/ACCEL position. Observe the
status of “Throttle Lock Switch” and “Throttle Lock
Mode” on the electronic service tool.
The status of “Throttle Lock Switch” should be
“Off” and the status of “Throttle Lock Mode” should
be “On”.
D. Move the throttle lock mode switch to the OFF
position and observe the status of “Throttle Lock
Switch” on the electronic service tool.
The status should be “Off”.
Expected Result:
The status should change accordingly as you change
switch positions.
Results:
• OK – The throttle lock mode switch switch appears
to be operating properly at this time. STOP.
• Not OK – There is a problem in the circuit for the
throttle lock mode switch. Proceed to Test Step 6.
Test Step 6. Short the Wires at the
Throttle Lock Mode Switch
A. Disconnect the throttle lock mode switch.
B. Turn the keyswitch to the ON position.
C. Connect a jumper wire with male spade terminals
on each end between terminal 2 (Return) and
terminal 6 (Throttle Lock (AUTO)) on the wiring
harness connector for the throttle lock mode
switch and observe the status of “Throttle Lock
Switch” on the electronic service tool.
The status should be “On”.
D. Move the jumper wire to terminal 2 (Return)
and terminal 1 (Throttle Lock (MAN)). Depress
the throttle speed set switch forward to the
SET/ACCEL position. Observe the status of
“Throttle Lock Switch” and “Throttle Lock Mode”
on the electronic service tool.
The status of “Throttle Lock Switch” should be
“Off” and the status of “Throttle Lock Mode” should
be “On”.
141
Troubleshooting Section
E. Move the jumper wire to terminal 2 (Return) and
terminal 4 (Throttle Lock OFF). Observe the status
of “Throttle Lock Switch” on the electronic service
tool.
The status should be “Off”.
F. Turn the keyswitch to the OFF/RESET position.
G. Remove the jumper wire and reconnect the switch.
Expected Result:
The status should change accordingly as you short
the terminals in the wiring harness connector.
Results:
• OK – The ECM and the wiring harness are
functioning properly.
Repair: Replace the throttle lock mode switch.
Verify that the repair eliminates the problem.
STOP.
• Not OK – There is a problem in the circuit between
the ECM and the throttle lock mode switch.
Proceed to Test Step 7.
Test Step 7. Short the Inputs at the ECM
for the Throttle Lock Mode Switch
A. Remove the following wires from the P1 ECM
connector:
• P1:18 (Switch Return)
• P1:35 (Throttle Lock (AUTO))
• P1:44 (Throttle Lock (MAN))
• P1:47 (Throttle Lock (OFF))
B. Turn the keyswitch to the ON position.
C. Install a jumper wire with Deutsch sockets on
each end between P1:18 (Switch Return) and
P1:35 (Throttle Lock (AUTO)). Observe the status
of “Throttle Lock Switch” on the electronic service
tool.
The status should be “On”.
D. Move the jumper wire to P1:18 (Switch Return)
and P1:44 (Throttle Lock (MAN)). Observe the
status of “Throttle Lock Switch” and “Throttle Lock
Mode” on the electronic service tool.
The status of “Throttle Lock Switch” should be
“Off” and the status of “Throttle Lock Mode” should
be “On”.
142 SENR9515-05
Troubleshooting Section

E. Move the jumper wire to P1:18 (Switch Return)
and P1:47 (Throttle Lock (OFF)). Observe the
status of “Throttle Lock Switch” on the electronic
service tool.
The status should be “Off”.
F. Turn the keyswitch to the OFF/RESET position.
G. Remove the jumper wire and reconnect the wires
to the P1 ECM connector.
Expected Result:
The status should change accordingly as you short
the terminals in the P1 ECM connector.
The output of the throttle position sensor is a pulse
width modulated signal that varies with the position
of the throttle. The throttle position sensor produces
a minimum duty cycle in the released position. The
throttle position sensor produces a maximum duty
cycle in the fully depressed position. When the pedal
is released, the ECM translates the output signal
to a throttle position of 0%. When the pedal is fully
depressed, the ECM translates the output signal to a
throttle position of 100%.
Note: The throttle position sensor receives a supply
of 8 VDC from the ECM. This supply is common with
all digital sensors. Troubleshoot any active diagnostic
codes that are related to the digital sensor supply
before attempting this troubleshooting procedure.

