3516B

RENR2270-02 June 2002Troubleshooting G3516B Generator Set Engines and G3516B Engines For Caterpillar Built Generator Sets and Power Modules CSC1-Up (Generator Set) CFD1-Up (Power Module) CME1-Up (Generator Set) CEY1-Up (Engine) 7EZ1-Up (Engine) CTW1-Up (Engine) 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 Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. 3 Table of Contents Table of Contents Troubleshooting Section Electronic Troubleshooting System Overview .................................................... 9 Self-Diagnostics .................................................... 10 Electrical Connectors and Functions .................... 11 Electronic Service Tools ........................................ 18 Engine Monitoring System .................................... 21 Programming Parameters Programming Parameters ..................................... Customer Passwords ............................................ Factory Passwords ................................................ Factory Passwords Worksheet ............................. Flash Programming .............................................. System Configuration Parameters ........................ Replacing the ECM ............................................... Replacing the ITSM .............................................. Troubleshooting Data Sheet ................................. 28 28 29 29 29 30 36 38 39 Intermittent Engine Shutdown ............................... 65 Jacket Water Inlet Pressure (High) ....................... 66 Jacket Water Pressure (Low) ................................ 67 Jacket Water to Engine Oil Differential Temperature (Low) ................................................................... 67 System Voltage ..................................................... 68 Turbocharger Turbine Temperature (High) ............ 68 Turbocharger Turbine Temperature (Low) ............. 69 Troubleshooting with a Diagnostic Code Diagnostic Codes .................................................. 70 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Value open circuit .......................................................... 71 MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short to ground ............................................................. 72 MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve malfunction .......................................................... 72 MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short to +batt ................................................................ 72 MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short to ground ............................................................. 73 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure open/short to +batt .............................................. 73 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure short to ground .................................................... 74 MID 036 - CID 0106 - FMI 03 Air Inlet Pressure Sensor short to +batt .......................................... 74 MID 036 - CID 0106 - FMI 08 Air Inlet Pressure Sensor noisy signal ............................................. 74 MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure open/short to +batt .............................................. 75 MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal ............................. 75 MID 036 - CID 0110 - FMI 03 Engine Coolant Temperature open/short to +batt ......................... 75 MID 036 - CID 0110 - FMI 04 Engine Coolant Temperature short to ground ............................... 76 MID 036 - CID 0145 - FMI 03 12 Volt DC Power Supply short to +batt ........................................... 76 MID 036 - CID 0145 - FMI 04 12 Volt DC Power Supply short to ground ........................................ 76 MID 036 - CID 0168 - FMI 02 System Voltage intermittent/erratic ............................................... 77 MID 036 - CID 0172 - FMI 03 Intake Manifold Air Temp open/short to +batt .................................... 77 MID 036 - CID 0172 - FMI 04 Intake Manifold Air Temp short to ground .......................................... 78 MID 036 - CID 0175 - FMI 03 Engine Oil Temperature open/short to +batt .............................................. 78 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature short to ground .................................................... 79 MID 036 - CID 0261 - FMI 13 Engine Timing calibration required ............................................. 79 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Supply short to +batt ........................................... 79 MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Supply short to ground ........................................ 80 MID 036 - CID 0301 - FMI 05 Cylinder 1 - Transformer Primary open circuit ............................................ 80 MID 036 - CID 0301 - FMI 06 Cylinder 1 - Transformer Primary short ...................................................... 81 MID 036 - CID 0302 - FMI 05 Cylinder 2 - Transformer Primary open circuit ............................................ 81 Troubleshooting without a Diagnostic Code Symptoms ............................................................. 41 Detonation ............................................................ 41 Driven Equipment ................................................. 43 ECM Will Not Accept Factory Passwords ............. 43 Electrohydraulic System Oil Pressure (Low) ......... 43 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) ..................................... 45 Engine Coolant Temperature (High) ..................... 45 Engine Coolant Temperature (Low) ...................... 47 Engine Cranks but Will Not Start .......................... 47 Engine Misfires, Runs Rough or Is Unstable ........ 48 Engine Oil Filter Differential Pressure ................... 50 Engine Oil Pressure (Low) .................................... 50 Engine Oil Temperature (High) ............................. 51 Engine Overcrank ................................................. 51 Engine Overload ................................................... 52 Engine Overspeed ................................................ 53 Engine Pre-Lube Pressure (Low) ......................... 53 Engine Shutdown .................................................. 54 Engine Shutdown (Unexpected) ........................... 55 Engine Shutdown without a Diagnostic Code ....... 56 Engine Starts but Stalls Immediately .................... 57 Engine Timing Does Not Match Programmed Timing ................................................................. 58 Engine Will Not Crank ........................................... 59 Exhaust Port Temperature (High) ......................... 60 Exhaust Port Temperature (Low) .......................... 61 Fuel Energy Content ............................................. 61 Fuel Pressure ....................................................... 62 Fuel Metering Valve .............................................. 62 Gas Fuel Differential Pressure (High) ................... 62 Gas Fuel Differential Pressure (Low) .................... 63 Gas Fuel Flow Rate (Low) .................................... 63 Gas Temperature (High) ....................................... 64 Inlet Air Temperature (High) .................................. 64 4 Table of Contents MID 036 - CID 0302 - FMI 06 Cylinder 2 - Transformer Primary short ...................................................... 81 MID 036 - CID 0303 - FMI 05 Cylinder 3 - Transformer Primary open circuit ............................................ 82 MID 036 - CID 0303 - FMI 06 Cylinder 3 - Transformer Primary short ...................................................... 82 MID 036 - CID 0304 - FMI 05 Cylinder 4 - Transformer Primary open circuit ............................................ 82 MID 036 - CID 0304 - FMI 06 Cylinder 4 - Transformer Primary short ...................................................... 83 MID 036 - CID 0305 - FMI 05 Cylinder 5 - Transformer Primary open circuit ............................................ 83 MID 036 - CID 0305 - FMI 06 Cylinder 5 - Transformer Primary short ...................................................... 84 MID 036 - CID 0306 - FMI 05 Cyinder 6 - Transformer Primary open circuit ............................................ 84 MID 036 - CID 0306 - FMI 06 Cylinder 6 - Transformer Primary short ...................................................... 84 MID 036 - CID 0307 - FMI 05 Cylinder 7 - Transformer Primary open circuit ............................................ 85 MID 036 - CID 0307 - FMI 06 Cylinder 7 - Transformer Primary short ...................................................... 85 MID 036 - CID 0308 - FMI 05 Cylinder 8 - Transformer Primary open circuit ............................................ 85 MID 036 - CID 0308 - FMI 06 Cylinder 8 - Transformer Primary short ...................................................... 86 MID 036 - CID 0309 - FMI 05 Cylinder 9 - Transformer Primary open circuit ............................................ 86 MID 036 - CID 0309 - FMI 06 Cylinder 9 - Transformer Primary short ...................................................... 87 MID 036 - CID 0310 - FMI 05 Cylinder 10 Transformer Primary open circuit ........................ 87 MID 036 - CID 0310 - FMI 06 Cylinder 10 Transformer Primary short .................................. 87 MID 036 - CID 0311 - FMI 05 Cylinder 11 Transformer Primary open circuit ........................ 88 MID 036 - CID 0311 - FMI 06 Cylinder 11 Transformer Primary short .................................. 88 MID 036 - CID 0312 - FMI 05 Cylinder 12 Transformer Primary open circuit ........................ 88 MID 036 - CID 0312 - FMI 06 Cylinder 12 Transformer Primary short .................................. 89 MID 036 - CID 0313 - FMI 05 Cylinder 13 Transformer Primary open circuit ........................ 89 MID 036 - CID 0313 - FMI 06 Cylinder 13 Transformer Primary short .................................. 90 MID 036 - CID 0314 - FMI 05 Cylinder 14 Transformer Primary open circuit ........................ 90 MID 036 - CID 0314 - FMI 06 Cylinder 14 Transformer Primary short .................................. 90 MID 036 - CID 0315 - FMI 05 Cylinder 15 Transformer Primary open circuit ........................ 91 MID 036 - CID 0315 - FMI 06 Cylinder 15 Transformer Primary short .................................. 91 MID 036 - CID 0316 - FMI 05 Cylinder 16 Transformer Primary open circuit ........................ 91 MID 036 - CID 0316 - FMI 06 Cylinder 16 Transformer Primary short .................................. 92 MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor short to +batt ....................................................... 92 MID 036 - CID 0320 - FMI 08 Engine Speed/Timing signal abnormal ................................................... 93 MID 036 - CID 0323 - FMI 03 Shutdown Lamp short to +batt ................................................................ 93 MID 036 - CID 0324 - FMI 03 Warning Lamp short to +batt .................................................................... 93 MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch inputs .................................................................. 94 MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open circuit ................................................................... 94 MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short to ground ............................................................. 94 MID 036 - CID 0339 - FMI 05 Engine Pre-lube Pressure Switch open circuit ............................... 95 MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer Secondary open circuit ....................................... 95 MID 036 - CID 0401 - FMI 06 Cylinder 1 - Transformer Secondary short to ground ................................. 95 MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer Secondary open circuit ....................................... 96 MID 036 - CID 0402 - FMI 06 Cylinder 2 - Transformer Secondary short to ground ................................. 96 MID 036 - CID 0403 - FMI 05 Cylinder 3 - Transformer Secondary open circuit ....................................... 97 MID 036 - CID 0403 - FMI 06 Cylinder 3 - Transformer Secondary short to ground ................................. 97 MID 036 - CID 0404 - FMI 05 Cylinder 4 - Transformer Secondary open circuit ....................................... 97 MID 036 - CID 0404 - FMI 06 Cylinder 4 - Transformer Secondary short to ground ................................. 98 MID 036 - CID 0405 - FMI 05 Cylinder 5 - Transformer Secondary open circuit ....................................... 98 MID 036 - CID 0405 - FMI 06 Cylinder 5 - Transformer Secondary short to ground ................................. 99 MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer Secondary open circuit ....................................... 99 MID 036 - CID 0406 - FMI 06 Cylinder 6 - Transformer Secondary short to ground ................................. 99 MID 036 - CID 0407 - FMI 05 Cylinder 7 - Transformer Secondary open circuit ..................................... 100 MID 036 - CID 0407 - FMI 06 Cylinder 7 - Transformer Secondary short to ground ............................... 100 MID 036 - CID 0408 - FMI 05 Cylinder 8 - Transformer Secondary open circuit ..................................... 100 MID 036 - CID 0408 - FMI 06 Cylinder 8 - Transformer Secondary short to ground ............................... 101 MID 036 - CID 0409 - FMI 05 Cylinder 9 - Transformer Secondary open circuit ..................................... 101 MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer Secondary short to ground ............................... 102 MID 036 - CID 0410 - FMI 05 Cylinder 10 Transformer Secondary open circuit ................. 102 MID 036 - CID 0410 - FMI 06 Cylinder 10 Transformer Secondary short to ground ........... 103 MID 036 - CID 0411 - FMI 05 Cylinder 11 Transformer Secondary open circuit ................. 103 MID 036 - CID 0411 - FMI 06 Cylinder 11 Transformer Secondary short to ground ........... 103 MID 036 - CID 0412 - FMI 05 Cylinder 12 Transformer Secondary open circuit ................. 104 5 Table of Contents MID 036 - CID 0412 - FMI 06 Cylinder 12 Transformer Secondary short to ground ........... 104 MID 036 - CID 0413 - FMI 05 Cylinder 13 Transformer Secondary open circuit ................. 104 MID 036 - CID 0413 - FMI 06 Cylinder 13 Transformer Secondary short to ground ........... 105 MID 036 - CID 0414 - FMI 05 Cylinder 14 Transformer Secondary open circuit ................. 105 MID 036 - CID 0414 - FMI 06 Cylinder 14 Transformer Secondary short to ground ........... 106 MID 036 - CID 0415 - FMI 05 Cylinder 15 Transformer Secondary open circuit ................. 106 MID 036 - CID 0415 - FMI 06 Cylinder 15 Transformer Secondary short to ground ........... 107 MID 036 - CID 0416 - FMI 05 Cylinder 16 Transformer Secondary open circuit ................. 107 MID 036 - CID 0416 - FMI 06 Cylinder 16 Transformer Secondary short to ground ........... 107 MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt ..................................................... 108 MID 036 - CID 0444 - FMI 05 Start Relay open circuit ................................................................. 108 MID 036 - CID 0444 - FMI 06 Start Relay short to ground ............................................................... 108 MID 036 - CID 0445 - FMI 03 Run Relay short to +batt .................................................................. 109 MID 036 - CID 0524 - FMI 03 Desired Engine Speed Sensor short to +batt ........................................ 109 MID 036 - CID 0524 - FMI 04 Desired Engine Speed Sensor short to ground ..................................... 109 MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure open/short to +batt ............................ 110 MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure short to ground .................................. 110 MID 036 - CID 1042 - FMI 09 Unable to communicate with ITSM .......................................................... 110 MID 036 - CID 1086 - FMI 09 Oxygen Sensor Element not communicating on link .................. 111 MID 036 - CID 1086 - FMI 13 Oxygen Sensor Element calibration required ............................. 111 MID 036 - CID 1087 - FMI 03 Oxygen Sensor Buffer Module short to +batt ........................................ 112 MID 036 - CID 1087 - FMI 08 Oxygen Sensor Buffer Module noisy signal .......................................... 112 MID 036 - CID 1088 - FMI 05 Oxygen Sensor Power Supply open circuit ............................................ 112 MID 036 - CID 1088 - FMI 06 Oxygen Sensor Power Supply short to ground ...................................... 113 MID 036 - CID 1440 - FMI 05 Throttle Actuator Driver open circuit ........................................................ 113 MID 036 - CID 1440 - FMI 06 Throttle Actuator Driver short to ground .................................................. 113 MID 036 - CID 1446 - FMI 05 Fuel Metering Module open circuit ........................................................ 114 MID 036 - CID 1446 - FMI 09 Unable to communicate with Fuel Metering Module ................................ 114 MID 036 - CID 1446 - FMI 12 Fuel Metering Module malfunction ........................................................ 114 MID 036 - CID 1446 - FMI 13 Fuel Metering Module calibration required ........................................... 115 MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Module malfunction ........................................... 115 MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation Sensor open/short to +batt ............................... 115 MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation Sensor short to ground ..................................... 116 MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Sensor open/short to +batt ............................... 116 MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Sensor short to ground ..................................... 116 MID 036 - CID 1505 - FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ............................... 117 MID 036 - CID 1505 - FMI 04 Cylinder #5 Detonation Sensor short to ground ..................................... 117 MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ............................... 117 MID 036 - CID 1506 - FMI 04 Cylinder #6 Detonation Sensor short to ground ..................................... 118 MID 036 - CID 1509 - FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ............................... 118 MID 036 - CID 1509 - FMI 04 Cylinder #9 Detonation Sensor short to ground ..................................... 118 MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Sensor open/short to +batt ............................... 119 MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Sensor short to ground ..................................... 119 MID 036 - CID 1513 - FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ............................... 119 MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation Sensor short to ground ..................................... 120 MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation Sensor open/short to +batt ............................... 120 MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Sensor short to ground ..................................... 120 MID 036 - CID 1758 - FMI 03 Specific Humidity Sensor open/short to +batt ............................... 121 MID 036 - CID 1758 - FMI 08 Specific Humidity Sensor signal abnormal .................................... 121 MID 036 - CID 1759 - FMI 03 Exhaust Back Pressure Sensor open/short to +batt ............................... 122 MID 036 - CID 1759 - FMI 08 Exhaust Back Pressure Sensor signal abnormal .................................... 122 MID 111 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed ........................... 122 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out Temp Sens short to +batt .................................. 123 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out Temp Sens short to ground ............................... 123 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out Temp Sens open circuit ..................................... 123 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt .................................. 124 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out Temp Sens short to ground ............................... 124 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..................................... 124 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In Temp Sens short to +batt .................................. 125 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In Temp Sens short to ground ............................... 125 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In Temp Sens open circuit ..................................... 125 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In Temp Sens short to +batt .................................. 126 6 Table of Contents MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In Temp Sens short to ground ............................... 126 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In Temp Sens open circuit ..................................... 126 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt ............................... 127 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground ............................ 127 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit ................................. 128 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ............................... 128 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............................ 128 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit ................................. 129 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............................... 129 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ............................ 130 MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit ................................. 130 MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt ............................... 130 MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ............................ 131 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ................................. 131 MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ............................... 132 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ............................ 132 MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit ................................. 132 MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ............................... 133 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground ............................ 133 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit ................................. 133 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt ............................... 134 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ............................ 134 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit ................................. 135 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ............................... 135 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ............................ 135 MID 111 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit ................................. 136 MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ............................... 136 MID 111 - CID 1539 - FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground ............................ 137 MID 111 - CID 1539 - FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit ................................. 137 MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ............................... 137 MID 111 - CID 1540 - FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground ............................ 138 MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit ................................. 138 MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ............................... 139 MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ............................ 139 MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ................................. 139 MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ............................... 140 MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground ............................ 140 MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit ................................. 141 MID 111 - CID 1543 - FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ............................... 141 MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground ............................ 141 MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit ................................. 142 MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ............................... 142 MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground ............................ 143 MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ................................. 143 MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............................... 143 MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ............................ 144 MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit ................................. 144 MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt ............................... 145 MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ............................ 145 MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit ................................. 145 Troubleshooting with an Event Code Event Codes ...................................................... E004 Engine Overspeed Shutdown .................... E015 High Engine Coolant Temperature Derate .. E016 High Engine Coolant Temperature Shutdown .......................................................... E017 High Engine Coolant Temperature Warning ............................................................. E019 High Engine Oil Temperature Shutdown ... E020 High Engine Oil Temperature Warning ...... E025 High Inlet Air Temperature Derate ............. E026 High Inlet Air Temperature Shutdown ........ E027 High Inlet Air Temperature Warning .......... E038 Low Engine Coolant Temperature Warning ............................................................. E040 Low Engine Oil Pressure Shutdown .......... E042 Low System Voltage Shutdown ................. E043 Low System Voltage Warning .................... E050 High System Voltage Warning ................... E053 Low Fuel Pressure Warning ...................... 147 149 149 149 150 150 150 151 151 151 151 152 152 152 153 153 7 Table of Contents E096 High Fuel Pressure .................................... E100 Low Engine Oil Pressure Warning ............. E127 Engine Oil Filter Diff Pressure Low Warning ............................................................. E128 Engine Oil Filter Diff Pressure Low Shutdown .......................................................... E129 Engine Oil Filter Diff Pressure High Warning ............................................................. E130 Engine Oil Filter Diff Pressure High Shutdown .......................................................... E135 Low Jacket Water Pressure Shutdown ...... E223 High Gas Temperature .............................. E224 High Jacket Water Inlet Pressure .............. E225 Engine Overcrank ...................................... E226 Driven Equipment Not Ready .................... E229 Fuel Energy Content Setting Low .............. E230 Fuel Energy Content Setting High ............. E231 Fuel Quality Out of Range ......................... E233 Low Engine Pre-Lube Pressure ................ E242 Engine Overload ........................................ E243 High Left Turbo Turbine Outlet Temperature ...................................................... E244 High Right Turbo Turbine Outlet Temperature ...................................................... E245 High Right Turbo Turbine Inlet Temperature ...................................................... E246 High Left Turbo Turbine Inlet Temperature .. E247 Low Left Turbo Turbine Outlet Temperature ...................................................... E248 Low Right Turbo Turbine Outlet Temperature ...................................................... E249 Low Right Turbo Turbine Inlet Temperature ...................................................... E250 Low Left Turbo Turbine Inlet Temperature .. E253 Detonation Derate Requested ................... E254 No Detonation Derate Action Taken .......... E264 Emergency Stop Activated ........................ E266 Low Hydrax Oil Pressure ........................... E268 Unexpected Engine Shutdown .................. E269 Customer Shutdown Requested ............... E270 Driven Equipment Shutdown Requested .. E337 High Engine Oil to Engine Coolant Diff Temp ................................................................. E401 Cylinder #1 Detonation .............................. E402 Cylinder #2 Detonation .............................. E403 Cylinder #3 Detonation .............................. E404 Cylinder #4 Detonation .............................. E405 Cylinder #5 Detonation .............................. E406 Cylinder #6 Detonation .............................. E407 Cylinder #7 Detonation .............................. E408 Cylinder #8 Detonation .............................. E409 Cylinder #9 Detonation .............................. E410 Cylinder #10 Detonation ............................ E411 Cylinder #11 Detonation ............................ E412 Cylinder #12 Detonation ............................ E413 Cylinder #13 Detonation ............................ E414 Cylinder #14 Detonation ............................ E415 Cylinder #15 Detonation ............................ E416 Cylinder #16 Detonation ............................ E421 Cylinder #1 Detonation Shutdown ............. E422 Cylinder #2 Detonation Shutdown ............. E423 Cylinder #3 Detonation Shutdown ............. E424 Cylinder #4 Detonation Shutdown ............. 153 153 154 154 154 155 155 155 155 156 156 156 156 157 157 157 157 158 158 159 159 159 160 160 161 161 161 161 162 162 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 168 E425 Cylinder #5 Detonation Shutdown ............. E426 Cylinder #6 Detonation Shutdown ............. E427 Cylinder #7 Detonation Shutdown ............. E428 Cylinder #8 Detonation Shutdown ............. E429 Cylinder #9 Detonation Shutdown ............. E430 Cylinder #10 Detonation Shutdown ........... E431 Cylinder #11 Detonation Shutdown ........... E432 Cylinder #12 Detonation Shutdown ........... E433 Cylinder #13 Detonation Shutdown ........... E434 Cylinder #14 Detonation Shutdown ........... E435 Cylinder #15 Detonation Shutdown ........... E436 Cylinder #16 Detonation Shutdown ........... E801 Cylinder #1 High Exhaust Port Temp ........ E802 Cylinder #2 High Exhaust Port Temp ........ E803 Cylinder #3 High Exhaust Port Temp ........ E804 Cylinder #4 High Exhaust Port Temp ........ E805 Cylinder #5 High Exhaust Port Temp ........ E806 Cylinder #6 High Exhaust Port Temp ........ E807 Cylinder #7 High Exhaust Port Temp ........ E808 Cylinder #8 High Exhaust Port Temp ........ E809 Cylinder #9 High Exhaust Port Temp ........ E810 Cylinder #10 High Exhaust Port Temp ...... E811 Cylinder #11 High Exhaust Port Temp ...... E812 Cylinder #12 High Exhaust Port Temp ...... E813 Cylinder #13 High Exhaust Port Temp ...... E814 Cylinder #14 High Exhaust Port Temp ...... E815 Cylinder #15 High Exhaust Port Temp ...... E816 Cylinder #16 High Exhaust Port Temp ...... E821 Cyl #1 Exhaust Port Temp Deviating High .. E822 Cyl #2 Exhaust Port Temp Deviating High .. E823 Cyl #3 Exhaust Port Temp Deviating High .. E824 Cyl #4 Exhaust Port Temp Deviating High .. E825 Cyl #5 Exhaust Port Temp Deviating High .. E826 Cyl #6 Exhaust Port Temp Deviating High .. E827 Cyl #7 Exhaust Port Temp Deviating High .. E828 Cyl #8 Exhaust Port Temp Deviating High .. E829 Cyl #9 Exhaust Port Temp Deviating High .. E830 Cyl #10 Exhaust Port Temp Deviating High ................................................................... E831 Cyl #11 Exhaust Port Temp Deviating High ................................................................... E832 Cyl #12 Exhaust Port Temp Deviating High ................................................................... E833 Cyl #13 Exhaust Port Temp Deviating High ................................................................... E834 Cyl #14 Exhaust Port Temp Deviating High ................................................................... E835 Cyl #15 Exhaust Port Temp Deviating High ................................................................... E836 Cyl #16 Exhaust Port Temp Deviating High ................................................................... E841 Cyl #1 Exhaust Port Temp Deviating Low .. E842 Cyl #2 Exhaust Port Temp Deviating Low .. E843 Cyl #3 Exhaust Port Temp Deviating Low .. E844 Cyl #4 Exhaust Port Temp Deviating Low .. E845 Cyl #5 Exhaust Port Temp Deviating Low .. E846 Cyl #6 Exhaust Port Temp Deviating Low .. E847 Cyl #7 Exhaust Port Temp Deviating Low .. E848 Cyl #8 Exhaust Port Temp Deviating Low .. E849 Cyl #9 Exhaust Port Temp Deviating Low .. E850 Cyl #10 Exhaust Port Temp Deviating Low ................................................................... 168 168 169 169 169 169 170 170 170 171 171 171 171 172 172 173 173 173 174 174 174 175 175 176 176 176 177 177 178 178 179 179 179 180 180 181 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 ............................................................. 295 Ignition Transformers Primary Circuit ................................. 193 +8V Sensor Voltage Supply ....................... 377 Index Section Index ... 320 Integrated Temperature Sensing Module (ITSM) ............................. 268 Electrical Power Supply ................................... 204 Analog Sensor Signal ................................... 342 Prelubrication System . 236 ECM Output Circuit (Prelubrication Oil Pump) .................................................................................................................................. 314 Inspecting Electrical Connectors .................................................................................... E852 Cyl #12 Exhaust Port Temp Deviating Low ............ E855 Cyl #15 Exhaust Port Temp Deviating Low ...............................8 Table of Contents E851 Cyl #11 Exhaust Port Temp Deviating Low ........................ 287 Fuel Metering Valve ... 375 Oxygen Sensor ........................ 258 ECM Status Indicator Output ................. E868 Gas Flow Control Valve Malfunction ................................ 222 Detonation Sensors .................... E854 Cyl #14 Exhaust Port Temp Deviating Low ...................... E864 Low Gas Fuel Differential Pressure ..................................................................... 358 Throttle Actuator Solenoid ..................................... 303 Ignition Transformers Secondary Circuit and Spark Plugs ................... E865 High Gas Fuel Differential Pressure .................................. 281 Fuel Metering Valve ..... 228 ECM Output Circuit (Fuel Control) ......................20 mA) .....................................Calibrate ........ 274 Engine Speed/Timing Sensor ............. E867 Improper Gas Flow Control Valve Response ....................................................... E856 Cyl #16 Exhaust Port Temp Deviating Low ........ 325 Oxygen Sensor Buffer Supply ........... 383 ........................ 333 Oxygen Sensor Signal .................................... 365 Calibration Procedures Engine Speed/Timing Sensor ......... 247 ECM Output Circuit (Starting Motor) ............................................................................................................................... E866 Low Gas Fuel Flow Rate .........Calibrate ............ 213 Desired Speed Input (4 ................................................................................................................ E853 Cyl #13 Exhaust Port Temp Deviating Low ............................................................. 188 189 189 189 190 190 191 191 191 191 192 Diagnostic Functional Tests +5V Sensor Voltage Supply ...................... 354 PWM Sensor ........................................................ The throttle position is controlled in open loop mode: there is no feedback from the throttle position. Actual engine speed is detected via a signal from the speed/timing sensor. If detonation reaches an unacceptable level. the ECM retards the ignition timing of the affected cylinder or cylinders. The sensors generate data on vibration that is processed by the ECM in order to determine detonation levels. The high pressure oil supply is monitored by a pressure switch that generates an event code if the pressure drops below an acceptable level. System Overview SMCS Code: 1901-038 Ignition Control The ECM provides variable ignition timing that is sensitive to detonation. The ECM issues a throttle command that represents a percent of the level of electrical current. etc at the appropriate levels. output drivers in the ECM. Detonation sensors monitor the engine for excessive detonation. the desired speed input (analog voltage or 4 to 20 mA).9 Troubleshooting Section Troubleshooting Section Electronic Troubleshooting i01726656 Desired engine speed is determined by the status of the idle/rated switch. The ECM determines the desired flow rates for the air and the fuel. The ECM monitors various inputs from sensors in order to activate relays. and maps in the ECM. Introduction The Electronic Control Module (ECM) controls most of the functions of the engine. To initiate combustion. The actuator is electrically controlled and hydraulically actuated. Parameters such as governor gain can be programmed with Cat ET. The following steps describe the basic operation: 1. an oxygen sensor. and parameters such as maximum engine high idle speed that are programmed into the software. Each sensor monitors two adjacent cylinders. A high pressure pump provides hydraulic pressure with oil from a system that is separate from the engine oil. The ECM provides extensive diagnostics for the ignition system. The transformers step up the voltage in order to create a spark across the spark plug electrode. The flow rates are determined by these factors: • Desired engine speed • Actual engine speed . The actuator is located at the flange of the air inlet manifold. Each cylinder has an ignition transformer that is located under the valve cover for the cylinder. The actual throttle position can be viewed on a mechanical pointer that is built into the mechanism of the throttle. The control compensates for changes in the BTU of the fuel in order to maintain desired emission levels. The ECM supports the following five primary functions: • Engine speed governing • Ignition control • Air/Fuel ratio control • Start/Stop sequencing • Engine monitoring and protection Engine Speed Governing The ECM maintains the desired engine speed by controlling the actuator for the throttle. Note: The 50 Hz applications and the 60 Hz applications use different fuel metering valves. If retarding the timing does not limit detonation to an acceptable level. The output can be viewed on the Caterpillar Electronic Technician (ET). The system consists of an electronic fuel metering valve. the ECM shuts down the engine. The G3516B Engine has eight detonation sensors. The module is an environmentally sealed unit that is mounted in a terminal box on the engine. solenoids. Air/Fuel Ratio Control The ECM provides control of the air/fuel mixture for performance and efficiency at low emission levels. The ECM also provides a switch for ignition timing in order to allow operation with alternate fuels such as propane that require a timing offset. the ECM sends a pulse of approximately 100 volts to the primary coil of each ignition transformer at the appropriate time and for the appropriate duration. Active codes require immediate attention. The maps of the data for the desired flow of air and fuel are sent in the form of a PWM signal to the fuel metering valve. The ECM removes the voltage when the programmable crank terminate speed is reached or when a programmable cycle crank time has expired. “Troubleshooting With An Event Code”. 3. Always service active codes prior to servicing logged codes. the ECM supplies +Battery voltage to the valve. When the programmable logic determines that fuel is required to start the engine or to run the engine. For example. 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. The codes are logged. For more information. This depends on the severity of the condition. a derating. see Troubleshooting. For more information on programmable parameters. . and the gas shutoff valve. Problems with engine operation such as low oil pressure produce an event code. When a problem is detected. The ECM can issue a warning. an event code will be generated if the oil pressure is too low. the starting motor. The ECM monitors the amount of oxygen in the exhaust gas via the oxygen sensor. Logged Code – Every generated code is stored in the permanent memory of the ECM. The ECM adjusts the signal for the flow of air and fuel in order to achieve the desired level of exhaust oxygen. To control the engine at the appropriate times. In this case. Diagnostic codes can have two different states: • Active • Logged Active Code – An active diagnostic code indicates that an active problem has been detected. “Troubleshooting With A Diagnostic Code”. the ECM supplies +Battery voltage to the relay for the starting motor. “Programming Parameters”. The system may also be programmed to perform a postlube cycle during engine shutdown in order to ensure that the turbocharger has adequate lubrication during shutdown. When the programmable logic determines that the prelubrication function is necessary. Engine Monitoring and Protection The ECM monitors both the engine operation and the electronic system. When the programmable logic determines that it is necessary to crank the engine. the ECM generates a diagnostic code. There are two types of codes: • Diagnostic • Event Diagnostic Code – When a problem with the electronic system is detected. i01727395 Start/Stop Sequencing The ECM contains the logic and the outputs for control of engine prelubrication. An alarm may also be generated. For more information. starting. the event code indicates the symptom of a problem. Problems with the electronic system such as an open circuit produce a diagnostic code. This process is repeated continuously during engine operation. or a shutdown.10 Troubleshooting Section • Calculated engine load 2. emergency stop switch. the ECM provides +Battery voltage to the relays for the prelube pump. and other inputs. see Troubleshooting. The customer programmable logic responds to signals from the following components: engine control switch. Event Code – An event code is generated by the detection of an abnormal engine operating condition. data link. a code is generated. the ECM supplies +Battery voltage to the relay for the prelube pump. This indicates the specific problem with the circuitry. remote start switch. The engine has an energize-to-run type of gas shutoff valve. and shutdown. see Troubleshooting. When the component is reconnected. For example. the code is no longer active. The actual wires are identified on the schematic. Electrical Connectors and Functions SMCS Code: 1408-038 Harness Wire Identification Caterpillar identifies different wires with eleven different solid colors.11 Troubleshooting Section Logged codes may not indicate that a repair is needed. Logged codes may be useful to help troubleshoot intermittent problems. . it is possible to generate an active diagnostic code whenever a component is disconnected. The problem may have been resolved since the logging of the code. This particular wire is the engine harness wire for the primary signal of the transformer in the number one cylinder. i01756530 The schematic also identifies the size of the wire. For all Caterpillar engine harnesses with electronic ignition systems. The size or gauge of the wire is called the American Wire Gauge (AWG). If the system is powered. The problem may have been temporary. Table 1 Color Codes for Wiring Code BK BR BU GN GY OR PK PU RD WH YL Color Black Brown Blue Green Gray Orange Pink Purple Red White Yellow In addition to the color. Table 1 lists the color codes of the wiring. a code of J011-RD on the schematic identifies a red wire that is stamped with the circuit number J011. Unless the schematic specifies a different size. the entire length of each wire is stamped with a specific circuit number that is repeated on every 25 mm (1 inch) of the wire. Logged codes can also be used to review the performance of the engine and the electronic system. you may assume that the wire is 16 AWG. the code of “J011-RD” identifies the wire for the primary signal of the transformer in the number one cylinder. 12 Troubleshooting Section Terminal Box Illustration 1 The connectors on the terminal box connect the Electronic Control Module (ECM) to various engine controls. and electrohydraulic actuator (11) Connector J5 for the Integrated temperature sensing module (12) Connector J7 (if equipped) for the versatile control module (13) Connector J9 for the customer g00886988 . etc. oxygen buffer. sensors. (1) Emergency stop button (2) Service tool connector J23 for the Caterpillar Electronic Technician (3) Connector J29 for the gauge panel (4) Connector J16 for the fuel metering valve (5) Connector J15 for the prelube pump (6) Connector J14 for the air starting motor (7) Connector J13 for the gas shutoff valve (8) Connector J12 for the analog sensors (9) Connector J11 for the detonation sensors (10) Connector J10 for the speed/timing sensor. actuators. throttle actuator. The information enables the module to control the engine as efficiently as possible over a wide range of operating conditions. derates. Illustrations 3 and 4 show the locations of the sensors. . and shutoffs in response to abnormal operation.13 Troubleshooting Section Illustration 2 Components inside the terminal box (14) Electronic Control Module (ECM) (15) ECM connector P2 (16) ECM connector P1 (17) Ground strap (18) P50 connector for calibration of the speed/timing sensor (19) Circuit breaker CB2 for the control panel (20) Circuit breaker CB1 for the ECM g00887002 Sensors Sensors provide information to the electronic control module. The sensors also enable the activation of alarms. The information is used for monitoring engine operation. 14 Troubleshooting Section Illustration 3 (1) Pressure switch for the coolant pump (inlet) (2) Detonation sensor (3) Electrohydraulic actuator’s pressure switch (4) Inlet air temperature sensor g00887029 (5) Engine coolant temperature sensor Illustration 4 (6) Pressure sensor for filtered oil (7) Pressure sensor for unfiltered oil (8) Engine coolant pressure sensor (outlet) (9) Oxygen sensor (10) Inlet manifold air pressure sensor (11) Engine oil temperature sensor (12) Buffer for the oxygen sensor (13) Speed/timing sensor g00887031 . The contact closes at a maximum of 1206 kPa (175 psi). a derating. if necessary. Excessive inlet air temperature can activate an alarm. If the inlet pressure is too high. The contact opens at 700 ± 103 kPa (102 ± 15 psi). Closure of the contact is required in order for the engine to run. the electronic control module retards the timing of the cylinder. the switch will activate a shutdown. use Cat ET to view the “Hydrax Pressure Switch Status”. To observe the status of the switch. To observe the value of the output of the sensors. If excessive detonation continues. This information is processed by the electronic control module in order to determine detonation levels. The contacts of the switch are between pin A and pin B. Closure of the contact is required in order for the engine to run. use Cat ET to view the “Cylinder #X Detonation Level”. The sensor produces a voltage signal that is proportional to the engine detonation. Electrohydraulic actuator’s pressure switch (3) – The electrohydraulic actuator has a pressure switch for the oil supply. use Cat ET to view the “Inlet Air Temperature” parameter. The trip points for activation can be programmed with Cat ET. or a shutdown during high load or low load operation.15 Troubleshooting Section Illustration 5 (14) The humidity sensor (if equipped) is located on the inlet air piping or the inside of the air cleaner housing. The contacts of the switch are between pin B and pin C. To eliminate detonation. Inlet air temperature sensor (4) – A sensor for monitoring the air inlet temperature is located in the elbow before the number one cylinder head. Each sensor monitors two cylinders. (15) Atmospheric pressure sensor (if equipped) g00886591 The functions of the sensors are described below. To observe the status of the switch. Insufficient oil pressure will activate an engine shutdown. The “X” is the number for the particular cylinder. To observe the value of the output of the sensor. use the Caterpillar Electronic Technician (ET) to view the “Engine Coolant Pump Pressure” parameter. Pressure switch for the coolant pump (inlet) (1) – A pressure switch is located at the inlet for the engine jacket water. The contact opens at 462 ± 41 kPa (67 ± 6 psi). . the electronic control module will shut down the engine. Detonation sensors (2) – The detonation sensors monitor the engine for mechanical engine vibrations. The sensor can measure a range of −40 to 120 C (−40 to 248 F). The electronic control module uses the position of the crankshaft in order to determine ignition timing. the electronic control module shuts down the engine. The trip point for the shutdown depends on the value of the signal from the engine coolant temperature sensor. The trip point is calculated according to the equation in Table 2. use Cat ET to view the “Actual Oxygen” parameter. A high oil temperature will activate an alarm or a shutdown. The speed for the trip point of the shutdown can be programmed with Cat ET. use Cat ET to view the “Inlet Manifold Air Pressure (abs)” parameter. The signal is also used for adjusting the air/fuel ratio in order to achieve the level of emissions that is desired. However. use Cat ET to view the “Engine Coolant Pressure (abs)” parameter.46 = X T is the temperature of the jacket water in Degree Celsius. To observe the output value of the sensor. To observe the engine speed in rpm. To observe the output value of the sensor. divide the kPa by 6. A low coolant temperature will only activate an alarm. To monitor the coolant temperature. The trip points for the activation can be programmed with Cat ET. To observe the output value of the sensor. This is the atmospheric pressure plus the gauge pressure. the element must be in contact with the coolant. An engine oil temperature that is significantly high in comparison to a lower coolant temperature will activate an alarm or a shutdown. Engine oil temperature sensor (11) – An oil temperature sensor measures the engine oil temperature. Calculation of the Trip Point for the Engine Coolant Pressure Shutdown (5. A high coolant temperature will activate an alarm. low oil filter differential pressure.16 Troubleshooting Section Engine coolant temperature sensor (5) – The temperature sensor is located in the water temperature regulator housing. To observe the value of the output of the sensor. use Cat ET to view the “Engine Oil Temperature” parameter. To convert kPa to psi. The engine speed/timing sensor provides accurate information to the electronic control module about the position of the crankshaft and the engine rpm. An alarm or a shutdown can be activated by any of the following occurrences: low filtered oil pressure. another shutdown will occur after one minute if the temperature remains high. If an overspeed occurs. the sensor will not function properly. Inlet air pressure sensor (10) – The sensor for inlet air pressure is connected to the air inlet manifold. To observe the value of the output of the engine coolant pressure sensor. use Cat ET to view the “Engine Speed” parameter. Humidity Sensor (14) – Refer to Illustration 5 for the location of the humidity sensor (if equipped). To observe the output value of the sensor. and high oil filter differential pressure. the electronic control module will activate a shutdown.665 × T) − 420. The information is used by the electronic control module to determine the engine load. use Cat ET to view the “Engine Oil Pressure” or the “Unfiltered Engine Oil Pressure” parameter. The trip point for the activation of an alarm or a shutdown for oil filter differential pressure can be programmed with Cat ET. . The signal is used for adjusting the air/fuel ratio in order to achieve the level of emissions that is desired. or a shutdown. use Cat ET to view the “Specific Humidity” parameter. The humidity sensor generates a digital signal that is proportional to the specific humidity of the inlet air. The measured pressure is absolute. a derating. The engine can be restarted after a shutdown due to high engine coolant temperature. The sensor can measure a range of −40 to 150 C (−40 to 302 F). If the outlet pressure is too low. Table 2 Oxygen sensor (9) and oxygen buffer (12) – The oxygen sensor and the oxygen buffer generate a signal that is proportional to the percent of oxygen in the exhaust manifold. The electronic control module uses the signal to adjust for variation of fuel energy content.89. If overheating occurs due to low coolant level or no coolant. The electronic control module compares the oil temperature to the coolant temperature. The sensor measures temperature in the range of −40 to 120 C (−40 to 248 F). The sensor monitors the absolute manifold air pressure. Oil pressure sensors (6) and (7) – The engine oil pressure is measured before the oil filters and after the oil filters. To observe the value of the output of the sensor. The sensor measures pressure in the range of 20 to 339 kPa (3 to 49 psi). Engine coolant pressure sensor (8) – A pressure switch is located at the outlet for the engine jacket water. Both of the sensors measure pressure in the range of 0 to 1135 kPa (0 to 165 psi). Speed/timing sensor (13) – The engine speed/timing sensor is located on the rear end of the left camshaft. The trip points can be programmed with Cat ET. The sensor measures pressure in the range of 0 to 472 kPa (0 to 69 psi). X is the trip point for the shutdown in kPa. use Cat ET to view the “Engine Coolant Temperature” parameter. Thermocouples Thermocouples provide information to the Integrated Temperature Sensing Module (ITSM). use Cat ET to view the “Left Bank Turbine Inlet Temp” or the “Right Bank Turbine Inlet Temp”. The “X” is the number for the particular cylinder. The thermocouples also enable alarms and shutoffs to be activated. An alarm or a shutdown is activated if the exhaust temperature from any cylinder is too high or if the exhaust temperature from any cylinder deviates excessively from the average temperature of all of the cylinders. The thermocouples measure temperature in the range of 0 to 600 C ± 10 C (32 to 1112 F ± 18 F). The sensor monitors the atmospheric pressure. To observe the output value of the sensor. To observe the value of the output of the thermocouples. . The electronic control module uses the signal to adjust the air/fuel ratio in order to achieve the level of emissions that is desired.17 Troubleshooting Section Exhaust Back Pressure(15) – The sensor for atmospheric pressure (if equipped) is located near the exhaust duct above the turbochargers. Exhaust Inlet to the Turbocharger Turbine (17) – A thermocouple is mounted at the inlet for the exhaust gas of each turbocharger turbine. Illustration 6 (16) Thermocouple for the temperature of the cylinder exhaust port (17) Thermocouple for the temperature of the exhaust inlet to the turbocharger turbine (18) Thermocouples for the temperature of the turbocharger exhaust outlet g00887039 Cylinder Exhaust Temperature (16) – Thermocouples measure the exhaust temperatures from the exhaust port of each cylinder. The thermocouples measure temperature in the range of 0 to 600 C ± 10 C (32 to 1112 F ± 18 F). use Cat ET to view the “Cylinder #X Exhaust Port”. To observe the value of the output of the thermocouples. The trip points can be programmed with Cat ET. An alarm or a shutdown is activated if the temperature of the exhaust to the turbine is too high or too low. The information is used to monitor engine operation. The trip points can be programmed with Cat ET. use Cat ET to view the “Exhaust Back Pressure” parameter. . To observe the value of the output of the thermocouples. The trip points can be programmed with Cat ET. • Diagnose problems. Event codes are generated if the following conditions occur: • The temperature is higher than the limit that is programmed. The tools that are listed in Table 3 are required in order to enable a service technician to perform the procedures. Thermocouples are also mounted at the inlets and outlets to the turbochargers. The temperatures are broadcast over data links for use with other modules. • Program parameters.18 Troubleshooting Section Exhaust Outlet from the Turbocharger Turbine (18) – A thermocouple is mounted at the outlet for the exhaust gas of each turbocharger turbine. use Cat ET to view the “Left Bank Turbine Outlet Temp” or the “Right Bank Turbine Outlet Temp”. • The temperature is lower than the limit that is programmed. An alarm or a shutdown is activated if the temperature of the exhaust from either turbine is too high or too low. Integrated Temperature Sensing Module Illustration 7 Integrated temperature sensing module g00688273 The integrated temperature sensing module monitors thermocouples that are located at the exhaust port of each cylinder. The thermocouples measure temperature in the range of 0 to 600 C ± 10 C (32 to 1112 F ± 18 F). i01726899 Electronic Service Tools SMCS Code: 1901-038 Caterpillar Electronic Service Tools are designed to help the service technician: • Obtain data. • The temperature of a cylinder deviates significantly from the average temperature for all of the cylinders. • Calibrate sensors. • Read parameters. The integrated temperature sensing module calculates the average temperature for each bank. The multimeter is used for the testing and the adjusting of electronic circuits. No.44-MB floppy disk drive Windows NT or Windows 95 RS232 port with 16550AF UART VGA monitor or display Single user license for Cat ET If a more recent version of this software is available. Data subscription for all engines The communication adapter is connected between the PC (Cat ET) and the ECM. This tool is used for work with CE electrical connectors. This breakout harness is for use between the jacks and the plugs of the sensors. the more recent version may be used. This cable connects the service tool connector on the engine mounted terminal box to the 139-4166 Adapter Cable As. and switches. bulbs. This cable connects the 171-4401 Communication Adapter II to the 7X-1414 Data Link Cable As. This cable connects the PC to the 171-4401 Communication Adapter II. The tester is used to test for voltage in circuits. Either the 160-0141 or the 196-0055 cable may be used. The communication adapter is connected between the PC (Cat ET) and the ECM. . This cable connects the 7X-1701 Communication Adapter to the 7X-1414 Data Link Cable As. This cable connects the PC (Cat ET) to the 7X-1701 Communication Adapter. This tool is used for the removal of pins and sockets from Deutsch connectors and AMP connectors. This cable connects the PC to the 171-4401 Communication Adapter II. N/A Personal Computer (PC) “JERD2124 Version 2001B” “JERD2129” 171-4401 196-0055 160-0141 207-6845 7X-1701 7X-1425 139-4166 7X-1414 8T-8726 151-6320 1U-5804 9U-7330 7X-1710 5P-7277 (1) (2) (3) Software Software Communication Adapter II (1) Serial Cable As Serial Cable As (1)(2) (2) Adapter Cable As (1)(3) Communication Adapter Serial Cable As Adapter Cable As Data Link Cable As Adapter Cable As Wire Removal Tool Crimp Tool Digital Multimeter Multimeter Probes Voltage Tester This item is included in the 171-4400 Communication Adapter Gp. Either the 160-0133 or the 207-6845 cable may be used.19 Troubleshooting Section Table 3 Service Tools Pt. N/A Description Personal Computer (PC) Functions This PC configuration is recommended: Intel Pentium II 333 mHz processor 64 megabyte of RAM 4. The probes are used with the multimeter to measure voltage in wiring harnesses without disconnecting the harnesses.3 GB hard drive 14X speed CD-ROM drive This PC configuration has the minimum requirements: IBM PC compatible 100 MHz processor 32 megabyte of RAM 10 MB of available hard drive space CD-ROM drive 3. wires. relays.5 inch 1. Connect cable (2) to communication adapter (3). . However. The engine should be OFF. Connect cable (4) to cable (5). refer to Troubleshooting. 5. Use the following procedure to connect Cat ET and the communication adapter to the engine. Connect cable (5) to the service tool connector of the terminal box. the 7X-1700 Communication Adapter Gp is no longer serviced. 1. “Electronic Service Tool Will Not Communicate With ECM”. (1) PC (2) 196-0055 Serial Cable or the 160-0141 Serial Cable (3) 171-4401 Communication Adapter II (4) 207-6845 Adapter Cable (5) 7X-1414 Data Link Cable 2. 4. 6. Connect cable (2) to the RS232 serial port of PC (1). Turn the engine control switch to the ON position. Connecting Cat ET with the 7X-1701 Communication Adapter The battery supplies the communication adapter with 24 VDC. Use the following procedure to connect Cat ET and the communication adapter to the engine. Connect cable (4) to communication adapter (3). Cat ET can display the following information: • Parameters • Diagnostic codes • Event codes • Engine configuration • Status of the monitoring system Cat ET can perform the following functions: • Diagnostic tests • Sensor calibration Illustration 8 g00694774 • Flash downloading • Set parameters Connecting Cat ET with the 171-4401 Communication Adapter II The battery supplies the communication adapter with 24 VDC. 7. If Cat ET and the communication adapter do not communicate with the ECM. 3. Turn the engine control switch to the OFF position. Caterpillar Electronic Technician (ET) The Caterpillar Electronic Technician (ET) is designed to run on a personal computer.20 Troubleshooting Section Note: Either the 171-4401 Communication Adapter II or the 7X-1700 Communication Adapter Gp can be used. Three possible responses may be available for each parameter: “WARNING”. Change the “State” to “On” or “Off”. “DERATE”. Then click on the “Change” button in the lower left corner of the screen. The “Change Monitor System” screen will appear. and “SHUTDOWN”. 5. i01726945 Engine Monitoring System SMCS Code: 1901-038 The Electronic Control Module (ECM) monitors the operating parameters of the engine. Some of the responses are not available for some of the parameters. The default settings for the parameters are programmed at the factory. 5. the parameters may be reprogrammed with Cat ET. The ECM can initiate responses if a specific engine parameter exceeds an acceptable range. If Cat ET and the communication adapter do not communicate with the ECM. If a password is required. 6. 4. “Electronic Service Tool Will Not Communicate With ECM”. 4. 2. Turn the engine control switch to the ON position. • Program the level for monitoring. Other parameters can be changed with customer passwords. To accommodate unique applications and sites. Note: Some of the parameters are protected by factory passwords. 7. Use the Caterpillar Electronic Technician (ET) to perform the following activities: • Select the available responses. Set the “Trip Point” and the “Delay Time” according to the “Allowed Values” in the lower half of the screen. Enter the correct passwords and then click the “OK” button. Connect cable (4) to communication adapter (3). • Program delay times for each response. Connect cable (2) to the RS232 serial port of PC (1). Connect cable (2) to communication adapter (3). 3. . Connect cable (5) to the service tool connector of the terminal box. Highlight the desired parameter. The new settings will be effective immediately.21 Troubleshooting Section 1. 2. refer to Troubleshooting. Illustration 9 (1) (2) (3) (4) (5) PC 7X-1425 Serial Cable 7X-1701 Communication Adapter 139-4166 Adapter Cable 7X-1414 Data Link Cable g00694776 Changing the Settings of the Monitoring System Use the following procedure to change settings of the parameters: 1. Click the “OK” button. Use Cat ET and select the “Service/Monitoring System” screen. Connect cable (4) to cable (5). 3. The screens of Cat ET provide guidance for the changing of trip points. the “Enter Passwords” screen will appear. The engine should be OFF. Turn the engine control switch to the OFF position. “High Engine Coolant Temperature” If the engine coolant temperature reaches the trip point. “High System Voltage” The trip point for this parameter is set at the factory. the trip point for the “High Inlet Air Temperature at High Engine Load” event is used for the logging of the high inlet air temperature. “High Jacket Water to the Engine Oil Temperature Differential” If the differential temperature of the jacket water and the engine oil reaches the trip point. A typical trip point is 118 percent of the engine’s rated speed. “High Fuel Temperature” If the engine oil temperature reaches the trip point. The trip point cannot be changed. The parameter is always ON. The possible responses of the system include warning. a derating.22 Troubleshooting Section Monitoring Parameters “Low System Voltage” The trip point for this parameter is set at the factory. or a shutdown. The trip point for the events is based on the engine load. . “High Inlet Air Temperature at Low Engine Load” The “Service/Configuration” screen of Cat ET defines the “High Inlet Air Temp Engine Load Set Point”. or a shutdown if the inlet air temperature reaches the trip point during the low load operation that is defined. The parameter cannot be turned off. If the load is greater than the trip point. “Low Oil Filter Differential Pressure” The trip point for this parameter is set at the factory. “Low Gas Fuel Differential Pressure” If the fuel differential pressure reaches the trip point. The trip point is used for events that involve high inlet air temperature. “Low Fuel Pressure” If the fuel pressure reaches the trip point. the ECM will generate a warning. The ECM can activate a warning. If the system voltage reaches the trip point. the ECM will generate a warning or a shutdown. the ECM will generate a warning. The trip point cannot be changed. “High Gas Fuel Differential Pressure” If the fuel differential pressure reaches the trip point. and shutdown. the ECM will generate a warning or a shutdown. the ECM will generate a warning. “High Engine Oil Temperature” If the engine oil temperature reaches the trip point. “High Oil Filter Differential Pressure” The trip point for this parameter is set at the factory. the ECM will generate a warning. If the engine oil filter differential pressure reaches to the trip point. The trip point cannot be changed. the ECM will generate a warning. the ECM will generate a warning or a shutdown. the trip point for the “High Inlet Air Temperature at Low Engine Load” event is used for the logging of the high inlet air temperature. The parameter is always ON. a derating. the ECM will generate a warning or a shutdown. If the engine oil filter differential pressure reaches the trip point. derating. Trip Points of the Engine Load for High Inlet Air Temperature This feature provides a trip point between high engine load and low engine load. the ECM will generate a warning. “Low Engine Coolant Temperature” If the engine coolant temperature reaches the trip point. the ECM will generate a warning or a shutdown. the ECM will generate a warning or a shutdown. The trip point cannot be changed. If the system voltage reaches the trip point. “Engine Overspeed” If the engine speed reaches the trip point. The parameter cannot be turned off. If the load is less than the trip point. the ECM will activate an engine shutdown. the ECM will reduce the desired engine speed by 0. Many of the items can be reprogrammed in order to accommodate the requirements of individual sites. Use the Cat ET to determine the programming for your engine. “High Fuel Pressure” The ECM will activate a warning if the fuel pressure reaches the trip point. the desired engine speed will be reduced to 1477 rpm in 20 seconds. the incident lasted for 40 seconds. if the desired engine speed is 1507 rpm and a derating is activated. The ECM can derate the engine power in response to the following operating conditions: • E015 High Engine Coolant Temperature • E025 High Inlet Air Temperature at Low Engine Load • E025 High Inlet Air Temperature at High Engine Load • E242 Engine Overload The derating for the engine coolant and the inlet air temperatures can be programmed to be ON or OFF with Cat ET. Engine Power Derating The ECM can automatically derate the engine power in order to protect the engine from undesirable operating conditions. If the condition that activated the derating is gone after 20 seconds. When a derating of 0 percent is achieved. or a shutdown if the inlet air temperature reaches the trip point during the high load operation that is defined.23 Troubleshooting Section “High Inlet Air Temperature at High Engine Load” The “Service/Configuration” screen of Cat ET defines the “High Inlet Air Temp Engine Load Set Point”.1 percent per each second. This derating cannot be adjusted via Cat ET. If one of these three deratings is activated.1 percent per each second. The range for the temperature for the trip point and the delay time is limited. For example. The ECM can activate a warning. Default Settings of the Monitoring System Examples of the default settings for the parameters are listed in Table 4. a derating. The derating is deactivated when a derating of 0 percent is achieved and the original desired engine speed is restored. After the condition which activated the derating is gone. The values may have changed. all of the deratings are deactivated. . The default setting for the derating is OFF. the desired engine speed will return to 1507 rpm in 20 seconds. The temperature for the trip point and the delay time are also programmable. The default value for the derating is 110 percent of the rated load. The derating for “Engine Overload” is programmed to be ON at the factory. the ECM will increase desired engine speed by 0. In this example. the ECM will automatically use the largest value that is programmed for a derating of the desired engine speed. If more than one derating is active. On On (1) 80 to 129 C 20 Customer 5 to 80 C 1200 to 2125 rpm 85 to 102 C 85 to 104 C 80 to 138 kPa 1 to 60 Off On E004 (3) E020 (1) E019 (3) E129 (1) E130 (3) E127 (1) E128 (3) E223 (1) Shutdown Warning Shutdown Warning Shutdown Warning Shutdown On (1) 0 20 Factory Customer Factory Customer Factory Customer Factory 0 103 kPa 138 kPa 35 kPa 7 kPa 60 C 20 10 10 7 to 80 kPa 0 to 60 C 1 to 60 On E053 (1) E123 (1) On E124 (3) Shutdown (1) Warning 105 kPa 14 C 20 C Customer 100 to 135 kPa 0 to 20 C 20 Factory E864 (1) On E865 (1) Warning On (1) 5 kPa 10 35 kPa Customer 0 to 35 kPa E050 (1) E027 (1) E025 (2) E026 (3) E027 (1) E025 (2) E026 (3) E096 (1) Derating Shutdown Warning Derating Shutdown Warning 34 volts 69 C 100 C 73 C 53 C 100 C 57 C 135 kPa 20 ec This item cannot be programmed. This parameter cannot be turned off. 32 to 85 C On Off On (1) 20 Customer On Off On (1) 32 to 100 C 1 to 60 On 10 100 to 135 kPa This parameter is permanently active. .24 Troubleshooting Section Table 4 Default Settings of the Programmable Monitoring System Parameter “Low System Voltage” “High Engine Coolant Temperature” “Low Engine Coolant Temperature” “Engine Overspeed” “High Engine Oil Temperature” “High Oil Filter Differential Pressure” “Low Oil Filter Differential Pressure” “High Fuel Temperature” “Low Fuel Pressure” “High Jacket Water to Engine Oil temperature Differential” “Low Gas Fuel Differential Pressure” “High Gas Fuel Differential Pressure” “High System Voltage” “High Inlet Air Temperature at Low Engine Load” “High Inlet Air Temperature at High Engine Load” “High Fuel Pressure” (1) Event Code E043 (1) E042 (3) “E017 (1)” “E016 (3)” “E015 (2)” E038 (1) System Response Warning Shutdown Warning Shutdown Derating Warning State Trip Point 20 volts Delay in Seconds 20 10 Security Level Password Range Range of the Delay in Seconds On (1) 18 volts 113 C 111 C 109 C 5 C 1770 rpm 102 C 104 C This item cannot be programmed. If the temperature is not reduced to less than 95 C within five seconds. Some parameters are not dependent upon any conditions. the event becomes active and the event is logged. Condition Use care when you program the trip points and the delay times.25 Troubleshooting Section Separate timers are used in the ECM for each response that is associated with a parameter. Table 5 Conditions for Activation for Monitoring the Parameters Parameter “Low System Voltage” “High Engine Coolant Temperature” “Low Engine Coolant Temperature” “Engine Overspeed” “High Engine Oil Temperature” “High Oil Filter Differential Pressure” “Low Oil Filter Differential Pressure” “High Fuel Temperature” “Low Fuel Pressure” “High Jacket Water to Engine Oil Temp Differential” “Low Gas Fuel Differential Pressure” “High Gas Fuel Differential Pressure” “High System Voltage” “High Inlet Air Temperature at Low Engine Load” “High Inlet Air Temperature at High Engine Load” “High Fuel Pressure” The fuel control relay is energized. Ensure that the response of the ECM is correct for the application. the timer for that event is started. The conditions are designed to eliminate false events during start-up if the customer has programmed a delay time to zero. The timer starts counting if the coolant temperature reaches 95 C. None None The crank terminate relay is energized for more than 30 seconds. If a trip point is reached. The fuel control relay is energized. Other parameters are allowed to function after the output for the fuel control relay is energized. The fuel control relay is energized. the warning for “High Engine Coolant Temperature E017 (1)” can be set to 95 C with a five second delay. Conditions for Parameters Some of the programmable parameters are dependent on the status of an ECM output before the parameters are allowed to function. None The crank terminate relay is energized for more than 30 seconds. The monitoring system will accept any settings within the ranges. For example. The conditions are listed in Table 5. None The crank terminate relay is energized for more than 30 seconds. Some of the parameters are allowed to function after the crank terminate relay has been energized for more than 30 seconds. The crank terminate relay is energized for more than 30 seconds. . The items can be reprogrammed in order to accommodate the requirements of individual sites. the engine will shut down and the warning will not be activated. Table 6 lists default examples of the values for the parameters. • Program delay times for each response. • Program the level for monitoring. Use Cat ET to perform the following activities: • Select the available responses. The default settings for the parameters are programmed at the factory. the values may have changed. To accommodate unique applications and sites. The monitoring system will accept any setting within the ranges. Use care when you program the trip points and the delay times. the ITSM sends commands to the ECM via the Cat Data Link. the parameters may be reprogrammed with Cat ET. and the outlets of the turbocharger turbines. Use Cat ET to determine the programming for your engine. the ITSM can initiate a “WARNING” or “SHUTDOWN”. the engine will shut down and the warning will not be activated. Note: To initiate the responses. If a temperature exceeds an acceptable range. the inlets of the turbocharger turbine. If the trip point for a shutdown is programmed to activate before the trip point for a warning. Ensure that the response of the ITSM is correct for the application. .26 Troubleshooting Section If the trip point for a shutdown is programmed to activate before the trip point for a warning. If the connection between the ITSM and the ECM is not correct. However. Programmable Parameters of the Integrated Temperature Sensing Module The Integrated Temperature Sensing Module (ITSM) monitors the temperatures of the cylinder exhaust ports. The screens of Cat ET provide guidance for changing trip points. the ITSM cannot initiate any response. Both of the responses are available for all of the parameters. The timer starts counting if the exhaust port temperature of the number 1 cylinder reaches 495 C. .27 Troubleshooting Section Table 6 Default Settings for the Integrated Temperature Sensing Module Parameter Event Code System Response State Trip Point Delay in Seconds Security Level Password Range Range of the Delay in Seconds “High Exhaust Temperature” E801 (1) through E816 (1) E801 (3) through E816 (3) Warning 495 C 5 100 to 1000 C Shutdown 650 C “Exhaust Port Temperature High Deviation” E821 (1) through E836 (1) E821 (3) through E836 (3) Warning On Shutdown 50 C 150 C 10 to 500  C “Exhaust Port Temperature Low Deviation” E841 (1) through E856 (1) E841 (3) through E856 (3) Warning 50 C Shutdown 150 C Customer 1 to 6000 495 C 650 C 495 C 650 C Off 250 C 100 C 250 C 100 C  “High Turbo Turbine Inlet Temperature” E245 (1) E246 (1) E245 (3) E246 (3) E243 (1) E244 (1) E243 (3) E244 (3) E249 (1) E250 (1) E249 (3) E250 (3) E247 (1) E248 (1) E247 (3) E248 (3) Warning Shutdown Warning Shutdown Warning Shutdown Warning Shutdown 10 “High Turbo Turbine Outlet Temperature” “Low Turbo Turbine Inlet Temperature” 100 to 1000 C “Low Turbo Turbine Outlet Temperature” Separate timers are used in the ITSM for each response that is associated with a parameter. If the temperature is not reduced to less than 495 C within five seconds. For example. the warning for the “High Exhaust Temperature” (E801 (1)) can be set to 495 C with a five second delay. the event becomes active and the event is logged. If a trip point is exceeded. the timer for that event is started. Use of the passwords helps to prevent free access to the modification of the parameters.28 Troubleshooting Section Programming Parameters i01726978 Programming Parameters SMCS Code: 1901-038 Programmable parameters enable the engine to be configured in order to meet the requirements of the application. speed control. If the Electronic Control Module (ECM) is replaced. The customer passwords or a factory password is needed in order to change the customer passwords. The same procedure is used to change the passwords: 1. The passwords can have a maximum of eight characters. Data from a gas analysis and data on engine performance are required in order to determine the correct settings for the ignition timing and the exhaust oxygen. This feature is enabled by programming two customer passwords. the settings can be recorded on paper and then programmed into the new module. the passwords are required in order to change certain parameters. the appropriate parameters must be copied from the old ECM. Alternatively. factory passwords can be acquired from Caterpillar. all of the parameters are unprotected. Alphanumeric characters may be used. Access the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. Once the passwords are entered successfully. The passwords are case sensitive. Highlight the “Customer Password #1” parameter. Store the passwords securely. This can be done with the “Copy Configuration” feature of the Caterpillar Electronic Technician (ET). NOTICE Changing the parameters during engine operation can cause the engine to operate erratically. Perform this programming before the initial engine start-up. Note: Be sure to record the customer passwords. Use the following procedure to program the passwords. Click on the “Change” button in the lower right corner of the screen. If the customer passwords are not programmed. Incorrect programming of parameters may lead to complaints about performance and/or to engine damage. Customer Passwords Customer Password #1 Customer Password #2 . timing control. The system configuration parameters must be programmed when the application is installed. After the customer passwords are entered. if necessary. Enter the password in the “Change Parameter Value” dialog box and click on the “OK” button. Only change the settings of the parameters when the engine is STOPPED. Make a copy of Table 7 and record your passwords. 2. Programmable parameters can be classified into the following types: engine identification. The customer passwords can be changed. The passwords are now programmed into the memory of the Electronic Control Module (ECM). If the customer passwords are forgotten. and start/stop control. 3. Table 7 i01726982 Customer Passwords SMCS Code: 1901 Certain monitoring system parameters and system configuration parameters may be protected with customer passwords. air/fuel ratio control. Click on the “Change” button in the lower right corner of the screen. 4. Store the passwords securely. 5. This can cause engine damage. Highlight the “Customer Password #2” parameter. the passwords are not requested again until another screen is accessed or the data link is interrupted. When the correct passwords are entered. Because of the passwords. Factory passwords are required to program the following shutdowns: Factory Passwords Worksheet SMCS Code: 1901-038 Note: A mistake in recording this information will result in incorrect passwords. The flash is accomplished by transferring the data from Cat ET to the module via data link wiring. Table 8 Factory Passwords Worksheet Dealer Code Customer’s Name Address • “Engine Overspeed” Telephone Number • “High Engine Oil Temperature” • “High Oil Filter Differential Pressure” • “Low Oil Filter Differential” • “High Jacket Water to Engine Oil Temperature Differential” The “Enter Factory Passwords” screen on Cat ET will display the following parameters. The Software.29 Troubleshooting Section i01727009 i01727016 Factory Passwords SMCS Code: 1901-038 Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. the changes are programmed into the ECM. This is the only method for updating the software. JERD2124 or Software. To obtain the proper passwords. Factory passwords are not required for the first hour of operation for a new ECM. JERD2129 is used. This eliminates the risk of moisture entry into the ECM due to improper seal installation. 2) • Current ECM • Serial number of the service tool • Serial number of the engine (1) Do not obtain this information from the service meter. The passwords are controlled by Caterpillar. After you exit the “Enter Factory Passwords” screen on Cat ET. the information must be given to an authorized Caterpillar dealer: Information from the “Enter Factory Passwords” Screen on the Caterpillar Electronic Technician (ET) Serial Number for Cat ET Engine Serial Number ECM Serial Number Diagnostic Clock(1) Total Tattletale Reason Code Factory Passwords Factory Password (No. factory passwords are required for some of the programming. The module that contains the software cannot be physically removed from the ECM. a different set of passwords will be required before you can program the ECM. 1) Factory Password (No. . The passwords may only be used for one programming session. only authorized personnel can make changes to some of the programmable items in the Electronic Control Module (ECM). The Caterpillar Electronic Technician (ET) can be used to flash new software into the ECM or the ITSM. The passwords may only be obtained by an authorized Caterpillar dealer. i01726985 • Serial number of the ECM • Diagnostic clock • Total Tattletale • Reason The old interlock code is required to change the interlock code on a used ECM. Flash Programming SMCS Code: 1901-038 Software is located in the flash memory of the Electronic Control Module (ECM) and the Integrated Temperature Sensing Module (ITSM). After the hour expires. Cat ET will not flash if the engine control switch is in the OFF or START position. 4. Table 9 is a list of the parameters that can be configured for G3500B Engines. Select the correct disk drive and the directory from “Drives” and “Directories” on Cat ET. Select the “Begin Flash” button in order to program the personality module. When an ECM has been detected. use the “Utilities/ Preferences” option on the Cat ET. Be sure to set the baud rate to the fastest rate for your PC.fls”. Then select the baud rate from the “Advanced Communication Settings” menu and click the “OK” button. the “ECM Selector” window will appear. 5. 1. The parameters must be programmed in order to ensure proper engine operation. this message will appear: “Flash Completed Successfully”. “WinFlash” Error Messages If you receive any error messages during flash programming. If a diagnostic code of 268-02 “Check Programmable Parameters” is generated. The values of the parameters can be viewed on the “Configuration” screen of the Caterpillar Electronic Technician (ET).fls” and Software. Table 9 Configuration Parameters for G3500B Engines Information for the Electronic Control Module (ECM) “Engine Serial Number” “Equipment ID” “Customer Password #1” “Customer Password #2” “Total Tattletale” (continued) .30 Troubleshooting Section Flash Programming If the slowest baud rate of Cat ET is selected. A list of flash files will appear. program that parameter. i01756490 System Configuration Parameters SMCS Code: 1901-038 Certain parameters are unique for each engine application. Select “WinFlash” from the “Utilities” menu on the Cat ET. Select the correct file from the list of flash files. All of the parameters should have a tattletale of 1 or more. If a communication error occurs. Access the “Configuration” screen under the “Service” menu in order to determine the parameters that require programming. Note: The 141-1957 Electronic Control (ITSM) will not function properly with the Software. Select the “Communications” tab and click on “Advanced. Do not use any subsequent version such as Software. Access the information about the “ECM Summary” under the “Information” menu. “190036602. Look under the “Tattletale” column.. “190036603. 6. select a slower baud rate in order to improve the reliability. If a parameter has a tattletale of 0. The flash files are located on a disk drive and in a directory. 2. 8. To select the baud rate. click on the “Cancel” button in order to stop the process. a. Select “Open”. 7.. 3. Make sure that you are flashing the correct file for your engine. “190036601. Turn the engine control switch to the STOP position. “System Configuration Parameters”. program any parameters that were not in the original software. etc. flash programming can last up to 15 minutes. Program the configuration parameters and the monitoring system parameters. 9. Read the “Description” and the “File Info” in order to verify that the correct file is selected.fls”. When the flash is completed. The “Flash File Selection” window will appear. Do not flash this software into the 141-1957 Electronic Control.”. “Engine Monitoring System” and Troubleshooting. Start the engine and check for proper operation. Refer to Troubleshooting. Connect Cat ET to the service tool connector. “WinFlash” will try to detect an ECM. b. Select the appropriate ECM and then select “OK”. the changes are programmed into the ECM.31 Troubleshooting Section (Table 9. Information for the Electronic Control Module (ECM) “Engine Serial Number” The engine serial number is programmed into the ECM at the factory. contd) (Table 9. only authorized personnel can make changes to some of the programmable items in the ECM. Then click the “Change” button in the lower left corner of the screen. “Desired Oxygen At Full Load” “Oxygen Feedback Feature Enabled Status” “Air/Fuel Proportional Gain” “Air/Fuel Integral Gain” Speed Control “Low Idle Speed” “Minimum Engine High Idle Speed” “Maximum Engine High Idle Speed” “Engine Accel. Rate” “Desired Speed Input Configuration” “Governor Type Setting” “Grid Status” “Engine Speed Droop” “Governor Proportional Gain” “Governor Integral Gain” “Governor Derivative Gain” “Auxiliary Proportional Governor Gain 1” “Auxiliary Integral Governor Gain 1” “Auxiliary Derivative Governor Gain 1” Start/Stop Control “Driven Equipment Delay Time” “Crank Terminate Speed” “Engine Purge Cycle Time” “Engine Cooldown Duration” “Cycle Crank Time” “Engine Overcrank Time” “Engine Speed Drop Time” “Engine Pre-lube Time Out Period” Monitoring and Protection “High Inlet Air Temp Engine Load Set Point” (continued) “Equipment ID” The customer can assign an “Equipment ID” for the purpose of identification. . “Total Tattletale” This item displays the number of changes that have been made to the configuration parameters. contd) Configuration Parameters for G3500B Engines “KW Meter Offset” “KW Meter KW/Volt” Timing Control “First Desired Timing” “Second Desired Timing” Air/Fuel Ratio Control “Fuel Quality” “Gas Specific Gravity” “Fuel Specific Heat Ratio” (1) Configuration Parameters for G3500B Engines Override Parameters “Oxygen Sensor Override” “Requested Detonation Derate Percentage Override” (1) This parameter is only for 60 Hz engines. Use Cat ET and select the “Service/Configuration” screen. The number is stamped on the engine Information Plate. Enter the password in the “Change Parameter Value” dialog box. Because of the passwords. Highlight “Customer Password #1” or “Customer Password #2”. When the correct passwords are entered. Then click the “OK” button. The password is immediately programmed into the ECM memory. 2. Note: Factory level security passwords are required for clearing certain logged events and for changing certain programmable parameters. Use the following procedure to enter the customer passwords: 1. 3. Customer Passwords Two customer passwords can be entered. The passwords are used to protect certain configuration parameters from unauthorized changes. The ECM reverts to the customer programmed “Fuel Energy Content” during start-up. The value that is entered for the desired timing is the ignition timing when the engine is operating at rated speed and at full load. the application. The operation in “Oxygen Feedback” is determined by the engine’s rating. Use the Engine Performance Sheet. Timing Control “First Desired Timing” The “First Desired Timing” is determined with the methane number of the primary fuel that is used. The desired timing is programmed with Cat ET. . “Fuel Usage Guide”. enter the same timing that was entered in the “First Desired Timing”. “Desired Timing” The “Desired Timing” parameter allows the customer to electronically program the timing of the ignition spark of the electronic system in order to meet the needs for specific applications and specific installations. the engine does not operate in “Oxygen Feedback” mode when the load is between 0 percent and up to 25 or 40 percent load. The “Fuel Quality” parameter can be used to change the air/fuel ratio when the engine is not operating in “Oxygen Feedback” mode. Note: The actual ignition timing at a given instance may vary from the desired timing value. Air/Fuel Ratio Control “Fuel Quality” This parameter is programmed to the Lower Heating Value (LHV) of the primary fuel. The operation of the engine will not change if the “Fuel Quality” parameter is changed and the “Oxygen Feedback Enable Status” is enabled.32 Troubleshooting Section “kW Meter Offset” This parameter is unavailable at the time of publication. The engine will not operate in “Oxygen Feedback” when the “Oxygen Feedback Enable Status” parameter is disabled. “Gas Specific Gravity” The value for the fuel metering valve requires an input for the “Gas Specific Gravity” in order to precisely meter the air/fuel ratio. The “Fuel Correction Factor” will automatically compensate. “Second Desired Timing” The “Second Desired Timing” is determined with the methane number of the alternate fuel that is used and the Engine Performance Sheet. This variance is due to variations in the engine speed or the detonation. The desired timing value can be changed while the engine is running or while the engine is stopped. An accurate customer programmed “Fuel Energy Content” value that is determined by a laboratory is recommended. The “Gas Specific Gravity” can be obtained by a gas analysis of the fuel. “Fuel Usage Guide”. The range for programming the desired timing is 0 to 40 degrees before the top center (TC) position. The ECM selects the “First Desired Timing” when the switch for the selection of the timing is in the open position. If an alternate fuel is not used. Normally. The ECM assumes a corrected value that is equal to the customer programmed “Fuel Energy Content” that is multiplied by the “Fuel Correction Factor”. “kW Meter kW/Volt” This parameter is unavailable at the time of publication. This factor is displayed on the Cat ET screen. and the load. The fuel ratio control of the ECM will compensate for some inaccuracy in this setting. The gas engine’s ECM selects the “Second Desired Timing” when the timing selection switch is in the closed position. An event code is generated if the “Fuel Correction Factor” exceeds a limit that is programmed at the factory. The ECM also reverts to the customer programmed “Fuel Energy Content” when a problem is detected in the oxygen sensor’s circuit. The event code will indicate the need to reprogram this value. The low idle rpm can be programmed from 500 to 1100 rpm. If the oil pressure is greater than the trip point for the low oil pressure warning and the switch is in the rated position. the ECM will always select the low idle speed. the disabling of this feature can help determine whether the air/fuel ratio control is the cause of instability. the ECM will always select low idle speed regardless of the position of the idle/rated switch. If the measured exhaust oxygen or the NOX emissions are not the required value. this is one of the last parameters that should be adjusted. If the engine oil pressure is less than the trip point for the low oil pressure warning. The engine risks a shutdown due to lean misfire or detonation. The factory default setting is 0. Note: Do not operate an engine that is unattended in the open loop mode if the fuel has an LHV that is changing. The parameter “Desired Speed Input Configuration” will determine the type of signal from the throttle position sensor. This feature allows the system for the fuel correction factor to be disabled in order to troubleshoot. For example. The speed is selected by the position of the idle/rated switch and by the status of the engine oil pressure. . The actual high idle speed is regulated by the desired speed input. the engine can be programmed to accelerate at a rate of 50 rpm per second when the “Idle/Rated” switch is turned to the “Rated” position. If the switch is in the idle position. increase the “Desired Oxygen at Full Load” parameter in order to lean the engine or decrease the “Desired Oxygen at Full Load” parameter in order to richen the fuel mixture. The adjustable range is −50 to +50. Negative values reduce the magnitude and positive values increase the magnitude. “Air/Fuel Ratio Integral Gain” The “Air/Fuel Ratio Integral Gain” determines the response of the fuel metering valve to the error that is accumulated over time for the air/fuel ratio. The “Fuel Quality” parameter must be adjusted in order to adjust the air/fuel mixture. this parameter can be set to “Disable” in order to allow the engine to run in the open loop mode until a new sensor is obtained. this is one of the last parameters that should be adjusted. The regulation is linear in proportion to the input. “Maximum Engine High Idle Speed” Program this parameter to the desired maximum high idle rpm. The actual high idle speed is regulated by the desired speed input. Speed Control “Low Idle Speed” Program this parameter to the desired low idle rpm. This value should not require adjustment. The output signal from the throttle position sensor can be either 0 to 5 VDC or 4 to 20 mA. An input of 0 percent results in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm. “Oxygen Feedback Enable Status” The “Oxygen Feedback Enable Status” can be set to “Enable” or “Disable”. An input of 0 percent results in the minimum high idle rpm and an input of 100 percent results in the maximum high idle rpm. If an exhaust oxygen sensor fails. Negative values reduce the magnitude and positive values increase the magnitude. Rate” This parameter controls the rate for engine response to a change in the desired engine speed. The regulation is linear in proportion to the input. If problems occur. An emissions analyzer must be used to verify the emissions level. For example. the ECM will select the high idle speed.33 Troubleshooting Section “Desired Oxygen at Full Load” Program the “Desired Oxygen at Full Load” parameter to the percent of exhaust oxygen that is stated in the Engine Performance Sheet for your application. This value should not require adjustment. If problems occur. The adjustable range is −50 to +50. The factory default setting is 0. “Engine Accel. “Minimum Engine High Idle Speed” Program this parameter to the desired minimum high idle rpm. Speed Selection The desired speed operates at low idle speed or high idle speed. This parameter is used to trim the oxygen map that is preprogrammed in the gas engine’s ECM at the factory. “Air/Fuel Ratio Proportional Gain” The “Air/Fuel Ratio Proportional Gain” determines the response of the fuel metering valve to the magnitude of error for the fuel ratio. “Desired Speed Input Configuration” The ECM reads the desired engine speed from a throttle position sensor. Engine Speed Droop This programmable parameter allows precise control of the droop for applications such as load sharing. The “Governor Type Setting” parameter must be set to “Droop”. The graph provides the best method for observing the effects of the adjustment on engine stability. If the gain is changed and the “Grid Status” is “On”. always investigate other causes before you adjust the governor gain settings. use the “Graph” feature on the “Governor Gain” screen. and position of the wastegate. “Governor Derivative Gain” This parameter changes the governor’s response to the rate of change in the engine speed fluctuation. the stability is not affected. the ECM is programmed to read the status of terminal J1-13. “Governor Type Setting” The “Governor Type Setting” parameter can be set to “Isochronous Mode” or to “Droop Mode”. If the terminal is grounded. This parameter changes the reaction of the governor when the “Grid Status” parameter is “OFF”. If you have a problem with instability. These other conditions can cause instability: diagnostic codes. To set the governor to “Droop Mode”. To change this parameter. To set the “Grid Status” to “On”. This parameter determines the throttle response of the governor to the error of engine speed that is accumulated over time. Connect one end to terminal J1-13 and connect the other end to terminal J1-31 (return). The graph provides the best method for observing the effects of the adjustment on engine stability. use the “Graph” feature on the “Governor Gain” screen. If changing this gain causes no effect. check the “Grid Status” in order to make sure that the status is “OFF”. “Governor Proportional Gain” Note: The default values that are programmed into the ECM for the governor gain settings should be sufficient for most applications. “Governor Integral Gain” “Grid Status” The generator’s “Grid Status” parameter can be set to “On” or “Off”. check the “Grid Status” in order to make sure that the status is “OFF”. This parameter is based on a derivative multiplier when the “Grid Status” parameter is “Off”. the stability of the engine will not change. If this gain is adjusted and the “Grid Status” is “ON”. the configuration parameter is programmed with Cat ET. For some engines. . The graph provides the best method for observing the effects of the adjustment on engine stability. If changing this gain causes no effect. The droop can be programmed to a value between 0 and 10 percent. The “Governor Proportional Gain” determines the throttle response of the governor to the magnitude of the error in engine speed. There are two methods for selecting the setting. the stability is not affected. check the “Grid Status” in order to make sure that the status is “OFF”. If changing this gain causes no effect. This parameter is based on a proportional multiplier. This parameter is changed with the “Graph” feature on the “Governor Gain” screen. the governor is set to “Droop Mode”. fabricate a jumper wire with Deutsch connectors on both ends. If the terminal is unconnected. The status of the “Governor Type Setting” can be observed on the “Status Group 5 Governor Type Setting” on Cat ET. the “Grid Status” is “On”. the “Grid Status” is “Off”. The ECM is programmed to read the status of terminal J1-66. The “Grid Status” can be observed on the “Status Group 5 Grid Status” on Cat ET. If the terminal is grounded. This parameter changes the reaction of the governor when the “Grid Status” parameter is “OFF”. For other engines. unstable gas pressure. If this gain is adjusted and the “Grid Status” is “ON”. The ECM is not configured to accept a pulse width modulated signal for input of the desired engine speed.34 Troubleshooting Section Note: Do not select “PWM” for the desired speed input. incorrect throttle angle. Connect one end to terminal J1-66 and connect the other end to terminal J1-31 (return). This setting is dependent upon the application of the engine. If the terminal is unconnected. To change this parameter. fabricate a jumper wire with Deutsch connectors on both ends. the governor is set to “Isochronous Mode”. This parameter is based on an integral multiplier. “Engine Cooldown Duration” When the ECM receives a “Stop” request. The delay time for the switch must be programmed to 0 in order to disable this feature. the engine will immediately shut down when the ECM receives a “Stop” request. An event code is generated if the programmed time for the driven equipment elapses without the closure of the switch. This parameter is changed with the “Graph” feature on the “Governor Gain” screen. check the “Grid Status” in order to make sure that the status is “ON”. “Crank Terminate Speed” The ECM disengages the starting motor when the engine speed exceeds the programmed “Crank Terminate Speed”. If changing this gain causes no effect. This parameter is based on a derivative multiplier when the engine’s “Grid Status” parameter is “On”. “Auxiliary Integral Governor Gain 1” This parameter changes the governor’s response. “Cycle Crank Time” The “Cycle Crank Time” is the amount of time for activation of the starting motor and the gas shutoff valve for start-up. If changing this gain causes no effect. Examples of the Settings for Start-up Parameter “Purge Cycle Time” “Cycle Crank Time” “Overcrank Time” Time 10 seconds 30 seconds 280 seconds The following sequence will occur if the parameters are programmed according to the example in Table 10: 1. Example Setting Table 10 Start/Stop Control Parameters “Driven Equipment Delay Time” The ECM provides a switch input for the driven equipment in order to delay engine start-up until the equipment is ready. The engine will crank for 10 seconds in order to purge gas from the engine via the exhaust system. The default value of 250 rpm should be sufficient for all applications. The “Engine Purge Cycle Time” allows any unburned fuel to exit through the exhaust before you fire the engine. check the “Grid Status” in order to make sure that the status is “ON”. the stability of the engine will not change. the stability of the engine will not change. The graph provides the best method for observing the effects of the adjustment on engine stability. the attempt to start is suspended for a “Rest Cycle” that is equal to the “Cycle Crank Time”. If the gain is changed and the “Grid Status” is “Off”. The graph provides the best method for observing the effects of the adjustment on engine stability. If the “Engine Cooldown Duration” is programmed to zero. The “Cooldown Mode” is exited early if a request for an emergency stop is received by the ECM. . The graph provides the best method for observing the effects of the adjustment on engine stability. An event is generated if the engine does not start within this period of time. the stability of the engine will not change. If changing this gain causes no effect. If the gain is changed and the “Grid Status” is “Off”. This parameter is changed with the “Graph” feature on the “Governor Gain” screen. check the “Grid Status” in order to make sure that the status is “OFF”. If the gain is changed and the “Grid Status” is “Off”. the engine will continue to run in the “Cooldown Mode” for the programmed cooldown period.35 Troubleshooting Section “Auxiliary Proportional Governor Gain 1” This parameter changes the governor’s response. This parameter is changed with the “Graph” feature on the “Governor Gain” screen. The ECM will not attempt to start the engine until the switch closes to ground and the prelubrication is complete. This parameter is based on a proportional multiplier when the engine’s “Grid Status” parameter is “On”. This parameter is based on an integral multiplier when the engine’s “Grid Status” parameter is “On”. If the engine does not start within the specified time. The fuel and the ignition are OFF. “Engine Purge Cycle Time” The “Engine Purge Cycle Time” is the duration of time for the engine to crank without fuel before the crank cycle. “Engine Overcrank Time” The “Engine Overcrank Time” determines the length of time for the ECM to attempt to start the engine. “Auxiliary Derivative Governor Gain 1” This parameter changes the governor’s response. 36 Troubleshooting Section 2. The fuel and the ignition are enabled. The engine will continue to crank for a maximum of 30 seconds. 3. If the engine does not start, the ignition, the fuel, and the starting motor are disabled for a 30 second “Rest Cycle”. With this example, a complete cycle is 70 seconds: a purge cycle of 10 seconds, a cycle crank of 30 seconds, and a rest cycle of 30 seconds. The “Overcrank Time” of 280 seconds allows a maximum of four crank cycles. Override Parameters “Oxygen Sensor Override” This parameter enables the oxygen sensor and the oxygen buffer to be energized when the engine is not running. The override facilitates troubleshooting of the sensor’s electrical circuit. “Requested Detonation Derate Percentage Override” This parameter is unavailable at the time of publication. i01727022 “Engine Speed Drop Time” After the cooldown period has elapsed, the ECM shuts off the gas shutoff valve. The ignition continues until the engine speed drops below 40 rpm. If the engine rpm does not drop at least 100 rpm within the programmed drop time, the ECM terminates the ignition and the ECM issues an emergency stop. Replacing the ECM SMCS Code: 1901-038 The Electronic Control Module (ECM) contains no moving parts. Replacement of the ECM can consume much time. Before you replace an ECM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ECM will correct the problem. Verify that the suspect ECM is the cause of the problem. Install a test ECM in place of the suspect ECM. Transfer the software from the suspect ECM to the test ECM. Program all the parameters for the test ECM in order to match the parameters of the suspect ECM. The parameters must match. Refer to the following test steps for details on programming the parameters. If the test ECM resolves the problem, reconnect the suspect ECM. Verify that the problem recurs. If the problem recurs, replace the suspect ECM with the test ECM. Note: If the parameters cannot be read from the suspect ECM, the parameters must be obtained from records or from the factory. Perform the following procedure to replace the ECM. 1. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET). Save the file. You can select “Load from ECM”. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ECM, record all of the logged events. “Engine Pre-Lube Time Out Period” The ECM can energize a prelube pump prior to cranking the engine. The ECM uses a switch input to monitor the engine for acceptable oil pressure. After the prelube is completed, the prelube switch closes. If the ECM does not detect closure of the prelube switch within the programmable “Engine Pre-Lube Time Out Period”, the ECM monitors the engine oil pressure sensor. If the oil pressure is insufficient, an event code is activated and the starting sequence is terminated. The range for the “Engine Pre-Lube Time Out Period” is 30 to 300 seconds. “Monitoring and Protection” “High Inlet Air Temp Engine Load Setpoint” The programmable setpoint is a value that separates low engine load from high engine load for events that are activated by high inlet air temperature. An “Engine Load Factor” can be displayed on a Cat ET status screen. If the load factor is less than the setpoint and the inlet air temperature reaches the trip point, a “High Inlet Air Temperature at Low Engine Load” event is activated. If the load factor is greater than the setpoint and the inlet air temperature reaches the trip point, a “High Inlet Air Temperature at High Engine Load” event is activated. 37 Troubleshooting Section a. Connect the Cat ET with the communications adapter. Select “Service/Copy Configuration/ECM Replacement” from the pull-down menu on Cat ET. Cat ET will load the configuration parameters and the monitoring system parameters of the suspect ECM. b. Select “Load from ECM” in the lower left corner of the Cat ET screen. Select the suspect ECM and select “OK”. After the loading is complete, the Cat ET will display this message: “The data has been successfully loaded from the ECM”. Select “OK”. c. Select “File/Disconnect F8” from the pull-down menu. Note: Do not terminate the Cat ET. 2. Replace the ECM. a. Turn the engine control switch to the “OFF/RESET” position. Note: Rubber grommets behind the ECM are held in place by the mounting studs. The grommets help to reduce vibration. The grommets may fall when the ECM is removed. Be sure not to lose the grommets. e. Remove the ECM from the terminal box. 3. Install the replacement ECM. a. Use the mounting hardware to install the new ECM. Use a mounting nut to fasten the ground strap for the ECM to the upper left mounting stud. Then install the other three mounting nuts. Check the mounting hardware and the ECM for correct installation. A correctly installed ECM will move slightly on the rubber grommets. If the ECM cannot move slightly on the grommets, check that the washers, spacers, and grommets are positioned correctly. b. Use a 4 mm Allen wrench to connect the P1 and P2 connectors to the ECM. Tighten the screws to a torque of 6 N·m (55 lb in). 4. Program the configuration parameters and the monitoring system parameters into the replacement ECM. a. Switch circuit breaker (1) to the ON position. b. Turn the engine control switch to the “STOP” position. c. Select “File/Select ECM” from the pull-down menu. d. Select the replacement ECM and click “OK”. e. Select “Service/Copy Configuration/ECM Replacement” from the pull-down menu. Click “OK” on the window. f. Select “Program ECM” from the lower left corner of the screen. Select the replacement ECM and click “OK”. If the correct ECM is shown, select “Yes”. g. After the loading is complete, a window with the message “Programming Conflict Warning” will appear. Select “OK”. h. A window with the message “Program ECM Results” will appear. Select “OK”. Note: When you program a new ECM, factory passwords are not required for the first hour of operation. After one hour, factory passwords are required for changing the parameters that are normally protected with factory passwords. Illustration 10 g00887172 b. Switch circuit breaker (1) to the OFF position. c. Use a 4 mm Allen wrench to disconnect connector P2 (3) and connector P1 (4). d. Remove mounting nut (2) in order to disconnect the ground strap. Remove the three remaining mounting nuts. 38 Troubleshooting Section 5. Calibrate the oxygen sensor and the speed/timing sensor. See Troubleshooting, “Oxygen Sensor - Calibrate” and Troubleshooting, “Engine Speed/Timing Sensor - Calibrate”. i01727067 a. Connect Cat ET with the communications adapter. Select “Service/Copy Configuration/ECM Replacement” from the pull-down menu. Cat ET will load the configuration parameters and the monitoring parameters from the ECM. b. Select “Load from ECM” in the lower left corner of the screen. Select the suspect ITSM and select “OK”. After the loading is complete, Cat ET will display this message: “The data has been successfully loaded from the ECM”. Select “OK”. c. Select “File/Disconnect F8” from the pull-down menu. Note: Do not exit from Cat ET. 2. Replace the ITSM. a. Turn the engine control switch to the “OFF/RESET” position. Replacing the ITSM SMCS Code: 1901-038 The Integrated Temperature Sensing Module (ITSM) contains no moving parts. Replacement of the ITSM can consume much time. Before you replace an ITSM, follow the troubleshooting procedures in this manual in order to be sure that replacement of the ITSM will correct the problem. Use the following guidelines to verify that the suspect ITSM is the cause of the problem: Install a test ITSM in place of the suspect ITSM. Transfer the software from the suspect ITSM to the test ITSM. Program all the parameters for the test ITSM in order to match the parameters of the suspect ITSM. The parameters must match. Refer to the following steps for details on programming the parameters. If the test ITSM resolves the problem, reconnect the suspect ITSM. Verify that the problem recurs. If the problem recurs, replace the suspect ITSM with the test ITSM. Note: The 141-1957 Electronic Control (ITSM) will not function properly with the Software, “190036601.fls”. Do not use any subsequent version such as Software, “190036602.fls” and Software, “190036603.fls”, etc. Do not flash this software into the 141-1957 Electronic Control. Use the following procedure to replace the ITSM: Note: If the parameters cannot be read from the suspect ITSM, the parameters must be obtained from records or from the factory. 1. Use the “Service/Copy Configuration/ECM Replacement” function of the Caterpillar Electronic Technician (ET) in order to transfer the software from the suspect ITSM. You may also select the “Print” function in order to obtain a paper copy of the parameter settings. Note: Before you replace an ITSM, record all of the logged events. Illustration 11 (1) Circuit breaker in the terminal box for the ECM g00887190 b. Switch the 16 amp circuit breaker for the ECM (1) to the OFF position. 39 Troubleshooting Section a. Use the mounting hardware to install the new ITSM. If all of the hardware has been removed, lubricate the bottom washers between the mounting plate and the rubber grommets. Be sure to install ground strap (9) between one of the washers on the mounting flange and the nut. Check the mounting hardware and the ITSM for correct installation. A properly installed ITSM will move slightly on the rubber grommets. If the ITSM cannot move slightly on the grommets, check that the washers and grommets are positioned correctly. Illustration 12 Connectors for the ITSM (2) P40 connector from the thermocouples to the ITSM (3) P18 connector from the ITSM to the terminal box g00743125 b. Connect connectors (2) and (3) to the ITSM. 4. Program the configuration parameters and the monitoring system parameters into the replacement ITSM. a. Switch the circuit breaker in the terminal box ON. b. Turn the engine control switch to the “STOP” position. c. Select “File/Select ECM” from the pull-down menu of Cat ET. d. Select the “Replacement ITSM” and click “OK”. e. Select “Service/Copy Configuration/ECM Replacement” from the pull-down menu. Click “OK” on the window. c. Disconnect connectors (2) and (3) from the ITSM. Illustration 13 Mounting hardware for the ITSM (4) (5) (6) (7) (8) (9) Nut Washer Mounting flange on the ITSM Rubber grommet Washer Ground strap g00743195 f. Select “Program ECM” from the lower left corner of the screen. Select the replacement ITSM and click “OK”. g. After the loading is complete, a window with the message “Programming Complete” will appear. Select “OK”. Note: When you program a new ITSM, factory passwords are not required. Also, the ITSM does not require calibration. i01727078 Note: One of the mounts for the ITSM has a ground strap that is attached between the nut and the washer. d. Remove the 4 mounting nuts (4) and washers (5) from mounting flanges (6) of the ITSM. The ground strap must also be detached from one of the studs. Note: Rubber grommets for the ITSM are held in place on the mounting studs. The grommets help to reduce vibration. The grommets may fall when the ITSM is removed. Be sure not to lose the grommets. e. Remove the ITSM from the engine. 3. Install the replacement ITSM. Orient the 54 pin P40 connector toward the right of the engine. Troubleshooting Data Sheet SMCS Code: 1901-038 To help troubleshoot a gas engine, complete the information in Table 11. Be sure to include the units of measurement. 40 Troubleshooting Section Table 11 Data Sheet for Troubleshooting Customer and installation Engine model and driven equipment Engine serial number Service hours LHV of fuel Compression ratio Methane number of fuel Application Altitude Fuel rate Brand of oil and type of oil Throttle angle Inlet manifold air temperature Turbocharger exhaust temperature PPM of NOx (3) (4) Jacket water temperature (5) (6) (7) (8) in out Detonation level Air restriction Ignition timing Pressure to the regulator Differential pressure of the regulator Engine rpm Percent load Inlet manifold air pressure Turbocharger boost pressure Exhaust stack temperature Cylinder exhaust port temperatures Aftercooler water temperature Comments left right % O2 (1) (2) in out Location of temperature probe left right PPM of CO (9) (10) Engine oil temperature (11) (12) Exhaust stack pressure Brand of exhaust analyzer (13) (14) in out (15) (16) Report the Service Information After you have successfully repaired the engine, it is important to provide good information about the repair. The following topics are recommended for your report: Complaint – Include a description of the customer’s complaint in the report. Cause – Provide a specific description of the cause of the failure. Include the method that was used in order to diagnose the problem. If diagnostic codes or event codes were generated, include all of the codes and the status of the codes. Indicate your determination of the problem. For example, if you performed a diagnostic functional test, identify the test procedure. For example, a visual inspection revealed abrasion of a wire in a harness. Be specific: dynamometer testing of the engine produced power below specifications at 1800 rpm due to the loss of an ignition transformer. Repair – Explain your repair of the problem. For example, you may have installed a new wiring harness. You may have replaced the ignition transformer per instructions from the factory. The providing of complete, accurate information will help Caterpillar to provide better service to you and to the customer. 41 Troubleshooting Section Troubleshooting without a Diagnostic Code i01305323 Operator Information Obtain the following information from the operator: • The occurrence and the time of the occurrence Symptoms SMCS Code: 1000-038; 1901-038 Some engine symptoms can be unrelated to the electronic control system. This section is for troubleshooting problems that have symptoms without active diagnostic codes. Conditions such as poor fuel quality or improperly adjusted valves can cause some engine symptoms. For basic troubleshooting of the engine, perform the following steps first in order to diagnose a malfunction. 1. Gather information about the complaint from the operator. 2. Verify that the complaint is not due to normal engine operation. Verify that the complaint is not due to error of the operator. 3. Perform a visual inspection. Inspect the following items: • Determine the conditions for the occurrence. The conditions will include the engine rpm and the load. • Determine if there are any systems that were installed by the dealer or the customer that could cause the symptom. • Determine whether any other occurrences happened in addition to the symptom. Diagnostic Codes and Event Codes Examine the following information regarding any codes: • The probable cause of the symptom is correlated to the code. • The code was generated when the symptom occurred. • Codes that are repeatedly logged • The complaint is not due to normal engine operation. • Fuel supply • Oil level • Oil supply • Wiring • Connectors 4. Check the diagnostic codes and event codes. Repair any active codes. If these inspections do not reveal any problems, identify the probable causes with the procedures in this manual that best describe the symptoms. See Troubleshooting, “Troubleshooting With A Diagnostic Code” or see Troubleshooting, “Troubleshooting With Event Codes”. Check each probable cause according to the tests that are recommended. Be sure to check the connectors. This is specially true for problems that are intermittent. See Troubleshooting, “Inspecting Electrical Connectors”. Narrow the probable cause. Consider the operator information, the conditions of operation, and the history of the engine. Other Symptoms If other occurrences happened in addition to the symptom, investigate the following conditions: • The other occurrences are related to the symptom. • The symptoms have a probable cause that is common. i01727325 Detonation SMCS Code: 1901-038 Probable Causes • Excessive load • High inlet air temperature • Incorrect air/fuel ratio • Incorrect timing • Faulty circuit for the timing selection switch 42 Troubleshooting Section • Changes in the fuel quality • The engine speed/timing sensor is not calibrated. • Faulty circuit for the detonation sensor(s) • Excessive deposits in the combustion chamber Use the Caterpillar Electronic Technician (ET) to check the ignition timing during engine operation with a load. Compare the timing to the recommended timing in the Engine Performance, “Fuel Usage Guide”. Adjust the ignition timing according to the recommended timing in the Engine Performance, “Fuel Usage Guide”. Recommended Repairs Excessive Load Make sure that the load is not excessive. Reduce the load. If necessary, disengage the driven equipment and test the engine. Check the Timing Selection Switch Check the position of the timing selection switch. Verify that the switch is in the correct position for the type of gas that is used. If the position of the switch is correct, troubleshoot the circuit for the switch. Refer to the electrical schematic for the engine. Check the Inlet Manifold Air Pressure The calculated engine load increases when the inlet manifold air pressure increases. Measure the inlet manifold air pressure during engine operation with a load. For specific data on the engine, refer to the engine Technical Marketing Information. Check for Event Codes Regarding the Fuel Check for the following event codes: Check the Inlet Air Temperature High inlet air temperature can cause detonation. Check the inlet air temperature. Look for the following event codes: • “E229 (1) Fuel Energy Content Setting Low” (warning) • “E230 (1) Fuel Energy Content Setting High” (warning) • “E025 (2) High Inlet Air Temperature” (derating) • “E026 (3) High Inlet Air Temperature” (shutdown) • “E027 (1) High Inlet Air Temperature” (warning) Refer to Troubleshooting, “Inlet Air Temperature (High)”. • “E231 (3) Fuel Quality Out Of Range” (shutdown) Refer to Troubleshooting, “Fuel Energy Content”. Calibrate the Engine Speed/Timing Sensor Note: Only perform this procedure if work on the engine may have affected the engine timing. Also, perform this procedure if the engine speed/timing sensor has not been calibrated. Calibrate the engine speed/timing sensor. Refer to Troubleshooting, “Engine Speed/Timing Sensor Calibrate”. Air/Fuel Ratio An air/fuel mixture that is too rich will cause detonation. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. The fuel supply pressure must be adequate and stable. Make sure that the fuel metering valve is operating correctly. Verify that the exhaust emissions are correct. Check the Detonation Sensors Troubleshoot the detonation sensors. Refer to Troubleshooting, “Detonation Sensors”. Check the Ignition Timing Note: Data from a fuel analysis is required for this procedure. Check for Deposits in the Cylinders Overfilling of engine oil can lead to deposits. Make sure that the engine oil level is correct. Note: Excessive deposits contribute to guttering of the valves. Verify that Cat ET is on the “Factory Password” screen. as needed. Make repairs. blue smoke. Verify that the correct passwords were entered. Check wiring between the driven equipment and the ECM connector for damage and/or corrosion. Determine the cause for the request. i01727423 • Passwords • Serial Numbers • Total Tattletale • Reason Code Driven Equipment SMCS Code: 1901-038 Recommended Repairs 1. Turn the engine control switch to the OFF/RESET position for 30 seconds and then retry. 3. • Serial Number of the engine • Serial Number of the ECM • Serial Number of the Cat ET • Total Tattletale • Reason Code i01754399 Check the Circuit for the Switch The circuit for the switch must remain closed in order to allow the engine to run. “Inspecting Electrical Connectors”. • The electrical circuit for the electrohydraulic oil pressure switch is open. If the resistance is greater than 5 ohms. as needed. Make repairs. 2.43 Troubleshooting Section Use a borescope to inspect the cylinders. • The circuit for the signal is faulty. and excessive detonation. Electrohydraulic System Oil Pressure (Low) SMCS Code: 1901-038 Probable Causes • The electrohydraulic system’s oil level is low. Verify that the following information from Cat ET has been recorded correctly: Probable Causes • The Electronic Control Module (ECM) has received a “Start Inhibit” or a “Shutdown” signal. Recommended Repairs Check the Driven Equipment Determine whether the driven equipment has generated a “Start Inhibit” or “Shutdown” request. investigate the cause of the condition. Refer to Troubleshooting. Repair the wiring. locate the source of the excessive resistance. The correct resistance of the circuit is 5 ohms or less. Check every character in each password. Check the resistance of the circuit between terminals 21 and 31 of the P1 connector. If excessive deposits and/or signs of internal leaks are found. Service the driven equipment according to the recommendations of the OEM of the equipment. . as needed. Look for the following conditions: i01727336 • Deposits on the valve seats • Deposits on the valve faces • Deposits on the cylinder walls that are above the upper limit of the piston stroke ECM Will Not Accept Factory Passwords SMCS Code: 1901-038 Probable Causes One of the following items may not be recorded correctly on the Caterpillar Electronic Technician (ET): • Signs of internal leaks Signs of internal leaks include excessive consumption of engine oil. Turn the engine control switch to the STOP position. 2. 1. replace the harness. Inspect the hydraulic pump. The status of the switch should be “Closed”. Make repairs to the harness. Disconnect the 3-pin connector at the electrohydraulic oil pressure switch. inspect the electrohydraulic system for leaks. The status of the switch should be “Open”. 5. Use the Caterpillar Electronic Technician (ET) to observe the “Hydrax Pressure Switch Status”. The status of the switch should still be “Closed”. locate the problem.44 Troubleshooting Section • There is an open circuit in the wiring harness between the electrohydraulic oil pressure switch and the Electronic Control Module (ECM). when possible. Use Cat ET to observe the “Hydrax Pressure Switch Status”. Apply a known pressure to the electrohydraulic system. Check the Oil Pressure of the Electrohydraulic System The electrohydraulic oil pressure switch is designed to close at 1206 kPa (175 psi). Wiggle the yellow wire and pull on the wire from the harness connector to the ECM P2 connector. While you apply the pressure. If necessary. If the harness cannot be repaired. Do not operate the engine during this procedure. The switch is designed to open at 700 ± 103 kPa (102 ± 15 psi). Open Circuit in the Wiring Harness Use the following procedure to check the harness. If the “Hydrax Pressure Switch Status” momentarily changes to “Open”. Use a gauge to check the oil pressure of the electrohydraulic system at the outlet for the hydraulic pump while the engine is cranking or running. Check for proper operation of the switch. If there is an intermittent circuit. 3. After the harness is repaired. If the pressure is less than 1206 kPa (175 psi). The switch must remain closed during engine operation. The switch closes at 1206 kPa (175 psi). Attach a jumper wire between pin A and pin B on the harness connector. as needed. an “E266 (3)” event code is generated and the engine is shut down. remove the jumper wire from the 3-pin connector. The switch opens at 700 ± 103 kPa (102 ± 15 psi). If the switch opens for more than 1 second. the harness has an intermittent circuit. when possible. 4. Check the pressure while the engine is at normal operating temperature. replace the switch. Reconnect the connector. Check for oil leaks. Make repairs. is insufficient. • The oil pressure for the electrohydraulic system Recommended Repairs Check the Electrohydraulic System’s Oil Level Observe the electrohydraulic system’s oil level in the sight gauge on the tank. . 6. pour oil into the tank until the oil level is between the “ADD” and “FULL” marks on the sight gauge. use a ohmmeter to observe the status of the contact for the switch between pin A and pin B. If the switch does not function properly. Continue to observe the “Hydrax Pressure Switch Status”. Open Circuit for the Electrohydraulic Oil Pressure Switch The electrohydraulic oil pressure switch must remain closed while the engine is running. “Communication Adapter II User’s Manual”. “Electrical Power Supply”. If you are using the 7X-1700 Communication Adapter Gp. check Cat ET and the related equipment in order to determine the cause of the problem. the modules will not communicate. 3. refer to Special Instruction. Disconnect the communication adapter and the cables from the service tool connector. Probable Causes • High ambient temperature and/or high inlet air temperature Electrical Connectors Check the following components: • Low coolant level and/or coolant leakage • Insufficient flow of air or coolant through the radiator or heat exchanger • Battery connections and ground to the ECM or the ITSM • Faulty water temperature regulators • Faulty coolant temperature sensor and/or circuit • Insufficient flow of coolant through the engine • Exhaust restriction • Excessive load • Incorrect ignition timing • Wiring harnesses and the connectors for the ECM or the ITSM • Wiring harnesses and the connectors for the ECM or the ITSM in the terminal box Refer to Troubleshooting.45 Troubleshooting Section i01727343 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM)) SMCS Code: 1901-038 2. Verify that battery voltage is present between terminal A and terminal B of the service tool connector. Communication Adapter and/or Cables 1. refer to Manual. “Inspecting Electrical Connectors”. If the communication adapter is not receiving power. Probable Causes • Electrical power supply • Electrical connectors • Communication adapter and/or cables • Electronic service tool Electronic Service Tool In order to eliminate Cat ET as the problem. Then reconnect the communication adapter. If the same problem occurs with a different engine. the display will be blank. “Using the 7X1700 Communication Adapter Group”. • Incorrect air/fuel ratio . Check the condition of the fuse for the communication adapter. NEHS0758. i01727351 Recommended Repairs Electrical Power Supply Engine Coolant Temperature (High) SMCS Code: 1901-038 Check power to the ECM or the ITSM. Note: If the modules are not receiving battery voltage. connect Cat ET to a different engine. SEHS9264. If you are using the 171-4401 Communication Adapter II. Refer to Troubleshooting. Make necessary repairs. determine the cause. determine the cause of the obstruction. Heat Exchanger Check for sufficient flow and temperature of the cooling water through the heat exchanger. make the necessary repairs. Ignition Timing Note: Data from a fuel analysis is required for this procedure. make the necessary repairs. “Analog Sensor Signal”. If the radiator fins are obstructed. If the temperature of the cooling water is too high. The temperature should rise steadily as the engine is warmed. Determine whether the leak occurs before the engine overheats. Compare the timing to the recommended timing in the Engine Performance. Make the necessary repairs. when possible. determine the cause of the excessive back pressure. Refer to Troubleshooting. If the fan does not operate properly. check the status of the following components: • Switch for the inlet pressure of the jacket water • Sensor for the outlet pressure of the jacket water If the flow of coolant through the engine is not sufficient. Replace the water temperature regulators. If leaking is found. if necessary. If the reading on Cat ET for the coolant temperature is not reasonable. Check the fan for proper operation. Make the necessary repairs. Refer to Systems Operation/Testing and Adjusting. . clean the fins. Add coolant. If necessary. If the flow of cooling water through the heat exchanger is insufficient. “Fuel Usage Guide”. Excessive Load Make sure that the load is not excessive. Use an electronic service tool to check for the correct desired ignition timing. Check the Exhaust Restriction Check the back pressure of the exhaust system. troubleshoot the circuit and the coolant temperature sensor. Check the Water Temperature Regulators Check the water temperature regulators for proper operation. Refer to Troubleshooting. Check the Flow of Coolant Through the Engine During normal operation. Refer to Systems Operation/Testing and Adjusting. Ensure that the temperature is reasonable. if necessary. Adjust the ignition timing according to the recommended timing in the Engine Performance. Check for a Low Coolant Level and/or Coolant Leakage Note: Low coolant level can be the effect of overheating rather than the cause. Check for Insufficient Flow of Air and Coolant Through the Radiator or Heat Exchanger Radiator Check the fins of the radiator for obstructions. “Inlet Air Temperature (High)”. “Air Inlet and Exhaust System”. disengage the driven equipment and test the engine. determine the location of the obstruction. Determine the cause of the high air temperature. Run the engine to operating temperature. Inspect the cooling system for leaks. Make corrections. Reduce the load. Check the Coolant Temperature Sensor and/or the Circuit Check the reading of the coolant temperature on Caterpillar Electronic Technician (ET). “Testing the Cooling System”. Check for high inlet air temperature. If the back pressure exceeds the specifications for the engine.46 Troubleshooting Section Recommended Repairs Check for High Ambient Temperature and/or High Inlet Air Temperature Determine if the ambient air temperature is within the design specifications for the cooling system. “Fuel Usage Guide”. Check the coolant level. “Analog Sensor Signal”. inspect the internal parts of the gas pressure regulator for wear. Refer to Troubleshooting. Strike the gas pressure regulator with a soft hammer. When possible. If the jacket water heaters are not functioning properly. i01727368 Check the Water Temperature Regulators The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. Obtain a fuel analysis. The valve must seat correctly. check the water temperature regulators according to Systems Operation/Testing and Adjusting. Make the necessary repairs. Recommended Repairs Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. determine the cause of the malfunction of the heaters. Ensure that the fuel metering valve is operating correctly. If the engine speed changes. Verify that the exhaust emissions are correct. Check the hose at the outlet for the jacket water. If the hose is warm and normal operating temperature is not achieved yet. . i01727427 Engine Cranks but Will Not Start SMCS Code: 1000-038. If the reading on Cat ET for the coolant temperature is not reasonable. The following conditions can cause the engine to malfunction: Check the Coolant Temperature Sensor and/or the Circuit Check the reading of the coolant temperature with the Caterpillar Electronic Technician (ET). The temperature should rise steadily as the engine is warmed. Ensure that the temperature is reasonable. a regulator may be stuck open. The fuel supply pressure must be adequate and stable. • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. interview the operator in order to determine if fuel quality is in question. If the water temperature regulators are malfunctioning. Allow the engine to cool and then start the engine.47 Troubleshooting Section Air/Fuel Ratio An air/fuel mixture that is too rich will cause overheating. Try to determine if the source of the fuel was changed. Make sure that the size of the fuel line is sufficient. Inspect the gas pressure regulator’s diaphragm for leaks. “Testing the Cooling System”. Inspect the fuel system for leaks. Make sure that the valve moves freely. A change in the fuel energy content will change the air/fuel ratio. if necessary. 