Results:

• OK – There is either an open circuit or a short

circuit in the wiring between the ECM and the
switch.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

• Not OK – The ECM is not responding to the inputs

from the switch.

Repair: Verify your results. Refer to

Troubleshooting, “Replacing the ECM”
before replacing the ECM.

Verify that the new ECM eliminates the problem.

STOP.

i02733309

Throttle Position Sensor

Circuit - Test
SMCS Code: 1408-081; 1913-038

System Operation Description:

The throttle position sensor is mounted to a pedal

assembly. The throttle position sensor provides
a signal to the ECM. The geometry of the pedal
assembly controls both the travel of the sensor and
the range of the output signal. The throttle position
sensor cannot be adjusted.
SENR9515-05
Illustration 70
Schematic
Test Step 1. Inspect Electrical Connectors
and Wiring
A. Turn the keyswitch to the OFF/RESET position.
B. Thoroughly inspect the J1/P1 ECM connector, the
J61/P61 machine connector, and the J403/P403
throttle position sensor connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for details.
Expected Result:
All connectors, pins, and sockets should be
completely inserted and coupled. The harness and
wiring should be free of corrosion, abrasion, and
pinch points.
Results:
• OK – Proceed to Test Step 2.
• Not OK
Repair: Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 2. Inspect the Throttle Pedal
Assembly
A. Inspect the throttle pedal assembly for components
that are loose, bent, missing, or worn.
B. Slowly depress the pedal and release the pedal.
Expected Result:
The throttle pedal assembly should operate smoothly
without excessive drag. The pedal should return to
the low idle position without assistance in less than
one second.
143
Troubleshooting Section
g00807537
Results:
• OK – The throttle pedal assembly functions
properly. Proceed to Test Step 3.
• Not OK
Repair: Repair the throttle pedal assembly, as
required.
STOP.
Test Step 3. Check the Status on ET
A. Connect ET to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Observe the status of “Throttle Position” on ET
while you operate the throttle pedal.
Expected Result:
The status should be approximately 0 percent when
the throttle pedal is released. The status should
progressively increase to 100 percent when the
throttle pedal is fully depressed.
Results:
• OK – The throttle position sensor is working
properly.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the problem is intermittent.
STOP.
• Not OK – Proceed to Test Step 4.
144 SENR9515-05
Troubleshooting Section

Test Step 4. Check the Supply Voltage at • Not OK – The sensor is not producing a valid
the Sensor signal.

A. Install a 7X-6370 Adapter Cable (3 Pin DT Repair: Replace the throttle position sensor.
Breakout) at the J403/P403 throttle position
sensor connector. Verify that the repair eliminates the problem.

B. Turn the keyswitch to the ON position. STOP.

C. Measure the voltage across terminal A (Digital
Sensor +8 VDC) and terminal B (Digital Return) at
the breakout.
Expected Result:
Test Step 6. Check for a Short Circuit in
the Wiring Harness
A. Disconnect the J1/P1 ECM connector and the
J403/P403 throttle position sensor connector.

The supply voltage should be 8.0 ± 0.5 VDC. B. Measure the following resistances:

Results: • P403:A (Digital Sensor +8 VDC) and P403:B

(Digital Return)
• OK – The sensor is receiving the correct supply
voltage. Proceed to Test Step 5. • P403:A (Digital Sensor +8 VDC) and P403:C
(Throttle Position)
• Not OK – The correct supply voltage is not
reaching the sensor. • P403:B (Digital Return) and P403:C (Throttle
Position)
Repair: Proceed to Troubleshooting, “Digital
Sensor Supply Circuit - Test”. Expected Result:

STOP. The resistance should be greater than 20,000 Ohms

for each measurement.
Test Step 5. Check the Isolated Signal
Frequency and the Duty Cycle at the Results:
Sensor
• OK – There are no shorts in the harness. Proceed
A. Remove the wire from the harness side of P403:C to Test Step 7.
(Signal).
• Not OK – There is a short circuit in the harness
B. Turn the keyswitch to the ON position. or connectors.

C. Measure the frequency and the duty cycle Repair: Repair the circuit.
between terminal B (Digital Return) and terminal
C (Signal) at the J403/P403 breakout while you Verify that the repair eliminates the problem.
operate the throttle pedal.
STOP.
D. Turn the keyswitch to the OFF/RESET position.

E. Reinstall the wire in P403:C (Signal).

Expected Result:

The frequency should be between 150 and 1000 Hz.

The duty cycle should be between 10 and 35 percent
when the pedal is released. The duty cycle should be
between 60 and 90 percent when the pedal is fully
depressed.

Results:

• OK – The sensor is producing a valid signal.

Proceed to Test Step 6.
SENR9515-05 145
Troubleshooting Section

Test Step 7. Check the Resistance

through the Harness

g00807533
Illustration 71
ECM connector P1

A. Fabricate a jumper wire with pins at both ends.

B. Use the jumper wire to short P403:A (Digital

Sensor +8 VDC) and P403:C (Throttle Position)
together.

C. Measure the resistance between P1:66 (Throttle

Position) and P1:4 (Digital Sensor +8 VDC).

D. Move the one end of the jumper wire from P403:A

(Digital Sensor +8 VDC) to P403:B (Digital
Return). Leave the other end in P403:C (Throttle
Position).

E. Measure the resistance between P1:66 (Throttle

Position) and P1:5 (Digital Sensor Return).

F. Remove the jumper wire and reconnect all of the

connectors.

Expected Result:

The resistance should be less than 10 Ohms for each

measurement.

Results:

• OK – The harness is good. Proceed to Test Step 8.

• Not OK – There is an open circuit or excessive
resistance in the harness or the connectors.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.
146 SENR9515-05
Troubleshooting Section

Test Step 8. Check the Signal Frequency

and the Duty Cycle at the ECM

g00807533
Illustration 72

A. Remove the signal wire from J2:66 (Throttle Expected Result:

Position).
B. Turn the keyswitch to the ON position.
C. Measure the frequency and the duty cycle
between the signal wire and the ECM ground
strap while you operate the throttle pedal.
The status should read approximately 0 percent
when the throttle pedal is released. The status should
progressively increase to 100 percent when the
throttle pedal is fully depressed.
Results:

D. Turn the keyswitch to the OFF/RESET position.
E. Reinstall the signal wire in J2:66.
Expected Result:
• OK – The throttle position sensor is working
properly.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the problem is intermittent.

The frequency should be between 150 and 1000 Hz. STOP.

The duty cycle should be between 0 and 35 percent
when the pedal is released. The duty cycle should be
between 55 and 100 percent when the pedal is fully
depressed.
Results:
• OK – A valid sensor signal is reaching the ECM.
Proceed to Test Step 9.
• Not OK – A valid signal appears at the ECM, but
the ECM is not reading the signal properly.
Repair: Replace the ECM. Refer to
Troubleshooting, “Replacing the ECM”
before replacing the ECM.
STOP.

• Not OK – There is an intermittent problem in the

wiring harness or the connectors.

Repair: Repair the circuit.

Verify that the repair eliminates the problem.

STOP.

Test Step 9. Check the Status on ET

A. Turn the keyswitch to the ON position.

B. Observe the status for “Throttle Position” on ET

while you operate the throttle pedal.
SENR9515-05 147
Troubleshooting Section

Calibration Procedures
i02092222

Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1912-524

System Operation Description:

Use this procedure if any of the following conditions

exist:

• The Electronic Control Module (ECM) has been

replaced.