1901-038 Engine Coolant Temperature (Low) SMCS Code: 1901-038 Probable Causes • Fuel supply • Electrical connectors or power supply • No signal from the speed/timing sensor • Ignition system • Excessive load Probable Causes • Faulty jacket water heater • Faulty coolant temperature sensor and/or circuit • Faulty water temperature regulators Recommended Repairs Check the Jacket Water Heater Determine if the jacket water heaters are functioning properly. troubleshoot the circuit and the coolant temperature sensor. Replace the water temperature regulators. Use the “Data Link/Select ECM” option on the Cat ET to select the ITSM. Check the wiring harnesses and the connectors. and the desired engine speed are also displayed.48 Troubleshooting Section Inspect the fuel system components: fuel filter. 3. “Electrical Power Supply”. engine operating temperature. short circuits. . gas shutoff valve. Ignition System Inspect the ignition transformers for loose connections. moisture. Replace the fuel filter. Make sure that the timing wheel is correctly installed. Inspect the extenders for signs or pin holes and arcing. Probable Causes • Cold cylinder • Electrical connectors or power supply • Ignition system • Fuel supply • Incorrect air/fuel ratio • Air inlet restriction • Exhaust restriction • Incorrect valve lash • Cylinder head and related components • Throttle No Signal from the Engine Speed/Timing Sensor Make sure that the speed/timing sensor is installed correctly. Use the following procedure: 1. Refer to Troubleshooting. Make sure that the ignition timing is correct. Refer to Troubleshooting. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen. and fuel metering valve. Select “Diagnostics/Diagnostic Tests”. etc). If necessary. full load. The output voltage of the transformer’s secondary circuit. Runs Rough or Is Unstable SMCS Code: 1000-038. disengage the driven equipment and test the engine. Inspect the connectors in the terminal box. 1901-038 Electrical Connectors or Power Supply There may be an intermittent interruption of power. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. Inspect the battery connections and the ground. Inspect the primary wiring and the secondary electrical connections. Make sure that the correct transformers and spark plugs are installed. 2. Inspect the wires and the power relay. Reduce the load. i01727449 Engine Misfires. Maintain the spark plug according to Operation and Maintenance Manual. test the engine under the conditions. “Speed/Timing Sensor”. the engine speed. Recommended Repairs Note: If the symptom only occurs under certain operating conditions (high idle. Verify that the system’s components are operating correctly. Inspect the wiring from the battery to the Electronic Control Module (ECM). if necessary. Check the power and ground connections. Cat ET will display a graph of the cylinder’s exhaust gas temperature. gas pressure regulator. and open circuits. Excessive Load Make sure that the load is not excessive. “Ignition System Spark Plugs”. Troubleshooting the symptom under other conditions can give misleading results. Refer to Troubleshooting. If the restriction remains too high. “Valve Lash and Valve Bridge Adjustment”. Testing And Adjusting. Electrical Connectors or Power Supply There may be an intermittent interruption of power. “Ignition Transformers Secondary Circuit and Spark Plugs”. For more information. Inspect the extenders for signs or pin holes and arcing. “Restriction of Air Inlet and Exhaust”. Throttle Make sure that the throttle actuator is operating properly. refer to Systems Operation/Testing and Adjusting. Inspect the connectors in the terminal box. Make sure that the correct transformers and spark plugs are installed. if necessary. “Restriction of Air Inlet and Exhaust”. If the indication is higher than the maximum permissible restriction. A change in the fuel energy content will change the air/fuel ratio. Air/Fuel Ratio An air/fuel mixture that is too rich or too lean will have an adverse effect on engine operation. etc. Exhaust Restriction Check for restriction in the exhaust system. Check the wiring harnesses and the connectors. The fuel supply pressure must be adequate and stable. For electrohydraulic actuators. and fuel metering valve. service the actuator. When possible. Verify that the exhaust emissions are correct. Inspect the fuel system components: fuel filter. cylinder head gasket. Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. Inspect the wiring from the battery to the control modules. Try to determine if the source of the fuel was changed. Inspect the extender for signs of pin holes and/or arcing. The following conditions can cause the engine to malfunction: Cylinder Head and Related Components Measure the cylinder compression. Make sure that the size of the fuel line is sufficient. Replace the fuel filter. Inspect the battery connections and the ground. gas shutoff valve. moisture.75 kPa (15 inches of H2O). Check the restriction again. “Cylinder Pressure .49 Troubleshooting Section Cold Cylinder Locate the misfiring cylinder. Make sure that the ignition timing is correct. If the motion of the actuator is sticky and/or rough. Incorrect Valve Lash Check the valve lash. Inspect the fuel system for leaks. Check for signs of damage and/or wear to the valves. . inspect the air inlet piping for obstructions. clean the filter element or install a new filter element. and primary wiring. Refer to Troubleshooting. extender. Refer to the engine’s Operation and Maintenance Manual. Verify that the system’s components are operating correctly. Refer to Systems Operation. Refer to Systems Operation/Testing and adjusting. Obtain a fuel analysis. Maintain the spark plug according to the engine’s Operation and Maintenance Manual. • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct.Measure/Record”. If a camshaft is replaced. and open circuits. “Electrical Power Supply”. new valve lifters must be installed. Ignition System Inspect the ignition transformers for loose connections. Check the following components for failure: spark plug. interview the operator in order to determine if fuel quality is in question. Air Inlet Restriction The maximum allowable air inlet restriction is 3. make sure that the hydraulic oil is not contaminated. short circuits. Inspect the primary wiring and the secondary electrical connections. ignition transformer. Inspect the condition of the camshafts. Inspect the components of the valve train for good condition. gas pressure regulator. when possible. Replace any suspect oil filter. If the oil filter bypass valve is faulty. if necessary. repair the valve. “Engine Oil”. “Engine Oil”. replace the suspect engine oil pressure sensor. “Analog Sensor Signal”. Inspect the oil filters for good condition. High engine oil level can be an indication of contamination. Make sure that the sensors are correctly wired. Faulty Engine Oil Pressure Sensors Use the Caterpiller Electronic Technician (ET) to compare the readings of the filtered engine oil pressure and the unfiltered engine oil pressure while the engine is OFF. refer to Operation and Maintenance Manual. Change the engine oil and the engine oil filter. . the sensors are wired improperly. Check the Oil Filter Bypass Valve An oil filter bypass valve that is stuck in the closed position can cause a high reading for differential pressure when the oil is cold. refer to Operation and Maintenance Manual. Check the Oil Pressure Sensors and/or Circuits Use the Caterpillar Electronic Technician (ET) to compare the readings for the filtered oil pressure and the unfiltered oil pressure while the engine is OFF. Add oil. For the correct engine oil to use. For more information. Recommended Repairs Low Engine Oil Level Check the oil level. Obtain an analysis of the engine oil.50 Troubleshooting Section i01727473 i01727510 Engine Oil Filter Differential Pressure SMCS Code: 1308-035 Engine Oil Pressure (Low) SMCS Code: 1901-038 Probable Causes • Low engine oil level • Incorrect viscosity • Contaminated engine oil • Faulty oil pressure sensors • Improper circulation of the engine oil • Worn components Probable Causes • Plugged oil filter or faulty oil filter • Faulty oil pressure sensor and/or circuit • Malfunctioning of the oil filter bypass valve Recommended Repairs Check the Oil Filters Check the oil filter differential pressure. see Systems Operation/Testing and Adjusting. An oil filter bypass valve that is stuck in the open position can cause a low reading for differential pressure when the oil is hot. Replace the valve. If the readings are not approximately zero for both of the sensors. Check the operation of the oil filter bypass valve. Contaminated Engine Oil Engine oil that is contaminated with another liquid will cause low engine oil pressure. Determine the reason for contamination of the engine oil and make the necessary repairs. Refer to Troubleshooting. “Measuring Engine Oil Pressure”. as needed. Incorrect Viscosity Make sure that the engine is supplied with the correct engine oil. Troubleshoot the sensor circuit(s). Do not allow the differential pressure to exceed 103 kPa (15 psi). Both readings should be close to zero pressure. If the oil filter differential pressure is too high. For the correct engine oil to use. change the oil filter elements. If a reading is significantly different from zero. Obtain an analysis of the engine oil. “Engine coolant Temperature (High)”. • The engine oil cooler is clogged. Thoroughly clean the engine oil cooler. i01727521 Check the Flow of Oil Through the Oil Cooler Run the engine at normal operating temperature. Ensure that the temperature is reasonable. Check the analysis for the level of wear metals in the engine oil. This restriction will cause cavitation and a loss of engine oil pressure. Determine the cause of the obstruction. Check the engine components for excessive clearance. • An engine oil line or a passage for engine oil is disconnected or broken. a restriction. Replace parts. Determine the pressure differential between the inlet and the outlet of the oil cooler. For comparative data. • There is a problem with the engine oil pump. Investigate the cause of the obstruction. Refer to Troubleshooting. Oil Coolers that are Cooled by the Separate Circuit Compare the temperature of the coolant at the inlet of the oil cooler to the regulated temperature. • The engine oil pump’s pressure regulating valve or a bypass valve is stuck in the open position. Check the inlet screen on the suction tube and remove any material that may be restricting engine oil flow. inspect the clearance between the rocker arm shafts and the rocker arms. Engine oil pressure is reduced by gears that have too much wear. check the temperature of the coolant at the outlet of the oil cooler. Replace the engine oil filter.51 Troubleshooting Section Improper Circulation of the Engine Oil Several factors could cause improper circulation of the engine oil: Recommended Repairs Check the Oil Temperature Sensor and/or the Circuit Check the reading of the oil temperature on the Caterpillar Electronic Technician (ET). Worn Components Excessive clearance at the crankshaft or camshaft bearings will cause low engine oil pressure. Refer to Troubleshooting. Check the joints of the tube for cracks or a damaged O-ring seal. Breakage. troubleshoot the circuit for the oil temperature sensor. Also. or incorrect installation of a piston cooling jet will cause seizure of the piston. If the reading on Cat ET for the oil temperature is not reasonable. • The engine oil filter is clogged. Make the necessary repairs. i01727544 Engine Oil Temperature (High) SMCS Code: 1901-038 Probable Causes • Faulty oil temperature sensor and/or circuit • Insufficient flow of coolant through the oil cooler • Insufficient flow of oil through the oil cooler Engine Overcrank SMCS Code: 1901-038 Probable Causes • The gas supply to the engine is insufficient. Check the gears of the engine oil pump for excessive wear. • The suction tube is drawing in air. Check the Flow of Coolant Through the Oil Cooler Oil Coolers that are Cooled with Jacket Water Check for “High Engine Coolant Temperature” events. If the inlet temperature is OK. A high temperature difference indicates an insufficient flow rate. . The temperature should rise steadily as the engine is warmed. • There is a problem with a piston cooling jet. Make the necessary repairs. if necessary. Clean the valve. refer to the Technical Marketing Information for the engine. “Analog Sensor Signal”. there is an insufficient flow of oil through the oil cooler. If the pressure differential between the inlet and the outlet of the oil cooler exceeds the data that is published for the engine. • The inlet screen of the suction tube for the engine oil pump can have a restriction. • There is no engine speed signal to the Electronic Control Module (ECM). Check for Diagnostic Codes Check for active diagnostic codes that relate to the ignition system. “Engine Speed/Timing Sensor”. • The quality of the gas does not match the parameter for “Fuel Quality”. Use Cat ET to monitor the engine speed while you crank the engine. Refer to Troubleshooting. . Turn the engine control switch to the OFF/RESET position. • The ignition system is not functioning or the switch for the ignition timing is not in the correct position. Check the position of the timing selection switch. If no engine speed is displayed on Cat ET or if the engine speed is not stable.52 Troubleshooting Section • A feature for engine protection prevents the engine from starting. program the ECM with the correct setting for the “Fuel Quality” parameter. Then turn the switch to the STOP position. • The oxygen sensor is not accurate. Probable Causes • Excessive inlet manifold air pressure • The Low Heat Value (LHV) of the gas or the specific gravity of the gas is significantly different from the value that is programmed. Observe the angle of the throttle plate while you crank the engine. Check the Fuel Quality Compare the Low Heat Value (LHV) of the gas supply to the “Fuel Quality” parameter that is programmed by the customer into the ECM. If the status of the relay for the starting motor indicates that the engine should crank but no cranking occurs. refer to Troubleshooting. Check the Engine Speed The ECM must detect a minimum of 50 rpm before the gas and the ignition are supplied to the engine. Correct the cause of the active code. If the engine should crank and cranking occurs. The ECM uses the setting for start-up and for air/fuel ratio control at low loads. If there is at least one active diagnostic code that relates to the ignition system. Refer to Systems Operation/Testing and Adjusting. troubleshoot the speed/timing sensor. i01746204 Check for Active Shutdowns Use the Caterpillar Electronic Technician (ET) to check for active diagnostic codes or event codes which may prevent the engine from starting. Before the engine can be started. If the gas pressure is low. If the LHV of the fuel does not match the “Fuel Quality” parameter that is programmed into the ECM. the control system must be power cycled. “Fuel Pressure”. “Air/Electric Starting System”. troubleshoot the starting circuit. If the throttle does not open. troubleshoot the diagnostic code. The gas supply lines may require purging before servicing. troubleshoot the electrohydraulic oil system. • The starting motor circuit is faulty. Verify that the switch is in the correct position for the type of gas that is used. Recommended Repairs Check the Gas Supply to the Engine Check for low gas pressure. Engine Overload SMCS Code: 1901-038 Check the Status of the Relay for the Starting Motor Attempt to start the engine while you observe the status of the relay for the starting motor on Cat ET. check the engine rpm. Calibrate”. Make the necessary repairs. Measure the inlet manifold air pressure during engine operation with a load. i01727564 Probable Causes • Low trip point for engine overspeed • Signal from the signal driver in the Electronic Control Module (ECM) for the actuator of the throttle • Binding of the actuator for the throttle • Energy of the driven equipment • Slow governor response Engine Pre-Lube Pressure (Low) SMCS Code: 1901-038 Recommended Repairs Check the Trip Point Note: Do not program the trip point for engine overspeed higher than the maximum ratings of the driven equipment. “Engine Misfires. refer to Troubleshooting. Make corrections to the installation in order to prevent the overspeed from recurring. Program the “Fuel Quality” configuration parameter to the average value of the LHV. obtain several analyses over a period of time. . For specific data on the engine. This parameter requires a factory password in order to change the trip point. “Oxygen Sensor . Investigate the diagnostic code(s). Program the correct LHV for the “Fuel Quality” configuration parameter. refer to Troubleshooting. i01727554 Check the Driven Equipment Determine if the driven equipment has additional inputs of energy that could drive the engine beyond the rated rpm. Check for Binding of the Actuator Slide the electrohydraulic actuator’s rod in and out while you feel the motion. “Oxygen Sensor Signal”. “Oxygen Sensor Buffer Supply” and Troubleshooting. Engine Overspeed SMCS Code: 1000-038. If the undershoot or the overshoot of the engine speed is excessive. Check for Diagnostic Codes that Relate to the Signal from the Signal Driver in the ECM Check for diagnostic codes that relate to the actuator of the throttle. Typically. Look for the engine response to the worst cases for step-loading and unloading. If the quality of the gas is not consistent. If the motion is sticky and/or rough. Change the trip point to an acceptable speed. Verify that the trip point for the engine overspeed is properly programmed. refer to the engine Technical Marketing Information.53 Troubleshooting Section Recommended Repairs Check the Inlet Manifold Air Pressure The calculated engine load increases when the inlet manifold air pressure increases. The trip point or engine overspeed may be too low. Runs Rough Or Is Unstable ”. investigate the cause of the binding. Make the necessary repairs. Use “Throttle Bump” feature of Cat ET in order to disturb steady state engine operation. If the oxygen sensor could not be calibrated successfully. this parameter is set at 118 percent of rated speed. Probable Causes • Low engine oil level • Low pressure from the prelube pump • The prelube pump is not energized. Refer to Troubleshooting. 1901-038 Check for Slow Governor Response Observe the “Speed Governor Adjustment” screen on the Caterpillar Electronic Technician (ET). Check the Oxygen Sensor Calibrate the oxygen sensor. Obtain a Fuel Analysis and Program the Fuel Energy Content Obtain an analysis of the gas in order to determine the LHV. Make repairs. If the diagnostic code is logged. Determine the cause of the low pressure. Check Cat ET for a logged “339 . close the switch and check the resistance between terminals 22 and 31 of the P1 connector. terminals “A” and “B” open. “ECM Start/Stop Output”. Inspect the wiring between the switches and the connector of the electronic control module.3 ± 0. Add oil until the oil level is between the “ADD” and “FULL” marks on the oil level gauge.FMI 06 Pre-lube Relay short to ground”. Check the Power Source for the Prelube Pump Make sure that the prelube pump is supplied with the correct voltage and current. For the emergency stop switch.4 psi) is achieved. Refer to Troubleshooting. • Either switch is activated by excessive vibration. as needed. Resume normal operation. • The circuit for the emergency stop is faulty. “Prelubrication System”. locate the source of the excessive resistance. reset the control system. close the switch and check the resistance between terminals 23 and 31 of the P1 connector. • When the engine oil pressure falls below 7 kPa (1 psi). Ensure that the pump is operating correctly. Check the Pressure of the Prelube Pump Measure pressure at the outlet of the prelube pump. i01727572 Recommended Repairs Check the Engine Oil Level Check the engine oil level. Reset the control system. Check the Caterpillar Electronic Technician (ET) for these logged diagnostic codes: “MID 036 .CID 338 . The prelube pressure switch will not close unless a pressure of 9 ± 3 kPa (1.FMI 05 Pre-lube Relay open circuit” and “MID 036 .3 ± 0. Look for leaks in the oil lines for the prelube pump. If the stop was accidental.54 Troubleshooting Section • The prelube pressure switch is faulty. as needed. Refer to Troubleshooting. Look for damage and/or corrosion. “Inspecting Electrical Connectors”. refer to Troubleshooting. Make repairs. Recommended Repairs Talk to the operator Ask the operator if the stop was intentional.CID 338 . Check the Circuit for the Stop Switches Note: The circuit for the normal stop switch and the circuit for the emergency stop switch must remain closed in order for the engine to run. If the resistance is greater than 5 ohms. Engine Shutdown SMCS Code: 1901-038 Probable Causes • The “Emergency Stop” button is pressed.05 Engine Pre-Lube Pressure switch open circuit” diagnostic code. Check the Prelube Pressure Switch The prelube pressure switch must close before the starting motor relay will be energized. . • The normal stop switch that is installed by the customer is activated. The correct resistance between the terminals is less than 5 ohms. Inspect the lubrication system for leaks. Make sure that the reason for the stop has been corrected. For the normal stop switch.4 psi). • The circuit for the normal stop switch is faulty. Make sure that the switch operates in the following manner: • When the engine oil pressure rises above 9 ± 3 kPa (1. Resume normal operation. terminals “A” and “B” close. “ECM Output Circuit (Starting Motor)”. “Prelubrication System”. Inspect the components for looseness. “ECM Status Indicator Output”. Check the Inputs to the ECS Troubleshoot for the “336-02 Incorrect ECS Switch inputs” diagnostic code. Make repairs. as needed. Refer to Troubleshooting. Check the Pressure Switch for the Prelube Troubleshoot for the “339-05 Engine Pre-Lube Pressure Switch open circuit” diagnostic code. Replace any faulty components. Refer to Troubleshooting. Make repairs. as needed. Check the “Crank Terminate” Relay Troubleshoot for the “443-03 Crank Terminate Relay short to +batt” diagnostic code. cracks. • There is a problem with the “Crank Terminate” relay. Recommended Repair Check the Circuit for the GSOV Troubleshoot for the following diagnostic codes: • 17-05 Fuel Shutoff Valve open circuit . “ECM Output Circuit (Prelubrication Oil Pump)”. • The delay time for the driven equipment is excessive. Disassemble the switches. Make repairs. Refer to Troubleshooting. i01727612 • 17-06 Fuel Shutoff Valve short to ground • 17-12 Fuel Shutoff Valve malfunction Refer to Troubleshooting. • The “Cycle Crank Time” is incorrectly programmed. “Electrical Power Supply”. • There is a problem with the relay for the starting motor. • Incorrect input(s) to the Engine Control Switch (ECS) • There is a problem with the relay for the prelube. • A shutdown has been requested by the driven equipment. Make repairs.55 Troubleshooting Section Inspect the Stop Switches Inspect the stop switches for evidence of damage that has been caused by vibration. Use an ohmmeter and toggle the switches in order to check for proper electrical operation. Make repairs. • There is a problem with the “Run” relay. Check the “Start” Relay Troubleshoot for the following diagnostic codes: • The “Engine Overcrank Time” is incorrectly programmed. as needed. Engine Shutdown (Unexpected) SMCS Code: 1901-038 Check the Relay for the Prelube Troubleshoot for the following diagnostic codes: Probable Causes • There is a problem with the Gas Shutoff Valve (GSOV). • 444-05 Start Relay open circuit • 444-06 Start Relay short to ground Refer to Troubleshooting. • The “Crank Terminate Speed” is incorrectly programmed. • There is a problem with the switch for the prelube. as needed. Make repairs. “ECM Output Circuit (Fuel Control)”. as needed. and abrasion. • 338-05 Pre-Lube Relay open circuit • 338-06 Pre-Lube Relay short to ground Refer to Troubleshooting. as needed. If the “Cycle Crank Time” is insufficient. If the programmed delay time is too long. program the delay time to zero. Use Cat ET to check the “Engine Overcrank Time”. the “Engine Overcrank Time” can elapse before the engine is able to start. 1901-038 Probable Causes • An external shutdown or a customer shutdown was requested. as needed. An “E225 (3) Engine Overcrank” event is generated. Make repairs. Use Cat ET to program the delay time to a reasonable amount of time. If the engine does not start within the programmed “Engine Overcrank time”. the engine will shut down. Use Cat ET to increase the “Engine Overcrank Time”. The ECM provides a switch input for the driven equipment in order to delay engine start-up until the driven equipment is ready. • A cylinder or cylinders are misfiring. the attempt to start is terminated. i01727650 Check the “Crank Terminate Speed” The “Crank Terminate Speed” is a parameter that can be configured. if necessary. Engine Shutdown without a Diagnostic Code SMCS Code: 1000-038. • The battery power to the Electronic Control Module (ECM) is lost. “Driven Equipment”. If the “Cycle Crank Time” is insufficient. Check the “Cycle Crank Time” The “Cycle Crank Time” is a parameter that can be configured. An event code is generated if the “Driven Equipment Delay Time” elapses without closure of the switch input. This parameter determines the time for engagement of the starting motor and the gas shutoff valve during the crank cycle. Use Cat ET to adjust the “Crank Terminate Speed”. if necessary. This parameter determines the length of time for the crank cycle. Use Cat ET to check the “Cycle Crank Time”. the engine may not start. Check the “Engine Overcrank Time” The “Engine Overcrank Time” is a parameter that can be configured. Refer to Troubleshooting. The default value of 250 rpm should be sufficient for all applications. • There is a problem with the fuel supply. Use the Caterpillar Electronic Technician (ET) to check the programmed “Crank Terminate” speed. the attempt to start is suspended for an equal “Rest” cycle. Make corrections. Refer to Troubleshooting. The ECM will not attempt to start the engine until the switch input for the driven equipment closes to ground and the prelubrication (if equipped) is complete. Use Cat ET to increase the time. if necessary. Check the “Driven Equipment Delay Time” The “Driven Equipment Delay Time” is a parameter that can be configured. “ECM Status Indicator Output”. To disable this feature.56 Troubleshooting Section Check for a Request for a Shutdown by the Driven Equipment Determine whether a shutdown for the driven equipment has been requested. as needed. Use Cat ET to check the “Driven Equipment Delay Time”. • The ECM has lost the supply voltage for the speed/timing sensor. If the engine does not start within the programmed “Cycle Crank Time”. The Electronic Control Module (ECM) disengages the starting motor when the engine exceeds the programmed “Crank Terminate Speed”. If the “Crank Terminate Speed” is too slow. Check the “Run” Relay Troubleshoot for the “445-03 Run Relay short to +batt” diagnostic code. the “Engine Overcrank Time” can elapse before the engine is able to start. . Inspect the fuel system components: fuel filter. Use the “Data Link/Select ECM” screen on Cat ET to select the ITSM. the engine speed. “Engine Speed/Timing Sensor”. • Inspect the fuel lines for foreign objects and for obstructions that can block the fuel supply. if necessary. “Ignition Transformers Secondary Circuit and Spark Plugs”. 3. Inspect the extender for signs of pin holes and/or arcing. Refer to Troubleshooting. 2. Try to determine if the source of the fuel was changed. fuel metering valve. Engine Starts but Stalls Immediately SMCS Code: 1000-038. the shutdown is likely to occur only when the engine is operating under a load. and actuator for the throttle. Replace the fuel filter. Refer to Troubleshooting. Refer to Troubleshooting. Inspect the ECM and the terminal box for proper installation of the connectors. gas shutoff valve. Use the following procedure: 1. and primary wiring. Verify that the system’s components are operating correctly. 2. When possible. 1901-038 Probable Causes • Fuel supply • Electrical connectors or power supply • Engine speed/timing sensor • Ignition system • Excessive load Speed/Timing Sensor A loss of supply voltage to the speed/timing sensor will cause a shutdown. Inspect the ground strap and the battery for connections that are loose and/or corroded. Select “Diagnostics/Diagnostic Tests”. 4. The following conditions can cause the engine to malfunction: Fuel Supply • Check the fuel supply pressure. ignition transformer. Inspect the fuel system for leaks. The transformer’s secondary circuit. Misfiring Cylinders For a shutdown that is due to misfiring cylinders. i01727661 Battery Power to the ECM 1. “Electrical Power Supply”. 3. Check the following components for failure: spark plug. Make sure that the size of the fuel line is sufficient. extender. Select the suspect cylinder and click the “Start” button in the lower left corner of the screen. interview the operator in order to determine if fuel quality is in question. gas pressure regulator. Check the circuit breaker for the ECM in the terminal box. and the desired engine speed are also displayed. Locate the misfiring cylinder. • Low fuel pressure • High fuel pressure • Poor fuel quality Make sure that the fuel pressure is correct. Recommended Repairs Fuel Supply Make sure that fuel is supplied at a sufficient pressure that is stable. Cat ET will display a graph of the cylinder’s exhaust gas temperature.57 Troubleshooting Section Recommended Repairs External Shutdown or Customer Shutdown Check the ECM and the integrated temperature sensing module for logged codes of events that are shutdowns. The Caterpillar Electronic Technician (ET) and the Integrated Temperature Sensing Module (ITSM) can be used to detect a misfiring cylinder. . test the engine under the conditions. Reduce the load. Make sure that the correct transformers and spark plugs are installed. The action of the lever is smooth. 3. Excessive Load Make sure that the load is not excessive. and open circuits. Map Use the “Service/Configuration” screen of Cat ET in order to verify the value that is programmed for the timing. The open position selects the “First Desired Timing” and the closed position selects the “Second Desired Timing”. Look for codes “E401-1” through “E416-1”. Inspect the wires and the power relay. Refer to Troubleshooting. moisture. “Programming Parameters”. If this diagnostic code is logged. Inspect the wiring from the battery to the Electronic Control Module (ECM). Detonation Use the Caterpillar Electronic Technician (ET) to review the logged codes. Troubleshooting the symptom under other conditions can give misleading results. Inspect the connectors in the terminal box. Engine Speed/Timing Sensor Make sure that the speed/timing sensor is installed correctly. Refer to the topic in Troubleshooting for the particular event code.58 Troubleshooting Section Electrical Connectors or Power Supply 1. Check the power and ground connections to the ECM. Refer to Systems Operation/Testing And Adjusting. 2. Use the Caterpillar Electronic Technician (ET) to check for the 168-02 diagnostic code for “System Voltage Intermittent”. i01727671 Engine Timing Does Not Match Programmed Timing SMCS Code: 1901-038 Probable Causes • The timing may be retarded due to detonation. “Electrical Power Supply”. proceed to Troubleshooting. Refer to the Electrical System Schematic. Inspect the primary wiring and the secondary electrical connections. Make sure that the timing wheel is correctly installed. Refer to Troubleshooting. • The timing selection switch may be closed. Verify that the circuit of the switch has continuity to terminals J1-20 (input) and J1-31 (return) at the electronic control module. See Troubleshooting. • The timing may be retarded due to the selection of the map for speed or the map for load. Ignition System Inspect the ignition transformers for loose connections. “Electrical Power Supply” for more information. etc). Maintain the spark plug according to the engine’s Operation and Maintenance Manual. . 2. “Speed/Timing Sensor”. short circuits. Timing Selection Switch 1. Check the wiring harnesses and the connectors. disengage the driven equipment and test the engine. If necessary. 3. Check the “First Desired Timing” and the “Second Desired Timing”. engine operating temperature. Recommended Repairs Note: If the symptom only occurs under certain operating conditions (high idle. “Inspecting Electrical Connectors”. full load. Make sure that the continuity is not inverted or incorrect. Inspect the extenders for signs or pin holes and arcing. Verify that the timing selection switch is in the correct position. Verify that the switch toggles properly. Inspect the battery connections and the ground. Static Load Make sure that the driven equipment is not preventing the crankshaft from turning. Refer to Special Instruction. Inspect the main power switch. refer to Troubleshooting. battery posts. If the solenoid does not operate properly. the engine must be disassembled in order to investigate internal mechanical problems. If the battery cables are corroded. try the starting motor again. Grease the splines of the drive shaft and the pinion. If the starting motor does not turn the crankshaft. Recommended Repairs Batteries and/or Battery Cables 1. If the teeth of the pinion and/or the flywheel ring gear are worn or broken. If the pinion does not engage the flywheel.59 Troubleshooting Section i01746410 Engine Will Not Crank SMCS Code: 1000-038. there may be a problem with the starting motor. Charge the batteries. the clutch jaws may be broken. disengage the driven equipment and test the engine. “Electrical Power Supply”. and battery cables for loose connections and corrosion. If the starting motor turns but the flywheel does not turn. Load test the batteries. Test the operation of the starting motor solenoid. turn the crankshaft by hand. 8 and 12 Volt Lead Acid Batteries”. inspect the gear teeth. If necessary. Probable Causes • Batteries and/or battery cables • Starting motor solenoid and/or starting circuit • Starter motor pinion or flywheel ring gear • Low air pressure • Static load • Wiring for the starting system • Internal mechanical problem Low Air Pressure Determine the cause of the low air pressure. Possible internal problems include the following conditions: Starting Motor Solenoid or Starting Circuit 1. Repair any leaks in the air lines. Ensure that a mechanical failure inside the engine is not preventing the crankshaft from turning. “Battery Test Procedure”. Check the wiring to the starting motor solenoid. remove the battery cables and clean the battery cables. 1901-038 Inspect the pinion and the flywheel ring gear for damage. Tighten any loose connections. Before you remove the starting motor. install a new solenoid. Remove the pinion. Refer to Special Instruction. 2. Try to turn the crankshaft by hand. Wiring If you suspect that the wiring is faulty. • Bearing seizure • Piston seizure • Valve and piston contact Starting Motor or Flywheel Ring Gear If the pinion engages the flywheel but the flywheel does not turn. “Use of 4C-4911 Battery Load Tester for 6. the pinion shaft may be stuck. the clutch jaws. . remove the spark plugs. replace the parts. or other parts. Check for fluid in the cylinders. If the crankshaft will turn by hand. If the pinion does not engage correctly with the flywheel. If this is not the problem. remove the starting motor. a. 2. Inspect the batteries. b. Repair the starting motor or replace the starting motor. Inspect the air lines for leaks. Internal Mechanical Problem If the crankshaft will not turn and the driven equipment is disengaged. Make repairs. Compare the timing to the recommended timing in the Engine Performance. Look for the following conditions: Inlet Air Restriction The maximum allowable inlet air restriction is 3. “Inlet Air Temperature (High)”. Refer to Troubleshooting. For data that is specific to the engine. clean the filter element or install a new filter element. “Fuel Usage Guide”. Measure the Exhaust Restriction Measure the exhaust restriction during engine operation with a load. investigate the cause of the condition.75 kPa (15 inches of H2O). • Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke. Check the restriction again. The fuel supply pressure must be adequate and stable. inspect the air inlet piping before the air cleaner for obstructions.60 Troubleshooting Section i01727679 Excessive Load Make sure that the load is not excessive. as needed. refer to the Technical Marketing Information. Recommended Repairs Check the Inlet Air Temperature High inlet air temperature can cause detonation. Check the inlet air temperature. disengage the driven equipment and test the engine. Verify that the exhaust emissions are correct. . Use the Caterpillar Electronic Technician (ET) to check the ignition timing during engine operation with a load. Exhaust Port Temperature (High) SMCS Code: 1901-038 Check the Ignition Timing Probable Causes • High inlet air temperature • Inlet air restriction • Air/fuel ratio • Excessive load • Incorrect timing • Exhaust restriction • A buildup of deposits in the cylinder or internal oil leaks Note: Data from a fuel analysis is required for this procedure. Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. Reduce the load. A change in the fuel energy content will change the air/fuel ratio. Obtain a fuel analysis. If excessive deposits and/or signs of internal oil leaks are found. If necessary. Note: Excessive deposits contribute to guttering of the valves. • Deposits on the valve seats • Deposits on the valve faces • Deposits on the cylinder walls that are above the upper limit of the piston stroke Air/Fuel Ratio An air/fuel mixture that is too rich will increase the exhaust temperature. Adjust the ignition timing according to the recommended timing in the Engine Performance. Investigate the cause of the exhaust restriction. Perform adjustments and/or make repairs. If the restriction remains too high. “Fuel Usage Guide”. as needed. If the indication is higher than the maximum permissible restriction. switch the suspect thermocouple for another thermocouple. sensor needs to be calibrated. Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM) Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples for exhaust temperatures.61 Troubleshooting Section i01727687 Check for Insufficient Ignition Use Cat ET to check for logged diagnostic codes that relate to the ignition system. replace the thermocouple. “Ignition Transformers Primary Circuit”. If no logged diagnostic codes are present for the suspect cylinder. the temperatures from similar locations are comparable. If the temperature problem stays at the original location of the suspect thermocouple. Program the “Fuel Quality” parameter to the actual value of the LHV. Troubleshoot the code. Refer to Troubleshooting. Exhaust Port Temperature (Low) SMCS Code: 1901-038 Probable Causes • Operation with a light load • Active diagnostic code from the Integrated Temperature Sensing Module (ITSM) Check the Cylinder Compression Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. Operate the engine at low idle or near low idle in order to identify a misfire problem. Refer to Troubleshooting. the temperatures from similar locations are reduced at a similar rate. Make repairs. Program the “Fuel Quality” parameter to the average value of the LHV. • The oxygen sensor is not accurate or the oxygen • Condensation is forming in the gas. i01727698 • A faulty thermocouple • Insufficient ignition • Low cylinder compression Recommended Repairs Check for Misfire Operation with a low load can result in low exhaust temperatures. as needed. . inspect the components of the ignition system for the cylinder. If low compression is found. “Oxygen Sensor . If the quality of the gas is not consistent. Refer to Troubleshooting. Fuel Energy Content SMCS Code: 1901-038 Probable Causes • The Low Heat Value (LHV) of the gas or the specific gravity of the gas is significantly different from the value that is programmed into the electronic control module. Check the Oxygen Sensor Calibrate the oxygen sensor. If any discrepancies are found. Also. Troubleshoot the cause of the misfire. “Ignition Transformers Secondary Circuit and Spark Plugs”. investigate the cause of the low compression. Troubleshoot the code. “Engine Misfires.Calibrate”. investigate the cause for the low temperature. When the engine is operating properly. If the temperature problem follows the thermocouple. Refer to Troubleshooting. Recommended Repairs Obtain a Fuel Analysis and Program the “Fuel Quality” Parameter Obtain an analysis of the gas in order to determine the LHV.Runs Rough or Is Unstable”. obtain several analyses over a period of time. Check for Suspect Thermocouples Observe the temperatures from the thermocouples after the engine is shut off. The maximum allowable pressure to the fuel metering valve is 35 kPa (5 psi). repair the regulator or replace the regulator. i01727704 Check the Fuel Metering Valve Shut OFF the fuel supply. Check for binding due to dirt and/or contamination. Disconnect the fuel lines from the fuel metering valve. refer to the literature that is provided by the OEM of the valve. Refer to Troubleshooting. Make repairs. If the gas pressure regulator cannot be adjusted to the correct setting. refer to Troubleshooting. If the fuel pressure is not within the acceptable range. Check the Dryer for the Gas Check the dryer for the gas for proper operation. Clean the valve. i01369481 Fuel Pressure SMCS Code: 1250-035 Probable Causes • Incorrect setting of the gas pressure regulator • Faulty gas pressure regulator Recommended Repairs Check the Gas Pressure Regulator Use the Caterpillar Electronic Technician (ET) to observe the absolute fuel pressure and the fuel differential pressure. If the valve is binding due to wear of internal components. i01369469 Gas Fuel Differential Pressure (High) SMCS Code: 1901-038 Probable Causes • Excessive fuel supply pressure • Leaks in the piping after the fuel metering valve Recommended Repairs Check the Fuel Supply Pressure Check the pressure of the fuel supply to the fuel metering valve for high pressure. repair the regulator or replace the regulator. adjust the gas pressure regulator in order to achieve the correct pressure.5 to 5 psi). “Oxygen Sensor Buffer Supply” and Troubleshooting. Repair the piping. as needed. Visually inspect the internal mechanism of the valve. if necessary. Adjust the gas pressure regulator in order to achieve the correct pressure. if necessary. . If the gas pressure regulator cannot be adjusted to the correct setting. Repair the dryer. The fuel metering valve requires a gas supply that is regulated to a pressure between 10 to 35 kPa (1. Verify that the emissions are within specifications. Recommended Repairs Check the Battery Voltage Check the battery voltage for the fuel metering valve. “Oxygen Sensor Signal”. Check for binding due to wear of internal components. if necessary.62 Troubleshooting Section If the oxygen sensor could not be calibrated successfully. “Electrical Power Supply”. Fuel Metering Valve SMCS Code: 1901-038 Probable Causes • Low battery voltage • Internal binding of the fuel metering valve Check for Leaks Use a gas detector to check for leaks in the piping between the outlet of the fuel metering valve and the turbocharger compressor. as needed. if necessary. determine the reason for the faulty signal from the fuel metering valve. Check Cat ET for a “E223 High Gas Temperature” event code. If the gas pressure regulator cannot be adjusted to the correct setting. Verify that the GSOV does not stick in a partially open position. Repair the GSOV. Ensure that the fuel metering valve is installed properly. Check for proper installation of the fuel metering valve. If the temperature on Cat ET is different. Adjust the gas pressure regulator in order to achieve the correct pressure. “Gas Temperature (High)”. repair the regulator or replace the regulator. i01727721 Recommended repairs Check the Installation of the Fuel Metering Valve An “E864 Low Gas Fuel Differential Pressure” event will be generated if the fuel metering valve is installed backward. If there is an active “E223 High Gas Temperature” event code. if necessary. Inspect the screen inside the inlet of the fuel metering valve for cleanliness. refer to Troubleshooting. Clean the lines and make repairs. Verify that the valve is fully open when the valve is energized. as needed. as needed. When the fuel metering valve is properly installed. Check the Gas Shutoff Valve (GSOV) for proper operation. Make repairs. if necessary. Check the Fuel Supply for Obstructions Check the fuel filter for restriction.5 psi) for the gas supply. The opposite end of the valve is connected to the pressurized gas supply. Replace the GSOV. Gas Fuel Flow Rate (Low) SMCS Code: 1901-038 Probable Causes • High fuel temperature • Faulty gas pressure regulator or low fuel supply pressure • Obstructions in the fuel supply • Inadequate fuel energy content or moisture in the gas Recommended Repairs Check the Fuel Temperature Measure the temperature of the gas that is entering the fuel metering valve. the end with the electrical connector is connected to the air system which leads to the inlet of the turbocharger compressor. Check the outlet pressure from the gas pressure regulator. Check the Gas Pressure Regulator The fuel metering valve requires a minimum pressure of 10 kPa (1. determine the cause of the high fuel temperature. . Replace the fuel filter. Clean the screen. Compare the measurement to the reading for the fuel temperature on the Caterpillar Electronic Technician (ET). Probable Causes • Improper installation of the fuel metering valve • Low fuel supply pressure • Obstructed fuel supply • Obstructed fuel outlet Check the Fuel Outlet for Obstructions Inspect the piping for obstructions between the fuel metering valve and the inlet to the turbocharger compressor.63 Troubleshooting Section i01727713 Gas Fuel Differential Pressure (Low) SMCS Code: 1901-038 Inspect the fuel supply lines to the fuel metering valve for obstructions. Check for proper operation of the equipment that treats the gas prior to the engine. Clean the piping and make repairs. If the fuel temperature is high. i01727732 Gas Temperature (High) SMCS Code: 1901-038 Probable Causes • The temperature of the gas is too high. If a problem is found for the equipment that treats the gas prior to the engine. refer to Troubleshooting. Verify that the valve is fully open when the valve is energized. Program the Fuel Energy Content to the actual value of the LHV. Make repairs. Check Cat ET for a “E230 (1) Fuel Energy Content Setting High” event code. i01623042 Obtain a Fuel Analysis If the fuel energy content is too low. Program the Fuel Energy Content to the average value of the LHV. If the pressure of the gas supply is too low. Inlet Air Temperature (High) SMCS Code: 1901-038 Probable Causes • High ambient air temperature • High coolant temperature • High inlet air restriction and/or high altitude • Faulty inlet air temperature sensor and/or circuit • Insufficient flow of cooling water through the aftercooler Check the Dryer for the Gas Check the dryer for the gas for proper operation.64 Troubleshooting Section Check the Gas Pressure Regulator Check the outlet pressure from the gas pressure regulator. adjust the gas pressure regulator in order to achieve the correct pressure. Obtain an analysis of the gas in order to determine the LHV. If the code is present. • The fuel metering valve has sent faulty data to the electronic control module. “Fuel Energy Content”. if necessary. Inspect the fuel supply lines to the fuel metering valve for obstructions. the fuel metering valve could demand an excessive supply of fuel. Replace the fuel filter. if necessary. determine the reason for the faulty data from the fuel metering valve. Clean the screen. Verify that the GSOV does not stick in a partially open position. If the gas pressure regulator cannot be adjusted to the correct setting. repair the regulator or replace the regulator. Repair the dryer. Check the Fuel Supply for Obstructions Check the fuel filter for restriction. • Insufficient flow of air through the aftercooler . Clean the lines and make repairs. The fuel metering valve requires a minimum pressure of 10 kPa (1. Compare the measurement to the reading for the temperature on the Caterpillar Electronic Technician (ET). as needed. Recommended Repairs Investigate the Cause of the High Temperature Check for proper operation of the equipment that treats the gas prior to the engine. as needed. Replace the GSOV.5 psi) for the gas supply. If the measurement for the temperature is significantly different from the reading on Cat ET. if necessary. repair the equipment. Repair the GSOV. Inspect the screen inside the inlet of the fuel metering valve for cleanliness. as needed. obtain several analyses over a period of time. Check the Data from the Fuel Metering Valve Measure the temperature of the gas that is entering the fuel metering valve. Check the Gas Shutoff Valve (GSOV) for proper operation. If the quality of the gas is not consistent. if necessary. If the sensor is OK. “Engine Coolant Temperature (High)”. If there is a high differential between the inlet temperature and the outlet temperature of the coolant for the aftercooler. Check for High Inlet Air Restriction and/or High Altitude When inlet air pressure is low. Check the reading for the inlet air temperature. Inlet Air Restriction Check for plugged air filters. • Check the pump for proper operation. clean the aftercooler. Compare the reading to the regulated temperature. Measure the inlet air pressure while the engine is operating under load. Probable Causes • Active engine shutdown • Electrical connectors • Circuit breaker • Engine speed/timing signal • Fuel supply • Spark plug Check the Temperature Sensor and/or the Circuit Allow the sensor to cool and remove the sensor. After correcting the problem. . Determine the reason for the shutdown. switch the sensor with a sensor that is known to be good. Determine the cause of the high air temperature. For specific data. if necessary. • Make repairs. i01727744 Coolant Temperature Refer to Troubleshooting. A high temperature differential indicates an insufficient flow rate. If the pressure differential of the air across the aftercooler does not match the specifications. Verify that the problem is solved. Check for Sufficient Flow of Cooling Water Through the Aftercooler Check the inlet temperature of the coolant for the aftercooler. check the outlet temperature of the coolant.65 Troubleshooting Section Recommended Repairs High Ambient Air Temperature Determine if the ambient air temperature is within the design specifications for the cooling system. perform the following procedures: • Check the water circuit of the aftercooler for obstructions. Check for Sufficient Flow of Air Through the Aftercooler Determine the pressure differential of the inlet air across the aftercooler. This increases inlet air temperature. Make corrections. cycle the engine control switch to the OFF/RESET position for at least 15 seconds before you try to restart the engine. High Altitude Make sure that the settings for the engine are correct for the altitude. Check for obstructions to the air inlet. refer to the Technical Marketing Information for the engine. the turbocharger works harder in order to achieve the desired inlet manifold pressure. the reading and the ambient temperature are approximately equal. 1901-038 Note: Use this procedure only if the engine shuts down completely and the engine must be restarted. If the temperature is OK. If the reading is not correct. Replace the air filters and/or remove the obstruction from the air inlet. Recommended Repairs Active Engine Shutdown Use the Caterpillar Electronic Technician (ET) to check for any active engine shutdowns and/or logged engine shutdowns. For specific data. when possible. Intermittent Engine Shutdown SMCS Code: 1000-038. refer to the Technical Marketing Information for the engine. Check the power and ground connections to the ECM. If the fuel pressure is still low. Inspect the connectors in the terminal box. Spark Plug An engine shutdown that is due to a faulty spark plug is likely to occur when the engine is operating under a load. repair the wiring. Check wiring for damage or corrosion. Check the Inlet Pressure of the Jacket Water The engine coolant pump pressure switch (inlet) is designed to open across pin B and pin C at a pressure of 462 ± 41 kPa (67 ± 6 psi). Refer to Troubleshooting. Refer to Troubleshooting. Use Cat ET to check for logged diagnostic codes. “Ignition Transformers Secondary Circuit and Spark Plugs”. Fuel Supply 1. Reset the circuit breaker if the circuit breaker is tripped. Refer to the Electrical System Schematic. as needed. Inspect the wires and the power relay. Check the wiring harnesses and the connectors. 3. “Engine Speed/Timing Sensor”. Check the fuel pressure. Use Cat ET to check for the 168-02 diagnostic code for “System Voltage Intermittent”. If the fuel pressure is low. Make repairs. check the gas regulator and the fuel metering valve. 3. Refer to Troubleshooting. If problems are found with the fuel lines. obstructions. “Inspecting Electrical Connectors”. 4. Check the fuel quality. If a problem with the wiring for the circuit is found. Check the restriction of the fuel filter. . i01368495 Jacket Water Inlet Pressure (High) SMCS Code: 1901-038 Probable Causes • The circuit for the engine coolant pump pressure switch (inlet) is OPEN. Recommended Repairs Check the Circuit for the Engine Coolant Pump Pressure Switch (Inlet) The circuit for the switch must remain closed in order to avoid an “E224 High Jacket Water Inlet Pressure” event. If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) is measured at the inlet for the jacket water. the high pressure may be caused by a restriction in the jacket water system. collapsed lines. Inspect the wiring from the battery to the electronic control module. replace the pressure switch at the inlet for the jacket water. Inspect the battery connections and the ground. The circuit breaker may exceed the trip point due to overheating. as needed. • The pressure at the inlet for the jacket water is excessive. If this diagnostic code is logged. “Inspecting Electrical Connectors”. If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) but the event code “E224 High Jacket Water Inlet Pressure” is occurring. 2. proceed to Troubleshooting. Use a gauge to check the pressure at the inlet for the jacket water. repair the lines and/or replace the lines. For more information. Inspect the system for restrictions. “Electrical Power Supply” for more information. “Electrical Power Supply”. 2. refer to Troubleshooting. Refer to Troubleshooting. replace the fuel filter. and pinched lines. Check the fuel lines for the following problems: restrictions. Circuit Breakers Check the circuit breaker in the terminal box.66 Troubleshooting Section Electrical Connectors 1. “Fuel System” for the correct pressure values. Engine Speed/Timing Signal Loss of the signal from the speed/timing sensor will cause a shutdown. Refer to Systems Operation/Testing and Adjusting. If this code is generated. The “Engine Coolant Outlet Pressure Sensor noisy signal” diagnostic will be generated although there is no malfunction in the electrical circuit. install a pressure gauge near the pressure sensor at the jacket water outlet. . “Analog Sensor Signal”. i01727753 Jacket Water to Engine Oil Differential Temperature (Low) SMCS Code: 1901-038 Jacket Water Pressure (Low) SMCS Code: 1901-038 Probable Causes • High oil temperature and low coolant temperature • Faulty temperature sensor and/or circuit • Faulty water temperature regulators Probable Causes • Low coolant level • Insufficient flow of coolant Recommended Repairs Check the Coolant Level and Inspect the Cooling System for Leaks Check coolant level. If the coolant level is low. • Inspect the jacket water pump for damage to the Make the necessary repairs. impeller. If one or both of the readings are incorrect. inspect the cooling system for leaks. verify the actual outlet pressure of the coolant with a pressure gauge. troubleshoot the circuit for the pressure sensor at the jacket water outlet. a 109-08 diagnostic code will be generated. i01727750 • Check for plugging of the radiator or the heat exchanger. Recommended Repairs Check the Engine Coolant Temperature and the Oil Temperature Use the Caterpillar Electronic Technician (ET) to check for the following event codes: • E123 (1) Jacket Water to Oil Temperature Low (warning) Check the Flow of Coolant Use the Caterpillar Electronic Technician (ET) to observe the pressure at the jacket water outlet with the engine OFF. Refer to Troubleshooting. If the coolant level is low. Then observe the reading during engine operation.67 Troubleshooting Section Note: If the outlet pressure of the coolant is greater than approximately 444 kPa (64 psi). This will prevent a false 109-08 from being logged. If the readings from the comparative gauge do not agree approximately with Cat ET. If the readings from the comparative gauge agree approximately with Cat ET. If leaks are found. troubleshoot the code(s). Refer to Troubleshooting. make the necessary repairs. Compare the gauge reading with the reading from Cat ET. If the actual pressure is greater than approximately 444 kPa (64 psi). Check the Temperature Sensors and/or Circuits Use Cat ET in order to verify that the oil temperature and the engine coolant temperature are reasonable. fill the cooling system. check the following components: • E124 (3) Jacket Water to Oil Temperature (shutdown) • E019 (3) High Engine Oil Temperature (shutdown) • E020 (1) High Engine Oil Temperature (warning) • E038 (1) Low Engine Coolant Temperature (warning) If one or more of the codes are active. reduce the pressure. If the reading is not reasonable or if the reading is not within specifications. “PWM Sensor”. • Check the water temperature regulators for proper operation. troubleshoot the circuit(s). if necessary. Check the tube at the outlet for the jacket water. i01727763 Recommended Repairs Troubleshoot the electrical system. i01368006 • E026 (3) High Inlet Air Temperature (shutdown) • E027 (1) High Inlet Air Temperature (warning) If one or more of the codes is active. “Fuel Usage Guide”. Look for the following conditions: • Deposits on the valve seats Probable Causes • High inlet manifold temperature • Advanced timing • Exhaust restriction • A buildup of deposits in the cylinder or internal oil leaks • Deposits on the valve faces • Deposits on the cylinder walls that are above the upper limit of the piston stroke • Signs of internal oil leaks Other signs of internal oil leaks include high oil consumption and blue smoke. as needed. Compare the timing to the recommended timing in the Engine Performance. “Testing the Cooling System”. Adjust the ignition timing according to the recommended timing in the Engine Performance. “Inlet Air Temperature (High)”. If excessive deposits and/or signs of internal oil leaks are found. a regulator may be stuck open. as needed. refer to the Technical Marketing Information. Check the Ignition Timing Note: Data from a fuel analysis is required for this procedure. Replace the water temperature regulators. Check the water temperature regulators according to Systems Operation/Testing and Adjusting. Use Cat ET to check the ignition timing during engine operation with a load. Investigate the cause of the exhaust restriction. System Voltage SMCS Code: 1901-038 Probable Causes There is a problem with the electrical system. “Electrical Power Supply”.68 Troubleshooting Section Check the Water Temperature Regulators The water temperature regulators should not begin to open until jacket water reaches opening temperature for the regulators. If the tube is warm and normal operating temperature is not achieved yet. Allow the engine to cool and then start the engine. Turbocharger Turbine Temperature (High) SMCS Code: 1052-038 Check for Deposits in the Cylinder and Check for Internal Oil Leaks Use a borescope to inspect the cylinders. Refer to Troubleshooting. For data that is specific to the engine. Note: Excessive deposits contribute to guttering of the valves. Measure the Exhaust Restriction Measure the exhaust restriction during engine operation with a load. investigate the cause of the condition. Perform adjustments and/or make repairs. “Fuel Usage Guide”. Recommended Repairs Check for Event Codes for High Inlet Manifold Air Temperature Use the Caterpillar Electronic Technician (ET) to check for the following event codes: • E025 (2) High Inlet Air Temperature (derating) . Make repairs. refer to Troubleshooting. investigate the cause of the low compression. Check the Temperatures of the Cylinder Exhaust Ports Observe the temperatures for the exhaust ports of the cylinders in the suspect bank. If the temperature problem stays at the original location of the thermocouple. Check for Diagnostic Codes from the Integrated Temperature Sensing Module (ITSM) Use the Caterpillar Electronic Technician (ET) to check for diagnostic codes that relate to the thermocouples. Operate the engine at low idle or near low idle in order to identify a misfire problem. as needed. investigate the cause for the low temperature. Troubleshoot the cause of the misfire. determine the reason for the difference in the exhaust port temperatures. Runs Rough or Is Unstable”. If the temperature problem follows the thermocouple. Troubleshoot the code. Make repairs. If any discrepancies are found. the temperatures from similar locations are comparable. as needed. Check the Cylinder Compression Measure the cylinder pressures of the suspect bank in order to check for problems that are related to compression. If low compression is found. switch the suspect thermocouple for another thermocouple. Check the Ignition System Inspect the components of the ignition system for the suspect cylinder bank. replace the thermocouple. Make repairs. Troubleshoot the code. the temperatures from similar locations are reduced at a similar rate. Refer to Troubleshooting. . Recommended Repairs Check for Misfire Operation with a low load can result in low exhaust temperatures. Probable Causes • Operation with a light load • Diagnostic code from the Integrated Temperature Sensing Module (ITSM) • Low temperature from the cylinder exhaust ports • A faulty temperature sensor • Faulty ignition • Low cylinder compression Check for Diagnostic Codes that Relate to Ignition Use Cat ET to check for diagnostic codes that relate to the ignition system. as needed. Also.69 Troubleshooting Section i01727766 Turbocharger Turbine Temperature (Low) SMCS Code: 1052-038 When the engine is operating properly. “Ignition Transformers Secondary Circuit and Spark Plugs”. If any of the temperatures for the exhaust ports are significantly different. Make repairs. “Engine Misfires. Check for Suspect Thermocouples Observe the temperatures from the thermocouples for the turbochargers after the engine is shut off. Refer to Troubleshooting. The MID for the Electronic Control Module (ECM) is 36. or period” “Abnormal update” “Abnormal rate of change” “Failure mode not identifiable” “Bad device or component” “Out of calibration” “Not used” “Not used” “Parameter not available” “Module not responding” “Sensor supply fault” “Condition not met” “Not used” Diagnostic Codes SMCS Code: 1901-038 Diagnostic codes alert the operator that a problem in the electronic system has been detected.70 Troubleshooting Section Troubleshooting with a Diagnostic Code i01727770 Table 12 Failure Mode Identifiers FMI 00 01 02 03 04 05 06 07 08 09 Description of Failure “Data valid but above normal operating range” “Data valid but below normal operating range” “Data erratic. see Troubleshooting. the CID number 0017 identifies the fuel shutoff valve. For example. Table 12 is a list of the failure mode identifiers that are adapted from the “SAE J1587” standard. The CID indicates the component that generated the code. Diagnostic codes may be viewed on a personal computer that has Cat ET software. the component identifier (CID). Diagnostic codes also indicate the nature of the problem to the service technician. For information on event codes. Failure Mode Identifier (FMI) – The FMI is a two digit code that indicates the type of failure. Illustration 14 represents the operating range of an oil temperature sensor. Some electronic displays do not display the MID because the module which generates the code is obvious. Module Identifier (MID) – The MID is a code with two or three digits that indicates the electronic module which generated the diagnostic code. intermittent or incorrect” “Voltage above normal or shorted high” “Voltage below normal or shorted low” “Current below normal or open circuit” “Current above normal or grounded circuit” “Mechanical system not responding properly” “Abnormal frequency. The diagram is a reference. The Caterpillar Electronic Technician (ET) is a software program that is designed to run on a personal computer. Do not use the diagram to troubleshoot the oil temperature sensor. and the failure mode identifier (FMI). . “Troubleshooting with an Event Code”. pulse. Component Identifier (CID) – The CID is a number with three or four digits. 