• Work has been performed on the front gear group.

• 261-13 Engine Timing Calibration required is active
or logged.

The primary engine speed/timing sensor provides an

engine speed signal (rpm) to the ECM. The signal
is created as the crankshaft gear rotates past the
pickup of the primary engine speed/timing sensor.

The secondary engine speed/timing sensor provides

the timing signal to the ECM. The signal is created
as the camshaft gear rotates past the pickup of the
secondary engine speed/timing sensor. A unique
pattern on the gear allows the ECM to determine the
crankshaft position. This unique pattern on the gear
allows the ECM to determine the top center position
of the piston in the No. 1 cylinder.

Timing calibration is accomplished by installing a

magnetic transducer into the side of the engine block.
The magnetic transducer senses a special slot on the
crankshaft counterweight. The magnetic transducer
is connected to the ECM through a harness. The
harness connector is located near the ECM.

Note: The timing calibration will not affect available

engine power. Do not expect a change in power due
to the performance of the timing calibration.
148 SENR9515-05
Troubleshooting Section

g00803894
Illustration 73
Installation of the TC probe

Table 17 D. Install the 7X-1171 Transducer Adapter into the

Required Special Tools
hole for the plug.

Part Number Description Results:

Magnetic Transducer (Timing
6V-2197 • OK – Proceed to Test Step 2.
Calibration Probe)
7X-1695 Cable (Timing Calibration) Test Step 2. Install the 6V-2197 Timing
7X-1171 Transducer Adapter Calibration Probe on the Engine
9S-9082 Engine Turning Tool
NOTICE
If the crankshaft is not in the correct position when
Test Step 1. Install the 7X-1171 the 6V-2197 Timing Calibration Probe is installed, the
Transducer Adapter probe will be damaged when the engine is started.

A. Turn the keyswitch to the OFF position.

B. Use the 9S-9082 Engine Turning Tool to put
either the No. 1 piston or the No. 6 piston at top
center. After the top center position has been
located, rotate the engine in the opposite direction
of the correct engine rotation for 60 degrees.
Note: Normal engine rotation is counterclockwise as
the engine is viewed from the flywheel end.
C. Remove the timing calibration plug. The plug is
located in the No. 4 cylinder on the right side of
the cylinder block.
A. Put the 2D-6392 O-Ring Seal on the end of the
timing calibration probe.
Note: A small amount of clean engine oil will allow
the seal to slide onto the sensor more easily.
B. Push the probe through the adapter until the probe
contacts the outermost portion of the crankshaft
counterweight. Move the O-ring seal downward
against the adapter.
C. Withdraw the probe 1.0 mm (0.04 inch) and hand
tighten the nut on the adapter sleeve in order to
secure the probe in place.
SENR9515-05
D. Connect the 6V-2197 Timing Calibration Probe
to the 7X-1695 Cable.
Results:
• OK – Proceed to Test Step 3.
Test Step 3. Start the Engine and
Allow the Coolant to Reach Operating
Temperature
A. Connect Cat ET to the service tool connector.
B. Start the engine and run at low idle until the engine
is at correct operating temperature.
C. Check for active diagnostic codes. Use the
procedures in this manual for troubleshooting.
Repair any active diagnostic codes before you
proceed. The engine must not have any diagnostic
conditions that are present during the timing
calibration except the following condition:
• 261-13
Results:
• OK – Proceed to Test Step 4.
Test Step 4. Connect the Cables for the
Timing Calibration Probe
A. After the engine has warmed up, access the
“Timing Calibration” screen on Cat ET. Access the
following display screens in order:
• “Service”
• “Calibrations”
• “Timing Calibration Screen”
B. Connect the 7X-1695 Cable to the timing
calibration probe connector that is located near
the ECM.
C. Ensure that all of the following connections are
made correctly:
• Timing calibration probe
• Cables for Cat ET and for the communication
adapter
Results:
• OK – Proceed to Test Step 5.
149
Troubleshooting Section
Test Step 5. Calibrate the Speed/Timing
Sensor
A. After the engine has reached the correct operating
temperature, set the engine speed to 1000 ± 50
rpm. The engine speed must be steady within this
rpm range in order to successfully perform a timing
calibration. To calibrate the timing to the correct
setting, select “Continue” on Cat ET. Wait until Cat
ET indicates that the timing is “CALIBRATED”.
Note: If the display for Cat ET reads “CALIBRATION
UNSUCCESSFUL”, the timing has not been
calibrated. Recheck the tool installation and tool
operation and try again. If the crankshaft and
camshaft gears have been reassembled incorrectly,
the engine will not calibrate.
Expected Result:
The timing calibration procedure was completed
successfully.
Results:
• OK – Proceed to Test Step 6.
• Not OK
Repair: Perform the following procedure:
1. Verify that the engine speed was stable during
the testing (± 50 rpm). If the engine speed
was unstable or the engine speed could not
be controlled within ± 50 rpm because of
mechanical factors or electrical factors, refer to
Troubleshooting, “Engine Misfires, Runs Rough
or Is Unstable”.
2. If all of the problems have been corrected but
the timing can not be calibrated, check the
cable of the 6V-2197 Transducer and check
the 6V-2197 Transducer in order to verify that
the transducer is not bent. If the 6V-2197
Transducer is not bent, restart this procedure.
STOP.
Test Step 6. Disconnect the 7X-1695
Cable Before Exiting the “ Timing
Calibration” Screen on Cat ET
A. Reduce the engine speed to low idle.
B. Disconnect the 7X-1695 Cable from the 6V-2197
Transducer.
C. Exit the “Timing Calibration” screen on Cat ET.
150 SENR9515-05
Troubleshooting Section

D. Turn the keyswitch to the OFF position. Remove Table 18

the 6V-2197 Magnetic Transducer and remove Injector Trim Code
the 7X-1171 Transducer Adapter from the timing
calibration port. Reinstall the plug into the cylinder Cylinder Old New
block. 1
Expected Result: 2
3
The timing probe was disconnected before exiting
the “Timing Calibration” screen on Cat ET. 4
5
Results:
6
• OK – STOP.
Note: If the ECM is replaced, all injector trim codes
• Not OK – If the timing probe is still connected must be recorded. The injector trim codes can be
to the ECM after exiting the “Timing Calibration” found in “Calibrations” under the “Service” menu on
screen on Cat ET, additional diagnostic codes may the Caterpillar Electronic Technician (ET).
be generated.
Expected Result:
Repair: If additional diagnostic codes are
generated, clear the diagnostic codes. All injector trim codes were obtained.
STOP. Results:

i02149153 • OK – All injector trim codes were obtained.

Proceed to Test Step 2.
Injector Code - Calibrate
• Not OK – The injector trim codes were not
SMCS Code: 1290-524 obtained.

System Operation Description:
If any of the following conditions have occurred,
calibrate the injector trim codes:
• Replacement of the Electronic Control Module
(ECM)
• Replacement of any of the unit injectors
Repair: Remove the valve cover and record the
injector trim code and the corresponding cylinder
number for each unit injector.
Proceed to Test Step 2.
Test Step 2. Replace Hardware
A. Replace the suspect unit injectors and/or the ECM.

A special code is stamped on the top of each unit B. Record the injector trim code and the
injector. The injector trim code allows the ECM to corresponding cylinder number for each unit
compensate for variances in manufacturing. injector.

Note: Changing the injector trim codes will not Expected Result:
increase the power that is available to the engine.
All hardware was successfully replaced and the new
Test Step 1. Record Injector Trim Codes injector trim codes were recorded.

A. Use Table 18 to record the injector trim code and Results:

the corresponding cylinder number for each unit
injector that will be replaced. • OK – The hardware was successfully replaced.
Proceed to Test Step 3.

Test Step 3. Enter Injector Trim Codes

into the ECM
A. Connect Cat ET to the service tool connector.
SENR9515-05 151
Troubleshooting Section

B. Turn the keyswitch to the ON position.

C. Open the “Injector Codes Calibration” in

“Calibrations” under the “Service” menu on Cat ET.

D. Enter the new injector trim code for each cylinder.

Results:

• OK – STOP.
152
Index Section
Index
Numerics
5 Volt Engine Pressure Sensor Supply Circuit -
Test ...................................................................... 73
A CID 0261 FMI 13 Engine Timing Calibration
Alternator (Charging Problem)............................... 22
Probable Causes ............................................... 22
Recommended Actions...................................... 22
Alternator (Noisy Operation).................................. 22
Probable Causes ............................................... 22
Recommended Actions...................................... 22
C CID 0273 FMI 03 Turbo Outlet Pressure open/short
Calibration Procedures ........................................ 147
Can Not Reach Top Engine RPM .......................... 23
Probable Causes ............................................... 23
Recommended Actions...................................... 23
Cat Data Link Circuit - Test.................................... 77
CID 0001 FMI 11 Injector Cylinder #1 fault............ 47
CID 0002 FMI 11 Injector Cylinder #2 fault............ 47
CID 0003 FMI 11 Injector Cylinder #3 fault............ 47
CID 0004 FMI 11 Injector Cylinder #4 fault............ 48
CID 0005 FMI 11 Injector Cylinder #5 fault............ 48
CID 0006 FMI 11 Injector Cylinder #6 fault............ 48
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 49
CID 0041 FMI 04 8 Volt DC Supply short to
ground.................................................................. 49
CID 0091 FMI 08 Throttle Position signal
abnormal.............................................................. 49
CID 0094 FMI 03 Fuel Pressure open/short to
+batt..................................................................... 50
CID 0094 FMI 04 Fuel Pressure short to ground... 50
CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt..................................................................... 50
CID 0100 FMI 04 Engine Oil Pressure short to
ground.................................................................. 50
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt............................................... 51
CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 51
CID 0168 FMI 00 System Voltage High................. 51
CID 0168 FMI 01 System Voltage Low.................. 51
CID 0168 FMI 02 System Voltage intermittent/
erratic................................................................... 52
CID 0172 FMI 03 Intake Manifold Air Temp open/short
to +batt................................................................. 52
CID 0172 FMI 04 Intake Manifold Air Temp short to
ground.................................................................. 52
CID 0174 FMI 03 Fuel Temperature open/short to
+batt..................................................................... 53
CID 0174 FMI 04 Fuel Temperature short to
ground.................................................................. 53
CID 0190 FMI 02 Loss of Engine Speed Signal .... 53
SENR9515-05
CID 0190 FMI 11 Engine Speed Sensor mechanical
failure ................................................................... 54
CID 0248 FMI 09 CAT Data Link communications.. 54
CID 0253 FMI 02 Personality Module mismatch ... 54
CID 0254 FMI 12 Electronic Control Module
Error..................................................................... 55
required................................................................ 55
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
short to +batt........................................................ 55
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
short to ground..................................................... 56
CID 0267 FMI 02 Incorrect Engine Shutdown Switch
inputs ................................................................... 56
CID 0268 FMI 02 Check Programmable
Parameters .......................................................... 56
to +batt................................................................. 57
CID 0273 FMI 04 Turbo Outlet Pressure short to
ground.................................................................. 57
CID 0274 FMI 03 Atmospheric Pressure open/short
to +batt................................................................. 57
CID 0274 FMI 04 Atmospheric Pressure short to
ground.................................................................. 58
CID 0290 FMI 03 Engine Fan Pump Pressure
open/short to +batt............................................... 58
CID 0290 FMI 04 Engine Fan Pump Pressure short
to ground.............................................................. 58
CID 0291 FMI 05 Engine Cooling Fan Solenoid open
circuit ................................................................... 58
CID 0291 FMI 06 Engine Cooling Fan Solenoid short
to ground.............................................................. 59
CID 0296 FMI 09 Unable to communicate with
Transmission ECM .............................................. 59
CID 0297 FMI 09 Unable to communicate with
All-Wheel Drive ECM ........................................... 60
CID 0342 FMI 02 Loss of Secondary Engine Speed
signal ................................................................... 60
CID 0342 FMI 11 Secondary Engine Speed Sensor
mechanical failure................................................ 60
CID 0545 FMI 05 Ether Start Relay open/short to
+batt..................................................................... 61
CID 0545 FMI 06 Ether Start Relay short to
ground.................................................................. 61
CID 0548 FMI 05 Throttle Lock Lamp open circuit.. 61
CID 0548 FMI 06 Throttle Lock Lamp short .......... 62
CID 0549 FMI 02 Incorrect Throttle Lock Switch
inputs ................................................................... 62
CID 0562 FMI 09 Unable to Communicate with Cat
Monitoring System ............................................... 62
CID 0600 FMI 03 Hydraulic Oil Temperature
open/short to +batt............................................... 63
CID 0600 FMI 04 Hydraulic Oil Temperature short to
ground.................................................................. 63
Coolant in Engine Oil............................................. 24
Probable Causes ............................................... 24
Recommended Actions...................................... 24
Coolant Temperature Is Too High .......................... 24
SENR9515-05
D Engine Stalls at Low RPM ..................................... 31
Diagnostic Codes .................................................. 46
Active Diagnostic Codes .................................... 46
Logged Diagnostic Codes.................................. 46
Diagnostic Functional Tests................................... 73
Digital Sensor Supply Circuit - Test ....................... 80
E Probable Causes ............................................... 32
E015 High Engine Coolant Temperature Derate ... 64
E017 High Engine Coolant Temperature Warning.. 65
E025 High Inlet Air Temperature Derate................ 66
E027 High Inlet Air Temperature Warning ............. 67
E039 Low Engine Oil Pressure Derate.................. 68
E053 Low Fuel Pressure Warning......................... 69
E096 High Fuel Pressure ...................................... 70
E100 Low Engine Oil Pressure Warning ............... 71
E190 Engine Overspeed Warning ......................... 72
ECM Will Not Accept Factory Passwords.............. 25
Probable Causes ............................................... 25
Recommended Actions...................................... 25
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 25
Probable Causes ............................................... 25
Recommended Actions...................................... 25
Electrical Connectors - Inspect.............................. 84
Electrical Power Supply Circuit - Test.................... 89
Electronic Display Module (If Equipped).................. 8
Electronic Service Tool Will Not Communicate with
ECM..................................................................... 25
Probable Causes ............................................... 25
Recommended Actions...................................... 26
Electronic Service Tools .......................................... 6
Caterpillar Electronic Technician (ET).................. 7
Optional Service Tools ......................................... 6
Required Service Tools ........................................ 6
Electronic Troubleshooting ...................................... 5
Elevated Idle.......................................................... 26
Conditions .......................................................... 27
Probable Causes ............................................... 26
Engine Cranks but Will Not Start ........................... 27
Probable Causes ............................................... 27
Recommended Actions...................................... 27
Engine Fan Control Solenoid Circuit - Test............ 95
Engine Has Early Wear ......................................... 28
Probable Causes ............................................... 28
Recommended Actions...................................... 28
Engine Misfires, Runs Rough or Is Unstable......... 29
Probable Causes ............................................... 29
Recommended Actions...................................... 29
Engine Oil in Cooling System ................................ 30
Probable Causes ............................................... 30
Recommended Actions...................................... 30
Engine Oil Temperature Is Too High...................... 30
Probable Causes ............................................... 30
Recommended Actions...................................... 30
Engine Pressure Sensor Open or Short Circuit -
Test ...................................................................... 98
Engine Shutdown Switch Circuit - Test................ 103
Engine Speed/Timing Sensor - Calibrate ............ 147
Engine Speed/Timing Sensor Circuit - Test ......... 106
153
Index Section
Probable Causes ............................................... 31
Recommended Actions...................................... 31
Engine Temperature Sensor Open or Short Circuit -
Test ..................................................................... 112
Engine Vibration .................................................... 31
Probable Causes ............................................... 31
Recommended Actions...................................... 32
Engine Will Not Crank ........................................... 32
Recommended Actions...................................... 32
Engine Wiring Information ..................................... 15
Harness Wire Identification ................................ 15
Ether Injection System - Test................................ 117
Event Codes .......................................................... 64
Monitoring System ............................................. 64
Excessive Black Smoke ........................................ 33
Probable Causes ............................................... 33
Recommended Actions...................................... 33
Excessive Engine Oil Consumption....................... 34
Probable Causes ............................................... 34
Recommended Actions...................................... 34
Excessive Fuel Consumption ................................ 34
Probable Causes ............................................... 34
Recommended Actions...................................... 34
Excessive Valve Lash............................................ 35
Probable Causes ............................................... 35
Recommended Actions...................................... 35
Excessive White Smoke ........................................ 35
Probable Causes ............................................... 35
Recommended Actions...................................... 36
Exhaust Temperature Is Too High ......................... 36
Probable Causes ............................................... 36
Recommended Actions...................................... 37
F
Factory Passwords ................................................ 17
Factory Passwords Worksheet.............................. 17
Flash Programming ............................................... 17
Programming a Flash File.................................. 18
Fuel Dilution of Engine Oil ..................................... 37
Probable Causes ............................................... 37
Recommended Actions...................................... 37
Fuel in Cooling System.......................................... 37
Probable Causes ............................................... 37
Recommended Actions...................................... 37
I
Important Safety Information ................................... 2
Injector Code - Calibrate...................................... 150
Injector Solenoid Circuit - Test............................. 124
Intermittent Engine Shutdown ............................... 38
Probable Causes ............................................... 38
Recommended Actions...................................... 38
Intermittent Low Power or Power Cutout............... 38
Probable Causes ............................................... 39
Recommended Actions...................................... 39
154 SENR9515-05
Index Section

L V

Low Engine Oil Pressure ....................................... 40 Valve Rotator or Spring Lock Is Free..................... 44
Probable Causes ............................................... 40 Probable Cause ................................................. 44
Recommended Actions...................................... 40 Recommended Actions...................................... 45
Low Power/Poor or No Response to Throttle ........ 40
Probable Causes ............................................... 40
Recommended Actions...................................... 41

Mechanical Noise (Knock) in Engine..................... 42

Probable Causes ............................................... 42
Recommended Repairs ..................................... 42

Noise Coming from Cylinder.................................. 42

Probable Causes ............................................... 42
Recommended Actions...................................... 43

Poor Acceleration or Response............................. 43

Probable Causes ............................................... 43
Recommended Actions...................................... 43
Programming Parameters ..................................... 17

Replacing the ECM.................................................. 9

Self-Diagnostics..................................................... 10
Sensors and Electrical Connectors ........................ 11
System Configuration Parameters......................... 19
Parameter Descriptions ..................................... 19
Parameter Table................................................. 20
Parameter Worksheet ........................................ 20
System Overview..................................................... 5
Passwords ........................................................... 6
Programmable Parameters.................................. 6
System Operation ................................................ 5

Table of Contents..................................................... 3
Throttle Lock Lamp Circuit - Test......................... 133
Throttle Lock Switch Circuit - Test ....................... 136
Throttle Position Sensor Circuit - Test ................. 142
Troubleshooting Section.......................................... 5
Troubleshooting with a Diagnostic Code ............... 46
Troubleshooting with an Event Code..................... 64
Troubleshooting without a Diagnostic Code .......... 22
SENR9515-05 155
Index Section
©2007 Caterpillar
All Rights Reserved Printed in U.S.A.