10 11 12 13 14 15 16 17 18 19 20 Note: Do not confuse diagnostic codes with event codes. Diagnostic codes consist of the module identifier (MID). The MID for the Integrated Temperature Sensing Module (ITSM) is 111. The sensor does not have an electronic problem. The most likely cause of an intermittent problem is a faulty connection or damaged wiring. or a shutdown for high oil temperature.1 volts. the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. Logged Diagnostic Codes When the ECM generates a diagnostic code the ECM logs the code in permanent memory.2 and 4.CID 0017 .FMI 05 Fuel Shutoff Value open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: (1) In these areas. the message disappears from the list of active diagnostic codes. (3) This area represents the normal operating temperature for the engine oil. The output is outside of the normal range. i01727809 Illustration 14 Typical operating range of an oil temperature sensor g00791619 MID 036 . The diagnostic code becomes logged. Correct the problem as soon as possible. Note: Always clear logged diagnostic codes after investigating and correcting the problem which generated the code. The next likely cause is a component failure. Some diagnostic codes may be easily triggered.71 Troubleshooting Section This information is a valuable indicator for troubleshooting intermittent problems. The electronic problem will generate a diagnostic code. The ECM has an internal diagnostic clock. a derating. • The output to the fuel control relay from the Electronic Control Module (ECM) is OFF. When an active diagnostic code is generated. Diagnostic codes that are logged repeatedly may indicate a problem that needs special investigation. The code is logged. Troubleshooting: Active Diagnostic Codes An active diagnostic code represents a problem with the electronic control system. If the condition that generated the code is momentary. Note: This code cannot be detected by the ECM when the output for the fuel control relay is ON. the output voltage of the sensor is too high or too low. The output is normally ON when the engine control switch is in the START position and the engine RPM is greater than zero. The ECM will record the following information when a code is generated: The most likely cause is one of the following conditions: • An open circuit in the harness or in the fuel control relay • The hour of the first occurrence of the code • The hour of the last occurrence of the code • The number of occurrences of the code • A short circuit to the +Battery in the harness or in the fuel control relay Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” . the oil temperature above 102 C (216 F) is higher than normal. The alarm output is activated. Any logged diagnostic codes will automatically be deleted if no additional occurrences are recorded in 100 hours. Some diagnostic codes may log occurrences that did not result in complaints. • When no electrical load is provided. (2) In this area. System Response: No fuel is provided to the engine. The output voltage of the sensor will generate an event code for a warning. a resistor in the fuel shutoff valve rises to the +Battery side. Possible Performance Effect: The engine will not start due to the lack of fuel. The normal output voltage of the sensor is between 0. The least likely cause is the failure of the ECM. . • OK – STOP. System Response: The ECM will disable the ignition system and the gas shutoff valve in order to shut down the engine. Troubleshooting: Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results: MID 036 . Possible Performance Effect: The engine will not start due to the lack of fuel.FMI 06 Fuel Shutoff Valve short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: • The output for the fuel control relay is ON.72 Troubleshooting Section Results: i01741131 • OK – STOP.FMI 03 8 Volt DC Supply short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage supply from the Electronic Control Module (ECM) to one of the following sensors has exceeded the normal range. • The Electronic Control Module (ECM) detects excessive current on the output for the fuel control relay.CID 0017 .FMI 12 Fuel Shutoff Valve malfunction SMCS Code: 1901-038 Conditions Which Generate This Code: The driver in the Electronic Control Module (ECM) for the gas shutoff valve is OFF but the engine still runs. • Detonation sensors • Sensor for inlet manifold air pressure • Sensor for engine coolant pressure System Response: Default values are assumed for the inputs to the ECM from all of the 8 volt analog sensors. Troubleshooting: The condition is probably caused by a short circuit in the harness or by an internal short circuit in the fuel control relay. Perform the following diagnostic procedure: “ECM Output Circuit (Fuel Control)” Results: • OK – STOP. All of the diagnostic codes for the 8 volt analog sensors to the ECM are disabled while this code is active. System Response: The ECM will continue attempting to energize the relay. i01727944 MID 036 . Note: This condition cannot be detected by the ECM when the output for the fuel control relay is OFF. The code is logged.CID 0041 . i01727848 MID 036 . The output is normally OFF when the engine control switch is in the OFF/RESET position. The shutdown output is activated. The alarm output is activated. The code is logged.CID 0017 . The engine may shut down due to a lack of fuel. Possible Performance Effect: The engine is shut down. • 262 .the engine is shut down. the engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: • OK – STOP. This disables the engine protection for low oil pressure and excessive oil pressure.FMI 04 8 Volt DC Supply short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage supply from the Electronic Control Module (ECM) to one of the following sensors is below the normal range.03 5 Volt Sensor DC Power Supply short to +batt MID 036 . The shutdown output is activated. Troubleshooting: Perform the following diagnostic procedure: “+8V Sensor Voltage Supply” Results: i01728439 MID 036 . i01727976 • 262 .8 VDC for at least five seconds. the engine is shut down. Possible Performance Effect: Since the engine protection is disabled.CID 0100 . The code is logged. The shutdown output is activated. The code is logged. Troubleshooting: This condition indicates an open circuit or a short circuit to a positive voltage source. Possible Performance Effect: Since the engine protection is disabled. . The code is logged. The shutdown output is activated. neither of the following diagnostic codes are active: • OK – STOP. • OK – STOP.04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the engine oil pressure.CID 0041 .73 Troubleshooting Section The fuel is shut off. All of the diagnostic codes for the 8 volt analog sensors to the ECM are disabled while this code is active. The fuel is shut off. The monitoring of the oil pressure is disabled. Additionally. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • Detonation sensors • Sensor for inlet manifold air pressure • Sensor for engine coolant pressure System Response: Default values are assumed for the inputs to the ECM from all of the 8 volt analog sensors. The fuel is shut off.FMI 03 Engine Oil Pressure open/short to +batt SMCS Code: 1924-038 Conditions Which Generate This Code: The signal from the filtered oil pressure sensor to the Electronic Control Module (ECM) is greater than 4. Possible Performance Effect: Since the engine protection is disabled. The code is logged. Perform the following diagnostic procedure: “PWM Sensor” Results: • 262 .CID 0106 . Additionally. neither of the following diagnostic codes are active: • 41 .03 8 Volt DC Supply short to +batt • 41 . . Possible Performance Effect: Since the engine protection is disabled.CID 0106 .74 Troubleshooting Section i01728444 MID 036 . Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. System Response: The fuel is shut off. the engine is shut down. The shutdown output is activated. The shutdown output is activated. The shutdown output is activated. Possible Performance Effect: The engine is shut down.FMI 08 Air Inlet Pressure Sensor noisy signal SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle or the frequency for the inlet manifold pressure sensor is out of range.03 5 Volt Sensor DC Power Supply short to +batt • 262 .04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the engine oil pressure.03 8 Volt DC Supply short to +batt • 41 .FMI 04 Engine Oil Pressure short to ground SMCS Code: 1924-038 Conditions Which Generate This Code: The signal from the filtered oil pressure sensor to the Electronic Control Module (ECM) is less than 0.04 8 Volt DC Supply short to ground System Response: The fuel is shut off. neither of the following diagnostic codes are active: Additionally.2 VDC for at least five seconds. i01636347 • 41 . Possible Performance Effect: The engine is shut down. The code is logged. Additionally. The code is logged. The fuel is shut off.04 8 Volt DC Supply short to ground MID 036 . neither of the following diagnostic codes are active: • OK – STOP. Troubleshooting: This condition indicates the possibility of an open circuit or a short circuit. This disables the engine protection for low oil pressure and excessive oil pressure. i01636377 MID 036 .CID 0100 . The monitoring of the oil pressure is disabled.FMI 03 Air Inlet Pressure Sensor short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle for the inlet manifold pressure sensor is greater than the maximum value. neither of the following diagnostic codes are active: The duty cycle or the frequency of the signal from the pressure sensor for the outlet of the engine coolant is out of range. Possible Performance Effect: The engine performance is not affected. Additionally.04 8 Volt DC Supply short to ground System Response: The alarm output is activated. i01631733 MID 036 .CID 0109 . Troubleshooting: Perform the following diagnostic procedure: “PWM Sensor” Results: • 41 . Troubleshooting: The condition indicates a possible open circuit or a short circuit. Perform the following diagnostic procedure: “PWM Sensor” Results: • OK – STOP.FMI 03 Engine Coolant Temperature open/short to +batt SMCS Code: 1906-038 Conditions Which Generate This Code: The signal from the engine coolant temperature sensor to the Electronic Control Module (ECM) is greater than 4.CID 0110 .04 8 Volt DC Supply short to ground System Response: The alarm output is activated. . Possible Performance Effect: The engine performance is not affected.CID 0109 .03 8 Volt DC Supply short to +batt • 41 .75 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “PWM Sensor” Results: i01691110 MID 036 . This disables the engine protection for low coolant temperature and high coolant temperature. The code is logged. The code is logged. • OK – STOP. The monitoring of the coolant temperature is disabled. i01728446 MID 036 .03 8 Volt DC Supply short to +batt • 41 .FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. System Response: The ECM assumes the last valid value for engine coolant temperature. neither of the following diagnostic codes are active: • 41 . Additionally.8 VDC for at least five seconds.FMI 03 Coolant Outlet Pressure open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The duty cycle of the pressure sensor for the outlet of the engine coolant is greater than the maximum limit. 76 Troubleshooting Section The fuel is shut off. the fuel is shut off. . The shutdown output is activated. This disables the engine protection for low coolant temperature and high coolant temperature. the engine is shut down. the engine is shut down.CID 0145 . The code is logged. The shutdown output is activated. The fuel is shut off.2 VDC for at least five seconds.CID 0110 . • OK – STOP.FMI 04 12 Volt DC Power Supply short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The electronic control module has been powered up for at least five seconds. The code is logged. The 12 volt sensor supply voltage becomes greater than 14. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: i01728448 MID 036 .FMI 03 12 Volt DC Power Supply short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The electronic control module has been powered up for at least five seconds. The code is logged. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: MID 036 . Possible Performance Effect: The engine is shut down or the engine will not start. System Response: The ECM assumes the last valid value for the engine coolant temperature. The shutdown output is activated. Possible Performance Effect: Since the engine protection is disabled.FMI 04 Engine Coolant Temperature short to ground SMCS Code: 1906-038 Conditions Which Generate This Code: The signal from the engine coolant temperature sensor to the Electronic Control Module (ECM) is less than 0. The shutdown output is activated. Possible Performance Effect: Since the engine protection is disabled. System Response: If the engine is running. System Response: If the engine is running. Troubleshooting: This condition indicates the possibility of an open circuit or a short circuit. The 12 volt sensor supply voltage becomes less than 11 VDC for at least one second. • OK – STOP. the fuel is shut off.2 V for at least one second. The monitoring of the coolant temperature is disabled.CID 0145 . i01728447 Possible Performance Effect: The engine is shut down or the engine will not start. i01728449 MID 036 . Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. 8 VDC for at least five seconds.060 seconds. The code is logged. The air/fuel ratio control cannot compensate for the inlet air temperature. The engine will shut down.03 5 Volt Sensor DC Power Supply short to +batt • 262 -04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the inlet manifold air temperature. Troubleshooting: Perform the following diagnostic procedure: “Electrial Power Supply” Results: • OK – STOP. and/or complete shutdowns. The engine is running. the engine may experience speed burps. Note: If battery voltage is lost and the voltage does not return. . Additionally. Possible Performance Effect: The engine is shut down. System Response: The alarm output is activated. intermittent shutdowns. the ECM will not log this diagnostic code. i01728450 MID 036 . • OK – STOP. The voltage returns to the normal range within 0. The shutdown output is activated.CID 0172 . This disables the engine protection for high inlet manifold air temperature. However.77 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: i01728451 MID 036 .015 seconds. The fuel is shut off.FMI 03 Intake Manifold Air Temp open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. Possible Performance Effect: The intermittent problem may not affect engine operation. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • The battery voltage is less than 6 VDC for a minimum of 0. Troubleshooting: The condition indicates a possible open circuit or a short circuit to a positive voltage source. The signal from the inlet manifold temperature sensor to the ECM is greater than 4. Either of the two following conditions occur: The Electronic Control Module (ECM) has been powered for at least five seconds. • There are three voltage readings of less than 6 VDC within 7 seconds. The code is logged.CID 0168 FMI 02 System Voltage intermittent/erratic SMCS Code: 1401-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered for at least 5 seconds. The monitoring of the inlet manifold air temperature is disabled. neither of the following diagnostic codes are active: • 262 . FMI 03 Engine Oil Temperature open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the Electronic Control Module (ECM) is greater than 4. The shutdown output is activated. Possible Performance Effect: Since engine protection is disabled.03 5 Volt Sensor DC Power Supply short to +batt • 262 . the engine is shut down. The code is logged. Additionally. Additionally. neither of the following diagnostic codes are active: MID 036 .03 5 Volt Sensor DC Power Supply short to +batt • 262 . Also. Troubleshooting: • 262 . The monitoring of the engine oil temperature is disabled. the monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled.78 Troubleshooting Section i01728453 i01728456 MID 036 . This disables the engine protection for high inlet manifold air temperature. Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. • OK – STOP.CID 0172 . The code is logged. This disables the engine protection for both parameters.FMI 04 Intake Manifold Air Temp short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The signal from the inlet manifold temperature sensor to the Electronic Control Module (ECM) is less than 0. neither of the following diagnostic codes are active: • 262 . The air/fuel ratio control cannot compensate for the inlet air temperature. .04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the engine oil temperature. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: The condition indicates a possible open circuit or a short circuit to a positive voltage source.2 VDC for at least five seconds. The fuel is shut off.CID 0175 .8 VDC for at least five seconds. The monitoring of the inlet manifold air temperature is disabled. The shutdown output is activated.04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the inlet manifold air temperature. monitoring for a high difference in temperature between the engine oil and the engine coolant is disabled. The code is logged. the engine is shut down.CID 0261 . neither of the following diagnostic codes are active: • 262 . This disables the engine protection for both parameters. The monitoring of the engine oil temperature is disabled.FMI 13 Engine Timing calibration required SMCS Code: 1905-038 Conditions Which Generate This Code: The timing calibration has not been performed. The shutdown indicator is activated. Possible Performance Effect: Since engine protection is disabled. All other diagnostic codes for the 5 volt analog sensors are disabled while this diagnostic code is active. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • OK – STOP. The shutdown output is activated. If the condition is not corrected. The code is logged.FMI 04 Engine Oil Temperature short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The signal from the engine oil temperature sensor to the Electronic Control Module (ECM) is less than 0. . Also. Possible Performance Effect: The timing will be advanced or the timing will be retarded.Calibrate” Results: MID 036 .03 5 Volt Sensor DC Power Supply short to +batt • 262 . Additionally. engine damage will result.FMI 03 5 Volt Sensor DC Power Supply short to +batt SMCS Code: 1408-038-NS Conditions Which Generate This Code: The supply voltage from the Electronic Control Module (ECM) to the sensors for the following parameters is exceeding the normal level: • Inlet manifold air temperature • Engine oil temperature • Filtered engine oil pressure • Unfiltered engine oil pressure System Response: All of the inputs to the ECM for the 5 volt analog sensors assume default values. This indicates that the sensors are not operating due to an active diagnostic code. i01636386 MID 036 . Perform the following diagnostic procedure: “Engine Speed/Timing Sensor . Troubleshooting: Calibrate the engine speed/timing sensor.2 VDC for at least five seconds. • OK – STOP.04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for the engine oil temperature.CID 0175 . Either condition will result in reduced engine performance.79 Troubleshooting Section i01728458 System Response: The alarm output is activated. The “Status” screen of Caterpillar Electronic Technician (ET) indicates a “Sensor Supply Fault” for each sensor. The code is logged. i01728460 MID 036 .CID 0262 . CID 0301 . the engine is shut down. The “Status” screen of the Caterpillar Electronic Technician (ET) indicates a “Sensor Supply Fault” for each sensor.FMI 04 5 Volt Sensor DC Power Supply short to ground SMCS Code: 1408-038-NS Conditions Which Generate This Code: The supply voltage from the Electronic Control Module (ECM) to the sensors for the following parameters is less than the normal level: MID 036 . Possible Performance Effect: Since engine protection is disabled. Possible Performance Effect: The cylinder will misfire. i01728462 • OK – STOP.FMI 05 Cylinder 1 . the engine is shut down. The code is logged. . System Response: The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. This indicates that the sensors are not operating due to an active diagnostic code. Troubleshooting: One of the following conditions is the source of the diagnostic code: • Inlet manifold air temperature • Engine oil temperature • Filtered engine oil pressure • Unfiltered engine oil pressure System Response: All of the inputs to the ECM for the 5 volt analog sensors assume default values. • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the electronic control module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.CID 0262 . Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results: • OK – STOP. All other diagnostic codes for the 5 volt analog sensors are disabled while this diagnostic code is active. Troubleshooting: Perform the following diagnostic procedure: “+5V Sensor Voltage Supply” Results: Troubleshooting: The condition indicates a possible short circuit to ground or a short circuit between the sensor supply and the return. The shutdown output is activated.80 Troubleshooting Section Possible Performance Effect: Since engine protection is disabled. i01728464 MID 036 . The code is logged. The code is logged.CID 0302 .FMI 05 Cylinder 2 .FMI 06 Cylinder 2 .Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. The code is logged. • There is an internal failure of the Electronic Control Module (ECM). Possible Performance Effect: The cylinder will misfire. • The wiring from the circuit driver for the transformer to the coil has a short circuit. MID 036 . System Response: The alarm output is activated. • There is a short circuit within the transformer. System Response: The alarm output is activated. Possible Performance Effect: The cylinder will misfire. i01728469 The cylinder will misfire.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0302 . System Response: The alarm output is activated. • There is an internal failure of the Electronic Control Module (ECM).81 Troubleshooting Section i01728465 Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . The code is logged.CID 0301 .FMI 06 Cylinder 1 . Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. i01728470 One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” . Troubleshooting: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: • There is a short circuit within the transformer. • There is a short circuit within the transformer. System Response: The alarm output is activated.CID 0304 . . i01728471 MID 036 . MID 036 . System Response: The alarm output is activated. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. • There is an internal failure of the Electronic Control Module (ECM). Possible Performance Effect: The cylinder will misfire. The code is logged. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.FMI 05 Cylinder 4 .Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.FMI 05 Cylinder 3 . i01728474 • OK – STOP. The code is logged.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.CID 0303 .FMI 06 Cylinder 3 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit.82 Troubleshooting Section Results: i01728473 • OK – STOP. The code is logged.CID 0303 . Possible Performance Effect: The cylinder will misfire. System Response: The alarm output is activated. Possible Performance Effect: The cylinder will misfire. . The code is logged.FMI 06 Cylinder 4 . The code is logged. Troubleshooting: MID 036 . System Response: The alarm output is activated. System Response: • OK – STOP.83 Troubleshooting Section Possible Performance Effect: The cylinder will misfire. transformer to the coil has a short circuit. Possible Performance Effect: The cylinder will misfire.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0305 . Troubleshooting: One of the following conditions is the source of the diagnostic code: One of the following conditions is the source of the diagnostic code: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • The wiring from the circuit driver for the • OK – STOP.CID 0304 .FMI 05 Cylinder 5 . i01728478 • An internal failure of the Electronic Control Module (ECM) Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 . • There is a short circuit within the transformer. Troubleshooting: One of the following conditions is the source of the diagnostic code: • There is an internal failure of the Electronic Control Module (ECM). i01728475 The alarm output is activated. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer • OK – STOP.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. • There is a short circuit within the transformer. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .84 Troubleshooting Section i01728479 Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . i01728480 The alarm output is activated.CID 0305 . i01728481 • The wiring from the circuit driver for the transformer to the coil has a short circuit.FMI 06 Cylinder 6 .CID 0306 .Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. • There is a short circuit within the transformer. System Response: The alarm output is activated. • The wiring from the circuit driver for the transformer to the coil has a short circuit. The code is logged. System Response: The alarm output is activated.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer • An internal failure of the Electronic Control Module (ECM) Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. The code is logged. Possible Performance Effect: The cylinder will misfire. • There is an internal failure of the Electronic Control Module (ECM). System Response: • OK – STOP. The code is logged.FMI 06 Cylinder 5 .CID 0306 .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire.FMI 05 Cyinder 6 . • There is a short circuit within the transformer. System Response: The alarm output is activated. Troubleshooting: One of the following conditions is the source of the diagnostic code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.CID 0308 . Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: i01728485 MID 036 . The code is logged. • There is an internal failure of the Electronic Control Module (ECM). Possible Performance Effect: The cylinder will misfire. • OK – STOP. . The code is logged.85 Troubleshooting Section • There is an internal failure of the Electronic Control Module (ECM).FMI 05 Cylinder 8 .FMI 05 Cylinder 7 . i01728484 MID 036 .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. The code is logged. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • OK – STOP. i01728490 • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 .CID 0307 .CID 0307 . Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit. System Response: The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.FMI 06 Cylinder 7 . Possible Performance Effect: The cylinder will misfire. • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: The cylinder will misfire.FMI 05 Cylinder 9 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. • There is a short circuit within the transformer.FMI 06 Cylinder 8 .CID 0308 . • There is an internal failure of the Electronic Control Module (ECM). i01728493 Possible Performance Effect: The cylinder will misfire. The code is logged.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” . The code is logged. • The wiring from the circuit driver for the transformer to the coil has a short circuit. System Response: The alarm output is activated. System Response: The alarm output is activated. i01728496 • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) MID 036 .Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .86 Troubleshooting Section Troubleshooting: One of the following conditions is the source of the diagnostic code: Results: • OK – STOP.CID 0309 . • There is an internal failure of the Electronic Control Module (ECM). • The wiring from the circuit driver for the transformer to the coil has a short circuit. Troubleshooting: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Possible Performance Effect: • There is a short circuit within the transformer.FMI 05 Cylinder 10 . MID 036 .CID 0310 . Possible Performance Effect: The cylinder will misfire. System Response: The alarm output is activated. The code is logged. System Response: The alarm output is activated. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . • There is a short circuit within the transformer. i01728508 One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit. i01728504 The cylinder will misfire. The code is logged.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. The code is logged. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. System Response: The alarm output is activated.FMI 06 Cylinder 9 .CID 0310 .FMI 06 Cylinder 10 .87 Troubleshooting Section i01728499 Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire. • There is an internal failure of the Electronic Control Module (ECM).CID 0309 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . Possible Performance Effect: The cylinder will misfire. • There is a short circuit within the transformer.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.FMI 06 Cylinder 11 . i01728515 • OK – STOP.88 Troubleshooting Section Results: i01728513 • OK – STOP.CID 0311 . Possible Performance Effect: The cylinder will misfire.CID 0311 . • There is an internal failure of the Electronic Control Module (ECM). Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. . MID 036 .CID 0312 . The code is logged.FMI 05 Cylinder 12 . i01728512 MID 036 . The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit. System Response: The alarm output is activated. System Response: The alarm output is activated. The code is logged. System Response: The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.FMI 05 Cylinder 11 . FMI 05 Cylinder 13 . Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer • OK – STOP.89 Troubleshooting Section Possible Performance Effect: The cylinder will misfire. Possible Performance Effect: The cylinder will misfire. • There is a short circuit within the transformer. System Response: • OK – STOP. i01728518 The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. The code is logged.CID 0312 .CID 0313 . System Response: The alarm output is activated.FMI 06 Cylinder 12 . Troubleshooting: One of the following conditions is the source of the diagnostic code: One of the following conditions is the source of the diagnostic code: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • The wiring from the circuit driver for the • OK – STOP. transformer to the coil has a short circuit. . i01728523 • An internal failure of the Electronic Control Module (ECM) Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 . Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: • There is an internal failure of the Electronic Control Module (ECM). The code is logged.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit. Troubleshooting: MID 036 . Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.90 Troubleshooting Section i01728527 Possible Performance Effect: The cylinder will misfire. .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.FMI 05 Cylinder 14 . • There is an internal failure of the Electronic Control Module (ECM). Possible Performance Effect: The cylinder will misfire.FMI 06 Cylinder 13 . i01728535 • The wiring from the circuit driver for the transformer to the coil has a short circuit. The code is logged. Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 . Troubleshooting: One of the following conditions is the source of the diagnostic code: MID 036 .CID 0314 . System Response: The alarm output is activated. • There is a short circuit within the transformer. • There is a short circuit within the transformer. The code is logged.CID 0314 . Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 .Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.CID 0313 . System Response: • OK – STOP. System Response: The alarm output is activated. • The wiring from the circuit driver for the transformer to the coil has a short circuit. i01728531 The alarm output is activated. Troubleshooting: One of the following conditions is the source of the diagnostic code: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer • An internal failure of the Electronic Control Module (ECM) Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. The code is logged.FMI 06 Cylinder 14 . The code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the diagnostic code: The path for the circuit driver of the transformer is diagnosed with a short circuit. i01728548 • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: MID 036 . . • There is an internal failure of the Electronic Control Module (ECM). Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: i01728545 MID 036 . System Response: The alarm output is activated. The code is logged.FMI 05 Cylinder 16 . i01728539 MID 036 . Possible Performance Effect: The cylinder will misfire.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP.FMI 06 Cylinder 15 . Troubleshooting: One of the following conditions is the source of the diagnostic code: • The wiring from the circuit driver for the transformer to the coil has a short circuit.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit.CID 0316 .91 Troubleshooting Section • There is an internal failure of the Electronic Control Module (ECM).CID 0315 . Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) • OK – STOP. Possible Performance Effect: The cylinder will misfire. The code is logged. System Response: The alarm output is activated.Transformer Primary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed with an open circuit. • There is a short circuit within the transformer. • OK – STOP.FMI 05 Cylinder 15 . System Response: The alarm output is activated.CID 0315 . Possible Performance Effect: The cylinder will misfire.FMI 06 Cylinder 16 . Possible Performance Effect: • 145 . The code is logged. The engine speed is greater than 150 rpm. System Response: The alarm output is activated.Transformer Primary short SMCS Code: 1901-038 Conditions Which Generate This Code: The path for the circuit driver of the transformer is diagnosed with a short circuit.5 seconds.03 12 Volt DC Power Supply short to +batt • 145 . Troubleshooting: One of the following conditions is the source of the diagnostic code: If the engine is running. However. • There is an internal failure of the Electronic Control Module (ECM). If the engine is not running.04 is activated during the 1. the engine will be shut down.FMI 03 Speed/Timing Sensor short to +batt SMCS Code: 1912-038 Conditions Which Generate This Code: To activate this code. The code is logged. the engine will not start. then the 0320 .03 code is deactivated. i01728552 MID 036 . The pattern of the timing reference gear is lost for more than one second.03 or 145 .92 Troubleshooting Section Troubleshooting: One of the following conditions is the source of the diagnostic code: Results: • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” • OK – STOP.CID 0320 . Neither of the following diagnostic codes are active: • An internal failure of the Electronic Control Module Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit” Results: • OK – STOP. the ignition signals stop.03 code is set after the pattern of the timing reference gear is lost for more than one second. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: • The wiring from the circuit driver for the transformer to the coil has a short circuit.5 seconds before the code is activated.CID 0316 . System Response: If the engine is running.04 12 Volt DC Power Supply short to ground Note: The 0320 . . the logic hesitates for 1. all of the following conditions must occur: The Electronic Control Module (ECM) has been powered for at least one second. The shutdown output is activated. i01728554 • A broken circuit driver’s wire for the transformer • A broken return wire for the transformer • An open circuit within the primary winding of the transformer (ECM) MID 036 . If a 145 . • There is a short circuit within the transformer. Troubleshooting: i01728557 MID 036 . the engine will not start. The engine speed is greater than 150 rpm. The code is logged. System Response: If the engine is running. the ignition signals stop. Troubleshooting: Perform the following diagnostic procedure: “Engine Speed/Timing Sensor” Results: MID 036 . reverse rotation is detected. For example.CID 0323 . • OK – STOP.CID 0324 . System Response: The ECM limits the current for the alarm output to 0. Note: This diagnostic condition cannot be detected when the alarm output is OFF. Possible Performance Effect: If the engine is running. The code is logged.FMI 03 Shutdown Lamp short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the shutdown output.93 Troubleshooting Section i01728556 System Response: The ECM limits the current for the shutdown output to 0. If the engine is not running. . i01728563 • The pattern for the timing reference gear is lost for less than one second. The shutdown output is activated. Possible Performance Effect: The engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: MID 036 .CID 0320 . The code is logged. Possible Performance Effect: The engine operation is not affected. • OK – STOP.3 amperes. One of the following two conditions occurs: • An invalid pattern for the timing reference gear is detected. Note: This diagnostic condition cannot be detected when the shutdown output is OFF. Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: • OK – STOP.FMI 08 Engine Speed/Timing signal abnormal SMCS Code: 1912-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) must be powered for at least one second.FMI 03 Warning Lamp short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the alarm output.3 amperes. the engine will be shut down. FMI 05 Pre-Lube Relay open circuit SMCS Code: 1319-038 Conditions Which Generate This Code: An open circuit or a short circuit to the +Battery side is detected while the output from the Electronic Control Module (ECM) to the prelube relay is OFF. Possible Performance Effect: If the engine is running. Troubleshooting: Perform the following diagnostic procedure: “ECM Output Circuit (Prelubrication Oil Pump)” Results: MID 036 .CID 0338 . System Response: The ECM will continue to attempt to energize the relay. “Start”. The alarm output is activated. The code is logged. The alarm output is activated. The code is logged. “Stop”.CID 0338 . This indicates an open circuit in the harness or the solenoid. Possible Performance Effect: The prelubrication will probably be disabled.FMI 02 Incorrect ECS Switch inputs SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects an invalid combination on these inputs from the Engine Control Switch (ECS): “Switched +Battery”. System Response: An internal resistor rises to the +Battery side when no electrical load is present. Note: This diagnostic condition can only be detected by the ECM when the output for the prelube relay is OFF. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is still OPEN. i01728575 MID 036 . i01728581 MID 036 .CID 0336 . Troubleshooting: Perform the following diagnostic procedure: “Electrical Power Supply” Results: • OK – STOP.FMI 06 Pre-Lube Relay short to ground SMCS Code: 1319-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the output to the prelube relay. System Response: The shutdown output is activated. The code is logged. This indicates a possible short circuit to the −Battery side. Note: This diagnostic condition can only be detected by the ECM when the output for the prelube relay is ON. . and “Auto”.94 Troubleshooting Section i01728570 Possible Performance Effect: The prelubrication will probably be disabled. Troubleshooting: Perform the following diagnostic procedure: “ECM Output Circuit (Prelubrication Oil Pump)” Results: • OK – STOP. The output is normally OFF when the engine control switch is in the STOP position and/or when the prelube pressure switch is CLOSED. the engine will be shut down. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Prelubrication System” Results: • There is a problem with the transformer’s ground. The oil pressure that is measured from the engine oil pressure sensor is greater than 50 kPa (7. System Response: The Electronic Control Module (ECM) normally monitors the prelube pressure switch. • The spark plug has internal damage or an open circuit. Possible Performance Effect: The cylinder will misfire.FMI 05 Cylinder 1 .95 Troubleshooting Section i01728588 System Response: The status of the transformer’s secondary output is set to 120 percent. MID 036 . the output to the starting motor will not be energized and the engine will not start. If an “E233 (3) Low Engine Prelube Pressure” event is active. . Possible Performance Effect: The prelubrication will probably be disabled.FMI 06 Cylinder 1 .25 psi). The output to the prelube relay remains energized until the engine control switch is turned to the STOP position. • The winding of the transformer’s secondary circuit is open. • The spark plug gap is too wide. System Response: The status of the transformer’s secondary output is set to zero percent.Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: i01685945 • OK – STOP. The code is logged. The alarm output is activated and the code is logged. The alarm output is activated and the code is logged.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Troubleshooting: One of the following conditions is the source of the problem: MID 036 . Possible Performance Effect: The cylinder will misfire.CID 0401 . The transformer’s secondary circuit is diagnosed with a short circuit. • There is a problem with the connection to the spark plug’s terminal post. In this case.FMI 05 Engine Pre-lube Pressure Switch open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The prelube pressure switch is OPEN. The alarm output is activated.CID 0401 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. i01632184 MID 036 . the engine oil pressure sensor will be monitored. This determines if the prelube pump is supplying oil to the engine.CID 0339 . • The spark plug gap is closed. The alarm output is activated and the code is logged.Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • There is a problem with the transformer’s ground.CID 0402 .FMI 06 Cylinder 2 . • OK – STOP. Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit.96 Troubleshooting Section Troubleshooting: One of the following conditions is the source of the problem: • The spark plug gap is too wide. i01685951 MID 036 . • The winding of the transformer’s secondary circuit is shorted. The alarm output is activated and the code is logged. System Response: The status of the transformer’s secondary output is set to 120 percent. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • The spark plug is fouled. • The spark plug gap is closed. i01632192 MID 036 .CID 0402 . • There is a problem with the connection to the spark plug’s terminal post.FMI 05 Cylinder 2 . Possible Performance Effect: The cylinder will misfire. circuit. The cylinder will misfire. • The winding of the transformer’s secondary circuit is open. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. • The winding of the transformer’s secondary circuit Troubleshooting: One of the following conditions is the source of the problem: is shorted. System Response: The status of the transformer’s secondary output is set to zero percent. • The spark plug has internal damage or an open . Possible Performance Effect: The transformer’s secondary circuit is diagnosed with an open circuit. Possible Performance Effect: The cylinder will misfire. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. • The spark plug has internal damage or an open circuit.CID 0404 .FMI 05 Cylinder 3 . Troubleshooting: One of the following conditions is the source of the problem: MID 036 . i01685958 • There is a problem with the transformer’s ground. • The spark plug gap is too wide. The alarm output is activated and the code is logged.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 05 Cylinder 4 . The alarm output is activated and the code is logged. • The winding of the transformer’s secondary circuit is shorted.FMI 06 Cylinder 3 . • There is a problem with the connection to the spark plug’s terminal post. i01632203 Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: MID 036 . • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open.CID 0403 .97 Troubleshooting Section i01685955 System Response: The status of the transformer’s secondary output is set to zero percent. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • The spark plug gap is closed. The alarm output is activated and the code is logged. . System Response: The status of the transformer’s secondary output is set to 120 percent. • The winding of the transformer’s secondary circuit is open.Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. MID 036 .CID 0403 . • The winding of the transformer’s secondary circuit is open. However. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. i01685960 • The spark plug has internal damage or an open • The spark plug gap is too wide. • The spark plug has internal damage or an open circuit. the engine will probably misfire.FMI 05 Cylinder 5 . circuit. • The spark plug gap is too wide. This will cause the engine to run rough.98 Troubleshooting Section • There is a problem with the connection to the spark plug’s terminal post.Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. Troubleshooting: One of the following conditions is the source of the problem: The status of the transformer’s secondary output is set to 120 percent. • OK – STOP. i01632257 MID 036 . • The spark plug gap is closed.CID 0404 . Possible Performance Effect: Generation of the diagnostic code does not affect engine performance.CID 0405 . System Response: • OK – STOP.FMI 06 Cylinder 4 . • There is a problem with the connection to the spark plug’s terminal post. System Response: The status of the transformer’s secondary output is set to zero percent. • The winding of the transformer’s secondary circuit is shorted. The alarm output is activated and the code is logged. The engine may shut down. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . The alarm output is activated and the code is logged.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Possible Performance Effect: The cylinder will misfire. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • The spark plug is fouled. • The spark plug has internal damage or an open circuit. Troubleshooting: One of the following conditions is the source of the problem: MID 036 .Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. • The spark plug gap is closed. • The spark plug gap is closed. • OK – STOP. • The winding of the transformer’s secondary circuit is shorted.FMI 05 Cylinder 6 . Troubleshooting: One of the following conditions is the source of the problem: MID 036 . The alarm output is activated and the code is logged.CID 0406 .Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent.CID 0405 . . • The winding of the transformer’s secondary circuit is open.CID 0406 . Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. i01685964 System Response: The status of the transformer’s secondary output is set to zero percent. • The spark plug is fouled.99 Troubleshooting Section i01632261 Possible Performance Effect: The cylinder will misfire. The alarm output is activated and the code is logged.FMI 06 Cylinder 6 .Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. Possible Performance Effect: The cylinder will misfire. System Response: The status of the transformer’s secondary output is set to 120 percent. • There is a problem with the connection to the spark plug’s terminal post. i01632269 • The spark plug is fouled. • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.FMI 06 Cylinder 5 . Troubleshooting: One of the following conditions is the source of the problem: The transformer’s secondary circuit is diagnosed with a short circuit. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01632278 MID 036 . System Response: The status of the transformer’s secondary output is set to zero percent. • OK – STOP.Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. i01685988 MID 036 . Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 05 Cylinder 7 . The alarm output is activated and the code is logged.FMI 05 Cylinder 8 .100 Troubleshooting Section • The winding of the transformer’s secondary circuit is shorted. • The winding of the transformer’s secondary circuit is open. Possible Performance Effect: The cylinder will misfire. • The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 . The alarm output is activated and the code is logged.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit.FMI 06 Cylinder 7 .CID 0407 .CID 0408 . i01685995 • There is a problem with the connection to the spark plug’s terminal post. Possible Performance Effect: The cylinder will misfire. System Response: The status of the transformer’s secondary output is set to 120 percent. • OK – STOP. circuit. • The spark plug has internal damage or an open • The spark plug gap is too wide. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • There is a problem with the transformer’s ground.CID 0407 . . Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. The alarm output is activated and the code is logged. • The winding of the transformer’s secondary circuit is open. MID 036 . • The spark plug has internal damage or an open circuit. The alarm output is activated and the code is logged. System Response: • The spark plug gap is too wide. • OK – STOP. The cylinder will misfire. • There is a problem with the connection to the spark plug’s terminal post. • The spark plug gap is closed. System Response: The status of the transformer’s secondary output is set to zero percent. • The winding of the transformer’s secondary circuit is open. Possible Performance Effect: The cylinder will misfire. The alarm output is activated and the code is logged. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit Troubleshooting: One of the following conditions is the source of the problem: is shorted.CID 0408 . Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP.FMI 06 Cylinder 8 . Possible Performance Effect: The cylinder will misfire. i01686000 • There is a problem with the connection to the spark plug’s terminal post. circuit. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • There is a problem with the transformer’s ground.Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. The status of the transformer’s secondary output is set to 120 percent. • The spark plug has internal damage or an open .101 Troubleshooting Section System Response: The status of the transformer’s secondary output is set to 120 percent. i01632318 MID 036 .CID 0409 . Possible Performance Effect: Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled.FMI 05 Cylinder 9 . 102 Troubleshooting Section • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01686011 MID 036 - CID 0410 - FMI 05 Cylinder 10 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. i01632336 MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • There is a problem with the connection to the spark plug’s terminal post. • The spark plug has internal damage or an open circuit. • The spark plug is fouled. • The spark plug gap is closed. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. • OK – STOP. 103 Troubleshooting Section i01632343 Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: MID 036 - CID 0410 - FMI 06 Cylinder 10 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • There is a problem with the connection to the spark plug’s terminal post. • The spark plug has internal damage or an open circuit. • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. i01632349 • The spark plug is fouled. • The spark plug gap is closed. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 - CID 0411 - FMI 06 Cylinder 11 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. • OK – STOP. i01686017 System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: MID 036 - CID 0411 - FMI 05 Cylinder 11 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. • The spark plug is fouled. • The spark plug gap is closed. 104 Troubleshooting Section • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01632360 MID 036 - CID 0412 - FMI 06 Cylinder 12 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. i01686022 MID 036 - CID 0412 - FMI 05 Cylinder 12 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled. • The spark plug gap is closed. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • OK – STOP. i01686029 • There is a problem with the connection to the spark plug’s terminal post. circuit. • The spark plug has internal damage or an open • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 - CID 0413 - FMI 05 Cylinder 13 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. • OK – STOP. 105 Troubleshooting Section System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: Troubleshooting: One of the following conditions is the source of the problem: • The spark plug is fouled. • The spark plug gap is closed. The cylinder will misfire. • The winding of the transformer’s secondary circuit Troubleshooting: One of the following conditions is the source of the problem: is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • OK – STOP. i01686036 • There is a problem with the connection to the spark plug’s terminal post. • The spark plug has internal damage or an open circuit. MID 036 - CID 0414 - FMI 05 Cylinder 14 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. i01632384 MID 036 - CID 0413 - FMI 06 Cylinder 13 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • There is a problem with the connection to the spark plug’s terminal post. circuit. • The spark plug has internal damage or an open 106 Troubleshooting Section • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: i01686039 MID 036 - CID 0415 - FMI 05 Cylinder 15 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. i01632392 MID 036 - CID 0414 - FMI 06 Cylinder 14 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • There is a problem with the connection to the spark plug’s terminal post. • The spark plug has internal damage or an open circuit. • The spark plug is fouled. • The spark plug gap is closed. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. • OK – STOP. 107 Troubleshooting Section i01632402 Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: MID 036 - CID 0415 - FMI 06 Cylinder 15 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: • There is a problem with the transformer’s ground. • The winding of the transformer’s secondary circuit is open. • There is a problem with the connection to the spark plug’s terminal post. • The spark plug has internal damage or an open circuit. • The spark plug gap is too wide. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: • OK – STOP. i01632407 • The spark plug is fouled. • The spark plug gap is closed. • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: MID 036 - CID 0416 - FMI 06 Cylinder 16 - Transformer Secondary short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with a short circuit. • OK – STOP. i01686042 System Response: The status of the transformer’s secondary output is set to zero percent. The alarm output is activated and the code is logged. Possible Performance Effect: The cylinder will misfire. Troubleshooting: One of the following conditions is the source of the problem: MID 036 - CID 0416 - FMI 05 Cylinder 16 - Transformer Secondary open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed with an open circuit. System Response: The status of the transformer’s secondary output is set to 120 percent. The alarm output is activated and the code is logged. • The spark plug is fouled. • The spark plug gap is closed. 108 Troubleshooting Section • The winding of the transformer’s secondary circuit is shorted. Perform the following diagnostic procedure: “Ignition Transformers Secondary Circuit and Spark Plugs” Results: Note: This diagnostic condition can only be detected by the ECM when the output for the starting motor relay is OFF. The output is normally OFF when the engine control switch is in the STOP position or when the crank terminate relay is energized. System Response: An internal resistor rises to the +Battery side when no electrical load is present. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will be unable to crank. Troubleshooting: The harness or the relay probably has an open circuit. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results: • OK – STOP. i01728635 MID 036 - CID 0443 - FMI 03 Crank Terminate Relay short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the crank terminate relay. Note: This diagnostic condition cannot be detected when the output for the crank terminate relay is OFF. The output is normally OFF when the engine control switch is in the STOP position. System Response: The ECM will limit the current for the crank terminate relay to 0.3 amperes. The alarm output is activated. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: • OK – STOP. i01728642 MID 036 - CID 0444 - FMI 06 Start Relay short to ground SMCS Code: 1426-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the output of the starting motor relay. Note: This diagnostic condition can only be detected by the ECM when the output for the starting motor relay is ON. The output is normally ON when the engine control switch is turned from the STOP position to the START position. The output is ON until the crank terminate relay is energized. System Response: The ECM will continue to attempt to energize the relay. The alarm output is activated. The code is logged. Possible Performance Effect: The engine will probably be unable to crank. • OK – STOP. i01728639 MID 036 - CID 0444 - FMI 05 Start Relay open circuit SMCS Code: 1426-038 Conditions Which Generate This Code: The output from the Electronic Control Module (ECM) for the starting motor relay is OFF. An open circuit or a short circuit to the +Battery is detected. Possible Performance Effect: The default value for the desired engine speed is equal to the “Minimum Engine High Idle Speed” that is programmed on the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). . System Response: The ECM will limit the current to 0. Possible Performance Effect: The default value for the desired engine speed is equal to the “Minimum Engine High Idle Speed” that is programmed on the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). i01728646 MID 036 . i01728659 MID 036 .FMI 03 Run Relay short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) detects excessive current for the run relay. The “Status” screen of the Caterpillar Electronic Technician (ET) will display “Relay Fault”.109 Troubleshooting Section Troubleshooting: This condition indicates an short circuit in the harness or the relay. The code is logged.CID 0445 .3 amperes.CID 0524 . The alarm output is activated. • OK – STOP. Perform the following diagnostic procedure: “ECM Output Circuit (Starting Motor)” Results: System Response: When the “Idle/Rated” switch is in the “Rated” position. The current to the ECM for the desired speed input is less than 2 mA for more than five seconds.FMI 03 Desired Engine Speed Sensor short to +batt SMCS Code: 1907-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. The code is logged.20 mA)” Results: • OK – STOP. the ECM assumes a default value for the desired engine speed. The output is normally OFF when the engine control switch is in the STOP position. The current to the ECM for the desired speed input is greater than 22 mA for more than five seconds. The alarm output is activated. Troubleshooting: The diagnostic code is generated by one of the following conditions: • OK – STOP. The code is logged. i01728651 MID 036 . Troubleshooting: Perform the following diagnostic procedure: “ECM Status Indicator Output” Results: • A short circuit to the +Battery side • A short circuit to ground Perform the following diagnostic procedure: “Desired Speed Input (4 .CID 0524 . System Response: When the “Idle/Rated” switch is in the “Rated” position. Note: This diagnostic condition cannot be detected when the output for the “Run” relay is OFF.FMI 04 Desired Engine Speed Sensor short to ground SMCS Code: 1907-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. the ECM assumes a default value for the desired engine speed. i01728675 The ECM assumes the last valid value for unfiltered engine oil pressure.CID 0542 .04 5 Volt Sensor DC Power Supply short to ground System Response: • OK – STOP. The alarm output is activated. . Possible Performance Effect: Engine operation is not affected. The code is logged. neither of the following diagnostic codes are active: • OK – STOP. Monitoring for restriction of the oil filters is disabled. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: • 262 .FMI 09 Unable to communicate with ITSM SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for at least five seconds. None of the messages have been received by the ECM.03 5 Volt Sensor DC Power Supply short to +batt MID 036 . Also. Troubleshooting: Perform the following diagnostic procedure: “Analog Sensor Signal” Results: MID 036 .2 VDC for at least five seconds.FMI 03 Unfiltered Engine Oil Pressure open/short to +batt SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is greater than 4.CID 1042 . The Integrated Temperature Sensing Module (ITSM) has sent ten consecutive messages to the ECM via the CAT Data Link. neither of the following diagnostic codes are active: • 262 . • OK – STOP. The alarm output is activated. Also.03 5 Volt Sensor DC Power Supply short to +batt • 262 .20 mA)” Results: MID 036 .8 VDC for at least five seconds. The code is logged.CID 0542 .FMI 04 Unfiltered Engine Oil Pressure short to ground SMCS Code: 1924-038 Conditions Which Generate This Code: The signal to the Electronic Control Module (ECM) from the sensor for unfiltered engine oil pressure is less than 0. i01728660 • 262 . Monitoring for restriction of the oil filters is disabled.04 5 Volt Sensor DC Power Supply short to ground System Response: The ECM assumes the last valid value for unfiltered engine oil pressure.110 Troubleshooting Section Troubleshooting: The diagnostic code is generated by one of the following conditions: i01728669 • An open circuit or a short circuit to ground • An open circuit or a short circuit to the +Battery Perform the following diagnostic procedure: “Desired Speed Input (4 . The code is logged.CID 1086 . The alarm output is activated. System Response: Compensation for fuel quality is disabled.Calibrate” Results: • OK – STOP. Troubleshooting: Calibrate the oxygen sensor. The code is logged. The code is logged. Perform the following diagnostic procedure: “Oxygen Sensor .111 Troubleshooting Section Note: This diagnostic code is logged by the ECM only. This code is not activated or logged by the ITSM. i01636406 MID 036 . • OK – STOP. The diagnostic code remains active until the duty cycle of the oxygen sensor is greater than 20 percent for at least five seconds.CID 1086 . The following diagnostic code is NOT active: 1088 .06 Oxygen Sensor Power Supply short to ground. Troubleshooting: A duty cycle of 10 to 20 percent is the default output when a load for the heater of the oxygen sensor is NOT detected by the oxygen buffer.FMI 13 Oxygen Sensor Element calibration required SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen sensor is out of tolerance. the ITSM may still be able to communicate with the Caterpillar Electronic Technician (ET).FMI 09 Oxygen Sensor Element not communicating on link SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. System Response: The alarm output is activated. check for one of the following conditions: Possible Performance Effect: Engine performance and emissions may be affected. The duty cycle for the oxygen signal is between 10 and 20 percent. In this case. Note: If ET cannot communicate with the ITSM. . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module” Results: • Disconnected oxygen sensor • Burned out heater for the oxygen sensor Perform the following diagnostic procedure: “Oxygen Sensor Signal” Results: • OK – STOP. Possible Performance Effect: Engine performance and emissions may be affected. MID 036 . The alarm output is activated. Although there is a failure to communicate with the ECM. The diagnostic code will remain active until calibration of the oxygen sensor is successfully completed. the values for the ITSM “Status Parameter” will display “Unavailable”. i01636401 System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until a consistent oxygen signal is present for at least five seconds. Troubleshooting: Perform the following diagnostic procedure: “Oxygen Sensor Signal” Results: • The frequency for the oxygen signal is less than 625 Hz. The following diagnostic code is NOT active: 1088 . The alarm output is activated. Troubleshooting: Perform the following diagnostic procedure: “Oxygen Sensor Buffer Supply” • OK – STOP. The frequency (PWM) for the oxygen signal is more than 625 Hz OR the duty cycle is not within the valid range of 10 to 90 percent.06 Oxygen Sensor Power Supply open circuit.FMI 08 Oxygen Sensor Buffer Module noisy signal SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. The following diagnostic code is NOT active: 1088 . The alarm output is activated. i01636422 MID 036 .112 Troubleshooting Section i01636414 System Response: Compensation for fuel quality is disabled.FMI 05 Oxygen Sensor Power Supply open circuit SMCS Code: 1096-038 Conditions Which Generate This Code: Power to the oxygen buffer is OFF but the Electronic Control Module (ECM) receives a signal from the buffer.CID 1088 . System Response: Compensation for fuel quality is disabled. The code is logged.FMI 03 Oxygen Sensor Buffer Module short to +batt SMCS Code: 1096-038 Conditions Which Generate This Code: The oxygen buffer has been powered for at least 60 seconds. The code is logged. The alarm output is activated.CID 1087 .CID 1087 . System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until the following conditions occur: MID 036 . Possible Performance Effect: Engine performance and emissions may be affected. Possible Performance Effect: Engine performance and emissions may be affected. i01728689 MID 036 . Troubleshooting: Perform the following diagnostic procedure: “Oxygen Sensor Signal” Results: • OK – STOP. The frequency (PWM) for the oxygen signal is below 375 Hz.06 Oxygen Sensor Power Supply open circuit. • A duty cycle between 10 and 90 percent is present for at least five seconds. The diagnostic code will remain active until the frequency for the oxygen signal is greater than 375 Hz for at least five seconds. Possible Performance Effect: Engine performance and emissions may be affected. The code is logged. . • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Oxygen Sensor Buffer Supply” Results: • The J2 . Troubleshooting: Perform the following diagnostic procedure: “Throttle Actuator Solenoid” MID 036 . The code is logged. The output current is above normal.63 circuit is shorted to ground. • The J2 . the output current is below normal.CID 1088 . System Response: Compensation for fuel quality is disabled. The diagnostic code will remain active until a consistent oxygen signal is present for at least five seconds. Possible Performance Effect: If the engine is operating.CID 1440 . Note: This diagnostic condition can only be detected by the Electronic Control Module (ECM) when the signal driver for the oxygen buffer is ON. Possible Performance Effect: If the engine is operating. MID 036 .FMI 06 Oxygen Sensor Power Supply short to ground SMCS Code: 1096-038 Conditions Which Generate This Code: The supply voltage for the oxygen buffer is shorted to the −Battery side. i01728706 • The J2 . i01728696 Module (ECM) for the throttle solenoid is energized. the engine is shut down.63 circuit is shorted to the +Battery. The alarm output is activated. This indicates a short circuit in the solenoid for the throttle actuator.113 Troubleshooting Section Results: • The signal driver inside the Electronic Control • OK – STOP. The code is logged. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Throttle Actuator Solenoid” Results: • OK – STOP. However. i01728715 MID 036 .64 circuit is shorted to ground.FMI 06 Throttle Actuator Driver short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: One of the following conditions will generate this code: • The signal driver inside the Electronic Control Module (ECM) for the throttle solenoid is energized. Possible Performance Effect: Engine performance and emissions may be affected. System Response: The shutdown output is activated. The signal driver is normally ON when the engine control switch is in the “START” position.CID 1440 . This indicates an open circuit. System Response: The shutdown output is activated.FMI 05 Throttle Actuator Driver open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: One of the following conditions will generate this code: . Terminal 13 of the J2/P2 connectors is the signal driver for the oxygen buffer. the engine is shut down. System Response: The “Alarm Status” is activated. and “Fuel Temperature” are frozen on the Caterpillar Electronic Technician (ET). The alarm output is activated. all of the following conditions must occur: • The Electronic Control Module (ECM) has been powered up for more than 5 seconds.FMI 05 Fuel Metering Module open circuit SMCS Code: 1901-038 Conditions Which Generate This Code: To generate this diagnostic code. The alarm output is activated.75 V 300 CFM Perform the following diagnostic procedure: “Fuel Metering Valve” Results: G is the flow of the fuel in CFM. The signal indicates that there is a problem with the fuel metering valve. The calculation for “X” is given in Table 13. “Fuel Pressure (abs)”. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: • OK – STOP.CID 1446 . • The voltage of the signal is less than “X” for 5 seconds. System Response: The “Status Parameter” for “Fuel Valve Position” will display “0 %” on the Caterpillar Electronic Technician (ET). • The battery voltage is greater than 20 VDC. • OK – STOP. • The flow rate of the fuel is less than 481 N·m3/hr (300 CFM). Possible Performance Effect: Engine performance is affected. Troubleshooting: MID 036 . i01728721 MID 036 . Possible Performance Effect: Engine performance is affected. System Response: The code is logged. The shutdown output is activated. Table 13 X = 3. . Ten consecutive messages have been sent from the fuel metering valve to the ECM via the CAN Data Link.CID 1446 . The code is logged.114 Troubleshooting Section Results: i01728733 • OK – STOP. “Fuel Valve Differential Pressure”.0 V − G × 1.FMI 09 Unable to communicate with Fuel Metering Module SMCS Code: 1901-038 Conditions Which Generate This Code: The Electronic Control Module (ECM) has been powered up for more than 5 seconds. i01728740 MID 036 .CID 1446 . The code is logged. None of the messages have been received by the ECM.FMI 12 Fuel Metering Module malfunction SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the Electronic Control Module (ECM) via the CAN data link. The “Status Parameter” for “Fuel Valve Position”. The shutdown output is activated.CID 1446 . Neither of the following diagnostic codes are active: • 0041 .115 Troubleshooting Section Possible Performance Effect: The engine is shut down.8 VDC for ten seconds. Possible Performance Effect: The fuel metering valve is shutdown. i01741170 MID 036 .CID 1447 . System Response: The code is logged.FMI 13 Fuel Metering Module calibration required SMCS Code: 1901-038 Conditions Which Generate This Code: The “Gas Fuel Properties” have not been programmed for the fuel metering valve. The alarm output is activated. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” • OK – STOP.FMI 03 Cylinder #1 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. i01728751 The shutdown output is activated. Possible Performance Effect: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: The engine is shut down. Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Fuel Metering Valve” Results: • OK – STOP. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4.CID 1501 .04 8 Volt DC Supply short to ground System Response: • OK – STOP. i01619975 Results: MID 036 . The signal indicates that there is a problem with the fuel metering valve’s sensor module. • OK – STOP. .FMI 12 Fuel Metering Sensor Module malfunction SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve sends a signal to the Electronic Control Module (ECM) via the CAN data link.03 8 Volt DC Supply short to +batt • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . The code is logged. This prevents the engine from running. Troubleshooting: System Response: The code is logged. 04 8 Volt DC Supply short to ground i01741181 • OK – STOP.04 8 Volt DC Supply short to ground .04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.116 Troubleshooting Section i01741177 System Response: The shutdown output is activated. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .FMI 04 Cylinder #2 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The code is logged. i01741184 • 0041 . Neither of the following diagnostic codes are active: • OK – STOP.03 8 Volt DC Supply short to +batt • 0041 . Neither of the following diagnostic codes are active: • OK – STOP. Possible Performance Effect: The engine is shut down. System Response: The shutdown output is activated. Possible Performance Effect: The engine is shut down. • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .03 8 Volt DC Supply short to +batt • 0041 . The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1.CID 1501 .CID 1502 . The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .CID 1502 .03 8 Volt DC Supply short to +batt • 0041 .8 VDC for ten seconds.FMI 03 Cylinder #2 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The code is logged. The code is logged.0 VDC for ten seconds.FMI 04 Cylinder #1 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1.0 VDC for ten seconds. Neither of the following diagnostic codes are active: • 0041 . Possible Performance Effect: The engine is shut down. CID 1505 . Neither of the following diagnostic codes are active: • OK – STOP. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1. Neither of the following diagnostic codes are active: • OK – STOP. i01741202 • 0041 .8 VDC for ten seconds.03 8 Volt DC Supply short to +batt • 0041 . The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4.FMI 03 Cylinder #5 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The code is logged. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4. The code is logged. Possible Performance Effect: The engine is shut down.03 8 Volt DC Supply short to +batt • 0041 . • 0041 .FMI 04 Cylinder #5 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .04 8 Volt DC Supply short to ground i01741197 • OK – STOP.FMI 03 Cylinder #6 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.04 8 Volt DC Supply short to ground .03 8 Volt DC Supply short to +batt • 0041 .0 VDC for ten seconds.CID 1506 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .117 Troubleshooting Section i01741187 System Response: The shutdown output is activated.8 VDC for ten seconds. The code is logged.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. Possible Performance Effect: The engine is shut down. Possible Performance Effect: The engine is shut down. Neither of the following diagnostic codes are active: • 0041 .CID 1505 . System Response: The shutdown output is activated. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . The code is logged. Possible Performance Effect: The engine is shut down.8 VDC for ten seconds.04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine is shut down. i01741208 • 0041 . • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .0 VDC for ten seconds.CID 1506 .03 8 Volt DC Supply short to +batt • 0041 . Neither of the following diagnostic codes are active: • OK – STOP.CID 1509 . Possible Performance Effect: The engine is shut down. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1.FMI 03 Cylinder #9 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Neither of the following diagnostic codes are active: • OK – STOP. Neither of the following diagnostic codes are active: • 0041 . The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4. System Response: The shutdown output is activated.04 8 Volt DC Supply short to ground i01741207 • OK – STOP.03 8 Volt DC Supply short to +batt • 0041 .04 8 Volt DC Supply short to ground .CID 1509 .0 VDC for ten seconds. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .03 8 Volt DC Supply short to +batt • 0041 .118 Troubleshooting Section i01741203 System Response: The shutdown output is activated. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1.FMI 04 Cylinder #9 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The code is logged.FMI 04 Cylinder #6 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . The code is logged. Neither of the following diagnostic codes are active: • OK – STOP.04 8 Volt DC Supply short to ground i01741210 • OK – STOP.FMI 04 Cylinder #10 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . • 0041 . i01741213 • 0041 .CID 1510 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .CID 1510 .04 8 Volt DC Supply short to ground System Response: The shutdown output is activated.03 8 Volt DC Supply short to +batt • 0041 .04 8 Volt DC Supply short to ground . Possible Performance Effect: The engine is shut down.0 VDC for ten seconds. Neither of the following diagnostic codes are active: • OK – STOP.CID 1513 . System Response: The shutdown output is activated. Possible Performance Effect: The engine is shut down. The code is logged. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4.119 Troubleshooting Section i01741209 System Response: The shutdown output is activated. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 .03 8 Volt DC Supply short to +batt • 0041 .FMI 03 Cylinder #10 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.8 VDC for ten seconds. The code is logged. Possible Performance Effect: The engine is shut down.FMI 03 Cylinder #13 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.8 VDC for ten seconds.03 8 Volt DC Supply short to +batt • 0041 . Neither of the following diagnostic codes are active: • 0041 . The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4. 04 8 Volt DC Supply short to ground System Response: The shutdown output is activated. i01741227 • 0041 . System Response: The shutdown output is activated. The input of a signal from a detonation sensor to the Electronic Control Module (ECM) is greater than 4.CID 1513 .03 8 Volt DC Supply short to +batt • 0041 .FMI 04 Cylinder #13 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.CID 1514 . The code is logged.04 8 Volt DC Supply short to ground .04 8 Volt DC Supply short to ground i01741222 • OK – STOP.0 VDC for ten seconds. Neither of the following diagnostic codes are active: • OK – STOP. • 0041 . Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . Possible Performance Effect: The engine is shut down. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . Possible Performance Effect: The engine is shut down.FMI 04 Cylinder #14 Detonation Sensor short to ground SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized. The code is logged.CID 1514 . The code is logged.FMI 03 Cylinder #14 Detonation Sensor open/short to +batt SMCS Code: 1901-038 Conditions Which Generate This Code: The run relay and the crank terminate relay are energized.8 VDC for ten seconds.03 8 Volt DC Supply short to +batt • 0041 .120 Troubleshooting Section i01741219 System Response: The shutdown output is activated. The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1. Troubleshooting: Perform the following diagnostic procedure: “Detonation Sensors” Results: MID 036 . Neither of the following diagnostic codes are active: • 0041 . Possible Performance Effect: The engine is shut down.0 VDC for ten seconds.03 8 Volt DC Supply short to +batt • 0041 . The input of the signal from the detonation sensor to the Electronic Control Module (ECM) is less than 1. Neither of the following diagnostic codes are active: • OK – STOP. 03 5 Volt DC Supply short to +batt • 262 . Possible Performance Effect: The engine performance is not affected.121 Troubleshooting Section i01741260 i01741264 MID 036 . The code is logged. neither of the following diagnostic codes are active: MID 036 .CID 1758 .FMI 08 Specific Humidity Sensor signal abnormal SMCS Code: 1901-038-NS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “PWM Sensor” Results: • OK – STOP. Possible Performance Effect: The engine performance is not affected. CTW1-Up Conditions Which Generate This Code: The duty cycle of the pressure sensor for the specific humidity of the inlet air is greater than the maximum limit.FMI 03 Specific Humidity Sensor open/short to +batt SMCS Code: 1901-038-NS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up. Additionally. .CID 1758 . neither of the following diagnostic codes are active: • 262 . Perform the following diagnostic procedure: “PWM Sensor” Results: • 262-035 Volt DC Supply short to +batt • 262-045 Volt DC Supply short to ground System Response: The alarm output is activated.04 5 Volt DC Supply short to ground System Response: The alarm output is activated. Troubleshooting: The condition indicates a possible open circuit or a short circuit. CTW1-Up Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the pressure sensor for the specific humidity of the inlet air is out of range. Additionally. The code is logged. Perform the following diagnostic procedure: “PWM Sensor” Results: Perform the following diagnostic procedure: “PWM Sensor” Results: • OK – STOP. . MID 111 . The alarm output is activated.04 8 Volt DC Supply short to ground System Response: • 41 .FMI 03 Exhaust Back Pressure Sensor open/short to +batt SMCS Code: 1061-038-PXS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up.CID 0591 .FMI 12 EEPROM checksum fault or ECM not programmed SMCS Code: 1901-038 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a problem within the EPROM circuit.CID 1759 . neither of the following diagnostic codes are active: • 41 . CTW1-Up Conditions Which Generate This Code: The duty cycle or the frequency of the signal from the atmospheric pressure sensor is out of range. Possible Performance Effect: Possible Performance Effect: The engine performance is not affected.CID 1759 . neither of the following diagnostic codes are active: MID 036 . The engine performance is not affected.03 8 Volt DC Supply short to +batt • 41 . Additionally. Additionally. Troubleshooting: Troubleshooting: The condition indicates a possible open circuit or a short circuit.04 8 Volt DC Supply short to ground System Response: The alarm output is activated.122 Troubleshooting Section i01741313 i01754491 MID 036 . i01636449 • OK – STOP. The code is logged.03 8 Volt DC Supply short to +batt • 41 . The code is logged.FMI 08 Exhaust Back Pressure Sensor signal abnormal SMCS Code: 1061-038-PXS S/N: CFD1-Up S/N: CME1-Up S/N: CEY1-Up S/N: CSC1-Up. CTW1-Up Conditions Which Generate This Code: The duty cycle of the pressure sensor for the atmospheric pressure is greater than the maximum limit. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Also. Possible Performance Effect: Engine operation is not affected. System Response: Monitoring of the temperature for the port of the turbine is lost.123 Troubleshooting Section System Response: Monitoring of the exhaust temperature is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. protection for the port is lost. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. . System Response: Monitoring of the temperature for the port of the turbine is lost. Also. Replace the ITSM. “Replacing the ITSM”. The code is logged. i01728782 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. • OK – STOP. protection for the port is lost. Results: i01728777 MID 111 .CID 1489 .FMI 04 Left Turbo Turbine Out Temp Sens short to ground SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger: • A short circuit to the −Battery side • A short circuit to the ground i01728761 • OK – STOP. The alarm output is activated. The code is logged. The code is logged. Also. System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Troubleshooting: There is a problem with the ITSM.CID 1489 .FMI 03 Left Turbo Turbine Out Temp Sens short to +batt SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger. Follow the instructions in Troubleshooting. Possible Performance Effect: Engine operation is not affected.FMI 05 Left Turbo Turbine Out Temp Sens open circuit SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. protection against high exhaust temperatures is lost. protection for the port is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . Also.CID 1489 . • OK – STOP. Also. MID 111 .FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger.CID 1490 . protection for the port is lost. System Response: Monitoring of the temperature for the port of the turbine is lost.CID 1490 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. The code is logged. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. .CID 1490 . Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728791 MID 111 . Possible Performance Effect: Engine operation is not affected.124 Troubleshooting Section Possible Performance Effect: Engine operation is not affected. i01728794 MID 111 . protection for the port is lost. Possible Performance Effect: Engine operation is not affected.FMI 04 Rt Turbo Turbine Out Temp Sens short to ground SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger: i01728785 • OK – STOP. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine.FMI 05 Rt Turbo Turbine Out Temp Sens open circuit SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728797 MID 111 . Also. The code is logged. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Monitoring of the temperature for the port of the turbine is lost.CID 1491 . System Response: Monitoring of the temperature for the port of the turbine is lost.125 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. Also. protection for the port is lost. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. i01728795 MID 111 . i01728800 MID 111 . Possible Performance Effect: Engine operation is not affected. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine.CID 1491 . System Response: Monitoring of the exhaust temperature for the port of the turbine is lost. . protection for the port is lost.FMI 05 Rt Turbo Turbine In Temp Sens open circuit SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. Also.CID 1491 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. protection for the port is lost. protection for the port is lost.FMI 03 Rt Turbo Turbine In Temp Sens short to +batt SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger.FMI 04 Rt Turbo Turbine In Temp Sens short to ground SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger: • A short circuit to the −Battery side • A short circuit to the ground System Response: • OK – STOP. The code is logged. The code is logged. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. • OK – STOP. The code is logged. Possible Performance Effect: Engine operation is not affected. i01728813 MID 111 . System Response: Monitoring of the temperature for the port of the turbine is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728806 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to Ground” for the port of the turbine. protection for the port is lost.CID 1492 . • OK – STOP. Also. Possible Performance Effect: Engine operation is not affected.FMI 03 Left Turbo Turbine In Temp Sens short to +batt SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the turbocharger. This diagnostic code remains active until the condition that caused the problem is not present for 30 seconds. The code is logged. Also. . MID 111 .126 Troubleshooting Section Possible Performance Effect: Engine operation is not affected.CID 1492 . The code is logged.CID 1492 .FMI 04 Left Turbo Turbine In Temp Sens short to ground SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the turbocharger: i01728804 • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the temperature for the port of the turbine is lost.FMI 05 Left Turbo Turbine In Temp Sens open circuit SMCS Code: 1052-038-NS Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the turbocharger. protection for the port is lost. .FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.CID 1531 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728826 MID 111 . Troubleshooting: MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. protection for the cylinder is lost. Also. protection for the port is lost. The code is logged. protection for the cylinder is lost. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the port of the turbine. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected. i01728819 • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected.CID 1531 .127 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the port of the turbine is lost.FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. Possible Performance Effect: Engine operation is not affected. • OK – STOP. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. MID 111 . Possible Performance Effect: Engine operation is not affected. The code is logged. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Also. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost.FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. Also. Possible Performance Effect: Engine operation is not affected. . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 .FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine.CID 1532 .CID 1531 .128 Troubleshooting Section i01728828 System Response: Monitoring of the exhaust temperature for the cylinder is lost. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. protection for the cylinder is lost. i01728833 • OK – STOP. i01728835 MID 111 . protection for the cylinder is lost. The code is logged.CID 1532 . 129 Troubleshooting Section The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: Results: • OK – STOP. i01728852 MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: • OK – STOP. i01728837 MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. 130 Troubleshooting Section i01728912 i01728915 MID 111 - CID 1533 - FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. MID 111 - CID 1533 - FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728917 • OK – STOP. MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. 131 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728928 MID 111 - CID 1534 - FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728923 MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. • OK – STOP. 132 Troubleshooting Section i01728934 • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: • OK – STOP. i01728953 Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 - CID 1535 - FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. • OK – STOP. i01728940 MID 111 - CID 1535 - FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • A short circuit to the −Battery side 133 Troubleshooting Section The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01728968 MID 111 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • OK – STOP. i01728959 • A short circuit to the −Battery side • A short circuit to the ground MID 111 - CID 1536 - FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728976 MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. • OK – STOP. 134 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01728999 MID 111 - CID 1537 - FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • OK – STOP. i01728993 MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. 135 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729015 MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP. i01729006 MID 111 - CID 1537 - FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also, protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01729019 MID 111 - CID 1538 - FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. • OK – STOP. • A short circuit to the −Battery side • A short circuit to the ground The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. protection for the cylinder is lost. Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” .136 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected.CID 1538 . protection for the cylinder is lost. i01729025 MID 111 . protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.CID 1539 . Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. The thermocouple is removed from the calculation for the average temperature of the engine. i01729257 MID 111 . The code is logged. Also. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected.FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Troubleshooting: • OK – STOP. Possible Performance Effect: Engine operation is not affected. The code is logged.FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. i01729267 Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 .FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. Troubleshooting: • OK – STOP. • OK – STOP. The code is logged. The code is logged. i01729262 MID 111 .FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1539 .CID 1540 .CID 1539 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.137 Troubleshooting Section Results: i01729264 • OK – STOP. Also. Also. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 . Possible Performance Effect: Engine operation is not affected.FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The code is logged. Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1540 . protection for the cylinder is lost. i01729270 MID 111 . • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder.FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. The code is logged. i01729271 MID 111 .138 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost.FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.CID 1540 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Also. Also. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The code is logged. System Response: • OK – STOP. protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. protection for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. . Also. Possible Performance Effect: Engine operation is not affected. CID 1541 . protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Also. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.CID 1541 . . i01729277 • OK – STOP. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also.FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.139 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729275 MID 111 . protection for the cylinder is lost. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP. i01729273 MID 111 . Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. Possible Performance Effect: Engine operation is not affected.CID 1541 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. The code is logged. MID 111 . Possible Performance Effect: Engine operation is not affected. Possible Performance Effect: Engine operation is not affected. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP.FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. • OK – STOP. System Response: Monitoring of the exhaust temperature for the cylinder is lost. protection for the cylinder is lost. The code is logged. . The code is logged. • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. protection for the cylinder is lost. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01729281 MID 111 . Also. Possible Performance Effect: Engine operation is not affected. The thermocouple is removed from the calculation for the average temperature of the engine.CID 1542 .140 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine.FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. protection for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Also. Also.CID 1542 . i01729278 MID 111 . Possible Performance Effect: Engine operation is not affected. i01729284 MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also.141 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729287 MID 111 . protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. Possible Performance Effect: Engine operation is not affected. System Response: Monitoring of the exhaust temperature for the cylinder is lost. • OK – STOP.CID 1542 .FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. • A short circuit to the −Battery side • A short circuit to the ground . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. i01729291 MID 111 . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine.CID 1543 . The thermocouple is removed from the calculation for the average temperature of the engine. Also. protection for the cylinder is lost.FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP.CID 1543 .FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. The code is logged. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds.FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder.CID 1543 . i01729294 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. The code is logged. protection for the cylinder is lost. The code is logged. The code is logged. Also.142 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. Troubleshooting: • OK – STOP. protection for the cylinder is lost. System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1544 . Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. i01729297 MID 111 . The thermocouple is removed from the calculation for the average temperature of the engine. Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” . protection for the cylinder is lost.FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Possible Performance Effect: Engine operation is not affected. Also. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Also.FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.CID 1545 . protection for the cylinder is lost. Also. The thermocouple is removed from the calculation for the average temperature of the engine. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. i01729307 Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 .CID 1544 .FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. Troubleshooting: • OK – STOP. The code is logged. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. The code is logged. Possible Performance Effect: Engine operation is not affected.CID 1544 . protection for the cylinder is lost. • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: MID 111 .143 Troubleshooting Section Results: i01729306 • OK – STOP. . • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Possible Performance Effect: Engine operation is not affected.FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. System Response: Monitoring of the exhaust temperature for the cylinder is lost. i01729303 MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. System Response: • OK – STOP. Also. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. protection for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. Possible Performance Effect: Engine operation is not affected. protection for the cylinder is lost.FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder. Monitoring of the exhaust temperature for the cylinder is lost. i01729312 MID 111 .144 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1545 . The code is logged.CID 1545 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder. Also. The code is logged.FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. The thermocouple is removed from the calculation for the average temperature of the engine. The thermocouple is removed from the calculation for the average temperature of the engine. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. protection for the cylinder is lost. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The code is logged. Also. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. i01729310 MID 111 . • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. MID 111 . The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Shorted to ground” for the cylinder.FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects a short circuit to the +Battery side for the input from the thermocouple of the cylinder.CID 1546 . The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. i01729314 MID 111 . • A short circuit to the −Battery side • A short circuit to the ground System Response: Monitoring of the exhaust temperature for the cylinder is lost. The thermocouple is removed from the calculation for the average temperature of the engine. Possible Performance Effect: Engine operation is not affected. The code is logged. System Response: Monitoring of the exhaust temperature for the cylinder is lost.CID 1546 . Also. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. protection for the cylinder is lost.FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground SMCS Code: 1919 Conditions Which Generate This Code: • OK – STOP. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. protection for the cylinder is lost. Possible Performance Effect: Engine operation is not affected. i01729319 • OK – STOP. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: The Integrated Temperature Sensing Module (ITSM) detects one of the following conditions for the input from the thermocouple of the cylinder.FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit SMCS Code: 1919 Conditions Which Generate This Code: The Integrated Temperature Sensing Module (ITSM) detects an open circuit for the input from the thermocouple of the cylinder. .CID 1546 .145 Troubleshooting Section Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: i01729316 MID 111 . Also. . The diagnostic code remains active until the condition that caused the code is not present for 30 seconds. The “Status” screen of the Caterpillar Electronic Technician (ET) displays “Open/Shorted High” for the cylinder. Troubleshooting: Perform the following diagnostic procedure: “Integrated Temperature Sensing Module (ITSM)” Results: • OK – STOP. protection for the cylinder is lost.146 Troubleshooting Section System Response: Monitoring of the exhaust temperature for the cylinder is lost. Also. Possible Performance Effect: Engine operation is not affected. The code is logged. The thermocouple is removed from the calculation for the average temperature of the engine. the event is active. the oil temperature above 102 C (216 F) is higher than normal. The following format is used for event codes: • “EXXX (X) Description of the code” The “E” means that the code is an event code. Event codes alert the operator that an abnormal engine operating condition such as low oil pressure or high coolant temperature has been detected. The output voltage of the sensor will generate an event code for a warning. Do not use the diagram to troubleshoot the oil temperature sensor. The sensor does not have an electronic problem.147 Troubleshooting Section Troubleshooting with an Event Code i01729324 Event Codes SMCS Code: 1901-038 Use this section for the troubleshooting of problems that have generated event codes but do not have active diagnostic codes. The fourth “(X)” represents a numeric identifier for the severity of the code. (3) This area represents the normal operating temperature for the engine oil. See the following example: • “E004 (3) Engine Overspeed Shutdown” The numbers that indicate the severity of the event code are defined below: Warning (1) – This condition represents a serious problem with engine operation. . The output is outside of the normal range. Any generated code becomes logged in the permanent memory of the Electronic Control Module (ECM). The electronic problem will generate a diagnostic code.1 volts. Event codes may be viewed on a personal computer that has the Cat ET software. Events do not indicate problems with the electronic system. or a shutdown for high oil temperature. The normal output voltage of the sensor is between 0. Shutdown (3) – For this condition. the engine power is reduced in order to help prevent possible engine damage. The Caterpillar Electronic Technician (ET) is designed to run on a personal computer. (2) In this area. the engine is shut down in order to help prevent possible engine damage. a derating. This is followed by a description of the code. The diagram is a reference.2 and 4. this condition does not require a deration or a shutdown. The “XXX” represents a numeric identifier for the event code. Derate (2) – For this condition. the output voltage of the sensor is too high or too low. However. When the event code is generated. Illustration 15 represents the operating range of an oil temperature sensor. Illustration 15 Typical operating range of an oil temperature sensor g00791619 (1) In these areas. Event codes also indicate the nature of the problem. • The symptoms have a probable cause that is common. 2. identify the probable causes with the procedures in this manual that best describe the symptoms. Narrow the probable cause. Gather information about the complaint from the operator. Operator Information Obtain the following information from the operator: • The occurrence and the time of the occurrence • Determine the conditions for the occurrence. perform the following steps first in order to diagnose a malfunction. If the responses are not programmed. the display will not appear. Check each probable cause according to the tests that are recommended. • Verify that the complaint is not due to normal • Repair all active diagnostic codes. Correct the problem as soon as possible. Perform the following tasks before you troubleshoot the event code: Be sure to check the connectors. See Troubleshooting. investigate the following conditions: • The other occurrences are related to the symptom. . the occurrence of any event will cause the event code to be logged in the ECM. This is specially true for problems that are intermittent. Perform a visual inspection. If these inspections do not reveal any problems. Repair any active codes. Cat ET can display the event. The conditions will include the engine rpm and the load. • Codes that are repeatedly logged • The complaint is not due to normal engine operation. See • Determine if there are any systems that were installed by the dealer or the customer that could cause the symptom. Verify that the complaint is not due to error of the operator. Troubleshooting For basic troubleshooting of the engine. For information on diagnostic codes. Note: Do not confuse event codes with diagnostic codes. • The code was generated when the symptom occurred. Check the diagnostic codes and event codes. Other Symptoms If other occurrences happened in addition to the symptom. Verify that the complaint is not due to normal engine operation. Troubleshooting. However. Active Event Codes An active event code represents a problem with engine operation. 3. • Fuel supply • Oil level • Oil supply • Wiring • Connectors 4. see Troubleshooting. and the history of the engine. If the responses are programmed. Inspect the following items: Diagnostic Codes and Event Codes Examine the following information regarding any codes: • The probable cause of the symptom is correlated to the code.148 Troubleshooting Section These responses to certain events may be programmed into the ECM. “Inspecting Electrical Connectors”. “Troubleshooting With A Diagnostic Code”. • Gather enough information about the complaint in order to describe the symptom(s) adequately. engine operation. the conditions of operation. • Determine whether any other occurrences happened in addition to the symptom. 1. Consider the operator information. “Troubleshooting with a Diagnostic Code”. The engine coolant temperature has exceeded the trip point and the delay time has expired. The event code will be logged in the ECM memory. The shutdown output is activated. System Response: The gas shutoff valve and the ignition are shut off. System Response: The alarm output is activated. E016 High Engine Coolant Temperature Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The ECM has an internal diagnostic clock.149 Troubleshooting Section When an event code is active. Logged events are listed in chronological order. i01637572 Logged Event Codes When the ECM generates an event code the ECM logs the code in permanent memory. i01633543 E004 Engine Overspeed Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The engine rpm has exceeded the trip point that is programmed into the Electronic Control Module (ECM) and the delay time has expired. Any logged event codes will automatically be deleted if no additional occurrences are recorded in 100 hours. “Engine Overspeed”. Logged codes can also be used to review the performance of the engine. The shutdown output is activated. The event is logged. Note: Always clear logged event codes after investigating and correcting the problem which generated the code. Results: • The hour of the first occurrence of the code • The hour of the last occurrence of the code • The number of occurrences of the code This information can be helpful for troubleshooting intermittent problems. The engine coolant temperature has exceeded the trip point and the delay time has expired. i01729333 • OK – STOP. System Response: The fuel is shut off. If the condition that generated the code is momentary. the “Active Alarm” indicator (“Engine Control Alarm Status” on Cat ET) is activated in order to alert the operator. Active event codes are listed in ascending numerical order. Results: • OK – STOP. No other codes for the engine coolant are active. “Engine Coolant Temperature (High)”. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. The code with the lowest number is listed first. The most recent event code is listed first. The ECM will record the following information when a code is generated: E015 High Engine Coolant Temperature Derate SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. . Troubleshooting: Refer to Troubleshooting. The ECM has determined that the detected speed is accurate. The code is logged. Possible Performance Effect: The engine power is reduced. No other codes for the engine coolant are active. The code is logged. the message disappears. Possible Performance Effect: • OK – STOP. Troubleshooting: Refer to Troubleshooting. No other codes for the engine coolant are active. However. i01633605 The engine operation is not immediately affected. Possible Performance Effect: The engine is shut off. No other codes for the engine oil temperature are active. The engine oil temperature has exceeded the trip point and the delay time has expired. The code is logged. the engine will be shut down. The code is logged. if the coolant temperature continues to rise. System Response: The alarm output is activated. The engine oil temperature has exceeded the trip point and the delay time has expired. if the engine oil temperature continues to rise. Results: E020 High Engine Oil Temperature Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. . Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine operation is not immediately affected. the engine can be shut down.150 Troubleshooting Section Possible Performance Effect: The engine is shut down. The shutdown output is activated. The code is logged. System Response: The alarm output is activated. However. System Response: The fuel is shut off. “Engine Coolant Temperature (High)”. The engine coolant temperature has exceeded the trip point and the delay time has expired. Results: i01633603 E019 High Engine Oil Temperature Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. Troubleshooting: Refer to Troubleshooting. “Engine Oil Temperature (High)”. i01633545 E017 High Engine Coolant Temperature Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. “Engine Coolant Temperature (High)”. • OK – STOP. No other codes for the engine oil temperature are active. Results: • OK – STOP. the engine may be shut down. Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting. “Inlet Air Temperature (High)”. “Inlet Air Temperature (High)”. The code is logged. Results: E025 High Inlet Air Temperature Derate SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. No other codes for the inlet air temperature are active. i01633755 E026 High Inlet Air Temperature Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. However. System Response: The alarm output is activated. The shutdown output is activated. The inlet air temperature has exceeded the trip point and the delay time has expired. Possible Performance Effect: The engine operation is not immediately affected. The event is logged. System Response: The alarm output is activated. System Response: The fuel is shut off. “Inlet Air Temperature (High)”. Results: • OK – STOP. Results: Possible Performance Effect: The engine is shut down. Troubleshooting: • OK – STOP. Results: • OK – STOP. i01633757 E038 Low Engine Coolant Temperature Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. if the inlet air temperature continues to rise. Refer to Troubleshooting. . The inlet air temperature has exceeded the setpoint and the delay time has expired. i01637574 Refer to Troubleshooting. No other codes for the coolant temperature are active. The temperature of the engine coolant is less than the trip point and the delay time has expired. The code is logged. Troubleshooting: • OK – STOP. The inlet air temperature has exceeded the trip point and the delay time has expired. i01633756 E027 High Inlet Air Temperature Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. No other codes for the inlet air temperature are active.151 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. No other codes for the inlet air temperature are active. “Engine Oil Temperature (High)”. • OK – STOP. • OK – STOP. The shutdown output is activated. The code is logged. No other codes for the system voltage are present. i01633762 E040 Low Engine Oil Pressure Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 10 seconds. Possible Performance Effect: The engine is shut down.152 Troubleshooting Section System Response: The alarm output is activated. Results: • OK – STOP. “Engine Oil Pressure (Low)”. Results: i01633763 E042 Low System Voltage Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired. System Response: The shutdown output is activated. The engine oil pressure is less than the trip point and the delay time has expired. System Response: The alarm output is activated. Results: • OK – STOP. The code is logged. System Response: The fuel is shut off. if the system voltage continues to be reduced. . No codes for the engine oil pressure sensor are active. the engine will be shut down. Troubleshooting: Refer to Troubleshooting. Results: Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. However. “System Voltage”. Troubleshooting: Refer to Troubleshooting. No other codes for the system voltage are present. “Engine Coolant Temperature (Low)”. i01633765 E043 Low System Voltage Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is less than the trip point and the delay time has expired. “System Voltage”. The code is logged. The code is logged. Possible Performance Effect: The engine operation is not immediately affected. Possible Performance Effect: The engine operation is not immediately affected. Troubleshooting: Refer to Troubleshooting. i01633787 • OK – STOP. “Engine Oil Pressure (Low)”. Troubleshooting: Refer to Troubleshooting. Results: E100 Low Engine Oil Pressure Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. No other codes for the system voltage are present. The code is logged. . • OK – STOP. The code is logged. if the oil pressure continues to be reduced. if the system voltage continues to increase the circuit breaker will switch OFF and the engine will be shut down. i01637578 E053 Low Fuel Pressure Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel pressure is less than the trip point and the delay time has expired. Results: E096 High Fuel Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel pressure is higher than the trip point and the delay time has expired. the supply may become inadequate for the fuel metering valve. System Response: The alarm output is activated. The code is logged. Troubleshooting: Refer to Troubleshooting. if the fuel pressure continues to increase. the supply may exceed the maximum limit for the fuel metering valve. “System Voltage”. Troubleshooting: Refer to Troubleshooting. There are no active codes for the engine oil pressure sensor. System Response: The alarm output is activated.153 Troubleshooting Section i01633766 i01637590 E050 High System Voltage Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The voltage is greater than the trip point and the delay time has expired. Possible Performance Effect: The engine operation is not immediately affected. System Response: The alarm output is activated. The code is logged. The engine oil pressure is less than the trip point and the delay time has expired. However. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine operation is not immediately affected. “Fuel Pressure”. However. However. if the fuel pressure continues to be reduced. Results: • OK – STOP. the engine may be shut down. Possible Performance Effect: The engine operation is not immediately affected. Possible Performance Effect: The engine operation is not immediately affected. “Fuel Pressure”. System Response: The alarm output is activated. However. “Engine Oil Filter Differential Pressure”. . However. System Response: • OK – STOP. if the engine oil filter differential pressure continues to be reduced. The oil filter differential pressure is less than the trip point and the delay time has expired. The oil filter differential pressure is greater than the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. However. the engine may be shut down. There are no active codes for the oil pressure sensors. The code is logged. i01633790 • OK – STOP. i01633828 E129 Engine Oil Filter Diff Pressure High Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The alarm output is activated. “Engine Oil Filter Differential Pressure”. “Engine Oil Filter Differential Pressure”. There are no active codes for the oil pressure sensors. Results: E128 Engine Oil Filter Diff Pressure Low Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. • OK – STOP. There are no active codes for the oil pressure sensors. Results: The crank terminate relay is set and the engine has been running for at least 30 seconds. the engine may be shut down.154 Troubleshooting Section Results: Possible Performance Effect: The engine is shut down. Possible Performance Effect: The engine operation is not immediately affected. The code is logged. Troubleshooting: Refer to Troubleshooting. i01633814 • OK – STOP. Possible Performance Effect: The engine operation is not immediately affected. The shutdown output is activated. if the oil filter differential pressure continues to increase. System Response: The fuel is shut off. System Response: The alarm output is activated. The code is logged. Results: E127 Engine Oil Filter Diff Pressure Low Warning SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The engine oil filter differential pressure is less than the trip point and the delay time has expired. The temperature of the gas has exceeded the trip point and the delay timer has expired. The code is logged.155 Troubleshooting Section i01633832 Results: E130 Engine Oil Filter Diff Pressure High Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The code is logged. However. if the fuel temperature continues to increase. The shutdown output is activated. There are no active codes for the fuel temperature sensor. The shutdown output is activated. System Response: The alarm output is activated. The code is logged. There are no active codes for the pressure sensor at the outlet for the jacket water. The trip point for high pressure at the inlet for the jacket water has been exceeded and the delay time has expired. System Response: The fuel is shut off. Possible Performance Effect: The engine is shut off. The shutdown output is activated. The code is logged. Results: • OK – STOP. The engine oil filter differential pressure is greater than the trip point and the delay time has expired. i01633833 • OK – STOP. • OK – STOP. . Possible Performance Effect: The engine is shut down. The pressure of the jacket water is less than the trip point and the delay time has expired. “Engine Oil Filter Differential Pressure”. Troubleshooting: Refer to Troubleshooting. Results: E135 Low Jacket Water Pressure Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least ten seconds. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. There are no active codes for the oil pressure sensors. System Response: The fuel is shut off. i01633954 E223 High Gas Temperature SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. System Response: The fuel is shut off. “Gas Temperature (High)”. the air/fuel ratio and the inlet manifold air temperature can be affected. “Jacket Water Pressure (Low)”. i01633956 E224 High Jacket Water Inlet Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 10 seconds. Possible Performance Effect: The engine operation is not immediately affected. The fuel correction factor is greater than the trip point for 20 seconds.156 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. “Engine Overcrank”. i01633972 E225 Engine Overcrank SMCS Code: 1901-038 Conditions Which Generate This Code: The engine did not start within the programmed parameters for starting. . Results: E229 Fuel Energy Content Setting Low SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. However. The fuel correction factor is less than the trip point for 20 seconds. System Response: The alarm output is activated. Possible Performance Effect: The engine will not start. E226 Driven Equipment Not Ready SMCS Code: 1901-038 Conditions Which Generate This Code: The engine is ready to start. The code is logged. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine performance may be erratic. Troubleshooting: Refer to Troubleshooting. i01633959 • OK – STOP. Possible Performance Effect: The engine will not start. The code is logged. “Fuel Energy Content”. Results: Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. System Response: The shutdown output is activated. The code is logged. Possible Performance Effect: The engine performance may be erratic. Engine cranking is prevented. “Jacket Water Inlet Pressure (High)”. Engine cranking is prevented. The code is logged. the Electronic Control Module (ECM) has received a signal which indicates that the driven equipment is not ready for the engine to start. System Response: The fuel is shut off. System Response: The alarm output is activated. Results: • OK – STOP. i01729345 • OK – STOP. i01633976 E230 Fuel Energy Content Setting High SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. “Driven Equipment”. i01729352 E231 Fuel Quality Out of Range SMCS Code: 1901-038 Conditions Which Generate This Code: E242 Engine Overload SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine has been running for at least 30 seconds. The code is logged. “Fuel Energy Content”. E243 High Left Turbo Turbine Outlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired. The signal driver for the prelube pump remains activated. The code is logged. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. “Fuel Energy Content”. Possible Performance Effect: The engine will not start. i01746483 • OK – STOP. Results: Possible Performance Effect: The engine power is reduced. System Response: The calculation by the Electronic Control Module (ECM) for the engine load is greater than 110 percent of the rated load. System Response: The following event codes are logged according to the trip points for the temperature: • E243 (1) High Left Turbo Turbine Outlet Temperature (warning) • E243 (3) High Left Turbo Turbine Outlet Temperature (shutdown) . Starting of the engine is prevented. “Engine Pre-Lube Pressure (Low)”. Results: • OK – STOP. The code is logged. The fuel is shut off. Possible Performance Effect: The engine is shut off. System Response: The shutdown output is activated. E233 Low Engine Pre-Lube Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: The prelube oil pressure is less than the trip point and the delay time has expired. “Engine Overload”. System Response: The alarm output is activated. Troubleshooting: Refer to Troubleshooting. The Low Heat Value (LHV) of the fuel is less than the trip point OR the LHV of the fuel is greater than the trip point for 20 seconds.157 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. i01634015 i01634004 • OK – STOP. The shutdown output is activated. Results: Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. Possible Performance Effect: If a warning is generated. the engine performance is not immediately affected. Results: Conditions Which Generate This Code: The temperature at the inlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. the alarm output is activated. the shutdown output is activated. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded.158 Troubleshooting Section If a warning is generated. E244 High Right Turbo Turbine Outlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the right turbocharger turbine has exceeded the trip point and the delay time has expired. System Response: i01634039 i01634041 E245 High Right Turbo Turbine Inlet Temperature • OK – STOP. If a warning is generated. “Turbocharger Turbine Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. Troubleshooting: SMCS Code: 1052-038 Refer to Troubleshooting. the engine performance is not immediately affected. Possible Performance Effect: • OK – STOP. If a shutdown is generated. the shutdown output is activated. If a warning is generated. Troubleshooting: Refer to Troubleshooting. “Turbocharger Turbine Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. If a shutdown is generated. “Turbocharger Turbine Temperature (High)”. Possible Performance Effect: Troubleshooting: Refer to Troubleshooting. the shutdown output is activated. Results: • E244 (1) High Right Turbo Turbine Outlet Temperature (warning) • E244 (3) High Right Turbo Turbine Outlet Temperature (shutdown) If a warning is generated. . System Response: The following event codes are logged according to the trip points for the temperature: The following event codes are logged according to the trip points for the temperature: • E245 (1) High Right Turbo Turbine Inlet Temperature (warning) • E245 (3) High Right Turbo Turbine Inlet Temperature (shutdown) If a warning is generated. “Turbocharger Turbine Temperature (Low)”. the shutdown output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E247 (1) Low Left Turbo Turbine Outlet Temperature (warning) • E247 (3) Low Left Turbo Turbine Outlet Temperature (shutdown) If a warning is generated. • E248 (1) Low Right Turbo Turbine Outlet Temperature (warning) • E248 (3) Low Right Turbo Turbine Outlet Temperature (shutdown) If a warning is generated. Results: • OK – STOP. . Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. If a shutdown is generated. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. the alarm output is activated.159 Troubleshooting Section i01634043 System Response: The following event codes are logged according to the trip points for the temperature: E246 High Left Turbo Turbine Inlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the inlet for the left turbocharger turbine has exceeded the trip point and the delay time has expired. • OK – STOP. i01634050 E248 Low Right Turbo Turbine Outlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the right turbocharger turbine is less than the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • E246 (1) High Left Turbo Turbine Inlet Temperature (warning) • E246 (3) High Left Turbo Turbine Inlet Temperature (shutdown) If a warning is generated. “Turbocharger Turbine Temperature (High)”. i01634046 System Response: The following event codes are logged according to the trip points for the temperature: E247 Low Left Turbo Turbine Outlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the outlet for the left turbocharger turbine is less than the trip point and the delay time has expired. the shutdown output is activated. If a shutdown is generated. Possible Performance Effect: If a warning is generated. the alarm output is activated. the engine performance is not immediately affected. “Turbocharger Turbine Temperature (Low)”. System Response: The following event codes are logged according to the trip points for the temperature: E249 Low Right Turbo Turbine Inlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: The temperature at the inlet for the right turbocharger turbine is less than the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. Results: Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. . the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: If a warning is generated. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. i01634054 The temperature at the inlet for the left turbocharger turbine is less than the trip point and the delay time has expired. • OK – STOP. the shutdown output is activated. “Turbocharger Turbine Temperature (Low)”. the alarm output is activated. the engine performance is not immediately affected. i01634056 E250 Low Left Turbo Turbine Inlet Temperature SMCS Code: 1052-038 Conditions Which Generate This Code: • OK – STOP. “Turbocharger Turbine Temperature (Low)”.160 Troubleshooting Section If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. the engine performance is not immediately affected. the shutdown output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: • E250 (1) Low Left Turbo Turbine Inlet Temperature (warning) • E250 (3) Low Left Turbo Turbine Inlet Temperature (shutdown) If a warning is generated. Results: • E249 (1) Low Right Turbo Turbine Inlet Temperature (warning) • E249 (3) Low Right Turbo Turbine Inlet Temperature (shutdown) If a warning is generated. the shutdown output is activated. If a shutdown is generated. If a shutdown is generated. . “Engine Shutdown”. System Response: The alarm output is activated. • OK – STOP. The code is logged. “Detonation”.161 Troubleshooting Section i01637596 System Response: The gas shutoff valve (GSOV) and the ignition are shut off. Results: • OK – STOP. Results: The crank terminate relay has been energized for at least 30 seconds. i01637600 E254 No Detonation Derate Action Taken SMCS Code: 1550 Conditions Which Generate This Code: A derating was requested for detonation but the derating did not occur. Results: E253 Detonation Derate Requested SMCS Code: 1550 Conditions Which Generate This Code: A derating is requested for detonation. The shutdown output is activated. Troubleshooting: Refer to Troubleshooting. System Response: The alarm output is activated. System Response: The fuel is shut off. This indicates no oil pressure to the system. i01634059 E264 Emergency Stop Activated SMCS Code: 1901-038 Conditions Which Generate This Code: The input for the emergency stop is activated. The code is logged. Results: • OK – STOP. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. The code is logged. Possible Performance Effect: The engine power is reduced. Troubleshooting: Refer to Troubleshooting. The code is logged. i01634061 E266 Low Hydrax Oil Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. Troubleshooting: Refer to Troubleshooting. The pressure switch for the electrohydraulic actuator system opens for more than one second. The shutdown output is activated. Possible Performance Effect: The engine is shut off. “Detonation”. “Electrohydraulic System Oil Pressure (Low)”. Possible Performance Effect: The engine is shut down. “Engine Shutdown”. System Response: The fuel is shut off. Troubleshooting: The crank terminate relay is set and the engine has been running for at least 30 seconds. The differential between the temperature of the engine oil and the temperature of the engine coolant has exceeded the trip point. The code is logged. System Response: The fuel is shut off. The input requests a shutdown for 200 ms. • OK – STOP. the delay time has expired. Results: Temp (shutdown) If a warning is activated. Possible Performance Effect: The engine is shut off. . The code is logged.162 Troubleshooting Section i01634063 i01634097 E268 Unexpected Engine Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. Results: • OK – STOP. The input for the stop is set for 200 ms. Results: E270 Driven Equipment Shutdown Requested SMCS Code: 1901-038 Conditions Which Generate This Code: The crank terminate relay is set and the engine is running. The code is logged. “Driven Equipment”. The shutdown output is activated. System Response: The fuel is shut off. The shutdown output is activated. Troubleshooting: Refer to Troubleshooting. Also. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine is shut down. “Engine Shutdown (Unexpected)”. • OK – STOP. The shutdown output is activated. System Response: The following event codes are logged according to the trip points for the temperature differential: • E337 (1) High Engine Oil to Engine Coolant Diff Temp (warning) • E337 (3) High Engine Oil to Engine Coolant Diff Refer to Troubleshooting. There are no active codes for the sensors for the engine oil temperature and the engine coolant. The engine rpm is less than the programmed speed of the postlube cycle for 200 ms. the alarm output is activated. i01634093 i01619830 E337 High Engine Oil to Engine Coolant Diff Temp SMCS Code: 1901-038 Conditions Which Generate This Code: E269 Customer Shutdown Requested SMCS Code: 1901-038 Conditions Which Generate This Code: The engine is either cranking or running. the shutdown output is activated. Results: E401 Cylinder #1 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point.163 Troubleshooting Section If a shutdown is activated. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. System Response: The alarm output is activated. Troubleshooting: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. “Jacket Water to Engine Oil Temperature (Low)”. i01637634 i01637623 • OK – STOP. Possible Performance Effect: System Response: The alarm output is activated. Possible Performance Effect: If a warning is generated. Results: Results: • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. i01637627 i01637607 • OK – STOP. System Response: The alarm output is activated. . E402 Cylinder #2 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. E404 Cylinder #4 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. E403 Cylinder #3 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Refer to Troubleshooting. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. the engine operation is not immediately affected. “Detonation”. The code is logged. Troubleshooting: Refer to Troubleshooting. i01637648 E405 Cylinder #5 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”.164 Troubleshooting Section System Response: The alarm output is activated. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. System Response: The alarm output is activated. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. “Detonation”. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. i01637651 E406 Cylinder #6 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. “Detonation”. Results: System Response: The alarm output is activated. The code is logged. i01637642 • OK – STOP. Results: • OK – STOP. Results: E407 Cylinder #7 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. . E408 Cylinder #8 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. System Response: The alarm output is activated. “Detonation”. Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. i01637646 • OK – STOP. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The alarm output is activated. Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. Results: System Response: The alarm output is activated. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. The code is logged. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. System Response: The alarm output is activated. Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. i01637653 • OK – STOP. i01637663 E409 Cylinder #9 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. “Detonation”. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. The code is logged.165 Troubleshooting Section System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. i01637665 E410 Cylinder #10 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Results: E411 Cylinder #11 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. . Results: • OK – STOP. E412 Cylinder #12 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. “Detonation”. i01637657 • OK – STOP. The code is logged. Results: System Response: The alarm output is activated. “Detonation”. Results: E415 Cylinder #15 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. i01637699 • OK – STOP. Results: • OK – STOP.166 Troubleshooting Section System Response: The alarm output is activated. Results: • OK – STOP. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. i01637706 E414 Cylinder #14 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The code is logged. The code is logged. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. . E416 Cylinder #16 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01637696 • OK – STOP. Troubleshooting: Refer to Troubleshooting. System Response: The alarm output is activated. “Detonation”. Troubleshooting: Refer to Troubleshooting. i01637702 E413 Cylinder #13 Detonation SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. System Response: The alarm output is activated. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The shutdown output is activated. System Response: • OK – STOP. System Response: The fuel is shut off. Possible Performance Effect: The engine is shut down. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. The code is logged. Results: The fuel is shut off. Possible Performance Effect: The engine performance may be affected by an adjustment of the timing in order to reduce detonation. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Results: • OK – STOP. Results: i01634746 E422 Cylinder #2 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Troubleshooting: Refer to Troubleshooting. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. Possible Performance Effect: The engine is shut down. The shutdown output is activated. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. . • OK – STOP. System Response: The fuel is shut off. i01634838 E423 Cylinder #3 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Possible Performance Effect: The engine is shut down. The shutdown output is activated. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed.167 Troubleshooting Section System Response: The alarm output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. “Detonation”. The code is logged. i01634664 E421 Cylinder #1 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. System Response: Troubleshooting: Refer to Troubleshooting. “Detonation”. The shutdown output is activated. “Detonation”. Possible Performance Effect: The engine is shut down. i01635416 • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. E426 Cylinder #6 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The code is logged. There is no active diagnostic code for the cylinder’s detonation sensor. The shutdown output is activated. Results: E425 Cylinder #5 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The shutdown output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. Results: The fuel is shut off. Possible Performance Effect: The engine is shut down. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. System Response: The fuel is shut off. The code is logged. “Detonation”.168 Troubleshooting Section Results: Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. There is no active diagnostic code for the cylinder’s detonation sensor. • OK – STOP. The code is logged. i01635417 The level of detonation has exceeded the trip point. Results: E424 Cylinder #4 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. . i01635415 • OK – STOP. System Response: The fuel is shut off. i01635421 • OK – STOP. The shutdown output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. i01635423 E429 Cylinder #9 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. System Response: The fuel is shut off. Troubleshooting: Refer to Troubleshooting. . i01635424 E430 Cylinder #10 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. “Detonation”. The code is logged. Possible Performance Effect: The engine is shut down. System Response: The fuel is shut off. • OK – STOP. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. The shutdown output is activated. System Response: The fuel is shut off. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine is shut down. The shutdown output is activated. System Response: The fuel is shut off. Possible Performance Effect: The engine is shut down. “Detonation”.169 Troubleshooting Section i01635420 Results: E427 Cylinder #7 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. The code is logged. Results: • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The code is logged. Troubleshooting: Refer to Troubleshooting. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Results: E428 Cylinder #8 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. “Detonation”. The shutdown output is activated. Results: E432 Cylinder #12 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01635428 The engine is shut down. . The code is logged. The engine is shut down.170 Troubleshooting Section Troubleshooting: Refer to Troubleshooting. System Response: The fuel is shut off. The code is logged. Results: • OK – STOP. “Detonation”. “Detonation”. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. The shutdown output is activated. System Response: The fuel is shut off. “Detonation”. Results: System Response: The fuel is shut off. The shutdown output is activated. There is no active diagnostic code for the cylinder’s detonation sensor. Possible Performance Effect: The engine is shut down. Possible Performance Effect: • OK – STOP. Troubleshooting: Refer to Troubleshooting. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. There is no active diagnostic code for the cylinder’s detonation sensor. There is no active diagnostic code for the cylinder’s detonation sensor. i01635431 E433 Cylinder #13 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01635429 Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: • OK – STOP. • OK – STOP. The code is logged. The shutdown output is activated. Results: E431 Cylinder #11 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Troubleshooting: Refer to Troubleshooting. “Detonation”. System Response: The fuel is shut off. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. “Detonation”. Possible Performance Effect: The engine is shut down. The code is logged. Possible Performance Effect: The engine is shut down. Troubleshooting: Refer to Troubleshooting. The code is logged. “Detonation”. There is no active diagnostic code for the cylinder’s detonation sensor. Troubleshooting: Refer to Troubleshooting. Results: E435 Cylinder #15 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. The shutdown output is activated. Troubleshooting: Refer to Troubleshooting. The shutdown output is activated. The shutdown output is activated. System Response: The fuel is shut off. i01635436 E436 Cylinder #16 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. There is no active diagnostic code for the cylinder’s detonation sensor. System Response: The following event codes are logged according to the trip points for the temperature: • E801 (1) Cylinder #1 High Exhaust Port Temp (warning) • E801 (3) Cylinder #1 High Exhaust Port Temp (shutdown) .171 Troubleshooting Section i01635433 Results: E434 Cylinder #14 Detonation Shutdown SMCS Code: 1901-038 Conditions Which Generate This Code: The level of detonation has exceeded the trip point. i01635435 • OK – STOP. There is no active diagnostic code for the cylinder’s detonation sensor. “Detonation”. • OK – STOP. Maximum retardation of the timing was unable to control the detonation adequately during the number of ignition sparks that are allowed. i01635494 E801 Cylinder #1 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Possible Performance Effect: The engine is shut down. System Response: The fuel is shut off. The code is logged. Results: • OK – STOP. the shutdown output is activated and the fuel is shut off. the alarm output is activated. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. . “Exhaust Port Temperature (High)”. Results: • OK – STOP. the engine performance is not immediately affected. the engine performance is not immediately affected. “Exhaust Port Temperature (High)”. Results: Possible Performance Effect: • E802 (1) Cylinder #2 High Exhaust Port Temp (warning) • E802 (3) Cylinder #2 High Exhaust Port Temp (shutdown) If a warning is generated. • OK – STOP. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. Troubleshooting: SMCS Code: 1901-038 Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. The engine will be shut down if the trip point for the shutdown is exceeded.172 Troubleshooting Section If a warning is generated. System Response: i01635500 i01635503 E803 Cylinder #3 High Exhaust Port Temp • OK – STOP. If a shutdown is generated. E802 Cylinder #2 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature: The following event codes are logged according to the trip points for the temperature: • E803 (1) Cylinder #3 High Exhaust Port Temp (warning) • E803 (3) Cylinder #3 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: Troubleshooting: Refer to Troubleshooting. If a warning is generated. the shutdown output is activated and the fuel is shut off. If a shutdown is generated. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. If a shutdown is generated. the alarm output is activated. If a warning is generated. Results: Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • E804 (1) Cylinder #4 High Exhaust Port Temp (warning) • E804 (3) Cylinder #4 High Exhaust Port Temp (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. i01635511 E806 Cylinder #6 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. “Exhaust Port Temperature (High)”. the alarm output is activated. “Exhaust Port Temperature (High)”. the alarm output is activated. If a shutdown is generated. the engine performance is not immediately affected. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. System Response: The following event codes are logged according to the trip points for the temperature: • E806 (3) Cylinder #6 High Exhaust Port Temp (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. i01635508 • E806 (1) Cylinder #6 High Exhaust Port Temp (warning) E805 Cylinder #5 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. Possible Performance Effect: If a warning is generated. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E805 (3) Cylinder #5 High Exhaust Port Temp (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. .173 Troubleshooting Section i01635505 • E805 (1) Cylinder #5 High Exhaust Port Temp (warning) E804 Cylinder #4 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • OK – STOP. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: • E808 (1) Cylinder #8 High Exhaust Port Temp (warning) • E808 (3) Cylinder #8 High Exhaust Port Temp (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. Results: i01635513 E808 Cylinder #8 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. i01635546 E809 Cylinder #9 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. the alarm output is activated. • OK – STOP. • OK – STOP. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. . “Exhaust Port Temperature (High)”. Results: • E807 (1) Cylinder #7 High Exhaust Port Temp (warning) • E807 (3) Cylinder #7 High Exhaust Port Temp (shutdown) If a warning is generated. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. i01635512 System Response: The following event codes are logged according to the trip points for the temperature: E807 Cylinder #7 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. If a shutdown is generated.174 Troubleshooting Section The engine will be shut down if the trip point for the shutdown is exceeded. • OK – STOP. i01635549 • E811 (1) Cylinder #11 High Exhaust Port Temp (warning) E810 Cylinder #10 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • E809 (1) Cylinder #9 High Exhaust Port Temp (warning) • E809 (3) Cylinder #9 High Exhaust Port Temp (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”. Possible Performance Effect: If a warning is generated. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E811 (3) Cylinder #11 High Exhaust Port Temp (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. Results: • E810 (1) Cylinder #10 High Exhaust Port Temp (warning) • E810 (3) Cylinder #10 High Exhaust Port Temp (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (High)”. i01635556 E811 Cylinder #11 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired.175 Troubleshooting Section System Response: The following event codes are logged according to the trip points for the temperature: Possible Performance Effect: If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • OK – STOP. “Exhaust Port Temperature (High)”. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. the engine performance is not immediately affected. the alarm output is activated. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. the engine performance is not immediately affected. If a shutdown is generated. . If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. Results: • OK – STOP. i01635577 E814 Cylinder #14 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Results: • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. the alarm output is activated. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. System Response: The following event codes are logged according to the trip points for the temperature: • E813 (1) Cylinder #13 High Exhaust Port Temp (warning) • E813 (3) Cylinder #13 High Exhaust Port Temp (shutdown) If a warning is generated. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. . If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. Results: • E812 (1) Cylinder #12 High Exhaust Port Temp (warning) • E812 (3) Cylinder #12 High Exhaust Port Temp (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. i01635570 System Response: The following event codes are logged according to the trip points for the temperature: E813 Cylinder #13 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. • OK – STOP. • E814 (1) Cylinder #14 High Exhaust Port Temp (warning) • E814 (3) Cylinder #14 High Exhaust Port Temp (shutdown) If a warning is generated.176 Troubleshooting Section i01635568 System Response: The following event codes are logged according to the trip points for the temperature: E812 Cylinder #12 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. If a shutdown is generated. the alarm output is activated. Possible Performance Effect: If a warning is generated. Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (High)”. “Exhaust Port Temperature (High)”. If a shutdown is generated. Possible Performance Effect: If a warning is generated. System Response: • OK – STOP. “Exhaust Port Temperature (High)”. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The following event codes are logged according to the trip points for the temperature: If a warning is generated. the shutdown output is activated and the fuel is shut off. System Response: • E816 (1) Cylinder #16 High Exhaust Port Temp (warning) • E816 (3) Cylinder #16 High Exhaust Port Temp (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. • OK – STOP. the shutdown output is activated and the fuel is shut off. Results: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. The engine will be shut down if the trip point for the shutdown is exceeded. The engine will be shut down if the trip point for the shutdown is exceeded.177 Troubleshooting Section If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. Results: • E815 (1) Cylinder #15 High Exhaust Port Temp (warning) • E815 (3) Cylinder #15 High Exhaust Port Temp (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. the alarm output is activated. the alarm output is activated. i01635584 E816 Cylinder #16 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: Refer to Troubleshooting. i01635578 The following event codes are logged according to the trip points for the temperature: E815 Cylinder #15 High Exhaust Port Temp SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. . the engine performance is not immediately affected. If a shutdown is generated. Troubleshooting: Results: • OK – STOP. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. The amount of deviation has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. .178 Troubleshooting Section i01635587 i01635593 E821 Cyl #1 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the alarm output is activated. Results: • OK – STOP. If a shutdown is generated. Possible Performance Effect: If a warning is generated. • OK – STOP. If a shutdown is generated. “Exhaust Port Temperature (High)”. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: E822 Cyl #2 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. Results: • E822 (3) Cyl #2 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E821 (1) Cyl #1 Exhaust Port Temp Deviating High (warning) • E822 (1) Cyl #2 Exhaust Port Temp Deviating High (warning) • E821 (3) Cyl #1 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. the alarm output is activated. “Exhaust Port Temperature (High)”. Results: • OK – STOP. • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. Results: • E823 (1) Cyl #3 Exhaust Port Temp Deviating High (warning) • E823 (3) Cyl #3 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. the engine performance is not immediately affected. .179 Troubleshooting Section i01635600 System Response: The following event codes are logged according to the trip points for the temperature: E823 Cyl #3 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. If a shutdown is generated. • E825 (1) Cyl #5 Exhaust Port Temp Deviating High (warning) • E825 (3) Cyl #5 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”. The amount of deviation has exceeded the trip point and the delay time has expired. the alarm output is activated. i01635605 E825 Cyl #5 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. System Response: The following event codes are logged according to the trip points for the temperature: • E824 (1) Cyl #4 Exhaust Port Temp Deviating High (warning) • E824 (3) Cyl #4 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. Troubleshooting: Refer to Troubleshooting. i01635604 System Response: The following event codes are logged according to the trip points for the temperature: E824 Cyl #4 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • E826 (1) Cyl #6 Exhaust Port Temp Deviating High (warning) • E826 (3) Cyl #6 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. i01635614 E827 Cyl #7 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. the engine performance is not immediately affected. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. the alarm output is activated. Results: Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: If a warning is generated. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. • OK – STOP. “Exhaust Port Temperature (High)”. “Exhaust Port Temperature (High)”. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. i01635612 E826 Cyl #6 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the engine performance is not immediately affected. Results: • OK – STOP. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E827 (1) Cyl #7 Exhaust Port Temp Deviating High (warning) • E827 (3) Cyl #7 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. . The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. If a shutdown is generated. the engine performance is not immediately affected. “Exhaust Port Temperature (High)”.180 Troubleshooting Section If a shutdown is generated. Results: • E828 (1) Cyl #8 Exhaust Port Temp Deviating High (warning) • E828 (3) Cyl #8 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. If a shutdown is generated. • OK – STOP.181 Troubleshooting Section i01635616 System Response: The following event codes are logged according to the trip points for the temperature: E828 Cyl #8 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. “Exhaust Port Temperature (High)”. The amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. i01635634 E830 Cyl #10 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • OK – STOP. • E830 (1) Cyl #10 Exhaust Port Temp Deviating High (warning) • E830 (3) Cyl #10 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E829 (1) Cyl #9 Exhaust Port Temp Deviating High (warning) • E829 (3) Cyl #9 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. i01635618 System Response: The following event codes are logged according to the trip points for the temperature: E829 Cyl #9 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. If a shutdown is generated. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. The amount of deviation has exceeded the trip point and the delay time has expired. . Possible Performance Effect: If a warning is generated. the engine performance is not immediately affected. the engine performance is not immediately affected. . Troubleshooting: Refer to Troubleshooting. Results: Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. i01635645 E832 Cyl #12 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. The engine will be shut down if the trip point for the shutdown is exceeded. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. Possible Performance Effect: If a warning is generated. Possible Performance Effect: If a warning is generated. Results: • E831 (1) Cyl #11 Exhaust Port Temp Deviating High (warning) • E831 (3) Cyl #11 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”. the shutdown output is activated and the fuel is shut off. the alarm output is activated. If a shutdown is generated. “Exhaust Port Temperature (High)”. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature: • E832 (1) Cyl #12 Exhaust Port Temp Deviating High (warning) • E832 (3) Cyl #12 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. the shutdown output is activated and the fuel is shut off. “Exhaust Port Temperature (High)”. the alarm output is activated.182 Troubleshooting Section If a shutdown is generated. The amount of deviation has exceeded the trip point and the delay time has expired. If a shutdown is generated. i01635641 E831 Cyl #11 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the engine performance is not immediately affected. the engine performance is not immediately affected. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. • OK – STOP. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. the engine performance is not immediately affected. • E835 (1) Cyl #15 Exhaust Port Temp Deviating High (warning) • E835 (3) Cyl #15 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. • OK – STOP. Results: • E833 (1) Cyl #13 Exhaust Port Temp Deviating High (warning) • E833 (3) Cyl #13 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E834 (1) Cyl #14 Exhaust Port Temp Deviating High (warning) • E834 (3) Cyl #14 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. “Exhaust Port Temperature (High)”. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: If a warning is generated. .183 Troubleshooting Section i01635653 System Response: The following event codes are logged according to the trip points for the temperature: E833 Cyl #13 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. “Exhaust Port Temperature (High)”. i01635658 E835 Cyl #15 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. the alarm output is activated. the shutdown output is activated and the fuel is shut off. Results: • OK – STOP. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. If a shutdown is generated. i01635656 System Response: The following event codes are logged according to the trip points for the temperature: E834 Cyl #14 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. The engine will be shut down if the trip point for the shutdown is exceeded. • OK – STOP. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. i01635661 E836 Cyl #16 Exhaust Port Temp Deviating High SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is higher than the average temperature for all of the cylinders. the engine performance is not immediately affected. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. Results: • OK – STOP. If a shutdown is generated. the shutdown output is activated and the fuel is shut off. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (Low)”. The amount of deviation has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. i01635664 E841 Cyl #1 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. the alarm output is activated. the shutdown output is activated and the fuel is shut off. If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. Results: Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (High)”. “Exhaust Port Temperature (High)”. Results: • E836 (1) Cyl #16 Exhaust Port Temp Deviating High (warning) • E836 (3) Cyl #16 Exhaust Port Temp Deviating High (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated.184 Troubleshooting Section If a shutdown is generated. the alarm output is activated. . System Response: The following event codes are logged according to the trip points for the temperature: • E841 (1) Cyl #1 Exhaust Port Temp Deviating Low (warning) • E841 (3) Cyl #1 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. If a shutdown is generated. “Exhaust Port Temperature (Low)”. The amount of deviation has exceeded the trip point and the delay time has expired. The amount of deviation has exceeded the trip point and the delay time has expired. • E844 (1) Cyl #4 Exhaust Port Temp Deviating Low (warning) • E844 (3) Cyl #4 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. . the alarm output is activated. Results: • E842 (1) Cyl #2 Exhaust Port Temp Deviating Low (warning) • E841 (3) Cyl #2 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. • OK – STOP. the shutdown output is activated and the fuel is shut off. the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. The amount of deviation has exceeded the trip point and the delay time has expired. System Response: The following event codes are logged according to the trip points for the temperature: • E843 (1) Cyl #3 Exhaust Port Temp Deviating Low (warning) • E843 (3) Cyl #3 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated.185 Troubleshooting Section i01635667 System Response: The following event codes are logged according to the trip points for the temperature: E842 Cyl #2 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (Low)”. i01635668 System Response: The following event codes are logged according to the trip points for the temperature: E843 Cyl #3 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. i01635670 E844 Cyl #4 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. the engine performance is not immediately affected. the alarm output is activated. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. The engine will be shut down if the trip point for the shutdown is exceeded. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • OK – STOP. “Exhaust Port Temperature (Low)”. “Exhaust Port Temperature (Low)”. . The amount of deviation has exceeded the trip point and the delay time has expired. the shutdown output is activated and the fuel is shut off. If a shutdown is generated. Results: Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (Low)”. Results: • E845 (1) Cyl #5 Exhaust Port Temp Deviating Low (warning) • E845 (3) Cyl #5 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Possible Performance Effect: If a warning is generated. the shutdown output is activated and the fuel is shut off. i01635673 E846 Cyl #6 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. System Response: The following event codes are logged according to the trip points for the temperature: • E846 (1) Cyl #6 Exhaust Port Temp Deviating Low (warning) • E846 (3) Cyl #6 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the engine performance is not immediately affected. The engine will be shut down if the trip point for the shutdown is exceeded.186 Troubleshooting Section If a shutdown is generated. The amount of deviation has exceeded the trip point and the delay time has expired. the alarm output is activated. the engine performance is not immediately affected. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. • OK – STOP. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. i01635672 E845 Cyl #5 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the alarm output is activated. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. • E849 (1) Cyl #9 Exhaust Port Temp Deviating Low (warning) • E849 (3) Cyl #9 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. . the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. The engine will be shut down if the trip point for the shutdown is exceeded. • OK – STOP.187 Troubleshooting Section i01635677 System Response: The following event codes are logged according to the trip points for the temperature: E847 Cyl #7 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the shutdown output is activated and the fuel is shut off. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (Low)”. If a shutdown is generated. If a shutdown is generated. Results: • E847 (1) Cyl #7 Exhaust Port Temp Deviating Low (warning) • E847 (3) Cyl #7 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. the engine performance is not immediately affected. Results: • OK – STOP. “Exhaust Port Temperature (Low)”. the engine performance is not immediately affected. i01635680 System Response: The following event codes are logged according to the trip points for the temperature: E848 Cyl #8 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. i01635683 E849 Cyl #9 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Possible Performance Effect: If a warning is generated. the alarm output is activated. System Response: The following event codes are logged according to the trip points for the temperature: • E848 (1) Cyl #8 Exhaust Port Temp Deviating Low (warning) • E848 (3) Cyl #8 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. Troubleshooting: Refer to Troubleshooting. System Response: The following event codes are logged according to the trip points for the temperature: • E851 (1) Cyl #11 Exhaust Port Temp Deviating Low (warning) • E851 (3) Cyl #11 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. If a shutdown is generated. the engine performance is not immediately affected. i01635685 E851 Cyl #11 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. “Exhaust Port Temperature (Low)”. . i01635684 E850 Cyl #10 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the alarm output is activated. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (Low)”. Results: • E850 (1) Cyl #10 Exhaust Port Temp Deviating Low (warning) • E850 (3) Cyl #10 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. Results: • OK – STOP. the shutdown output is activated and the fuel is shut off. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. “Exhaust Port Temperature (Low)”. The engine will be shut down if the trip point for the shutdown is exceeded. The amount of deviation has exceeded the trip point and the delay time has expired. The amount of deviation has exceeded the trip point and the delay time has expired. The engine will be shut down if the trip point for the shutdown is exceeded. Possible Performance Effect: If a warning is generated. the alarm output is activated. If a shutdown is generated. the engine performance is not immediately affected. • OK – STOP. the shutdown output is activated and the fuel is shut off. Results: Troubleshooting: Refer to Troubleshooting.188 Troubleshooting Section If a shutdown is generated. Possible Performance Effect: If a warning is generated. “Exhaust Port Temperature (Low)”. Possible Performance Effect: If a warning is generated. Troubleshooting: Refer to Troubleshooting. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. the alarm output is activated. the shutdown output is activated and the fuel is shut off. The amount of deviation has exceeded the trip point and the delay time has expired.189 Troubleshooting Section i01635688 System Response: The following event codes are logged according to the trip points for the temperature: E852 Cyl #12 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. The amount of deviation has exceeded the trip point and the delay time has expired. The engine will be shut down if the trip point for the shutdown is exceeded. “Exhaust Port Temperature (Low)”. . i01635692 E854 Cyl #14 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. • E854 (1) Cyl #14 Exhaust Port Temp Deviating Low (warning) • E854 (3) Cyl #14 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. If a shutdown is generated. i01635691 System Response: The following event codes are logged according to the trip points for the temperature: E853 Cyl #13 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the alarm output is activated. the engine performance is not immediately affected. the shutdown output is activated and the fuel is shut off. The amount of deviation has exceeded the trip point and the delay time has expired. Results: • E852 (1) Cyl #12 Exhaust Port Temp Deviating Low (warning) • E852 (3) Cyl #12 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. System Response: The following event codes are logged according to the trip points for the temperature: • E853 (1) Cyl #13 Exhaust Port Temp Deviating Low (warning) • E853 (3) Cyl #13 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. • OK – STOP. the engine performance is not immediately affected. Results: • OK – STOP. Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. System Response: The following event codes are logged according to the trip points for the temperature: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. the alarm output is activated. The engine will be shut down if the trip point for the shutdown is exceeded. Results: • OK – STOP. System Response: The following event codes are logged according to the trip points for the temperature: • E856 (1) Cyl #16 Exhaust Port Temp Deviating Low (warning) • E856 (3) Cyl #16 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. “Exhaust Port Temperature (Low)”. Possible Performance Effect: If a warning is generated. If a shutdown is generated. “Exhaust Port Temperature (Low)”. Possible Performance Effect: If a warning is generated. The amount of deviation has exceeded the trip point and the delay time has expired. Possible Performance Effect: If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. i01635695 E856 Cyl #16 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: • OK – STOP. the shutdown output is activated and the fuel is shut off.190 Troubleshooting Section If a shutdown is generated. Results: Troubleshooting: Refer to Troubleshooting. If a shutdown is generated. • OK – STOP. Results: • E855 (1) Cyl #15 Exhaust Port Temp Deviating Low (warning) • E855 (3) Cyl #15 Exhaust Port Temp Deviating Low (shutdown) If a warning is generated. The engine will be shut down if the trip point for the shutdown is exceeded. the engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting. “Exhaust Port Temperature (Low)”. the engine performance is not immediately affected. i01635694 E855 Cyl #15 Exhaust Port Temp Deviating Low SMCS Code: 1901-038 Conditions Which Generate This Code: The cylinder exhaust temperature is less than the average temperature for all of the cylinders. Troubleshooting: Refer to Troubleshooting. The amount of deviation has exceeded the trip point and the delay time has expired. the alarm output is activated. the shutdown output is activated and the fuel is shut off. . the shutdown output is activated and the fuel is shut off. the engine performance is not immediately affected. The engine performance is not immediately affected. The alarm output is activated. The engine performance is not immediately affected. The code is logged. The difference in fuel pressure between the inlet and the outlet of the fuel metering valve is greater than the trip point. “Gas Fuel Differential Pressure (Low)”. • OK – STOP. System Response: E867 Improper Gas Flow Control Valve Response SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve is not responding correctly to the ECM and the delay time has expired. the flow rate that is computed by the valve does not match the fuel demand for a delay time of 5 seconds. Results: i01637716 • OK – STOP. i01637722 E865 High Gas Fuel Differential Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: The Gas Shutoff Valve (GSOV) is energized. “Fuel Metering Valve”. Troubleshooting: Refer to Troubleshooting. “Gas Fuel Differential Pressure (High)”. The code is logged. . The delay time has expired. Possible Performance Effect: Possible Performance Effect: The engine performance is not immediately affected. However. “Gas Fuel Flow Rate (Low)”. The code is logged. The delay time has expired. Refer to Troubleshooting. i01637720 E866 Low Gas Fuel Flow Rate SMCS Code: 1901-038 Conditions Which Generate This Code: The fuel metering valve is fully open. The code is logged. • OK – STOP. System Response: The alarm output is activated. Results: Possible Performance Effect: The engine performance is not immediately affected. Troubleshooting: Refer to Troubleshooting. System Response: Possible Performance Effect: The alarm output is activated.191 Troubleshooting Section i01637712 Results: E864 Low Gas Fuel Differential Pressure SMCS Code: 1901-038 Conditions Which Generate This Code: The gas shutoff valve (GSOV) is energized. System Response: The alarm output is activated. The difference in fuel pressure between the outlet and the inlet of the fuel metering valve is less than the trip point. Troubleshooting: Troubleshooting: Refer to Troubleshooting. 192 Troubleshooting Section Results: • OK – STOP. Results: • OK – STOP. . The code is logged. “Fuel Metering Valve”. Troubleshooting: Refer to Troubleshooting. Possible Performance Effect: The engine performance is not immediately affected. i01637725 E868 Gas Flow Control Valve Malfunction SMCS Code: 1901-038 Conditions Which Generate This Code: The ECM has detected a malfunction for the fuel metering valve and the delay time has expired. System Response: The alarm output is activated. Clear the diagnostic codes after the problem is resolved.5 VDC to the sensors for these parameters: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure • Humidity (if equipped) The ECM also provides 5 VDC to the “DESIRED SPEED” potentiometer (if equipped). Logged diagnostic codes provide an historical record. A “+5 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness. .193 Troubleshooting Section Diagnostic Functional Tests i01726283 +5V Sensor Voltage Supply SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 5. Keep your mind on correcting the cause of the original diagnostic code. This troubleshooting procedure may generate additional diagnostic codes. The next likely cause is a sensor problem. A “+5 Volt Sensor DC Power Supply short to ground” diagnostic code will be activated if both of these conditions occur: • The desired speed signal wire is shorted to ground. • The “DESIRED SPEED” potentiometer is near the maximum desired speed or at the maximum desired speed. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Before you begin this procedure. The least likely cause is a problem with the ECM. The next likely cause is a sensor problem. The least likely cause is a problem with the ECM. The 5 V diagnostic code is probably caused by a short circuit or an open circuit in a harness.0 ± 0. 194 Troubleshooting Section Illustration 16 Schematic for the analog sensors g00888350 . Turn the engine control switch to the OFF/RESET position. Inspect the Electrical Connectors and Wiring A. Switch the 16 amp circuit breaker for the ECM OFF. Note: For the following steps. Illustration 18 Harness side of the ECM P1 connector (2) +5 volt supply (3) Return (11) Signal for the humidity (14) Signal for the inlet manifold air temperature (16) Signal for the desired speed (17) Signal for the engine oil temperature (18) +5 volt supply (24) Signal for the filtered engine oil pressure (26) Signal for the unfiltered engine oil pressure (35) Return g00888440 Illustration 17 g00888377 (1) ECM connectors J1/P1 (2) J12/P12 connectors for the 5 V sensors (3) J19/P19 connectors for the harness from the control panel (if equipped) (4) 16 amp circuit breaker (5) J9/P9 connectors for the customer (if equipped) B. Illustration 19 Harness side of the P12 connector (A) +5 volt supply (C) Return (E) Signal for the unfiltered engine oil pressure (F) Signal for the filtered engine oil pressure (G) Signal for the humidity (H) Signal for the engine oil temperature (K) Signal for the inlet air temperature g00888444 .195 Troubleshooting Section Test Step 1. Check the torque of the Allen head screw for the ECM connector. “Inspecting Electrical Connectors”. J19/P19. Thoroughly inspect each of the following connectors: • ECM J1/P1 connectors • J12/P12. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). refer to Troubleshooting. and J9/P9 connectors on the terminal box a. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 5 V sensors. Illustration 22 (7) Filtered oil pressure sensor (8) Unfiltered oil pressure sensor (9) Oil temperature sensor g00888432 Illustration 21 (5) Inlet air temperature sensor (6) Engine coolant temperature sensor g00888384 .196 Troubleshooting Section Illustration 20 Harness side of the P19 connector (if equipped) (S) +5 volt supply (T) Signal for desired speed (U) Return g00888526 b. Expected Result: are connected properly. and pinch points. and pinch points. Expected Result: All of the connectors. B. Rotate the “DESIRED SPEED” potentiometer (if equipped) counterclockwise to the minimum speed position. abrasion. Switch the 16 amp circuit breaker for the ECM ON. Results: • No codes – There are no active codes or logged codes. Observe the “Active Diagnostic” screen on Cat ET. At least one of the connectors and the wiring has corrosion. The components are in good condition with proper connections. and sockets • 262-04 5 Volt Sensor DC Power Supply short to ground E. STOP. Turn the engine control switch to the STOP position. pins. D. Connect Cat ET to the service tool connector on the terminal box. • Active code – The 262-03 code or the 262-04 code is active. abrasion. . pins. and/or pinch points. Results: C. However. or sockets are not connected properly. there is at least one logged code for the +5 volt sensor supply. Check for Diagnostic Codes A. Look for these codes: • 262-03 5 Volt Sensor DC Power Supply short to +batt • OK – All of the connectors. pins. The 262-03 code or the 262-04 code is not active or logged. • Logged code – The 262-03 code or the 262-04 code is not active. Look for the same codes. Proceed to Test Step 2.197 Troubleshooting Section Illustration 23 (10) Humidity sensor (if equipped) g00888429 c. The connectors and the wiring are free of corrosion. Test Step 2. The connectors and the wiring are free of corrosion. • Not OK – At least one of the connectors. if necessary. and sockets are connected properly. abrasion. Check the harness and wiring for abrasion and pinch points from the 5 V sensors to the ECM. Repair: Perform the necessary repairs and/or replace parts. Wait at least 30 seconds so that any codes may become activated. Observe the “Logged Diagnostic” screen on Cat ET. Proceed to Test Step 6. Proceed to Test Step 3. “Inspecting Electrical Connectors”. Proceed to Test Step 5. Proceed to Test Step 4. Refer to Troubleshooting. Results: • OK – The resistance is greater than 20. Measure the resistance from terminal B to T on harness connector P19. STOP. B. Rotate the “DESIRED SPEED” potentiometer (if equipped) clockwise to the maximum speed position. Switch the 16 amp circuit breaker for the ECM OFF. • Active code – Rotating the “DESIRED SPEED” potentiometer clockwise to the maximum speed position caused an active code.000 ohms. Test Step 4. There is a problem with the analog speed circuit. Expected Result: The 262-03 code or the 262-04 code is not active.198 Troubleshooting Section Repair: There may be a problem with the wiring and/or a connector. Disconnect the P19 connector from the terminal box. Disconnect the P19 Connector and Check the Wiring for the Potentiometer A. Verify that the wiring and/or connectors are OK. Check the Analog Speed Circuit Note: If the engine is not equipped with a “DESIRED SPEED” potentiometer. The +5 V sensor voltage supply is operating correctly at this time. proceed to Test Step 8. Resume normal operation. Check for diagnostic codes again. Test Step 3. Proceed to Test Step 3. Illustration 24 g00888515 Results: P19 connector on the terminal box • No codes – Rotating the “DESIRED SPEED” potentiometer clockwise to the maximum speed position did not cause an active code. if necessary. . Illustration 25 Harness connector P19 (P19-B) -BATT (P19-T) Signal wire for the “DESIRED SPEED” potentiometer g00888532 C. Expected Result: The resistance is greater than 20. The wiring on the outside of the terminal box for the “DESIRED SPEED” potentiometer appears to be OK. Turn the engine control switch to the OFF/RESET position.000 ohms. A. Verify that the original problem is resolved. Repair: Repair the connector and/or wiring. Test Step 5. • OK – The resistance is greater than 20. There is a problem with a connector and/or the wiring inside the terminal box. STOP. Resume normal operation.000 ohms. Disconnect the P1 connector from the ECM. Isolate the Wiring Harnesses from the ECM A. Replace the wiring. 3. Repair: Reconnect all of the connectors.000 ohms. Reconnect the P1 connector to the ECM.199 Troubleshooting Section • Not OK – The resistance is less than 20. if necessary. Measure the resistance between terminals 16 and 69 of connector P1. Reconnect all of the connectors and perform this procedure again. Test Step 6. Expected Result: The resistance is greater than 20. Switch the 16 amp circuit breaker for the ECM OFF. Repair: Perform the following procedure: 1.000 ohms. Perform any necessary repairs or replace parts. Verify that all connections are in good condition and free of moisture.000 Results: ohms. • Not OK – The resistance is less than 20. The wiring inside the terminal box appears to be OK. Turn the engine control switch to the OFF/RESET position. if necessary. The initial diagnostic code was probably caused by a poor electrical connection. Illustration 27 ECM connector P1 (P1-2) + 5 volt supply for the analog sensors (P1-18) +5 volt supply for the “DESIRED SPEED” potentiometer g00888555 . when possible. Check the Wiring Inside the Terminal Box A. 4. There is a problem with the wiring on the outside of the terminal box for the “DESIRED SPEED” potentiometer. Carefully inspect the following items: • Connector P19 • The harness from the P19 connector to the “DESIRED SPEED” potentiometer 2. STOP. STOP. The problem appears to be resolved. Verify that the harness from the P19 connector to the “DESIRED SPEED” potentiometer is in good condition. Illustration 26 ECM side of the P1 connector g00862380 (P1-16) Signal wire for the “DESIRED SPEED” potentiometer (P1-69) Ground B. B. Switch the 16 amp circuit breaker for the ECM ON. Insert terminal 18 into the P1 connector. Expected Result: No active codes Results: • Active code – The 262-03 code or the 262-04 • No codes – The 262-03 code or the 262-04 code is not active. Proceed to Test Step 8. Connect the +5 V Wiring for the Sensors to the ECM A. D. Connect the +5 V Wiring for the Analog Speed Circuit to the ECM A. Use Cat ET to look for diagnostic codes. Connecting the wiring for the analog speed circuit to the ECM caused a diagnostic code. Use a 151-6320 Wire Removal Tool to remove terminal 2 and terminal 18 from the P1 connector. code is active. E. If the problem is not resolved. • Active codes – The 262-03 code or the 262-04 code is active. Expected Result: No active codes Results: • No codes – The 262-03 code or the 262-04 code Illustration 28 ECM connector P1 (P1-18) +5 V supply g00862455 is not active. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Test Step 8. E. Turn the engine control switch to the OFF/RESET position. Turn the engine control switch to the STOP position. Disconnecting all of the +5 V wiring from the ECM eliminated the active “5 Volt Sensor Supply” diagnostic code. D. Disconnecting all of the +5 V wiring from the ECM did not eliminate the +5 V diagnostic code. Proceed to Test Step 7. Refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. C. Connecting the wiring for the analog speed circuit to the ECM did not cause a diagnostic code. There may be a problem with the ECM. Use Cat ET to look for diagnostic codes. Exit this procedure and perform this procedure again. Switch the 16 amp circuit breaker for the ECM ON. Switch the 16 amp circuit breaker for the ECM OFF. The wiring for the analog speed circuit appears to be OK. Rotate the “DESIRED SPEED” potentiometer clockwise to the maximum speed position. Repair: It is unlikely that the ECM has failed. “Replacing the ECM”. If the new ECM operates correctly and the original ECM does not operate correctly. If the problem is resolved with the new ECM. Refer to Troubleshooting.200 Troubleshooting Section C. Test Step 7. Turn the engine control switch to the STOP position. STOP. There is a problem with a connector and/or the wiring in a harness. Turn the engine control switch to the OFF/RESET position. “Replacing the ECM”. B. replace the original ECM. . perform the following steps: Temporarily install a new ECM. install the original ECM and verify that the problem returns. Proceed to Test Step 4. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the OFF/RESET position. D. Turn the engine control switch to the STOP position. replace the sensor.201 Troubleshooting Section • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure • Humidity (if equipped) C. 2. Repair: Perform the following procedure: 1. Test Step 9. The sensor and/or the wiring for the sensor has a short circuit. wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET. Resume normal operation. Use Cat ET to clear the Logged 262-03 or 262-04 code. Disconnect the sensors for the following parameters: 3. Disconnect the suspect sensor. Connecting the 5 VDC for the sensors did not cause a diagnostic code. Connecting the 5 VDC for the sensors caused a diagnostic code. Results: • Yes – The original “5 Volt Sensor” diagnostic • Active code – The 262-03 code or the 262-04 code is active. • Inlet air temperature • Engine oil temperature Expected Result: • Unfiltered engine oil pressure No active codes • Filtered engine oil pressure Results: • Humidity • No codes – The 262-03 code or the 262-04 code is not active. Verify that the 262-03 code or the 262-04 code is not active. Use Cat ET to look for diagnostic codes. Switch the 16 amp circuit breaker for the ECM OFF. B. Repair: The initial diagnostic code was probably caused by a poor electrical connection. Verify that the diagnostic code recurs. Pull on the wire in order to verify that the terminal is fully inserted into the connector. Insert terminal 2 into the P1 connector. E. Disconnect the +5 V Sensors and Look For Active Diagnostic Codes. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. Proceed to Test Step 9. Illustration 29 ECM connector P1 (P1-2) +5 V supply g00862457 B. code is activated when a particular sensor is reconnected. Observe the “Active Diagnostic” screen on Cat ET. If these conditions are true. C. Expected Result: The original “5 Volt Sensor” diagnostic code is activated when a particular sensor is disconnected. • Inlet air temperature . After you reconnect each sensor. Clear the codes after you complete this procedure. D. 4. The problem appears to be resolved. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. This is normal. Turn the engine control switch to the STOP position. STOP. Switch the 16 amp circuit breaker for the ECM ON. Reconnect the sensors for the following parameters one at a time. Reconnect the suspect sensor. A. The problem appears to be resolved. Be sure to wiggle the harnesses near each of the connectors for the disconnected sensors. Proceed to Test Step 11. Turn the engine control switch to the OFF position. . Disconnect the P12 connector. STOP. Check the Harnesses A. Connector and Terminal P1-2 +5 V supply Connector and Terminal P1-14 (inlet air temperature) P1-17 (engine oil temperature) P1-26 (unfiltered engine oil pressure) P1-24 (filtered engine oil pressure) P1-11 (humidity) P1-3 (analog return) Ground strap for the engine P1-69 (−battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal) • No – The original “5 Volt Sensor” diagnostic code was still active while all of the +5 V sensors were disconnected. Verify that all of the sensors are disconnected. Results: • OK – Each check of the resistance is greater than 20. Test Step 10. During each measurement. Verify that all of the sensors for the following parameters are disconnected from the engine harness: • Inlet air temperature • Engine oil temperature • Unfiltered engine oil pressure • Filtered engine oil pressure • Humidity Expected Result: Each check of the resistance is greater than 20. • Not OK – At least one check of the resistance is Illustration 30 ECM side of the P1 connector g00888578 less than 20.000 ohms. The initial diagnostic code was probably caused by a poor electrical connection. Also. Table 14 Measure the Resistance for the Engine Harness. STOP. Disconnect the P1 connector. The +5 V wires in the engine harnesses do not have a problem.000 ohms. Verify that the problem is eliminated. Resume normal operation. Check the Engine Harness A. wiggle the harness at the P12 connector. Do not reconnect the sensors. Proceed to Test Step 10. There is a problem with a connector and/or at least one of the +5 V wires in a harness. Test Step 11. Measure the resistance between terminal (2) of the P1 connector and the points that are listed in Table 14. B. wiggle the harnesses in order to check for an intermittent problem with the harness. C.000 ohms. Switch the 16 amp circuit breaker for the ECM OFF. Clear all of the diagnostic codes. Repair: Reconnect all of the connectors.202 Troubleshooting Section 5. This will isolate the terminal box’s harness. when possible. Replace the harness. Connector and Terminal P1-2 +5 V supply Connector and Terminal P1-14 (inlet air temperature) P1-17 (engine oil temperature) P1-26 (unfiltered engine oil pressure) P1-24 (filtered engine oil pressure) P1-11 (humidity) P1-3 (analog return) Ground strap for the engine P1-69 (−battery terminal) P1-57 (unswitched +battery terminal) Expected Result: Each check of the resistance is greater than 20.000 ohms. Proceed to Test Step 12. Results: Expected Result: P1-70 (switched +battery terminal) • OK – Each check of the resistance is greater than 20. if necessary. Disconnect the P19 connector. • OK – Each check of the resistance is greater than 20. Verify that P12. and P1 are also disconnected. Measure the resistance between terminal A of the P12 connector and the points that are listed in Table 15. Be sure to wiggle the harnesses near each of the connectors. During each measurement.000 ohms. The +5 V wires in the engine harness do not have a problem. Each check of the resistance is greater than 20. The problem seems to be resolved.000 ohms. . Results: • Not OK – Repair the engine harness. During each measurement.000 ohms. Table 16 P12-K (inlet air temperature) P12-H (engine oil temperature) P12-E (unfiltered engine oil pressure) P12-F (filtered engine oil pressure) P12-G (humidity) Ground strap for the engine P1-57 (unswitched +battery terminal) P1-69 (−battery terminal) P1-70 (switched +battery terminal) Measure the Resistance for the Engine Harness. Check the Terminal Box’s Harness A. wiggle the harnesses in order to check for an intermittent problem with the harness. Table 15 Illustration 32 ECM side of the P1 connector g00888578 Measure the Resistance for the Engine Harness. Measure the resistance between terminal 2 of the P1 connector and the points that are listed in Table 16. wiggle the wires in the terminal box in order to check for an intermittent problem. Connector and Terminal P12-A +5 V supply Connector and Terminal P12-C (analog return / shield) B. Illustration 31 Harness connector P12 g00888586 B. Be sure to wiggle the wires near each of the connectors.203 Troubleshooting Section Test Step 12. The initial diagnostic code was probably caused by a poor electrical connection. STOP. . i01731152 +8V Sensor Voltage Supply SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 8. Repair: Repair the terminal box’s harness. if necessary. The next likely cause is a sensor problem.000 ohms. There is a problem with a connector and/or at least one of the +5 V wires in the terminal box.204 Troubleshooting Section Repair: Reconnect all of the connectors and resume normal operation. Before you begin this procedure. STOP. when possible. This troubleshooting procedure may generate additional diagnostic codes. The least likely cause is a problem with the ECM.0 ± 0. • Not OK – At least one check of the resistance is less than 20. Clear the diagnostic codes after the problem is resolved. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Logged diagnostic codes provide an historical record.8 VDC to these sensors: • Sensor for engine coolant pressure (outlet) • Sensor for inlet air pressure • Sensor for atmospheric pressure (if equipped) • All of the detonation sensors A “+8 V sensor supply” diagnostic code is probably caused by a short circuit or an open circuit in a harness. STOP. Replace the harness. Keep your mind on correcting the cause of the original diagnostic code. 205 Troubleshooting Section Illustration 33 Schematic for the 8 V sensors g00888910 . A. Turn the engine control switch to the OFF/RESET position. Illustration 35 Harness side of the ECM P1 connector (P1-4) +8 V supply for the pressure sensors (P1-5) Return for the pressure sensors g00888926 Illustration 34 (1) ECM J2/P2 connectors (2) ECM connectors J1/P1 (3) J12/P12 connectors for the 8 V sensors (4) J11/P11 connectors for the detonation sensors (5) 16 amp circuit breaker g00888914 Illustration 36 Harness side of the ECM P2 connector (P2-54) (P2-55) (P2-56) (P2-57) Return for the detonation sensors Return for the detonation sensors +8 V supply for the detonation sensors +8 V supply for the detonation sensors g00888929 B. “Inspecting Electrical Connectors”. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Switch the 16 amp circuit breaker for the ECM OFF. Thoroughly inspect each of the following connectors: • ECM J1/P1 and J2/P2 connectors • J12/P12 and J11/P11 connectors on the terminal box a. Check the torque of the Allen head screw for the ECM connector. refer to Troubleshooting. Note: For the following steps. Illustration 37 Harness side of the P11 connector (A) Return for the detonation sensors (E) Return for the detonation sensors (F) +8 V supply for the detonation sensors (J) +8 V supply for the detonation sensors g00888905 .206 Troubleshooting Section Test Step 1. Inspect the Electrical Connectors and Wiring. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the 8 V sensors.207 Troubleshooting Section Illustration 38 Harness side of the P12 connector (L) +8 V supply for the sensors (N) Return g00888904 b. Illustration 39 (6) Sensor for engine coolant pressure (outlet) (7) Detonation sensor (8) Sensor for inlet air pressure g00888920 . The connectors and the wiring are free of corrosion. Observe the “Logged Diagnostic” screen on Cat ET. • Active code – The 41-03 code or the 41-04 code is active. The +8 volt sensor supply is operating correctly at this time. there is at least one logged code for the 8 volt sensor supply. pins. and sockets are connected properly. Expected Result: All of the connectors. Proceed to Test Step 2. Repair: Perform the necessary repairs and/or replace parts. C. Observe the “Active Diagnostic” screen on Cat ET. STOP. Wait at least 30 seconds so that any codes may become activated. and pinch points. abrasion. if necessary. pins. Switch the 16 amp circuit breaker for the ECM ON. and sockets are not connected properly. Connect Cat ET to the service tool connector on the terminal box. STOP. and sockets are connected properly. Test Step 2. . • Not OK – At least one of the connectors. However. • Logged code – The 41-03 code or the 41-04 code is not active. Expected Result: The 41-03 code or the 41-04 code is not active. At least one of the connectors and/or the wiring have corrosion. • OK – All of the connectors. and/or pinch points.208 Troubleshooting Section Illustration 40 (9) Sensor for atmospheric pressure (if equipped) g00888924 c. Results: B. Check for Diagnostic Codes A. Check the harness and wiring for abrasion and pinch points from the 8 V sensors to the ECM. The connectors and the wiring are free of corrosion. abrasion. and pinch points. The components are in good condition with proper connections. abrasion. Look for the same codes. Proceed to Test Step 3. Look for these codes: • 41-03 8 Volt DC Supply short to +batt • 41-04 8 Volt DC Supply short to ground D. Results: • No codes – The 41-03 code or the 41-04 code is not active. Turn the engine control switch to the STOP position. pins. Determine if a 41-03 code or a 41-04 code is active. STOP. Proceed to Test Step 4. Turn the engine control switch to the OFF/RESET position. D. Verify that the problem is eliminated. The sensor and/or the wiring for the sensor has a short circuit. Results: • Yes – The original “8 Volt DC Supply” diagnostic code is deactivated when a particular sensor is disconnected. B. • No – The original “8 Volt DC Supply” diagnostic code is still active when a particular sensor is disconnected. Verify that the diagnostic code is deactivated. Disconnect the 8 V Sensors and Look for Active Diagnostic Codes. 2. Clear the codes after you complete this procedure. After you disconnect each sensor. Check for diagnostic codes again. Verify that the “41-03” or “41-04” code is active. Reconnect the suspect sensor. . Repair: Perform the following procedure: 1. 3. A. Turn the engine control switch to the STOP position. Illustration 41 Harness side of ECM P1 connector and P2 connector (P1-4) +8 V supply for the pressure sensors (P2-56) +8 V supply for the detonation sensors (P2-57) +8 V supply for the detonation sensors g00888983 B. Test Step 4. Test Step 3. Do not reconnect the sensors. Expected Result: The original “8 Volt DC Supply” diagnostic code is deactivated when a particular sensor is disconnected. Turn on the “Active Diagnostic” screen on Cat ET. Proceed to Test Step 3. Note: An “Open Circuit” code will be generated for each sensor that is disconnected. “Inspecting Electrical Connectors”. if necessary. Disconnect the suspect sensor.209 Troubleshooting Section Repair: There may be a problem with the wiring and/or a connector. if necessary. Disconnect each 8 V sensor one at a time. This is normal. Isolate the Wiring Harnesses from the ECM A. Replace parts. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the wires from the following terminals: • Terminal 56 and 57 of the P2 connector (1) • Terminal 4 of the P1 connector (2) C. Verify that the diagnostic code recurs. Clear all of the diagnostic codes. If these conditions are true. Verify that the wiring and/or connectors are OK. Switch the 16 amp circuit breaker for the ECM ON. wait for at least 30 seconds and then observe the “Active Diagnostic” screen on Cat ET. repair the sensor or the sensor’s harness. Refer to Troubleshooting. Wait for at least 30 seconds and then observe the “Active Diagnostics” screen on Cat ET. . Illustration 42 Harness side of the ECM P2 connector (P2-56) +8 V supply for the detonation sensors (P2-57) +8 V supply for the detonation sensors g00888992 Test Step 5. “Replacing the ECM”. Disconnecting all of the +8 V wiring from the ECM did not eliminate the active “8 Volt DC Supply” diagnostic code. replace the original ECM. B. Insert terminal 4 into the P1 connector. Insert terminals 56 and 57 into the P2 connector. Proceed to Test Step 5. Repair: It is unlikely that the ECM has failed. C.210 Troubleshooting Section Expected Result: No active codes Results: • No codes – The 41-03 code or the 41-04 code is not active. Disconnecting all of the +8 V wiring from the ECM eliminated the active “8 Volt DC Supply” diagnostic code. Refer to Troubleshooting. Disconnect the following connectors: • Connectors P2 and P1 • Connectors P11 and P12 This will isolate the +8 V wiring inside the terminal box. If the problem is resolved with the new ECM. “Replacing the ECM”. If the new ECM operates correctly and the original ECM does not operate correctly. Exit this procedure and perform this procedure again. Refer to Troubleshooting. There may be a problem with the ECM. STOP. Pull on the wires in order to verify that the terminals are fully inserted into the connector. perform the following steps: Temporarily install a new ECM. There is a problem in a connector and/or the wiring in a harness. • Active code – There is an active 41-03 or 41-04 code. Switch the 16 amp circuit breaker for the ECM OFF. install the original ECM and verify that the problem returns. If the problem is not resolved. Check the Wiring Harness Inside the Terminal Box A. Turn the engine control switch to the OFF position. 211 Troubleshooting Section Table 17 Points for the Measurement of Resistance Connector and Terminal P1-4 (+8 VDC) Connector and Terminal P1-5 (Digital return) P1-10 (Digital sensor signal) P1-12 (Digital sensor signal) P2-68 (Digital sensor signal) P2-56 (+8 VDC) P2-36 (Detonation sensor signal) P2-37 (Detonation sensor signal) P2-38 (Detonation sensor signal) P2-39 (Detonation sensor signal) P2-54 (Digital return) P2-57 (+8 VDC) P2-44 (Detonation sensor signal) P2-45 (Detonation sensor signal) P2-46 (Detonation sensor signal) P2-47 (Detonation sensor signal) P2-55 (Digital return) P1-4 (+8 VDC) P2-56 P2-57 P1-4 P2-56 P2-57 P1-4 P2-56 P2-57 P1-4 P2-56 P2-57 P1-70 (Switched +Battery) P1-57 (Unswitched +Battery) P1-69 (−Battery terminal) Engine ground Illustration 43 (1) ECM side of the P1 connector (2) ECM side of the P2 connector g00717770 Note: For the functions of the terminals. Be sure to wiggle the wires near each of the connectors. Measure the resistance between the terminals that are listed in Table 17. wiggle the wires inside the terminal box in order to check for an intermittent problem. Expected Result: Each check of the resistance is greater than 20. D. refer to Table 17. During each measurement.000 ohms. . Repair: Repair the terminal box’s harness. During each measurement. Replace the harness. Be sure to wiggle the wires near each of the connectors. STOP. Verify that all of the detonation sensors are disconnected. P11-E (return) P11-G (detonation sensor signal) P11-H (detonation sensor signal) P11-I (detonation sensor signal) P11-K (detonation sensor signal) P11-L (detonation sensor signal) Ground strap for the engine P1-69 (−battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal) P11-J +8 V supply P11-A (return) P11-B (detonation sensor signal) P11-C (detonation sensor signal) P11-D (detonation sensor signal) P11-E (return) Test Step 6. The +8 V wires and connectors in the terminal box do not have a short circuit. Measure the Resistance for the Harness. B. Measure the resistance between the points that are listed in Table 18. Illustration 44 Harness connector P11 g00889123 P11-G (detonation sensor signal) P11-H (detonation sensor signal) P11-I (detonation sensor signal) Note: For the functions of the terminals. P11-K (detonation sensor signal) P11-L (detonation sensor signal) Ground strap for the engine P1-69 (−battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal) Expected Result: Each check of the resistance is greater than 20. . refer to Table 18.000 ohms. when possible. if necessary. Proceed to Test Step 6. Check the Harness for the Detonation Sensors A. There is a problem with the wiring inside the terminal box.000 ohms. wiggle the wires in the harness in order to check for an intermittent problem.000 ohms.212 Troubleshooting Section Results: Table 18 • OK – Each check of the resistance is greater than 20. Connector and Terminal P11-F +8 V supply Connector and Terminal P11-A (return) P11-B (detonation sensor signal) P11-C (detonation sensor signal) P11-D (detonation sensor signal) • Not OK – At least one check of the resistance is less than 20. refer to Table 19. STOP. Repair: Repair the harness.000 ohms. when possible. Replace the harness. • Not OK – At least one check of the resistance is less than 20. Repair: Repair the harness. if necessary. Results: • OK – Each check of the resistance is greater than 20.000 ohms.213 Troubleshooting Section Results: Table 19 • OK – Each check of the resistance is greater than 20. STOP. During each measurement. Check the Harness for the +8 V Pressure Sensors A. There is a problem with a connector and/or at least one of the +8 V wires in the harness for the detonation sensors. Analog Sensor Signal SMCS Code: 1901-038 System Operation Description: Use this procedure to troubleshoot diagnostic codes for open circuits or short circuits for the sensors of these parameters: • Engine coolant temperature • Inlet air temperature . Replace the harness.000 ohms. Measure the Resistance for the Harness. STOP.000 ohms. The problem seems to be resolved. The harness for the detonation sensors appears to be OK. Measure the resistance between the points that are listed in Table 19. Verify that the sensors for the following parameters are disconnected: Expected Result: • Engine coolant pressure • Inlet air pressure • Atmospheric pressure Each check of the resistance is greater than 20. Test Step 7. B. wiggle the wires in the harness in order to check for an intermittent problem. when possible.000 ohms. Be sure to wiggle the wires near each of the connectors. Connector and Terminal P12-L +8 V supply Connector and Terminal P12-D (atmospheric pressure) P12-M (inlet air pressure) P12-N (return) P12-P (engine coolant pressure) Ground strap for the engine P1-69 (−battery terminal) P1-57 (unswitched +battery terminal) P1-70 (switched +battery terminal) • Not OK – At least one check of the resistance is less than 20. The initial diagnostic code was probably caused by a poor electrical connection. if necessary. i01734297 Illustration 45 Harness connector P12 g00889141 Note: For the functions of the terminals. Repair: Reconnect all of the connectors and resume normal operation. Proceed to Test Step 7. There is a problem with a connector and/or at least one of the +8 V wires in the harness for the pressure sensors. Logged diagnostic codes provide an historical record. The next likely cause is a sensor problem. The -04 code is probably caused by a short circuit to ground in an engine harness. a 262-03 or 262-04 diagnostic code may be activated. The engine coolant temperature sensor is a passive sensor of the analog type. This troubleshooting procedure may generate additional diagnostic codes. If the “DESIRED SPEED” potentiometer has a short circuit or the potentiometer’s wiring has a short circuit. The ECM can be configured for one of these types of speed control: • Potentiometer • 4-20 ma The “DESIRED SPEED” potentiometer (if equipped) must be supplied with +5 VDC from the ECM. There are no diagnostic codes for the circuit of the “DESIRED SPEED” potentiometer.214 Troubleshooting Section • Engine oil temperature • Filtered engine oil pressure • Unfiltered engine oil pressure Note: The engine coolant temperature sensor does not require +5 VDC from the Electronic Control Module (ECM). The -03 code is probably caused by a problem in an engine harness. The sensor operates without a voltage supply from the ECM. Before you begin this procedure. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Clear the diagnostic code after the problem is resolved. The least likely cause is a problem with the ECM. The next likely cause is a sensor problem. or a short circuit to a positive voltage source in a harness. Keep your mind on correcting the cause of the original diagnostic code. The least likely cause is a problem with the ECM. There may be an open circuit in a harness. . Note: For the following steps. Switch the 16 amp circuit breaker for the ECM OFF. Inspect the Electrical Connectors and Wiring A. “Inspecting Electrical Connectors”.215 Troubleshooting Section Illustration 46 Schematic for the analog sensors g00889282 Test Step 1. refer to Troubleshooting. . Turn the engine control switch to the OFF/RESET position. Thoroughly inspect the following connectors: • ECM J1/P1 connectors • J12/P12 connectors on the terminal box a. Illustration 50 g00755481 g00889766 (4) Inlet air temperature sensor (5) Engine coolant temperature sensor Illustration 48 Harness side of the ECM P1 connector (2) +5 volt supply (3) Return (14) Signal for the inlet manifold air temperature (17) Signal for the engine oil temperature (24) Signal for the filtered engine oil pressure (26) Signal for the unfiltered engine oil pressure (27) Signal for the engine coolant temperature . Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors. B.216 Troubleshooting Section Illustration 49 Harness side of the P12 connector (A) +5 volt supply (C) Return (K) Signal for the inlet manifold air temperature (H) Signal for the engine oil temperature (F) Signal for the filtered engine oil pressure (E) Signal for the unfiltered engine oil pressure (J) Signal for the engine coolant temperature g00889763 Illustration 47 Terminal box (1) ECM connectors J1/P1 (2) J12/P12 connectors for the analog sensors (3) 16 amp circuit breaker g00889286 b. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). If necessary. Check for Active Analog Sensor Diagnostic Codes A. Look for the codes that are listed in Table 20: • OK – All of the connectors. and/or pinch points. and sockets are connected properly. “+5V Sensor Supply”. The connectors and the wiring are free of corrosion. c. STOP. Switch the 16 amp circuit breaker for the ECM ON. B. abrasion. Results: • No codes – There are no active “5 Volt Sensor DC Power Supply” diagnostic codes. At least one of the connectors and/or the wiring have corrosion. Observe the “Active Diagnostic” screen on ET. Check for Diagnostic Codes for the Power Supply A. This procedure will not work when this type of code is active. abrasion. . • Not OK – At least one of the connectors.217 Troubleshooting Section C. Wait at least 30 seconds so that any codes may become activated. Test Step 2. Repair: Perform the necessary repairs and/or replace parts. Test Step 3. if necessary. Proceed to Test Step 2. The connectors and the wiring are free of corrosion. return to this functional test in order to troubleshoot the analog sensor after the “+5 V Sensor Supply” diagnostic code has been resolved. Results: Repair: Refer to Troubleshooting. and pinch points. and sockets are connected properly. Illustration 51 (6) Filtered oil pressure sensor (7) Unfiltered oil pressure sensor (8) Oil temperature sensor g00889767 • Active code – There is an active “5 Volt Sensor DC Power Supply” diagnostic code. Turn the engine control switch to the STOP position. STOP. pins. Check the harness and wiring for abrasion and pinch points from the analog sensors to the ECM. pins. Expected Result: All of the connectors. pins. The components are in good condition with proper connections. Proceed to Test Step 3. Connect Cat ET to the service tool connector on the terminal box. Allow a minimum of 30 seconds for any codes to activate. Look for these codes: • 262-03 5 Volt Sensor DC Power Supply short to +batt • 262-04 5 Volt Sensor DC Power Supply short to ground Expected Result: There are no active “5 Volt Sensor DC Power Supply” diagnostic codes. and/or sockets are not connected properly. Observe the “Active Diagnostic” screen on Cat ET. abrasion. and pinch points. If one of the above codes is active. Test Step 5. there may be an intermittent problem in the harness that is causing the codes to be logged. there was an active “open/short to +batt” diagnostic code for the sensor. Proceed to Test Step 4. Expected Result: There is an active “open/short to +batt” diagnostic code for the disconnected sensor. • No active codes – None of the above codes are active. replace the original sensor. proceed to Test Step 6. If the engine is running properly at this time. Disconnect the sensor that has the “short to ground” diagnostic code. STOP. Repair: If any of the above codes are logged and the engine is not running properly.5 volts. The voltage between terminal “A” and terminal “B” is +5. proceed to Test Step 6. refer to Troubleshooting. Look for an active “open/short to +batt” diagnostic code. Repair: Reconnect the sensor.218 Troubleshooting Section Table 20 Analog Sensor Diagnostic Codes 100-03 100-04 110-03 110-04 172-03 172-04 175-03 175-04 542-03 542-04 Engine Oil Pressure open/short to +batt Engine Oil Pressure short to ground Engine Coolant Temperature open/short to +batt Engine Coolant Temperature short to ground Intake Manifold Air Temp open/short to +batt Intake Manifold Air Temp short to ground Engine Oil Temperature open/short to +batt Engine Oil Temperature short to ground Unfiltered Engine Oil Pressure open/short to +batt Unfiltered Engine Oil Pressure short to ground Test Step 4. B. Expected Result: None of the above codes are active. Observe the “Active Diagnostic” screen on Cat ET. If you are troubleshooting the sensor for engine coolant temperature.0 ± 0. Results: • Yes – Before the suspect sensor was disconnected. After the suspect sensor was disconnected. Verify that the code does not activate when the new sensor is installed. If the active “short to ground” diagnostic code recurs. identify the type of diagnostic according to the condition: the diagnostic code is either “open/short to +batt” (FMI 03) or “short to ground” (FMI 04). Turn the engine control switch to the OFF/RESET position. STOP. If you are troubleshooting the sensor for engine coolant temperature. • Active “short to ground” (FMI 04) – There is an active “short to ground” diagnostic code. Otherwise. Check the Supply Voltage at the Sensor Connector A. proceed to Test Step 5. Verify that the suspect sensor is disconnected from the engine harness. there was an active “short to ground” diagnostic code for the sensor. “Troubleshooting Without a Diagnostic Code”. Clear the logged diagnostic code from the ECM. Refer to Troubleshooting. • No – Before the suspect sensor was disconnected. there was an active “short to ground” diagnostic code for the sensor. C. “Inspecting Electrical Connectors”. Otherwise. • Active “open/short to +batt” (FMI 03) – There is an active “open/short to +batt” diagnostic code. Create an Open Circuit for the Sensor A. D. proceed to Test Step 5. Results: B. . the active “open/short to +batt” diagnostic code remained. After the suspect sensor was disconnected. Turn the engine control switch to the STOP position. Allow a minimum of 30 seconds for any codes to activate. The pull-up voltage that is created by the ECM is not present at the sensor connector.219 Troubleshooting Section Illustration 52 Harness connectors for the various sensors (A) +5 volt supply (B) Return (C) Signal g00889729 Illustration 53 Harness connectors for the various sensors (A) +5 volt supply (B) Return (C) Signal (1) Signal (2) Return g00889801 B. Repair: Verify that the wiring and/or connectors are OK.5 ± 0. Results: • OK – The voltage between terminal “A” and terminal “B” is +5. Verify that the suspect sensor’s connector is disconnected from the engine harness. +5 V is present at the sensor connector. or in the engine harness. or between terminal “1” and terminal “2”. Proceed to Test Step 8.0 ± 0. Turn the engine control switch to the OFF/RESET position. Replace any faulty wiring and/or connectors. Refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. Check the Pull-Up Voltage at the ECM A.5 VDC. The signal wire and the return wire for the suspect sensor appear to be OK. Proceed to Test Step 7. The +5 V supply voltage must be present at the sensor in order to continue this procedure. Repair any faulty wiring and/or connectors. At the harness connector for the suspect sensor. “Inspecting Electrical Connectors”.5 VDC. +5 V is not present at the sensor connector. if necessary. measure the voltage between terminal “A” and terminal “B”.0 ± 0.5 ± 0. measure the voltage between terminal “B” and terminal “C”.5 VDC. Results: B. Proceed to Test Step 6. At the harness connector for the suspect sensor. terminal “C” is not +5.0 ± 0. Expected Result: The voltage between terminal “A” and terminal “B” is +5. Check the Pull-Up Voltage at the Sensor A. Test Step 6.5 VDC. • OK – The voltage between the signal terminal and the return terminal is +6. The +5 V wiring problem may be inside the terminal box.5 VDC.5 VDC. • Not OK – The voltage between terminal “B” and • Not OK – The voltage between the signal terminal and the return terminal is not +6. when possible. STOP. Expected Result: The voltage between the signal terminal and the return terminal is +6. . Test Step 7. The pull-up voltage that is created by the ECM is present at the sensor connector. Check for diagnostic codes again.5 ± 0. 5 VDC. Insert one end of the jumper wire into the open terminal of the P1 connector. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Connect the other multimeter lead to the probe. Observe the “Active Diagnostic” screen on Cat ET. Temporarily connect a sensor that is known to be good to the engine harness. “Inspecting Electrical Connectors”. There may be a problem with a connector. Connect a multimeter lead to the end of the jumper wire that is not inserted into the connector. C.5 VDC. Test Step 8. F. B. insert a 7X-1710 Multimeter Probe along terminal 3. Turn the engine control switch to the STOP position.5 ± 0. H. Turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM OFF. Expected Result: No diagnostic codes are activated. The ECM is producing a pull-up voltage that is valid. Refer to Troubleshooting.5 ± 0. Check the Sensor A. Switch the 16 amp circuit breaker for the ECM ON.5 VDC. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Pull on the wire in order to verify proper installation of the terminal. if necessary.220 Troubleshooting Section Expected Result: The pull-up voltage for the suspect sensor at the ECM is +6. Measure the pull-up voltage at the ECM. when possible. Illustration 54 Harness side of the ECM P1 connector (3) Analog return (14) Inlet air temperature (17) Oil temperature (24) Filtered oil pressure (26) Unfiltered oil pressure (27) Engine coolant temperature g00890023 B.5 ± 0. Use a jumper wire with Deutsch terminals on the ends. Verify that the wiring and/or connectors are OK. At the harness side of the P1 connector. Switch the 16 amp circuit breaker for the ECM ON. Replace any wiring and/or connectors. Allow a minimum of 30 seconds for any codes to activate. E. G. D. Reinstall the terminal that was removed from the P1 connector. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P1 connector. • Not OK – The pull-up voltage for the suspect sensor at the ECM is not +6. C. Disconnect the multimeter leads. There is a problem with the signal wire between P1 and the harness connector for the sensor. STOP. Proceed to Test Step 9. Repair any faulty wiring and/or connectors. Results: • OK – The pull-up voltage for the suspect sensor at the ECM is 6. . 3. Connecting a new sensor did not resolve the problem. Observe the “Active Diagnostic” screen on ET. Install one end of the jumper wire into the terminal for the signal wire that was removed from the P1 connector. STOP. If these conditions are true. Turn the engine control switch to the OFF/RESET position. Verify that the “open/short to +batt” diagnostic code is deactivated. Check the Operation of the ECM • OK – No diagnostic codes are activated when a good sensor is temporarily installed. Use a jumper wire that is the appropriate length with Deutsch terminals on the ends. An active “open/short to +batt” diagnostic code is generated for the sensor. E. Verify that no diagnostic codes are activated. replace the faulty sensor with the new sensor. D. Verify that the signal wire for the suspect sensor has been removed from the P1 connector. Install the other end of the jumper wire into terminal (19) of the P1 connector. Clear all of the diagnostic codes. Repair: Perform the following procedure: 1. C. refer to the Specifications manual. . For the proper torque value for the new sensor. Clear any existing diagnostic codes. 4. B. This will replace the sensor circuit with a short circuit. Verify that the “open/short to +batt” diagnostic code recurs. Switch the 16 amp circuit breaker for the ECM to the OFF position. Allow a minimum of 30 seconds for any codes to activate. Illustration 55 Harness side of the ECM P1 connector (3) Analog return (14) Inlet manifold air temperature (17) Oil temperature (19) Unused ground for the ECM (24) Filtered oil pressure (26) Unfiltered oil pressure (27) Engine coolant temperature g00890135 A.221 Troubleshooting Section Results: Test Step 9. Connect the new connector. • Not OK – The active “open/short to +batt” code remains. Connecting a new sensor resolved the problem. Disconnect the suspect sensor. Reconnect the suspect sensor. 2. Verify that the problem has been resolved. Proceed to Test Step 9. The initial diagnostic code was probably caused by a poor electrical connection. a current value of 4. Observe the “Active Diagnostic” screen on Cat ET. Pull on the wire in order to verify proper installation of the terminal. i01738063 Desired Speed Input (4 . Switch the 16 amp circuit breaker for the ECM ON. STOP. “Replacing the ECM”. install the original ECM and verify that the problem returns. When the “Idle/Rated” switch is in the Rated position.0 mA corresponds to the programmed “Minimum Engine High Idle Speed”. Do not select “PWM”. Refer to Troubleshooting. The Electronic Control Module (ECM) cannot be configured to accept a PWM input signal for control of the engine speed. The ECM will generate a diagnostic code in response to current outside of the range of 4 to 20 mA. “Electronic Control System Parameters”. Results: If the problem is resolved with the new ECM. If the “Desired Speed Input” is set to “0-5 VDC Input”. Allow a minimum of 30 seconds for any codes to activate. • OK – Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Turn the engine control switch to the STOP position. • Not OK – No active “open/short to +batt” and “short to ground” diagnostic codes were generated. refer to Systems Operation/Testing and Adjusting. The ECM is not operating correctly.20 mA) SMCS Code: 1901-038 System Operation Description: Note: For this troubleshooting procedure. perform the following steps: Temporarily install a new ECM. The ECM is operating correctly. The “Minimum Engine High Idle Speed” and the “Maximum Engine High Idle Speed” are set with the “Service/Configuration” screen of ET. Resume normal operation. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P1 connector. Switch the 16 amp circuit breaker for the ECM OFF. The selection of the “4-20 mA Input” setting requires a 4 to 20 mA signal for regulation of the desired engine speed. replace the ECM. Repair: It is unlikely that the ECM has failed. A current value of 20. STOP. . the “Desired Speed Input” configuration parameter must be set to “4-20 mA Input” in the “Service/Configuration” screen of the Caterpillar Electronic Technician (ET). Perform this entire procedure again. do not use this procedure to troubleshoot the circuit.0 mA corresponds to “Maximum Engine High Idle Speed”. Reinstall the terminal that was removed from the P1 connector. Current values within this range will vary the desired engine speed in a linear fashion between “Minimum Engine High Idle Speed” and “Maximum Engine High Idle Speed”. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Refer to Troubleshooting. “Replacing the ECM”. If the problem is not resolved. If the new ECM operates correctly and the original ECM does not operate correctly. When the desired speed input is correspondingly configured. the ECM controls the engine speed according to the 4 to 20 mA current. G. For more information. An active “short to ground” diagnostic code is generated. The value of the current corresponds to a range of desired engine speeds between minimum high idle and maximum high idle.222 Troubleshooting Section F. Turn the engine control switch to the OFF/RESET position. The next likely cause is a problem with a component. Logged diagnostic codes provide an historical record. Check the torque of the Allen head screw for the ECM connector.0 mA will activate the “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code. Illustration 57 (1) ECM connectors J1/P1 (2) 16 amp circuit breaker (3) J9/P9 Connectors for the customer (if equipped) g00890178 B. Note: For the following steps. Thoroughly inspect the following components: • ECM J1/P1 connectors • J9/P9 connectors on the terminal box • Wiring and the connections between the terminal box and the device that supplies the 4 to 20 mA signal Illustration 56 Schematic of the 4 to 20 mA desired speed input g00890150 a. . Clear the diagnostic codes after the problem is resolved. refer to Troubleshooting. Before you begin this procedure. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. Current values that are less than 2. Inspect the Electrical Connectors and Wiring A.0 mA will activate the “524-04 Desired Engine Speed Sensor short to ground” diagnostic code. The least likely cause is a problem with the ECM. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Switch the 16 amp circuit breaker for the ECM OFF. Test Step 1. Keep your mind on correcting the cause of the original diagnostic code. “Inspecting Electrical Connectors”. use ET to print the logged codes to a file. The troubleshooting procedure may generate additional diagnostic codes.223 Troubleshooting Section Current values that are greater than 22. Disconnect the ECM P1 connector. c. • Not OK – The components are not in good condition and/or at least one connection is improper. STOP.224 Troubleshooting Section Expected Result: All of the connectors. If you are troubleshooting a “524-03 Desired Engine Speed Sensor short to +batt” diagnostic code. If you are troubleshooting a “524-04 Desired Engine Speed Sensor short to ground” diagnostic code. Illustration 59 Harness side of the P9 connector (P9-K) + Signal (P9-P) . . and pinch points. proceed to Test Step 3. Repair: Perform the necessary repairs and/or replace parts. Test Step 2.Signal g00870629 b. C. Check for an Open Circuit Illustration 58 Harness side of the ECM P1 connector (1) ECM P1 connector (P1-36) + Signal (P1-37) . abrasion. B. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 4 to 20 mA circuit. and sockets are connected properly. Use an ohmmeter to measure the resistance between terminals (P1-36) and (P1-37) on the ECM side of the P1 connector. D.Signal g00890187 A. Check the harness and wiring for abrasion and pinch points between the device that supplies the 4 to 20 mA signal and the ECM. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. Install a jumper wire between the two wires (“+” and “-”) that were removed from the device that supplies the 4 to 20 mA signal.Signal g00890197 Illustration 60 ECM side of the P1 connector (P1-36) + Signal (P1-37) . if necessary. proceed to Test Step 5. The connectors and the wiring are free of corrosion. Results: • OK – The components are in good condition with proper connections. pins. Verify that the problem is resolved. if necessary. . B. • No – The resistance is less than 20. Results: • Yes – The resistance is greater than 20.000 ohms. Proceed to Test Step 3. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal.000 ohms. Illustration 61 (1) Harness connector P1 (P1-36) + Signal (P1-57) +Battery g00890245 Test Step 3. Alternatively. C. Alternatively. when possible. Repair the connection and/or the wire. Verify that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. when possible. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. Expected Result: The resistance is greater than 20. Do not reconnect any connectors. Repair: The problem may be between the ECM P1 connector and the J9 connector. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. STOP. Repair: Remove the jumper wire. Use an ohmmeter to measure the resistance between terminals (P1-36) and (P1-57). There is a problem with a connector and/or the wiring from the P1 connector. STOP. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal. if necessary. The circuit is not open. Replace parts. • Not OK – The resistance is greater than 5 ohms. Repair the connection and/or the wire. There is a problem with a connection and/or the wiring from terminal P1-36.225 Troubleshooting Section Expected Result: The resistance is less than 5 ohms. Verify that the problem is resolved.000 ohms. Check for a Short Circuit to the +Battery Side at the ECM P1 Terminal 36 A. Repair: The problem may be between the ECM P1 connector and the J9 connector. Results: • OK – The resistance is less than 5 ohms. The wiring from terminal P1-36 is not shorted to the +Battery side. Replace parts. Proceed to Test Step 4. B. Make sure that there is no electrical power to the device that provides the 4 to 20 mA signal.000 ohms. B. Repair: The problem may be between the ECM P1 connector and the J9 connector.Signal g00890258 C. Expected Result: The resistance is greater than 20. • No – The resistance is less than 20. Make sure that the leads of the wires for the 4 to 20 mA signal do not create a short circuit. Locate the wire with the short circuit and replace the wire. D. Check for a Short to Ground at the ECM P1 Terminal 37 A. Illustration 62 (1) Ground strap (2) P1 connector (P1-37) . The wiring from terminal P1-37 appears to be OK. Repair: Reconnect the ECM P1 connector. Use an ohmmeter to measure the resistance between terminal (P1-37) and the ECM ground strap.000 ohms.226 Troubleshooting Section Test Step 4. Proceed to Test Step 7. STOP. Verify that the problem is resolved. Reconnect the two wires (“+” and “-”) for the 4 to 20 mA signal to the device that supplies the 4 to 20 mA signal. Check for a Short Circuit to the +Battery Side at the ECM P1 Terminal 37 A. .000 ohms. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. Disconnect the ECM P1 connector. Results: • Yes – The resistance is greater than 20. C. Insulate the wire leads with electrical tape in order to ensure that the leads do not create a short circuit. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. Remove the two wires (“+” and “-”) for the 4 to 20 mA signal from the device that supplies the 4 to 20 mA signal. Alternatively. There is a problem with a connection and/or the wiring that is connected to P1-37. Test Step 5. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. Expected Result: The resistance is greater than 20. Make sure that the ends of the wires for the 4 to 20 mA signal do not create a short circuit.Signal (P1-57) +Battery g00890265 E. Expected Result: The resistance is greater than 20. Results: Illustration 64 (1) Ground strap (2) P1 connector (P1-36) + Signal g00890269 • Yes – The resistance is greater than 20. Results: • No – The resistance is less than 20. C.000 ohms. Alternatively.000 ohms. Check for a Short Circuit to Ground at the ECM P1 Terminal 36 A. STOP. Use an ohmmeter to measure the resistance between terminals (P1-37) and (P1-57). Verify that the problem is resolved. Do not reconnect any connectors.000 ohms.000 ohms. • No – The resistance is less than 20. The wiring from terminal P1-37 is not shorted to the +Battery side. Use an ohmmeter to measure the resistance between terminal (P1-36) and the ECM ground strap.000 ohms. • Yes – The resistance is greater than 20. The wiring from terminal P1-36 appears to be OK. . B. Illustration 63 (1) Connector P1 (P1-37) . Proceed to Test Step 2.227 Troubleshooting Section Test Step 6. There is a problem with a connection and/or the wiring from terminal P1-36. if necessary. Do not reconnect any connectors. There is a problem with a connection and/or the wiring from terminal P1-37. Proceed to Test Step 6.000 ohms. Repair: The problem may be between the ECM P1 connector and the J9 connector. Repair the connection and/or the wire. Verify that the engine control switch is in the OFF/RESET position and the 16 amp circuit breaker for the ECM OFF. Replace parts. when possible. when possible. If the problem is not resolved. The detonation sensors provide electrical signals to the ECM that indicate mechanical engine vibrations. Repair the connection and/or the wire. There is probably a problem with the device that provides the 4 to 20 mA.228 Troubleshooting Section Repair: The problem may be between the ECM P1 connector and the J9 connector. Expected Result: The correct 4 to 20 mA signal is provided to the ECM. Results: • Yes – The correct 4 to 20 mA signal is provided to the ECM. the engine is shut down. Verify that the problem is resolved. The timing may be retarded for a single cylinder or for more than one cylinder. STOP. Each sensor monitors two adjacent cylinders.Signal g00890187 Verify the correct 4 to 20 mA signal at the ECM P1 terminals (36) and (37). Each sensor outputs an electrical signal. i01738479 Detonation Sensors SMCS Code: 1559-038 System Operation Description: Detonation sensors are located on the upper cylinder block between every two cylinders. . The timing may be retarded for all of the cylinders. The ECM retards the timing in order to limit detonation levels. The Electronic Control Module (ECM) supplies 8 VDC in order to power the sensors. Test Step 7. the problem may be between the P9 connector and the device that provides the 4 to 20 mA signal. if necessary. Repair: It is unlikely that the ECM is faulty. For example. Verify that the correct signal is provided to the ECM. Verify that the problem is resolved. Verify that the problem is resolved. Check the Device that Provides the 4 to 20 mA Signal Measure the 4 to 20 mA signal according to the literature that is provided by the OEM of the device that provides the 4 to 20 mA signal. However. Alternatively. There may be a problem with the ECM. the ECM is not responding correctly to the signal. if necessary. Replace parts. STOP. Illustration 65 Harness side of the P1 connector (1) ECM P1 connector (P1-36) + Signal (P1-37) . The frequency of the signal corresponds to the mechanical frequency of the vibrations. Repair: Service the device that provides the 4 to 20 mA according to the literature that is provided by the OEM of the device. one sensor monitors cylinders 1 and 3. Exit this procedure and perform this procedure again. STOP. replace the ECM according to Troubleshooting. The amplitude of the signal is proportional to the intensity of the vibrations. If retardation of the timing does not sufficiently limit the detonation. The ECM monitors the signals in order to determine the presence and the severity of the detonation. “Replacing the ECM”. The signal is amplified and the signal is filtered. • No – The ECM is not receiving the correct 4 to 20 mA signal. The ECM will diagnose the detonation sensors for a signal that is shorted to the −Battery side. The least likely cause is a problem with the ECM. the +Battery side. the “Block Tap” method of testing the detonation sensors does not work for the G3500B Engine. Detonation protection is disabled when the engine speed is less than 250 rpm. An input from a detonation sensor that is diagnosed by the ECM as “open/shorted to +battery” may measure 0 VDC on a voltmeter. the minimum allowable actual timing is ten degrees BTC (five degrees BTC for propane operation). Before you begin this procedure. the ECM only monitors a detonation sensor on the firing stroke. The ECM also supports related event codes when the levels of detonation warrant a reaction from the ECM. or an open circuit. Logged diagnostic codes provide an historical record. A proportional strategy is used for advancing the timing after the timing has been retarded. Clear the diagnostic codes after the problem is resolved. The troubleshooting procedure may generate additional diagnostic codes. . when one of the sensor’s cylinders is between top center and 40 degrees after top center. For most applications. the ECM will shut down the engine. Keep your mind on correcting the cause of the original diagnostic code. The timing can be retarded up to six degrees for severe detonation. The rate of advance is based upon the level of detonation. The fastest rate of proportional timing advance is one degree per minute. The next likely cause is a problem with a sensor. The most likely causes of the diagnostic code are a poor connection or a problem in a wiring harness. To avoid detecting vibrations that are not related to detonation. Therefore. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. If the timing has been retarded by the maximum amount and the level of detonation remains high. The rate is faster for lighter detonation.229 Troubleshooting Section The ECM can retard timing by as few as three degrees for light detonation levels. Turn the engine control switch to the OFF/RESET position. . Note: For the following steps. “Inspecting Electrical Connectors”. Inspect the Electrical Connectors and Wiring A.230 Troubleshooting Section Illustration 66 Schematic for the detonation sensors g00890368 Test Step 1. refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM “OFF”. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the detonation sensors. Check the torque of the Allen head screw for the ECM connector. pins. d. Thoroughly inspect each of the following connectors: • ECM J2/P2 connectors • J11/P11 connectors on the terminal box a. b. Check the harness and wiring for abrasion and pinch points from the detonation sensors to the ECM. and sockets are connected properly. All of the detonation sensors are properly installed. Make sure that the detonation sensors are properly installed according to the torque in Specifications. The connectors and the wiring are free of corrosion. “Detonation Sensors”. abrasion. Expected Result: All of the connectors. Illustration 70 Detonation sensors g00752902 Illustration 68 Harness side of the side of the ECM P2 connector (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-45) (P2-46) (P2-47) (P2-54) (P2-55) (P2-56) (P2-57) Signal for cylinders 1 and 3 Signal for cylinders 5 and 7 Signal for cylinders 9 and 11 Signal for cylinders 13 and 15 Signal for cylinders 2 and 4 Signal for cylinders 6 and 8 Signal for cylinders 10 and 12 Signal for cylinders 14 and 16 Return (right side) Return (left side) +8 V supply (right side) +8 V supply (left side) g00890407 c.231 Troubleshooting Section Illustration 69 Harness side of the side of the P11 connector (J11-B) Signal for cylinders 1 and 3 (J11-C) Signal for cylinders 5 and 7 (J11-D) Signal for cylinders 9 and 11 (J11-G) Signal for cylinders 13 and 15 (J11-L) Signal for cylinders 14 and 16 (J11-K) Signal for cylinders 10 and 12 (J11-I) Signal for cylinders 6 and 8 (J11-H) Signal for cylinders 2 and 4 (J11-A) Return (right side) (J11-E) Return (left side) (J11-J) +8 V supply (right side) (J11-F) +8 V supply (left side) g00890429 Illustration 67 (1) ECM connectors J2/P2 (2) J11/P11 connectors for the detonation sensors (3) 16 amp circuit breaker g00890369 B. and pinch points. . Proceed to Test Step 3. Observe the “Active Diagnostic” screen of Cat ET. B. Exit this procedure and refer to Troubleshooting. B. 1510-04 1513-03 1513-04 1514-03 1514-04 13 and 15 . Check for Active Diagnostic Codes for the Detonation Sensors Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Results: 1505-03 1505-04 1506-03 1506-04 1509-03 1509-04 1510-03 5 and 7 • OK – Neither of the “8 Volt DC Supply” diagnostic codes are active. Repair: The “8 Volt DC Supply” diagnostic code must be resolved before you can proceed with this functional test. Look for these codes: Code 1501-03 1501-04 1502-03 1502-04 Description Cylinder #1 Detonation Sensor short to +batt Cylinder #1 Detonation Sensor short to ground Cylinder #2 Detonation Sensor short to +batt Cylinders 1 and 3 2 and 4 Cylinder #2 Detonation Sensor short to ground Cylinder #5 Detonation Sensor short to +batt Cylinder #5 Detonation Sensor short to ground Cylinder #6 Detonation Sensor short to +batt 6 and 8 Cylinder #6 Detonation Sensor short to ground Cylinder #9 Detonation Sensor short to +batt Cylinder #9 Detonation Sensor short to ground Cylinder #10 Detonation Sensor short to +batt Cylinder #10 Detonation Sensor short to ground Cylinder #13 Detonation Sensor short to +batt Cylinder #13 Detonation Sensor short to ground Cylinder #14 Detonation Sensor short to +batt Cylinder #14 Detonation Sensor short to ground 14 and 16 10 and 12 • “41-03 8 Volt DC Supply short to +batt” • “41-04 8 Volt DC Supply short to ground” Expected Result: Neither of the “8 Volt DC Supply” diagnostic codes are active. STOP. Start the engine and run the engine. Wait at least 30 seconds so that any codes may become activated. Test Step 2. 9 and 11 • Not OK – At least one of the “8 Volt DC Supply” diagnostic codes is active. • Not OK – The components are not in good condition and/or at least one connection is improper. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. if necessary. Switch the 16 amp circuit breaker for the ECM ON. “+8V Sensor Voltage Supply”. Allow a minimum of 30 seconds for any diagnostic codes to become active. C. Check for Diagnostic Codes for the +8 V Sensor Supply A. Therefore. If necessary. A. STOP. Turn the engine control switch to the STOP position. Repair: Perform the necessary repairs and/or replace parts. the engine must be running. return to this functional test in order to troubleshoot the detonation sensor after the “8 Volt DC Supply” diagnostic code has been resolved. Proceed to Test Step 2.232 Troubleshooting Section Results: Test Step 3. Observe the “Active Diagnostic” screen of Cat ET and look for the diagnostic codes that are listed in Table 21: Table 21 • OK – The components are in good condition with proper connections. Connect Cat ET to the service tool connector on the terminal box. 233 Troubleshooting Section Note: A “short to ground” diagnostic code can indicate either an actual short to ground or an open circuit. Switch the 16 amp circuit breaker for the ECM OFF. “Inspecting Electrical Connectors”. Results: D. Results: • OK (No active codes) – None of the above codes are active at this time. The correct voltage is not available to the sensor. • Not OK (Active Code) – A “short to +batt” or “short to ground” diagnostic code was activated. use the following procedure to locate the open circuit for the +8 volt supply: 1. Turn the engine control switch to the STOP position. Expected Result: None of the above diagnostic codes are active. Illustration 71 Harness connector for the detonation sensors (A) +8 V (B) Return (C) Signal g00890518 Illustration 72 (1) P11 connector (2) J11 connector g00890558 2.4 VDC. If more than one detonation sensor has a diagnostic code. The original diagnostic code was probably caused by a poor electrical connection in one of the harness connectors. Proceed to Test Step 4. Disconnect the sensor with the diagnostic code. The correct voltage is available to the sensor. STOP. Refer to Troubleshooting. . Measure the voltage between terminal “A” and terminal “B” on the harness connector for the sensor. the open circuit for the +8 volt supply is in the engine harness. Switch the 16 amp circuit breaker for the ECM ON.6 VDC and 8. There is probably an open circuit in the +8 volt supply or in the return for the sensor. Expected Result: The voltage is between 7. refer to Troubleshooting. Disconnect the P11 connector (1) from the J11 connector (2) on the side of the terminal box. Turn the engine control switch to the OFF/RESET position. Verify the Presence of the Supply Voltage at the Sensor A.6 VDC and 8. Turn the engine control switch to the OFF/RESET position. Repair: Note the diagnostic code and note the location of the suspect detonation sensor. “Troubleshooting Without a Diagnostic Code”. Repair: If any of the above codes are logged and the engine is not running properly. when possible. Proceed to Test Step 5.4 VDC. The problem seems to be resolved. Do not reconnect the sensor. • OK – The voltage is between 7. • Not OK – The voltage is not between 7. there may be an intermittent problem in a connector or a wiring harness.6 VDC and 8. Repair: The open circuit may be caused by a poor electrical connection or a wiring problem between the ECM and the connector for the sensor. Repair the electrical connection and/or the wiring.4 VDC. Test Step 4. C. B. If only one detonation sensor has a diagnostic code. If any of the above codes are logged and the engine is running properly. Switch the 16 amp circuit breaker for the ECM OFF. 6 VDC.6 VDC and 8. If either of the voltage measurements are not between 7. the open circuit is in the terminal box’s harness.4 VDC and 0.6 VDC. If the voltage is greater than 4.4 VDC. Test Step 6. Measure the voltage between terminals (B) and (C) on the harness connector for the suspect sensor. if necessary. Check the Operation of the ECM A. 4. Proceed to Test Step 6. Repair: Reconnect the suspect sensor. . STOP. Repair the terminal box’s harness.6 VDC. “Detonation Sensor”. when possible. Start the engine again and check for the diagnostic code. Expected Result: The voltage is between 0. if necessary. the open circuit is in the engine harness.8 VDC.234 Troubleshooting Section 3. Turn the engine control switch to the OFF/RESET position.6 VDC and 8. Replace the harness. Verify that the problem is resolved. there is probably a short to ground or an open circuit between the connector for the detonation sensor and the ECM. Measure the Voltage of the Signal Wire at the Sensor Illustration 74 Harness connector for the detonation sensors (A) +8 V (B) Return (C) Signal g00890518 A. Test Step 5.4 VDC and 0. Tighten the detonation sensor according to the torque in Specifications. Turn the engine control switch to the STOP position. Illustration 73 Side view of the terminal box and the J11 connector g00890378 Results: • Yes – The voltage is between 0. STOP.4 VDC.4 VDC and 0. If the diagnostic code recurs. Table 22 Points for the Measurement of Voltage Connector and Terminal J11-J +8 V supply for the detonation sensors on the right side of the engine J11-F +8 V supply for the detonation sensors on the left side of the engine Connector and Terminal J11-A Return (right side) J11-E Return (left side) • No – The voltage is not between 0. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM ON. If both of the voltage measurements are between 7. Measure the voltage between the terminals that are listed in Table 22. Replace the harness. replace the detonation sensor with a known good detonation sensor. Repair the engine harness. there is probably a short circuit to a +Battery source between the connector for the detonation sensor and the ECM.4 VDC. If the voltage is less than 0. when possible. Observe the “Active Diagnostic” screen on Cat ET. Install one end of the jumper wire (2) into the terminal for the signal wire that was removed from the P2 connector (1). Note: The run relay and the crank terminate relay must be energized before a diagnostic code for a detonation sensor can be generated. Turn the engine control switch to the STOP position. Therefore. Fabricate a jumper wire that is long enough to reach between the P1 connector and the P2 connector.235 Troubleshooting Section Illustration 75 (P1-19) (P2-36) (P2-37) (P2-38) (P2-39) (P2-44) (P2-45) (P2-46) (P2-47) Unused ground for the ECM Signal for cylinders 1 and 3 Signal for cylinders 5 and 7 Signal for cylinders 9 and 11 Signal for cylinders 13 and 15 Signal for cylinders 2 and 4 Signal for cylinders 6 and 8 Signal for cylinders 10 and 12 Signal for cylinders 14 and 16 g00890899 Illustration 76 (1) ECM connector P2 (2) Jumper wire (3) ECM connector P1 g00890937 B. Use a 151-6320 Wire Removal Tool to remove the signal wire for the suspect sensor from the P2 connector. Install the other end of the jumper wire into terminal 19 of the P1 connector (3). G. . C. An active “open/short to +batt” diagnostic code is generated for the sensor. Results: • OK – Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Start the engine. D. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the OFF/RESET position. An active “short to ground” diagnostic code is generated for the sensor. E. Allow a minimum of 30 seconds for any codes to activate. F. Allow a minimum of 30 seconds for any codes to activate. The engine will shut down soon after the diagnostic code for the detonation sensor is activated. The ECM is operating correctly. Expected Result: Active “open/short to +batt” and “short to ground” diagnostic codes are generated according to the above steps. Start the engine. Install Deutsch terminals on the ends. There is probably an open circuit in the engine harness between the ECM and the connector for the sensor. Observe the “Active Diagnostic” screen on Cat ET. the engine must be running. “Replacing the ECM”. The fuel control relay is energize-to-run. data link. The logic for starting and stopping is customer programmable.236 Troubleshooting Section Repair: Remove the jumper wire. emergency stop switch. when possible. replace the original ECM. STOP. remote start switch. The logic responds to inputs from the following components: engine control switch. the ECM removes the voltage from the fuel control relay. Before you begin this procedure. if necessary. If the new ECM operates correctly and the original ECM does not operate correctly. i01741418 ECM Output Circuit (Fuel Control) SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) contains the logic and the outputs for control of prelubrication. Refer to Troubleshooting. starting. This stops the fuel flow. Exit this procedure and perform this procedure again. The troubleshooting procedure may generate additional diagnostic codes. Replace the harness. Refer to Troubleshooting. and other inputs. • Not OK – No active “open/short to +batt” and “short to ground” diagnostic codes were generated. If the problem is not resolved. If the problem is resolved with the new ECM. Logged diagnostic codes provide an historical record. Pull on the wire in order to verify that the terminal is fully inserted into the connector. STOP. . Repair: It is unlikely that the ECM has failed. the relay for the Gas Shutoff Valve (GSOV) must be energized. and shutdown of the engine. Clear the diagnostic codes after the problem is resolved. The ECM provides +Battery voltage to the relay for the GSOV when the logic determines that fuel is required for engine operation. For engine shutdown. Insert the terminal that was removed from the P2 connector. Keep your mind on correcting the cause of the original diagnostic code. To enable fuel flow to the engine. The least likely cause is a problem with the ECM. perform the following steps: Temporarily install a new ECM. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. The next likely cause is a problem with the GSOV. The ECM is not operating correctly. Repair the harness. “Replacing the ECM”. install the original ECM and verify that the problem returns. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. Note: For the following steps. Illustration 78 g00891870 Illustration 79 Harness side of the ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return g00891875 (1) ECM J2/P2 connectors (2) Terminal box’s J13/P13 connectors for the fuel control relay (3) 16 amp circuit breaker (4) 6 amp circuit breaker A. refer to Troubleshooting. Inspect the Electrical Connectors and Wiring • ECM J2/P2 connectors • Terminal box’s connectors (J13/P13) • Connector for the fuel control relay a. Thoroughly inspect the following connectors and the wiring harnesses for the connectors: . The proper torque is 6 ± 1 N·m (55 ± 9 lb in). “Inspecting Electrical Connectors”. Turn the engine control switch to the OFF/RESET position. Switch the 6 amp circuit breaker OFF. B. Switch the 16 amp circuit breaker for the ECM OFF.237 Troubleshooting Section Illustration 77 Schematic of the output circuit for the fuel control relay g00891759 Test Step 1. Check the torque of the Allen head screw for the 70-pin connectors. Switch the 6 amp circuit breaker ON. The connectors and the wiring are free of corrosion. To prevent the engine from starting. Otherwise. b. and pinch points. Turn the engine control switch to the START position for at least 30 seconds. c. B. Check the harness and wiring for abrasion and pinch points from the ECM to the fuel control relay. abrasion. D. Note: This diagnostic condition cannot be detected by the ECM when the output for the fuel control relay is OFF. . Turn the engine control switch to the STOP position. Expected Result: All of the connectors. Test Step 2. Note: To provide the output for the fuel control relay. STOP. Illustration 80 (5) Connector P13 for the fuel control relay (P13-A) Circuit driver for the fuel control relay (P13-B) Return g00891878 If there is an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Check for Diagnostic Codes A. Replace parts. G. Otherwise. continue this procedure. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel control relay. Wait for 30 seconds and use Cat ET to check for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. proceed to the “Results” for this Test Step. the sequence for engine start-up must be initiated. when possible. a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code cannot be generated. Then turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM ON. If there is a “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code. pins. Connect Cat ET to the service tool connector on the terminal box. Proceed to Test Step 2. The output is OFF when the engine control switch is in the STOP position.238 Troubleshooting Section • Not OK – The components are not in good condition and/or at least one connection is improper. clear the code. The output is ON when the engine control switch is in the START position and the engine speed is not zero. Results: • OK – The components are in good condition with proper connections. Use Cat ET to check the logged diagnostic codes. C. and sockets are connected properly. F. if necessary. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code cannot be detected when the output for the fuel control relay is ON. Illustration 81 Fuel control relay g00869737 E. Repair: Perform the necessary repairs. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” or a “17-12 Fuel Shutoff Valve malfunction” diagnostic code again. shut the gas supply OFF. The Gaseous fuel is present. Repair: Turn the engine control switch to the OFF/RESET position. refer to Troubleshooting. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. STOP. STOP. Disconnect the connector (1) from the relay (2). • Not OK (“17-05 Fuel Shutoff Valve open circuit” diagnostic code) – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. Then reconnect the connector. B. After the engine was cranked. there was no logged “17-06 Fuel Shutoff Valve short to ground” or “17-12 Fuel Shutoff Valve malfunction” diagnostic code. . Switch the 16 amp circuit breaker for the ECM OFF. The ECM disabled the ignition. “Inspecting Electrical Connectors”. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Replace the fuel control relay. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code was generated. Proceed to Test Step 8. Check for a Short Circuit to the +Battery Side • OK – No diagnostic codes were generated.239 Troubleshooting Section Expected Result: When the engine control switch was in the STOP position. Make sure that no combustible gas is present in the surrounding atmosphere. touch the relay when the relay is reconnected in order to feel the vibration. diagnostic code) – After the engine was cranked. Repair: If there is an intermittent problem that is causing the codes to be logged. Note: Open sparks can be generated during this test. A. Results: Test Step 3. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. • Not OK (“17-06 Fuel Shutoff Valve short to ground” • Not OK (“17-12 Fuel Shutoff Valve malfunction” diagnostic code) – After the engine was cranked. there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Listen for an audible click from the relay. output for the fuel control relay seems to be OK at this time. Proceed to Test Step 3. The relay is not energized when the engine control switch is in the STOP position. Contact you local gas provider immediately for assistance in the event of a leak. Illustration 82 Fuel control relay (1) Connector for the fuel control relay (2) Relay g00891892 C. Ensure that the engine control switch is in the STOP position. The initial diagnostic code was probably caused by a poor electrical connection. a “17-12 Fuel Shutoff Valve malfunction” diagnostic code was generated. If the ambient noise is too loud. The relay will vibrate when the relay is de-energized and energized. 240 Troubleshooting Section Results: B. touch the relay when the relay is reconnected in order to feel the vibration. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. • Not OK – There is an audible click and/or vibration when the relay is disconnected and connected. C. There is probably a short circuit to the +Battery side in a connector or a wiring harness. If the ambient noise is too loud. Determine the Cause of the Energized Relay Gaseous fuel is present. The relay is receiving power when the engine control switch is in the STOP position. There is an open circuit. Proceed to Test Step 4. The relay is not energized when the P13 connector is disconnected. Disconnect the connector (2) from the relay (3). Listen for an audible click from the relay. There is no short circuit to the +Battery side. Then reconnect the connector. Disconnect connector P13 (1) from the terminal box. Switch the 16 amp circuit breaker for the ECM OFF. A. Test Step 4. Turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM ON. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The solenoid is not energized when the P13 connector is disconnected. Turn the engine control switch to the OFF/RESET position. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty: Illustration 83 g00891900 (1) Terminal box’s P13 connector for the fuel control relay . Results: • OK – There is no audible click and/or vibration when the solenoid is disconnected and reconnected. The relay will vibrate when the relay is de-energized and energized. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Proceed to Test Step 5. Note: Open sparks can be generated during this test. • OK – There is no audible click and/or vibration when the relay is disconnected and connected. Illustration 84 Fuel control relay (2) Connector for the fuel control relay (3) Relay g00891901 D. Contact you local gas provider immediately for assistance in the event of a leak. Continue with this procedure. Disconnect the connector from the fuel control relay. 4. 2. 8. Pull on the wires in order to verify proper installation of the terminals. Repair the wiring and/or the connector. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM ON. Then reconnect the connector. Reinstall terminal 11 and terminal 21 into the P2 connector. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. touch the relay when the relay is reconnected in order to feel the vibration. . Use a 151-6320 Wire Removal Tool to remove terminals (P2-11) and (P2-21) from the P2 connector (1). there may be a problem with the ECM. 6. when possible. 7. If the relay is not energized. Then reconnect the connector. touch the relay when the relay is reconnected in order to feel the vibration. Contact you local gas provider immediately for assistance in the event of a leak. there is a problem with a connector and/or wiring in the terminal box. The relay will vibrate when the relay is de-energized and energized. If the ambient noise is too loud.241 Troubleshooting Section Gaseous fuel is present. If the relay is energized. “Inspecting Electrical Connectors”. 9. If the relay is not energized. If the ambient noise is too loud. Illustration 86 Fuel control relay (2) Connector for the fuel control relay (3) Relay g00891901 5. Switch the 16 amp circuit breaker for the ECM OFF. Listen for an audible click from the relay. Illustration 85 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return g00891995 3. Listen for an audible click from the relay. Refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM ON. Note: Open sparks can be generated during this test. there is an intermittent problem with a connector and/or the wiring. Switch the 16 amp circuit breaker for the ECM OFF. Reconnect the P13 connector to the terminal box. Replace parts. Turn the engine control switch to the OFF/RESET position. Turn the engine control switch to the STOP position. if necessary. Disconnect the connector (2) from the relay (3). Turn the engine control switch to the STOP position. The relay will vibrate when the relay is de-energized and energized. Switch the 16 amp circuit breaker for the ECM OFF. If the problem is not resolved. There is a problem with the relay. “Replacing the ECM”. If the new ECM operates correctly and the original ECM does not operate correctly. • OK – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was not generated when the jumper wire was installed. Exit this procedure and perform this procedure again. replace the original ECM. Expected Result: A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was not generated when the jumper wire was installed. • Not OK – A “17-05 Fuel Shutoff Valve open circuit” diagnostic code was generated when the jumper wire was installed. Disconnect the fuel control relay. E. Switch the 16 amp circuit breaker for the ECM ON. “Replacing the ECM”. There may be an open circuit in the engine harness. there may be a problem with the ECM. when possible. There is a short circuit to the +Battery side in the engine harness. Repair: Perform the following procedure: 1. Remove the jumper wire from the relay’s connector on the engine harness. Results: • Not OK – There is an audible click and/or vibration when the relay is disconnected and reconnected. 3. moisture. Refer to Troubleshooting. and corrosion. The harness and the ECM are OK. Install a jumper wire (2) into the two terminals of the relay’s connector (1) on the engine harness. Repair: Repair the connector and/or wiring in the engine harness. if necessary. STOP. The output is OFF when the engine control switch is in the STOP position and the engine is not running. B. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for a “17-05 Fuel Shutoff Valve open circuit” diagnostic code. 4. Refer to Troubleshooting. If the problem is resolved with the new ECM. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. Inspect the relay’s connectors for damage. 2. The relay is energized when the P13 connector is disconnected. If the problem is not resolved. Turn the engine control switch to the STOP position. STOP. Make repairs.242 Troubleshooting Section If the relay is energized. as needed. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code can only be detected when the output for the fuel control relay is OFF. It is unlikely that the ECM has failed. C. perform the following steps: Temporarily install a new ECM. D. replace the fuel control relay. install the original ECM and verify that the problem returns. Replace the engine harness. Turn the engine control switch to the OFF/RESET position. STOP. Test Step 5. Proceed to Test Step 6. . Test Step 6. Check the Engine Harness Illustration 87 (1) Connector for the fuel control relay (2) Jumper wire g00891959 A. Turn the engine control switch to the OFF/RESET position. Create a Short Circuit in order to Check for an Open Circuit A. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM OFF. . Check the ECM A. Turn the engine control switch to the STOP position. Test Step 7. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code can only be detected when the output for the fuel control relay is OFF. Wait for 30 seconds and use Cat ET to check for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. if necessary. Replace the engine harness. B. Make repairs. Repair: Repair the engine harness. a “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. Disconnect the P13 connector from the terminal box. Remove the jumper wire from the J13 connector. STOP.243 Troubleshooting Section B. if necessary. • Not OK – When the jumper wire was installed. Proceed to test Step 7. Switch the 16 amp circuit breaker for the ECM ON. Use the 151-6320 Wire Removal Tool to remove terminals (P2-11) and (P2-21). E. • OK – When the jumper wire was installed. and corrosion. Inspect the P13 and J13 connectors for damage. The output is OFF when the engine control switch is in the STOP position and the engine is not running. There is a problem in the engine harness. Install a jumper wire into the two terminals of the J13 connector. there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. moisture. The ECM did not detect the jumper wire in the J13 connector. Illustration 88 (1) Connector J13 for the fuel control relay (2) Jumper wire g00891989 C. Results: Illustration 89 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-11) Circuit driver for the fuel control relay (P2-21) Return g00891995 C. Expected Result: There is no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Turn the engine control switch to the OFF/RESET position. There is a problem in the terminal box. D. when possible. However.244 Troubleshooting Section Results: • OK – When the jumper wire was installed. the circuit has good continuity. Illustration 90 Harness side of the ECM P2 connector (2) Jumper wire (P2-11) Circuit driver for the fuel control relay (P2-21) Return g00892003 5. Switch the 16 amp circuit breaker for the ECM OFF. Expected Result: There is no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Pull on the jumper wire in order to verify proper installation. E. D. Make repairs. Turn the engine control switch to the STOP position. Reinstall the terminals into P2-11 and P2-21. a “17-05 Fuel Shutoff Valve open circuit” diagnostic code was activated. Use an ohmmeter to measure the resistance between the P2-11 terminal and the J13-A terminal. The ECM detects the jumper wire at the P2 connector. 3. 2. measure the resistance between the P2-21 terminal and the J13-B terminal. There is a problem between the ECM P2 connector and the terminal box J13 connector. Repair: Perform the following procedure: 1. STOP. Thoroughly inspect the terminal box J13 connector for the engine harness. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for an active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. if necessary. Switch the 16 amp circuit breaker for the ECM ON. Reinstall the terminals into P2-11 and P2-21. Pull on the wires in order to verify proper installation of the terminals. Also. moisture. . Inspect the connectors for damage. If the resistance measurements are less than 5 ohms. 4. there was no active “17-05 Fuel Shutoff Valve open circuit” diagnostic code. Note: The “17-05 Fuel Shutoff Valve open circuit” diagnostic code can only be detected when the output for the fuel control relay is OFF. • No – When the jumper wire was installed. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. there is an open circuit. Otherwise. Disconnect the ECM J2/P2 connectors. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. the ECM did not detect the jumper wire at the J13 connector. Pull on the wires in order to verify proper installation of the terminals. Install a jumper wire (2) into terminals (P2-11) and (P2-21). There is a problem with the ECM. and corrosion. The output is OFF when the engine control switch is in the STOP position and the engine is not running. F. Repair: Perform the following procedure: 1. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. 2. Turn the engine control switch to the OFF/RESET position. 6. 3. The ECM did not detect the jumper wire. Test Step 8. Note: To provide the output for the fuel control relay.245 Troubleshooting Section 4. B. shut OFF the main gas supply. Create an Open Circuit at the Terminal Box A. Turn the engine control switch to the STOP position. Repair: Perform the following procedure: 1. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. C. Proceed to Test Step 9. E. G. Expected Result: A “17-06 Fuel Shutoff Valve short to ground” was not generated. Then turn the engine control switch to the STOP position. F. Illustration 92 (1) P13 connector for the fuel control relay g00891900 B. Disconnect the connector (1) from the relay (2). Otherwise. Turn the engine control switch to the OFF/RESET position. When the relay was disconnected. STOP. Turn the engine control switch to the START position for at least 30 seconds. replace the relay. Disconnect connector P13 (1) from the terminal box. If the problem is not resolved. as needed. Turn the engine control switch to the OFF/RESET position. Results: • OK – When the relay was connected. D. no “short to ground” diagnostic code was generated. Verify that the problem is resolved. There is a problem with the relay. Illustration 91 Fuel control relay (1) Connector for the fuel control relay (2) Relay g00891892 Test Step 9. Create an Open Circuit in order to Check for a Short Circuit to Ground A. STOP. “Replacing the ECM”. Replace the ECM according to Troubleshooting. To prevent the engine from starting. Make repairs. Switch the 16 amp circuit breaker for the ECM OFF. 2. 3. Turn the engine control switch to the OFF/RESET position. Inspect the connections of the relay for damage and/or corrosion. a “short to ground” diagnostic code was generated. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code. . a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. Switch the 16 amp circuit breaker for the ECM OFF. • Not OK – A “short to ground” diagnostic code was generated when the relay was disconnected. the sequence for engine start-up must be initiated. F. Turn the engine control switch to the START position for at least 30 seconds. Reconnect the P13 connector. Switch the 16 amp circuit breaker for the ECM ON. . Proceed to Test Step 10. D. Use the 151-6320 Wire Removal Tool to remove terminal (P2-11). To prevent the engine from starting. E. D. Note: To provide the output for the fuel control relay. Then turn the engine control switch to the STOP position. F. Turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM OFF. E. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. STOP. when possible. Turn the engine control switch to the STOP position. Illustration 93 Harness side of the ECM P2 connector (P2-11) Circuit driver for the fuel control relay g00892016 B. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code.246 Troubleshooting Section C. Expected Result: A “17-06 Fuel Shutoff Valve short to ground” was not generated. C. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. Turn the engine control switch to the START position for at least 30 seconds. 3. • OK – A “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated when the P13 connector was disconnected. the sequence for engine start-up must be initiated. Then turn the engine control switch to the STOP position. shut OFF the main gas supply. Check the ECM A. Switch the 16 amp circuit breaker for the ECM ON. Repair: Reconnect the P13 connector. Use Cat ET to clear the logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code. Otherwise. Turn the engine control switch to the OFF/RESET position. • Not OK – A “17-06 Fuel Shutoff Valve short to ground” diagnostic code was generated when the P13 connector was disconnected. There is a problem in the engine harness. To prevent the engine from starting. shut OFF the main gas supply. Turn the engine control switch to the OFF/RESET position. 2. Replace the harness. if necessary. the sequence for engine start-up must be initiated. Repair the engine harness. There is probably a short circuit to ground in the terminal box. G. Otherwise. Switch the 16 amp circuit breaker for the ECM OFF. Repair: Perform the following procedure: 1. Results: Test Step 10. Note: To provide the output for the fuel control relay. a “17-06 Fuel Shutoff Valve short to ground” diagnostic code cannot be generated. the prelube pump will operate until one of the following occurrences: • OK – When the output to the relay was disconnected from the ECM P2 connector. The output for the prelube relay will not operate if the emergency stop button is activated or if the engine speed is greater than 0 rpm. when possible. a “short to ground” diagnostic code was generated when the P13 connector was disconnected from the terminal box. Turn the engine control switch to the OFF/RESET position.247 Troubleshooting Section G. the ECM also provides +Battery voltage to the “Prelube Active” indicator in the control panel (if equipped). • The programmable “Engine Pre-lube Time Out Period” expires. the output for the prelube relay will operate for three minutes. the “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated. Refer to the engine’s electrical schematic. STOP. Switch the 16 amp circuit breaker for the ECM OFF. Pull on the wire in order to verify proper installation of the terminal. This ensures that the turbocharger has adequate lubrication during coastdown. The prelubrication system also operates after shutdown. . Turn the engine control switch to the OFF/RESET position. The logic responds to inputs from the following components: engine control switch. 2. Verify that the problem is resolved. Repair: Perform the following procedure: 1. Expected Result: The “17-06 Fuel Shutoff Valve short to ground” diagnostic code was not generated. The ECM provides +Battery voltage to the prelube relay until the switch is released or until the prelube pressure switch closes. • The emergency stop button is pressed. Replace the ECM according to Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. the ECM provides +Battery voltage to the prelube relay. Use Cat ET to look for a logged “17-06 Fuel Shutoff Valve short to ground” diagnostic code again. • The prelube pressure switch closes. Make sure that the hardware is installed: prelube pump. Results: i01742661 ECM Output Circuit (Prelubrication Oil Pump) SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) contains the logic and the outputs for control of prelubrication. The “Engine Pre-Lube Time Out Period” must be programmed to a value between 30 and 300 seconds. Repair the terminal box’s harness. STOP. a +Battery signal is sent to the ECM. The logic for starting and stopping is customer programmable. When +Battery voltage is supplied to the prelube relay. prelube pressure switch. starting. Reinstall the terminal that was removed from P2-11. Pull on the wire in order to verify proper installation of the terminal. The output for the prelube relay can also be operated with a manual switch. 3. and other inputs. prelube relay. and shutdown of the engine. Replace the harness. When the switch is closed. if necessary. Make sure that the wiring is installed. There is a problem in the terminal box between the P2 connector and the terminal box P13 connector. After activation. make sure that the ECM is programmed properly. 3. Before you troubleshoot the prelubrication system. remote start switch. When the engine reaches 0 rpm. and manual prelube switch. 2. • Not OK – A “17-06 Fuel Shutoff Valve short to ground” diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. Reinstall the terminal that was removed from P2-11. “Replacing the ECM”. However. data link. emergency stop switch. When the conditions permit operation and the logic determines that lubrication is required. There seems to be a problem with the ECM. Repair: Perform the following procedure: 1. Illustration 94 Schematic for the prelube relay g00892150 . use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Clear the diagnostic codes after the problem is resolved. The least likely cause is a problem with the ECM. The troubleshooting procedure may generate additional diagnostic codes. Logged diagnostic codes provide an historical record.248 Troubleshooting Section If Caterpillar did not supply the prelubrication system. “Inspecting Electrical Connectors”. Before you begin this procedure. Inspect the Electrical Connectors and Wiring Illustration 95 g00892158 (1) ECM J2/P2 connectors (2) Terminal box’s J15/P15 connectors for the prelube relay (3) 16 amp circuit breaker (4) 6 amp circuit breaker A. Thoroughly inspect the following connectors and the wiring harnesses for the connectors: • ECM J2/P2 connectors • Terminal box’s connectors (J15/P15) • Connector for the prelube relay a. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). and 339-05 diagnostic codes are also disabled. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 6 amp circuit breaker OFF. Note: For the following steps. 338-06. Check the torque of the Allen head screw for the 70-pin connectors. The 338-05. refer to Troubleshooting. the prelubrication function and the E233 (3) event code are disabled. Test Step 1. The next likely cause is a problem with the prelube relay. Keep your mind on correcting the cause of the original diagnostic code. B. Switch the 16 amp circuit breaker for the ECM ON. there was no logged “338-06 Prelube Relay short to ground” diagnostic code. Otherwise. STOP. Replace parts. proceed to the “Results” for this Test Step. C. c. • OK – The components are in good condition with proper connections. abrasion. Activate the manual prelube switch for at least 30 seconds. Switch the 6 amp circuit breaker ON. clear the code. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. Proceed to Test Step 3. After the manual prelube switch was operated. Check for Diagnostic Codes A. F. Turn the engine control switch to the STOP position. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. Results: Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the prelube relay is ON. If there is a “338-06 Prelube Relay short to ground” diagnostic code. Connect Cat ET to the service tool connector on the terminal box. E. Then release the switch. Use Cat ET to look for a logged “338-06 Prelube Relay short to ground” diagnostic code again. Repair: Perform the necessary repairs. Check the harness and wiring for abrasion and pinch points from the ECM to the prelube relay. pins. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the prelube relay. Illustration 96 Harness side of the ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return g00892163 B. . Wait for 30 seconds and use Cat ET to check for an active “338-05 Prelube Relay open circuit” diagnostic code. If there is an active “338-05 Prelube Relay open circuit” diagnostic code. Expected Result: All of the connectors. there was no active “338-05 Prelube Relay open circuit” diagnostic code. Illustration 97 (5) Connector P15 for the prelube relay (P15-A) Circuit driver for the prelube relay (P15-B) Return g00892166 b. continue this procedure. when possible. Expected Result: When the engine control switch was in the STOP position. Use Cat ET to check the logged diagnostic codes. and sockets are connected properly. and pinch points. if necessary. Note: The “338-05 Prelube Relay open circuit” diagnostic code can only be detected when the ECM output for the prelube relay is OFF. Test Step 2. D.249 Troubleshooting Section • Not OK – The components are not in good condition and/or at least one connection is improper. The connectors and the wiring are free of corrosion. Proceed to Test Step 4. Listen for an audible click from the relay.250 Troubleshooting Section Results: Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. Gaseous fuel is present. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Then reconnect the connector. Results: • OK – No diagnostic codes were generated. . Proceed to Test Step 3. Switch the 16 amp circuit breaker for the ECM OFF. Note: Open sparks can be generated during this test. refer to Troubleshooting. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. • Not OK (“338-05 Prelube Relay open circuit” diagnostic code) – A “338-05 Prelube Relay open circuit” diagnostic code was activated. Check for a Short Circuit to the +Battery Side Gaseous fuel is present. If the ambient noise is too loud. Contact you local gas provider immediately for assistance in the event of a leak. Determine the Cause of the Energized Relay Test Step 3. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. • Not OK – There is an audible click and/or • Not OK (“338-06 Prelube Relay short to ground” diagnostic code) – After the manual prelube switch was operated. Turn the engine control switch to the OFF/RESET position. There is an open circuit. STOP. Contact you local gas provider immediately for assistance in the event of a leak. Proceed to Test Step 5. The relay is receiving power when the engine control switch is in the STOP position. Ensure that the engine control switch is in the STOP position. There is no short circuit to the +Battery side. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. The initial diagnostic code was probably caused by a poor electrical connection. The output for the prelube relay seems to be OK at this time. The relay is not energized when the engine control switch is in the STOP position. • OK – There is no audible click and/or vibration when the relay is disconnected and connected. Test Step 4. vibration when the relay is disconnected and connected. Proceed to Test Step 8. a “338-06 Prelube Relay short to ground” diagnostic code was generated. Make sure that no combustible gas is present in the surrounding atmosphere. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Note: Open sparks can be generated during this test. Repair: If there is an intermittent problem that is causing the codes to be logged. C. B. touch the relay when the relay is reconnected in order to feel the vibration. Disconnect the connector from the prelube relay. A. The relay will vibrate when the relay is de-energized and energized. A. “Inspecting Electrical Connectors”. Results: Illustration 99 Harness side of the ECM P2 connector (2) ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return g00892199 • OK – There is no audible click and/or vibration when the relay is disconnected and reconnected. Contact you local gas provider immediately for assistance in the event of a leak. Reconnect the P15 connector to the terminal box. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty: 3. touch the relay when the relay is reconnected in order to feel the vibration. Listen for an audible click from the relay. Disconnect the connector from the prelube relay. Disconnect connector P15 (1) from the terminal box. 4. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. D. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Use a 151-6320 Wire Removal Tool to remove terminals (P2-12) and (P2-22) from the P2 connector (2). The relay is not energized when the P15 connector is disconnected. Switch the 16 amp circuit breaker for the ECM ON. Illustration 98 (1) Terminal box’s P15 connector for the prelube relay g00892192 B. The relay is not energized when the P15 connector is disconnected. If the ambient noise is too loud. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. The relay will vibrate when the relay is de-energized and energized. . C. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Note: Open sparks can be generated during this test. 2. 1.251 Troubleshooting Section Gaseous fuel is present. Turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM ON. Then reconnect the connector. Reinstall terminal 12 and terminal 22 into the P2 connector. “Inspecting Electrical Connectors”. If the relay is energized. STOP. Listen for an audible click from the relay. Install a jumper wire into the two terminals of the relay’s connector on the engine harness. “Replacing the ECM”. when possible. Illustration 100 Typical solenoid connector on an engine harness g00892215 C. Refer to Troubleshooting. The relay is energized when the P15 connector is disconnected. It is unlikely that the ECM has failed. “Replacing the ECM”. B. Continue with this procedure. Create a Short Circuit in order to Check for an Open Circuit A. Refer to Troubleshooting. If the problem is not resolved. If the problem is resolved with the new ECM. perform the following steps: Temporarily install a new ECM. Switch the 16 amp circuit breaker for the ECM ON. if necessary. The relay will vibrate when the relay is de-energized and energized. Note: The “338-05 Prelube Relay open circuit” diagnostic code can only be detected when the ECM output for the prelube relay is OFF. Exit this procedure and perform this procedure again. there is an intermittent problem with a connector and/or the wiring. Disconnect the connector from the prelube relay. If the relay is energized. • Not OK – There is an audible click and/or vibration when the relay is disconnected and reconnected. Switch the 16 amp circuit breaker for the ECM OFF. 8. STOP. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. If the ambient noise is too loud. There is a short circuit to the +Battery side in the engine harness. D. touch the relay when the relay is reconnected in order to feel the vibration.252 Troubleshooting Section 5. Switch the 16 amp circuit breaker for the ECM OFF. there may be a problem with the ECM. when possible. Replace parts. Disconnect the connector from the prelube relay. 6. . touch the relay when the relay is reconnected in order to feel the vibration. replace the original ECM. Turn the engine control switch to the STOP position. Listen for an audible click from the relay. The relay will vibrate when the relay is de-energized and energized. Test Step 5. Pull on the wires in order to verify proper installation of the terminals. Turn the engine control switch to the OFF/RESET position. If the new ECM operates correctly and the original ECM does not operate correctly. if necessary. 7. Then reconnect the connector. If the relay is not energized. Disconnect the harness connector from the prelube relay. Then reconnect the connector. Refer to Troubleshooting. Repair: Repair the connector and/or wiring in the engine harness. 9. Repair the wiring and/or the connector. If the relay is not energized. Replace the harness. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. install the original ECM and verify that the problem returns. there may be a problem with the ECM. Turn the engine control switch to the OFF/RESET position. If the ambient noise is too loud. there is a problem with a connector and/or wiring in the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the OFF/RESET position. Check the Engine Harness A. Remove the jumper wire from the relay’s connector on the engine harness. replace the relay. Note: The “338-05 Prelube Relay open circuit” diagnostic code can only be detected when the ECM output for the prelube relay is OFF. There is a problem with the relay. There is a problem in the engine harness. STOP. Switch the 16 amp circuit breaker for the ECM OFF. . Results: • OK – A “338-05 Prelube Relay open circuit” diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. STOP. Inspect the relay’s connectors for damage. moisture. Repair: Repair the engine harness. Expected Result: There is no active “338-05 Prelube Relay open circuit” diagnostic code. moisture. Proceed to Test Step 6. as needed. when possible. and corrosion. 3. Test Step 6. Illustration 101 (1) Connector J15 for the prelube relay (2) Jumper wire g00892226 C. Repair: Perform the following procedure: 1. If the problem is not resolved. Results: 4. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. if necessary.253 Troubleshooting Section E. Make repairs. if necessary. Expected Result: A “338-05 Prelube Relay open circuit” diagnostic code was not generated when the jumper wire was installed. Make repairs. Install a jumper wire (2) into the two terminals of the J15 connector (1). Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for a “338-05 Prelube Relay open circuit” diagnostic code. B. Replace the harness. • OK – When the jumper wire was installed. • Not OK – A “338-05 Prelube Relay open circuit” diagnostic code was generated when the jumper wire was installed. Disconnect the P15 connector from the terminal box. and corrosion. 2. E. Inspect the P15 and J15 connectors for damage. D. there was no active “338-05 Prelube Relay open circuit” diagnostic code. Turn the engine control switch to the STOP position. There may be an open circuit in the engine harness. Wait for 30 seconds and use Cat ET to check for an active “338-05 Prelube Relay open circuit” diagnostic code. . Proceed to test Step 7. Pull on the jumper wire in order to verify proper installation. Switch the 16 amp circuit breaker for the ECM OFF. F. Illustration 102 Harness side of the ECM P2 connector (1) ECM P2 connector (P2-12) Circuit driver for the prelube relay (P2-22) Return g00892236 Note: The “338-05 Prelube Relay open circuit” diagnostic code can only be detected when the ECM output for the prelube relay is OFF. Turn the engine control switch to the STOP position. E. Illustration 103 Harness side of the ECM P2 connector (2) Jumper wire (P2-12) Circuit driver for the prelube relay (P2-22) Return g00892247 D.254 Troubleshooting Section • Not OK – When the jumper wire was installed. The output is normally OFF when the engine control switch is in the STOP position and when the prelube pressure switch is closed. Use the 151-6320 Wire Removal Tool to remove terminals (P2-12) and (P2-22). Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for an active “338-05 Prelube Relay open circuit” diagnostic code. a “338-05 Prelube Relay open circuit” diagnostic code was activated. Remove the jumper wire from the J15 connector. The ECM did not detect the jumper wire in the J15 connector. Check the ECM A. Switch the 16 amp circuit breaker for the ECM ON. Install a jumper wire (2) into terminals (P2-12) and (P2-22). Test Step 7. There is a problem in the terminal box. Expected Result: There is no active “338-05 Prelube Relay open circuit” diagnostic code. Turn the engine control switch to the OFF/RESET position. B. C. if necessary. . • No – When the jumper wire was installed. “Replacing the ECM”. Use an ohmmeter to measure the resistance between the P2-12 terminal and the J15-A terminal. and corrosion. moisture. However. The ECM did not detect the jumper wire. 3. There is a problem with the relay. When the relay was disconnected. Also. Otherwise. Replace the ECM according to Troubleshooting. the ECM did not detect the jumper wire at the J15 connector. Verify that the problem is resolved. the circuit has good continuity. There is a problem between the ECM P2 connector and the terminal box J15 connector. Repair: Perform the following procedure: 1. Pull on the wires in order to verify proper installation of the terminals. Make repairs. Switch the 16 amp circuit breaker for the ECM OFF. a “short to ground” diagnostic code was generated. Switch the 16 amp circuit breaker for the ECM OFF. 4. measure the resistance between the P2-22 terminal and the J15-B terminal. • OK – When the relay was connected. Repair: Perform the following procedure: 1. Make repairs. Turn the engine control switch to the OFF/RESET position. Results: STOP. Reinstall the terminals into P2-12 and P2-22. Reinstall the terminals into P2-12 and P2-22. F. 2. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Turn the engine control switch to the OFF/RESET position. Activate the manual prelube switch for at least 30 seconds. Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the prelube relay is ON. Use Cat ET to clear the logged “338-06 Prelube Relay short to ground” diagnostic code. 5. Turn the engine control switch to the STOP position.255 Troubleshooting Section Results: • OK – When the jumper wire was installed. 4. there is an open circuit. The ECM detects the jumper wire at the P2 connector. E. If the problem is not resolved. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Create an Open Circuit in order to Check for a Short Circuit to Ground A. 2. no “short to ground” diagnostic code was generated. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. 3. Expected Result: After the manual prelube switch was operated. B. Turn the engine control switch to the OFF/RESET position. Disconnect the connector from the prelube relay. Turn the engine control switch to the OFF/RESET position. replace the relay. Disconnect the ECM J2/P2 connectors. Pull on the wires in order to verify proper installation of the terminals. Thoroughly inspect the terminal box J15 connector for the engine harness. Inspect the connectors for damage. 2. 6. There is a problem with the ECM. If the resistance measurements are less than 5 ohms. as needed. D. Repair: Perform the following procedure: 1. there was no active “338-05 Prelube Relay open circuit” diagnostic code. a “338-05 Prelube Relay open circuit” diagnostic code was activated. Inspect the connections of the relay for damage and/or corrosion. C. STOP. Use Cat ET to look for a logged “338-06 Prelube Relay short to ground” diagnostic code again. Then release the switch. Switch the 16 amp circuit breaker for the ECM OFF. Test Step 8. 3. STOP. there was no logged “338-06 Prelube Relay short to ground” diagnostic code. Repair: Reconnect the P15 connector. B. Use Cat ET to clear the logged “338-06 Prelube Relay short to ground” diagnostic code. Use Cat ET to look for a logged “338-06 Prelube Relay short to ground” diagnostic code again. Test Step 10. Switch the 16 amp circuit breaker for the ECM OFF. Illustration 104 (1) P15 connector for the prelube relay g00892192 Proceed to Test Step 10. Expected Result: A “338-06 Prelube Relay short to ground” was not generated. Check the ECM A. F. C. • OK – A “338-06 Prelube Relay short to ground” diagnostic code was not generated when the P15 connector was disconnected. Switch the 16 amp circuit breaker for the ECM OFF. if necessary. Switch the 16 amp circuit breaker for the ECM OFF.256 Troubleshooting Section • Not OK – After the manual prelube switch was operated. Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the prelube relay is ON. There is probably a short circuit to ground in the terminal box. Switch the 16 amp circuit breaker for the ECM ON. Replace the harness. E. when possible. Proceed to Test Step 9. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. Turn the engine control switch to the OFF/RESET position. D. . Activate the manual prelube switch for at least 30 seconds. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. Repair the engine harness. Reconnect the P15 connector. Results: Test Step 9. 2. Disconnect connector P15 (1) from the terminal box. a “338-06 Prelube Relay short to ground” diagnostic code was logged. STOP. Then release the switch. Create an Open Circuit at the Terminal Box A. There is a problem in the engine harness. 3. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. • Not OK – A “338-06 Prelube Relay short to ground” diagnostic code was generated when the P15 connector was disconnected from the terminal box. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM OFF. C. Replace the harness. the “338-06 Prelube Relay short to ground” diagnostic code was not generated. Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the prelube relay is ON. Expected Result: The “338-06 Prelube Relay short to ground” diagnostic code was not generated. “Replacing the ECM”. . There is a problem in the terminal box between the ECM connector and the terminal box J15 connector. The output is normally ON when the engine control switch is in the START position and the prelube pressure switch is open. Pull on the wire in order to verify proper installation of the terminal. Use the 151-6320 Wire Removal Tool to remove terminal (P2-12). Use Cat ET to look for a logged “338-06 Prelube Relay short to ground” diagnostic code again. when possible. Activate the manual prelube switch for at least 30 seconds. Reinstall the terminal that was removed from P2-12. a “short to ground” diagnostic code was generated when the P15 connector was disconnected from the terminal box. Illustration 105 Harness side of the ECM P2 connector (P2-12) Circuit driver for the prelube relay g00892315 • Not OK – A “338-06 Prelube Relay short to ground” diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. Switch the 16 amp circuit breaker for the ECM ON. E. Pull on the wire in order to verify proper installation of the terminal. D. Reinstall the terminal that was removed from P2-12. Turn the engine control switch to the OFF/RESET position. Repair: Perform the following procedure: 1. There seems to be a problem with the ECM. Use Cat ET to clear the logged “338-06 Prelube Relay short to ground” diagnostic code. Repair: Perform the following procedure: 1. However. 3. 2. if necessary. 3. B. Repair the harness. STOP. Replace the ECM according to Troubleshooting. Verify that the problem is resolved. STOP.257 Troubleshooting Section Results: • OK – When the output to the relay was disconnected from the ECM P2 connector. Turn the engine control switch to the OFF/RESET position. Turn the engine control switch to the STOP position. 2. Then release the switch. F. emergency stop switch. The next likely cause is a problem with the starter motor relay. The ECM supplies +Battery voltage to the starter motor relay when the logic determines that it is necessary. The logic responds to inputs from the following components: engine control switch. remote start switch. The troubleshooting procedure may generate additional diagnostic codes. The logic for starting and stopping is customer programmable. and shutdown of the engine. Inspect the Electrical Connectors and Wiring Illustration 107 g00892383 (1) ECM J2/P2 connectors (2) Terminal box’s J14/P14 connectors for the starter motor relay’s circuit (3) 16 amp circuit breaker (4) 6 amp circuit breaker . Illustration 106 Schematic for the starter motor relay’s circuit g00892362 Test Step 1. Clear the diagnostic codes after the problem is resolved. The ECM removes the voltage when the crank terminate relay is energized. Before you begin this procedure. Logged diagnostics provide an historical record. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file.258 Troubleshooting Section i01742945 ECM Output Circuit (Starting Motor) SMCS Code: 1901-038 System Operation Description: The ECM contains the logic and the outputs for control of prelubrication. data link. and other inputs. The least likely cause is a problem with the ECM. Keep your mind on correcting the cause of the original diagnostic code. The voltage is also removed if the customer programmable “Overcrank Time” has expired. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. starting. C. Use Cat ET to check the logged diagnostic codes. Otherwise. • Not OK – The components are not in good condition and/or at least one connection is improper. when possible. STOP. shut the gas supply OFF. Illustration 109 (5) Connector P14 for the starter motor relay’s circuit (P14-A) Terminal for the starter motor relay’s circuit (P14-B) Return g00892368 . Test Step 2.259 Troubleshooting Section A. and sockets are connected properly. Note: For the following steps. Expected Result: All of the connectors. • OK – The components are in good condition with proper connections. Switch the 16 amp circuit breaker for the ECM OFF. Connect Cat ET to the service tool connector on the terminal box. c. E. Note: The “444-05 Start Relay open circuit” diagnostic code can only be detected when the ECM output for the starter motor relay is OFF. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the starter motor relay. clear the code. Turn the engine control switch to the OFF/RESET position. The connectors and the wiring are free of corrosion. If there is an active “444-05 Start Relay open circuit” diagnostic code. continue this procedure. Repair: Perform the necessary repairs. refer to Troubleshooting. Turn the engine control switch to the STOP position. if necessary. Check the harness and wiring for abrasion and pinch points from the ECM to the starter motor relay. pins. proceed to the “Results” for this Test Step. “Inspecting Electrical Connectors”. Switch the 16 amp circuit breaker for the ECM ON. abrasion. B. If there is a “444-06 Start Relay short to ground” diagnostic code. Check for Diagnostic Codes A. Illustration 108 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relay’s circuit (P2-20) Return g00892365 B. Thoroughly inspect the following connectors and the wiring harnesses for the connectors: b. Switch the 6 amp circuit breaker ON. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). The output is normally OFF when the engine control switch is in the STOP position or when the crank terminate relay is energized. Results: • ECM J2/P2 connectors • Terminal box J14/P14 connectors • Connector for the starter motor relay’s circuit a. Proceed to Test Step 2. To prevent the engine from starting. Replace parts. and pinch points. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. D. Check the torque of the Allen head screw for the 70-pin connectors. Expected Result: When the engine control switch was in the STOP position. F. Proceed to Test Step 3. STOP. Contact you local gas provider immediately for assistance in the event of a leak. The relay is not energized when the engine control switch is in the STOP position. C. a “444-06 Start Relay short to ground” diagnostic code was generated. Repair: If there is an intermittent problem that is causing the codes to be logged. diagnostic code) – After the engine was cranked. . Make sure that no combustible gas is present in the surrounding atmosphere. Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. If the ambient noise is too loud. • Not OK (“444-06 Start Relay short to ground” • Not OK – There is an audible click and/or vibration when the relay is disconnected and connected. • Not OK (“444-05 Start Relay open circuit” diagnostic code) – A “444-05 Start Relay open circuit” diagnostic code was activated. A. There is probably a short circuit to the +Battery side in a connector or a wiring harness. Results: Test Step 3. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. The output is normally ON when the engine control switch is turned from the “STOP” position to the “START” position.260 Troubleshooting Section Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the starter motor relay is ON. There is an open circuit. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Proceed to Test Step 8. Disconnect the connector from the starter motor relay. B. there was no logged “444-06 Start Relay short to ground” diagnostic code. G. there was no active “444-05 Start Relay open circuit” diagnostic code. touch the starter motor relay when the relay is reconnected in order to feel the vibration. This can be caused by an actual open circuit or by a short circuit to the +Battery side. Results: • OK – No diagnostic codes were generated. Turn the engine control switch to the START position for at least 30 seconds. The relay will vibrate when the relay is de-energized and energized. “Inspecting Electrical Connectors”. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. refer to Troubleshooting. Check for a Short Circuit to the +Battery Side Gaseous fuel is present. Proceed to Test Step 5. After the engine was cranked. The output remains ON until the crank terminate relay is energized. Listen for an audible click from the relay. Then turn the engine control switch to the STOP position. Ensure that the engine control switch is in the STOP position. Proceed to Test Step 4. The initial diagnostic code was probably caused by a poor electrical connection. The output for the starter motor relay seems to be OK at this time. • OK – There is no audible click and/or vibration when the relay is disconnected and connected. Note: Open sparks can be generated during this test. There is no short circuit to the +Battery side. The relay is receiving power when the engine control switch is in the STOP position. Then reconnect the connector. The relay will vibrate when the relay is de-energized and energized. Listen for an audible click from the relay. Determine the Cause of the Energized Relay Expected Result: There is no audible click and/or vibration when the relay is disconnected and reconnected. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM ON. The relay is not energized when the P14 connector is disconnected. • OK – There is no audible click and/or vibration when the relay is disconnected and reconnected. Note: Open sparks can be generated during this test. Switch the 16 amp circuit breaker for the ECM OFF. Turn the engine control switch to the STOP position. 2. C. Reconnect the P14 connector to the terminal box. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. If the ambient noise is too loud. Disconnect the connector from the starter motor relay. 1. Note: Open sparks can be generated during this test. D. Results: Gaseous fuel is present. Then reconnect the connector.261 Troubleshooting Section Test Step 4. The relay is not energized when the P14 connector is disconnected. . Turn the engine control switch to the OFF/RESET position. A. Personal Injury or Death can result from an open flame or spark igniting the gaseous fuel causing an explosion and/or fire. Always use a gas detector to determine the presence of gaseous fuel when maintaining and servicing. Contact you local gas provider immediately for assistance in the event of a leak. Illustration 110 (1) Connector P14 for the starter motor relay’s circuit g00892397 B. Repair: Use the following procedure to determine whether the circuit driver for the relay is faulty: Gaseous fuel is present. Turn the engine control switch to the OFF/RESET position. Disconnect connector P14 (1) from the terminal box. Contact you local gas provider immediately for assistance in the event of a leak. touch the relay when the relay is reconnected in order to feel the vibration. Reinstall terminal 10 and terminal 20 into the P2 connector. Pull on the wires in order to verify proper installation of the terminals. If the relay is energized. Refer to Troubleshooting. The relay will vibrate when the relay is de-energized and energized. 4. Replace parts. The relay will vibrate when the relay is de-energized and energized. Use a 151-6320 Wire Removal Tool to remove terminals (P2-10) and (P2-20) from the P2 connector (1).262 Troubleshooting Section 6. Listen for an audible click from the relay. If the relay is not energized. Switch the 16 amp circuit breaker for the ECM ON. “Replacing the ECM”. there is an intermittent problem with a connector and/or the wiring. Continue with this procedure. if necessary. Exit this procedure and perform this procedure again. Refer to Troubleshooting. If the new ECM operates correctly and the original ECM does not operate correctly. If the problem is not resolved. 7. when possible. STOP. If the problem is resolved with the new ECM. Repair: Repair the connector and/or wiring in the engine harness. The relay is energized when the P14 connector is disconnected. Turn the engine control switch to the OFF/RESET position. perform the following steps: Temporarily install a new ECM. If the ambient noise is too loud. Turn the engine control switch to the STOP position. there is a problem with a connector and/or wiring in the terminal box. touch the relay when the relay is reconnected in order to feel the vibration. 9. when possible. Illustration 111 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relay’s circuit (P2-20) Return g00892468 3. “Replacing the ECM”. Switch the 16 amp circuit breaker for the ECM ON. There is a short circuit to the +Battery side in the engine harness. 8. there may be a problem with the ECM. Disconnect the connector from the starter motor relay. . 5. Then reconnect the connector. Switch the 16 amp circuit breaker for the ECM OFF. Refer to Troubleshooting. Replace the engine harness. there may be a problem with the ECM. If the ambient noise is too loud. STOP. install the original ECM and verify that the problem returns. Disconnect the connector from the starter motor relay. It is unlikely that the ECM has failed. • Not OK – There is an audible click and/or vibration when the relay is disconnected and reconnected. Repair the wiring and/or the connector. replace the original ECM. If the relay is not energized. Turn the engine control switch to the STOP position. “Inspecting Electrical Connectors”. Then reconnect the connector. Listen for an audible click from the relay. touch the relay when the relay is reconnected in order to feel the vibration. If the relay is energized. if necessary. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM ON. . B. Turn the engine control switch to the OFF/RESET position.263 Troubleshooting Section Test Step 5. Make repairs. as needed. 2. replace the relay. Inspect the P14 and J14 connectors for damage. Results: Illustration 113 (1) Connector J14 for the starter motor relay’s circuit (2) Jumper wire g00892491 • OK – A “444-05 Start Relay open circuit” diagnostic code was not generated when the jumper wire was installed. Inspect the relay’s connectors for damage. Install a jumper wire into the two terminals of the relay’s connector on the engine harness. D. Check the Engine Harness A. STOP. Switch the 16 amp circuit breaker for the ECM OFF. if necessary. Install a jumper wire (2) into the two terminals of the J14 connector (1). B. Test Step 6. E. Turn the engine control switch to the STOP position. 3. Ensure that the engine control switch is in the OFF/RESET position and that the 16 amp circuit breaker for the ECM is OFF. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for a “444-05 Start Relay open circuit” diagnostic code. and corrosion. Illustration 112 Typical relay connector on an engine harness g00892215 C. Make repairs. Wait for 30 seconds and use Cat ET to check for an active “444-05 Start Relay open circuit” diagnostic code. Disconnect the harness connector from the starter motor relay. Remove the jumper wire from the relay’s connector on the engine harness. Switch the 16 amp circuit breaker for the ECM ON. Repair: Perform the following procedure: 1. moisture. Disconnect the P14 connector from the terminal box. moisture. Proceed to Test Step 6. Switch the 16 amp circuit breaker for the ECM OFF. and corrosion. Expected Result: There is no active “444-05 Start Relay open circuit” diagnostic code. If the problem is not resolved. C. Create a Short Circuit in order to Check for an Open Circuit A. D. There is a problem with the relay. E. 4. Turn the engine control switch to the STOP position. • Not OK – A “444-05 Start Relay open circuit” diagnostic code was generated when the jumper wire was installed. Expected Result: A “444-05 Start Relay open circuit” diagnostic code was not generated when the jumper wire was installed. The harness and the ECM are OK. There may be an open circuit in the engine harness. the ECM did not detect the jumper wire at the J14 connector. Results: Illustration 114 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relay’s circuit (P2-20) Return g00892468 • OK – When the jumper wire was installed. F. Turn the engine control switch to the OFF/RESET position. There is a problem in the engine harness. B. when possible. a “444-05 Start Relay open circuit” diagnostic code was activated. There is a problem in the terminal box. There is a problem between the ECM P2 connector and the terminal box J14 connector. • Not OK – When the jumper wire was installed. However. Check the ECM A. STOP. Install a jumper wire (1) into terminals (P2-10) and (P2-20). Proceed to test Step 7. The ECM detects the jumper wire at the P2 connector. Switch the 16 amp circuit breaker for the ECM OFF. Wait for 30 seconds and use the “Active Diagnostic” screen of Cat ET to look for an active “444-05 Start Relay open circuit” diagnostic code. there was no active “444-05 Start Relay open circuit” diagnostic code. Repair: Repair the engine harness. Test Step 7. Expected Result: There is no active “444-05 Start Relay open circuit” diagnostic code. Turn the engine control switch to the STOP position.264 Troubleshooting Section Results: • OK – When the jumper wire was installed. Replace the harness. The ECM did not detect the jumper wire in the J14 connector. there was no active “444-05 Start Relay open circuit” diagnostic code. Illustration 115 Harness side of the ECM P2 connector (1) Jumper wire (P2-10) Terminal for the starter motor relay’s circuit (P2-20) Return g00892516 D. E. C. Use the 151-6320 Wire Removal Tool to remove terminals (P2-10) and (P2-20). Remove the jumper wire from the J14 connector. . Switch the 16 amp circuit breaker for the ECM ON. Pull on the jumper wire in order to verify proper installation. if necessary. moisture. Create an Open Circuit in order to Check for a Short Circuit to Ground A. • Not OK – A “short to ground” diagnostic code was generated when the relay was disconnected. 3. 3. Pull on the wires in order to verify proper installation of the terminals. If the resistance measurements are less than 5 ohms. Use an ohmmeter to measure the resistance between the P2-10 terminal and the J14-A terminal. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM OFF. 2. no “short to ground” diagnostic code was generated. as needed. Repair: Perform the following procedure: 1. Proceed to Test Step 9. C. shut OFF the main gas supply. Then turn the engine control switch to the STOP position. Test Step 8. 6. Inspect the connectors for damage. Verify that the problem is resolved. The ECM did not detect the jumper wire. There is a problem with the relay. the circuit has good continuity. 3. Also. Turn the engine control switch to the OFF/RESET position. Use Cat ET to clear the logged “444-06 Start Relay short to ground” diagnostic code. 2. Disconnect the connector from the starter motor relay. STOP. Reinstall the terminals into P2-10 and P2-20. Switch the 16 amp circuit breaker for the ECM OFF. There is a problem with the ECM. Expected Result: A “444-06 Start Relay short to ground” was not generated. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. “Replacing the ECM”. 2. • OK – When the relay was connected. measure the resistance between the P2-20 terminal and the J14-B terminal. Inspect the connections of the relay for damage and/or corrosion. The output is normally ON when the engine control switch is turned from the “STOP” position to the “START” position. Turn the engine control switch to the OFF/RESET position. Repair: Perform the following procedure: 1. Make repairs. Turn the engine control switch to the START position for at least 30 seconds. there is an open circuit. STOP. if necessary. D. Pull on the wires in order to verify proper installation of the terminals. replace the relay. Turn the engine control switch to the OFF/RESET position. 5. G. Thoroughly inspect the terminal box J14 connector for the engine harness. Reinstall the terminals into P2-10 and P2-20. Make repairs. a “short to ground” diagnostic code was generated. The output remains ON until the crank terminate relay is energized. 4. Replace the ECM according to Troubleshooting. Note: The “338-06 Prelube Relay short to ground” diagnostic code can only be detected when the ECM output for the starter motor relay is ON. and corrosion. Turn the engine control switch to the STOP position. Results: • No – When the jumper wire was installed. F. . Disconnect the ECM J2/P2 connectors. Otherwise. If the problem is not resolved.265 Troubleshooting Section Repair: Perform the following procedure: 1. a “444-05 Start Relay open circuit” diagnostic code was activated. 4. When the relay was disconnected. STOP. E. To prevent the engine from starting. B. Turn the engine control switch to the OFF/RESET position. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. if necessary. D. 2. 3. Switch the 16 amp circuit breaker for the ECM OFF. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. Use Cat ET to clear the logged “444-06 Start Relay short to ground” diagnostic code. To prevent the engine from starting. Switch the 16 amp circuit breaker for the ECM OFF. . Reconnect the P14 connector. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Disconnect connector P14 (1) from the terminal box. a “444-06 Start Relay short to ground” diagnostic code cannot be generated. Repair: Reconnect the P14 connector. Replace the harness. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the OFF/RESET position. Otherwise. Create an Open Circuit at the Terminal Box A. Repair the harness. There is a problem in the engine harness. G. F. Illustration 116 (1) Connector P14 for the starter motor relay’s circuit g00892397 Proceed to Test Step 10. Then turn the engine control switch to the STOP position. E. Expected Result: A “444-06 Start Relay short to ground” was not generated. shut OFF the main gas supply. • Not OK – A “444-06 Start Relay short to ground” diagnostic code was generated when the P14 connector was disconnected from the terminal box. Note: To provide the output for the starter motor relay. C. Results: • OK – A “444-06 Start Relay short to ground” diagnostic code was not generated when the P14 connector was disconnected. Turn the engine control switch to the OFF/RESET position. when possible.266 Troubleshooting Section Test Step 9. Switch the 16 amp circuit breaker for the ECM OFF. Turn the engine control switch to the STOP position. B. the sequence for engine start-up must be initiated. Turn the engine control switch to the START position for at least 30 seconds. There is probably a short circuit to ground in the terminal box. Check the ECM A. STOP. Test Step 10. E.267 Troubleshooting Section Results: • OK – When the output to the relay was disconnected from the ECM P2 connector. . Otherwise. Replace the ECM according to Troubleshooting. Reinstall the terminal that was removed into P2-10. Then turn the engine control switch to the STOP position. 2. if necessary. the sequence for engine start-up must be initiated. Turn the engine control switch to the START position for at least 30 seconds. D. Use Cat ET to look for a logged “444-06 Start Relay short to ground” diagnostic code again. Use the 151-6320 Wire Removal Tool to remove terminal (P2-10). when possible. To prevent the engine from starting. “Replacing the ECM”. G. 3. STOP. B. a “444-06 Start Relay short to ground” diagnostic code cannot be generated. Reinstall the terminal that was removed into P2-10. Repair: Perform the following procedure: 1. However. C. shut OFF the main gas supply. 2. a “short to ground” diagnostic code was generated when the P14 connector was disconnected from the terminal box. Replace the harness. Switch the 16 amp circuit breaker for the ECM OFF. Pull on the wire in order to verify proper installation of the terminal. Use Cat ET to clear the logged “444-06 Start Relay short to ground” diagnostic code. 3. Repair the harness. F. Switch the 16 amp circuit breaker for the ECM OFF. Note: To provide the output for the starter motor relay. Illustration 117 Harness side of the ECM P2 connector (P2-10) Terminal for the starter motor relay’s circuit g00892526 • Not OK – A “444-06 Start Relay short to ground” diagnostic code was generated when the output to the relay was disconnected from the ECM P2 connector. STOP. Verify that the problem is resolved. There seems to be a problem with the ECM. the “444-06 Start Relay short to ground” diagnostic code was not generated. Expected Result: The “444-06 Start Relay short to ground” diagnostic code was not generated. There is a problem in the terminal box between the ECM connector and the terminal box J14 connector. Turn the engine control switch to the OFF/RESET position. Repair: Perform the following procedure: 1. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the OFF/RESET position. Turn the engine control switch to the STOP position. Pull on the wire in order to verify proper installation of the terminal. “Engine Control Alarm Status”. replace the lamp with the lamp that is specified in the engine’s Parts Manual. The ECM cannot diagnose this output while the output is OFF. “Fault Relay” – This is the shutdown output. Before you begin this procedure. The output provides a maximum current of 0. “Troubleshooting with an Event Code” or Troubleshooting. Failure to correct these serious conditions can result in engine damage. Logged diagnostic codes provide an historical record. Clear the diagnostic codes after the problem is resolved. While this output is energized. The ECM cannot diagnose this output while the output is OFF. A “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt” diagnostic code can only be generated if a shutdown condition or an alarm condition is active. a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. use ET to print the logged codes to a file. If a lamp is burned out. a diagnostic code is generated. a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. “Run Relay” – This output indicates that the engine is in the “Run” status. the circuit is open. . The ECM cannot diagnose this output while the output is OFF. Refer to Troubleshooting.3 amperes to the ECM. Note: These outputs do not provide enough current for illumination of standard incandescent lights. and “Fault Relay”. The ECM cannot diagnose this output while the output is OFF. The troubleshooting procedure may generate additional diagnostic codes. “Engine Control Alarm Status” – This is the alarm output. If any of the outputs have a short circuit to the +Battery side or excessive current. The ECM grounds the current to the negative terminal of the battery in order to activate the appropriate output. “Crank Terminate Relay” – This output indicates that the engine rpm is greater than the programmed engine speed that is required for disengagement of the starting motor. Keep your mind on correcting the cause of the original diagnostic code. This output indicates that the ECM has detected an electrical problem or an abnormal operating condition. a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become activated. The engine will start soon or the engine is running. “Crank Terminate Relay”. The next likely cause is a problem with an indicator. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. While this output is energized. a short circuit to a positive voltage source or excessive electrical current on the output will cause a diagnostic code to become Activated. These outputs can be used to energize indicator lamps or the outputs can be used to interface with other controls. “Troubleshooting with a Diagnostic Code”. This output indicates that a potentially damaging operating condition was detected by the ECM. The ECM has shut down the engine. When the output is OFF. While this output is energized. The least likely cause is a problem with the ECM.268 Troubleshooting Section i01740308 ECM Status Indicator Output SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) has four outputs in order to indicate the status of engine operation: “Run Relay”. While this output is energized. Use the Caterpillar Electronic Technician (ET) to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. The most likely causes of a diagnostic code for a status indicator is a poor electrical connection or a problem in a wiring harness. do not proceed with this test. Thoroughly inspect each of the following connectors: . Note: Some indicators may obtain the status of the engine via a data link. Illustration 119 (1) ECM J2/P2 connectors (2) Connector J19/P19 for the optional control panel (3) 16 amp circuit breaker for the ECM (4) 6 amp circuit breaker (5) Customer connector J9/P9 (if equipped) g00891254 B. Inspect the Electrical Connectors and Wiring A.269 Troubleshooting Section Illustration 118 Schematic for the status indicators g00891245 Test Step 1. Switch circuit breakers (3) and (4) OFF. If all of the status indicators are not directly controlled by the ECM. Turn the engine control switch to the OFF/RESET position. c. Illustration 122 Harness side of the P19 connector (if equipped) (P19-E) Crank Terminate Relay (P19-F) Fault Relay (P19-G) Engine Control Alarm Status g00891276 Illustration 120 Harness side of the P2 connector (P2-28) (P2-29) (P2-30) (P2-31) Run Relay Crank Terminate Relay Fault Relay Engine Control Alarm Status g00891259 b. STOP. • Not OK – The components are not in good condition and/or at least one connection is improper. d. The connectors and the wiring are free of corrosion. and sockets are connected properly. Expected Result: All of the connectors. replace the lamp with the lamp that is specified in the engine’s Parts Manual. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the status indicators. pins. if necessary. . Note: These outputs do not provide enough current for illumination of standard incandescent lights. Check the torque of the Allen head screw for the ECM connector. Illustration 121 Harness side of the P9 connector (if equipped) (P9-V) Run Relay (P9-R) Crank Terminate Relay (P9-M) Fault Relay (P9-U) Engine Control Alarm Status g00891278 Results: • OK – The components are in good condition with proper connections. and pinch points. If a lamp is burned out. Inspect the wiring and the receptacles for the status indicators. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Check the harness and wiring for abrasion and pinch points from the customer’s equipment to the ECM. Proceed to Test Step 2. Repair: Perform the necessary repairs and/or replace parts. abrasion.270 Troubleshooting Section • ECM J2/P2 connectors • J19/P19 and J9/P9 connectors on the terminal box a. “Troubleshooting with an Event Code” or Troubleshooting. The original diagnostic code was probably caused by a poor electrical connection. refer to Troubleshooting. Diagnostic Codes and Descriptions with Corresponding ECM Outputs Code 323-03 324-03 443-03 Description Shutdown Lamp short to +batt Warning Lamp short to +batt Crank Terminate Relay short to +batt Run Relay short to +batt ECM Output “Fault Relay” “Engine Control Alarm Status” “Crank Terminate Relay” “Run Relay” Repair: The 323-03 and 324-03 diagnostic codes can only be activated when the corresponding indicator is activated. “Inspecting Electrical Connectors”. The “Active Alarm” indicator and the “Engine Failure” indicator did not illuminate. Repair: Use Cat ET to determine the event code or the diagnostic code that corresponds to the 323-03 or 324-03 diagnostic code. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. After you have resolved the condition. The “Engine On” indicator and the “Crank Terminate” indicator (if equipped) illuminated normally. if necessary. If there is an intermittent problem that is causing the codes to be logged. Attempt to start the engine and observe the status indicators. Refer to Troubleshooting. Expected Result: There are no active diagnostic codes. Switch the 16 amp circuit breaker for the ECM ON. Troubleshoot that event code or that diagnostic code before you troubleshoot the 323-03 or 324-03 diagnostic code. “Troubleshooting with a Diagnostic Code”. Both of these conditions are serious. Allow the engine operation to continue. . There must be an alarm condition before a 324-03 diagnostic code can be generated. Use the “Active Diagnostic” screen on Cat ET to look for the codes that are listed in Table 23: Table 23 • Yes (Original 323-03 or 324-03 Diagnostic Code) – The original diagnostic code was “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt”. STOP. the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. The alarm and/or the shutdown must be activated. There is a problem with the output for the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped). A 443-03 or 445-03 diagnostic code was activated. There may still be a problem with the output for the alarm indicator or the shutdown indicator. Check for Diagnostic Codes A. Exit this procedure. return to this procedure in order to troubleshoot the 323-03 and/or 324-03 diagnostic code. • Not OK (Active 323-03 or 324-03 Diagnostic 445-03 Code) – There is an active “323-03 Shutdown Lamp short to +batt” or “324-03 Warning Lamp short to +batt”. When the engine was started. Results: • Yes (Original 443-03 or 445-03 Diagnostic Code) – The original diagnostic code was “443-03 Crank Terminate Relay short to +batt” or “445-03 Run Relay short to +batt”. Switch the 6 amp circuit breaker ON. There are no active diagnostic codes. Connect Cat ET to the service tool connector on the terminal box. Proceed to Test Step 4. There are no active diagnostic codes. the “Run Relay” indicator and the “Crank Terminate Relay” indicator (if equipped) illuminated normally. the “Run Relay” indicator and/or the “Crank Terminate Relay” indicator (if equipped) did not illuminate normally. Allow a minimum of 30 seconds for any diagnostic codes to activate. The “Engine Control Alarm Status” indicator and the “Fault Relay” indicator did not illuminate. • Not OK (Active 443-03 or 445-03 Diagnostic Code) – When the engine was started. Repair: The outputs for the status indicators seem to be operating correctly at this time. There must be a shutdown condition before a 323-03 diagnostic code can be generated. STOP. When the engine was started. Proceed to Test Step 3. B.271 Troubleshooting Section Test Step 2. A “323-03 Shutdown Lamp short to +batt” and/or a “324-03 Warning Lamp short to +batt” diagnostic code was generated. Disconnect the connector (3) that is appropriate for the filtered engine oil pressure sensor. refer to Troubleshooting. • Not OK – The “Engine Control Alarm Status” indicator and/or the “Fault Relay” indicator did not illuminate normally when the sensors were disconnected. “Inspecting Electrical Connectors”. Observe the “Engine Control Alarm Status” indicator on the control panel (if equipped). The original problem seems to be resolved. C. proceed to the “Expected Result”.272 Troubleshooting Section Test Step 3. The “Fault Relay” indicator illuminated and a “100-03 Engine Oil Pressure open/short to +batt” diagnostic code was activated when the filtered engine oil pressure sensor is disconnected. Check for Proper Operation of the Status Indicators for the Alarm and Shutdown Allow the engine operation to continue for this procedure. disconnect the connector (3) that is appropriate for the unfiltered engine oil pressure sensor. Expected Result: The “Engine Control Alarm Status” indicator illuminated and a “542-03 Unfiltered Engine Oil Pressure open/short to +batt” diagnostic code was activated when the unfiltered engine oil pressure sensor is disconnected. the engine will shut down. Results: • OK – The indicators. During engine operation. The outputs for the status indicators seem to be operating correctly at this time. Proceed to Test Step 4. Note: When the filtered engine oil pressure sensor is disconnected. Observe the “Fault Relay” indicator on the control panel (if equipped). The “542-03” and the “100-03” diagnostic codes were generated. STOP. If you are only troubleshooting a “324-03 Warning Lamp short to +batt”. Use the “Diagnostics” screen on Cat ET to look for active diagnostic codes. The engine was shut down. diagnostic codes. If there is an intermittent problem that is causing the codes to be logged. B. . Repair: The original diagnostic code was probably caused by a poor electrical connection. and shutdown were activated according to the “Expected Result”. There is a problem with the output for the status indicators. The engine was shut down. Illustration 123 (1) Unfiltered engine oil pressure sensor (2) Filtered engine oil pressure sensor (3) Connectors for the engine oil pressure sensors (4) Terminal box g00891388 A. or a component in the customer’s equipment. C. The problem is between the indicator and the ECM. Insulate the end of the wire with electrical tape in order to ensure that the wire does not create a short circuit. • No – Before the suspect indicator was disconnected. Location of the output wires for the status indicators on the harness side of the P2 connector (1) Ground strap (2) ECM J2/P2 connectors (3) Connector J19/P19 for the optional control panel (4) 16 amp circuit breaker (5) 6 amp circuit breaker (6) Customer connector J9/P9 (if equipped) (P2-28) Run Relay (P2-29) Crank Terminate Relay (P2-30) Fault Relay (P2-31) Engine Control Alarm Status A. Verify that the problem is resolved. Expected Result: Before the suspect indicator was disconnected.273 Troubleshooting Section Test Step 4. Switch circuit breakers (4) and (5) ON. the voltage was still displayed on the voltmeter. the voltmeter displayed approximately zero volts. “Inspecting Electrical Connectors”. Replace parts. Turn the engine control switch to the OFF/RESET position. voltage was displayed on the voltmeter. a wire. After the suspect indicator was disconnected. when possible. temporarily install a known good indicator for the suspect indicator. Disconnect the end of the wire that is attached to the indicator. Repair: Do not disconnect the voltmeter. Note the voltage that is displayed on the voltmeter. Refer to Troubleshooting. Measure the Voltage of the Suspect Indicator at the ECM P2 Connector G. if necessary. Test the indicator. F. Connect the positive lead of a voltmeter to the end of the 7X-1710 Multimeter Probe. Insert a 7X-1710 Multimeter Probe into the suspect control terminal in the ECM P2 connector. Switch circuit breakers (4) and (5) OFF. After the suspect indicator was disconnected. Note the voltage that is displayed on the voltmeter. If the customer has equipment for the status indicators. Connect the voltmeter’s negative lead to ground strap (1). Turn the engine control switch to the OFF/RESET position. After the suspect indicator was disconnected. Switch circuit breakers (4) and (5) OFF. the voltmeter displayed approximately zero volts. disconnect the output wire from the suspect indicator. H. Make the necessary repairs. Turn the engine control switch to the STOP position. voltage was displayed on the voltmeter. B. D. Results: • Yes – Before the suspect indicator was Illustration 124 g00891389 disconnected. Switch circuit breakers (4) and (5) ON. I. voltage was displayed on the voltmeter. There is a problem in the control panel (if equipped) or in the customer’s equipment. If you suspect that the indicator has an internal short circuit. E. Switch circuit breakers (4) and (5) OFF. Repair: The problem could be caused by a poor electrical connection. Thoroughly inspect all of the wiring and the connectors in the customer’s equipment. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. STOP. J. Perform the following procedure: . if necessary. It is unlikely that the ECM has failed. Repair the connection and/or the wiring. Replace parts. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. Replace parts. Switch circuit breakers (4) and (5) ON. when possible. . voltage was still displayed on the voltmeter. the Integrated Temperature sensing Module. Use a 151-6320 Wire Removal Tool to remove the suspect terminal from the ECM P2 connector. Turn the engine control switch to the STOP position. 6. The power supply should be routed through a dedicated fuse or through a dedicated circuit breaker. use this procedure if you suspect that the ECM. 8. – After the suspect terminal was removed from connector P2(2). If the problem is not resolved. The cause of an intermittent power supply can occur on either the positive side or the negative side of the power supply. There is a problem with a connection and/or the wiring between customer connector P9 and the indicator in the customer’s equipment. Fabricate a jumper wire with Deutsch terminals on the ends. If the problem is resolved with the new ECM. if necessary. “Replacing the ECM”. “Replacing the ECM”. Disconnect customer connector P9 (5) (if equipped) from the terminal box. i01756459 Electrical Power Supply SMCS Code: 1401-038 System Operation Description: This procedure tests whether proper voltage is supplied to the Electronic Control Module (ECM). Switch circuit breakers (3) and (4) OFF. Repair the connection and/or the wiring. Connect a voltmeter lead to the end of the jumper wire that is not inserted into the connector. Turn the engine control switch to the OFF/RESET position. 5. or the fuel metering valve are not receiving the proper supply voltage. when possible. 9. 7. In addition to troubleshooting diagnostic codes. Switch circuit breakers (4) and (5) ON. There may be a problem with the ECM. Perform this entire procedure again. Stop The voltage remained. Results The voltage is approximately zero. Switch circuit breakers (4) and (5) OFF. The 24 VDC power supply for the engine can be provided by a battery or by an electrical power supply. Stop The voltage remained. The minimum requirement for the power supply is 22 VDC at 16 amperes. voltage was still displayed on the voltmeter. – After customer connector P9 was disconnected. There is a problem with a connection and/or the wiring between the customer’s equipment and the terminal box. Refer to Troubleshooting. – After the suspect terminal was removed from connector P2 (2). Results The voltage is approximately zero. Proceed to the next Step. Observe the reading on the voltmeter. 2. perform the following steps: Temporarily install a new ECM. Observe the voltage reading on the voltmeter. the reading on the voltmeter was approximately zero.274 Troubleshooting Section 1. Insulate the output wire with electrical tape in order to ensure that the wire does not create a short circuit. Connect the other lead of the voltmeter to the ECM ground strap (1). replace the ECM. – After customer connector (P9) was disconnected. Insert one end of the jumper wire into the open terminal of the P1 connector. If the new ECM operates correctly and the original ECM does not operate correctly. install the original ECM and verify that the problem returns. the reading on the voltmeter was approximately zero. STOP. Refer to Troubleshooting. the Integrated Temperature Sensing Module. 4. Switch circuit breakers (4) and (5) OFF. 3. and the fuel metering valve. Turn the engine control switch to the OFF/RESET position. . Before you begin this procedure. This procedure may generate additional diagnostic codes. The “336-02” diagnostic code indicates that the ECM has detected a problem with the circuit for the engine control switch. The engine will shut down. When the ECM detects battery voltage at this input. If the supply voltage drops to zero and stays at zero. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Keep your mind on correcting the cause of the original diagnostic code. STOP. When battery voltage is removed from this input. the ECM will not log this code. The “168-02” diagnostic code indicates that the voltage of the power supply is intermittent or low while the engine is running. Logged diagnostic codes provide an historical record. Clear the diagnostic codes after the problem is resolved. the ECM will power down after the engine has shut down. or AUTO position.275 Troubleshooting Section The ECM input at terminal 70 of the P1 connector (“Switched +Battery”) receives battery voltage from the engine control switch when the switch is in the START. the ECM will power up. 276 Troubleshooting Section Illustration 125 Schematic for the electrical power source g00898519 . “Inspecting Electrical Connectors”. pins. Make sure that the connectors are properly fastened. and pinch points. Turn the engine control switch to the OFF/RESET position. Check the harness and wiring for abrasion and pinch points from the power supply to the ECM and from the engine control switch to the ECM. condition and/or at least one connection is improper. Inspect the Electrical Connectors and Wiring A. STOP. Reconnect the J1/P1 connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). and 57 • −Battery terminals 63. abrasion. . The connectors and the wiring are free of corrosion. • Not OK – The components are not in good • Electrical connections to each of the circuit breakers • Connectors for the 24 VDC power supply • Connectors for the engine control switch a. Disconnect the J1/P1 connectors.277 Troubleshooting Section Test Step 1. Thoroughly inspect the following connections: • OK – The components are in good condition with proper connections. Repair: Perform the necessary repairs and/or replace parts. Note: For the following steps. and 69 • Switched +Battery terminal 70 g00897515 Illustration 126 (1) J1/P1 connectors for the ECM (2) J16/P16 connectors for the fuel metering valve (3) J23 connector for the service tool (4) J19/P19 connector for the gauge panel (5) 16 amp circuit breaker (6) 6 amp circuit breaker (7) J15/P5 connectors for the ITSM (8) J9/P9 connector for the customer c. Illustration 127 ECM connector P1 g00897516 b. corrosion. Verify that the repair has eliminated the problem. Expected Result: All of the connectors. C. 67. Ensure that all of the seals are properly installed. 65. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply: • Unswitched +Battery terminals 52. Proceed to Test Step 2. Check the torque of the Allen head screw for the ECM connector. Inspect the J1 connector and the P1 connector for damage. if necessary. and sockets are connected properly. refer to Troubleshooting. and moisture. 53. 55. Results: B. Switch the 16 amp circuit breaker for the ECM OFF. Check the Engine Control Switch A. Remove the probes from connector P1. Use a voltmeter to check the wiring. Measure the voltage at the terminals for the power supply. D. C. Record the voltage. Expected Result: The voltage that is measured at the terminals for the power supply is at least 22 VDC. Remove the probes from connector P1. Note: If a power supply is used instead of batteries. 2. For an engine with an air starting motor. make sure that the pressurized air supply is OFF. The voltage measurements are constant. Switch the 16 amp circuit breaker for the ECM ON. Switch the 16 amp circuit breaker for the ECM OFF. make sure that the battery cables are disconnected from the motor. B. the minimum voltage for the power supply is 22 VDC at 16 amperes. as needed. B. E. • Not OK – The ECM is not receiving the correct voltage at the P1 connector. Locate the source of the voltage drop. make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor. Insert the second probe into terminal 63. Connect a multimeter to the probes. The voltage that is measured at the P1 connector is within 2 VDC of the voltage that was measured at the terminals for the power supply. Connect Cat ET to the service tool connector. Illustration 128 Harness side of ECM connector P1 g00897519 Test Step 3. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC. Check the Voltage at the Power Supply and at the ECM A. During the measurement. Results: • OK – The ECM is receiving the correct voltage at the P1 connector. Repair: Perform the following procedure: Switch the 16 amp circuit breaker for the ECM OFF. Repair: Perform the following procedure: 1. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. For an engine with an electric starting motor. 4. Measure the power supply voltage at the P1 connector. Make sure that the air is purged from the system. Be sure to wiggle the harness near each of the connections. Insert the first probe into terminal 52. For an engine with an electric starting motor. Make repairs. make sure that the pressurized air supply is OFF. Make sure that the engine will not crank during this procedure. STOP. . Make sure that the engine will not crank during this procedure. 3. wiggle the harness in order to check for an intermittent problem. Make sure that the air is purged from the system.278 Troubleshooting Section Test Step 2. Refer to the appropriate schematic for the electrical system. Proceed to Test Step 3. Insert the second probe into terminal 61. STOP. The inputs to the engine control switch are correct. Proceed to Test Step 4. Refer to Troubleshooting. Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during this step. After you have completed this step. Results: • OK – A “336-02 Incorrect ECS Switch inputs” diagnostic code was not activated. clear the events from the “Logged Events” screen of Cat ET. The problem seems to be resolved. and the AUTO position. Note: An “E225 Engine Overcrank” and/or an “E233 Low Engine Prelube Pressure” event code may be generated during the test. Remove the probe from terminal 61 and insert the probe into terminal 62. make sure that the pressurized air supply is OFF. and the AUTO position.279 Troubleshooting Section C. Switch the 16 amp circuit breaker for the ECM ON. Expected Result: A “336-02 Incorrect ECS Switch inputs” diagnostic code was not activated when the engine control switch was turned to the STOP position. Be sure to wiggle the harness near each of the connections. E. Illustration 129 Harness side of ECM connector P1 g00897520 C. Connect a multimeter to the probes. Check the Circuit of the Engine Control Switch A. Turn the engine control switch to the OFF/RESET position. Repeat this step several times. The correct voltage measurement is less than one volt. F. Make sure that the engine will not crank during this procedure. • Not OK – A “336-02 Incorrect ECS Switch inputs” diagnostic code was activated. wiggle the harness in order to check for an intermittent problem. Insert the first probe into terminal 31. Note: During these measurements. D. the START position. B. Repair: The problem may be intermittent. the START position. For an engine with an air starting motor. Observe the “Active Diagnostic” screen on Cat ET and turn the engine control switch to the STOP position. D. Turn the engine control switch to the STOP position and measure the voltage between terminal 31 and terminal 61 of the P1 connector. make sure that the battery cables are disconnected from the motor. “Inspecting Electrical Connectors”. Look for an active “336-02 Incorrect ECS Switch inputs” diagnostic code. Make sure that the air is purged from the system. Switch the 16 amp circuit breaker for the ECM ON. For an engine with an electric starting motor. clear the events from the “Logged Events” screen of Cat ET. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Switch the 16 amp circuit breaker for the ECM OFF. . After you have completed the test. Test Step 4. The ECM has detected an invalid pattern for the input to the engine control switch. STOP.280 Troubleshooting Section G. Refer to Troubleshooting. K. Start the engine and run the engine. Disconnect the wires for the STOP. Repair: It is unlikely that the ECM has failed. the ECM may have a problem. The correct voltage measurement is at least +20 VDC. Turn the engine control switch to the STOP position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. . Remove the probe from terminal 64 and insert the probe into terminal 70. Turn the engine control switch to the OFF/RESET position. The correct voltage measurement is at least +20 VDC. Use an ohmmeter to check the contacts for the switch. Remove the probes from the P1 connector. The correct voltage measurement is less than one volt. Turn the engine control switch to the START position and measure the voltage between terminal 31 and terminal 62 of the P1 connector. if necessary. Remove the probe from terminal 31 and insert the probe into terminal 69. • Not OK – The P1 connector does not have the correct voltage. 4. The correct voltage measurement is less than one volt. “Replacing the ECM”. Repair: Perform the following steps: 1. 3. Turn the switch to each position in order to check the contacts. Turn the engine control switch to the AUTO position and measure the voltage between terminal 31 and terminal 64 of the P1 connector. M. L. Expected Result: The voltage checks are within the specifications. Results: If the problem is resolved with the new ECM. START. Refer to Troubleshooting. replace the switch. “Replacing the ECM”. 2. If the new ECM operates correctly and the original ECM does not operate correctly. • OK – The voltage checks are within the specifications. STOP. J. Replace the harness. Switch the 16 amp circuit breaker for the ECM OFF. Perform the following procedure: Temporarily install a new ECM. install the original ECM and verify that the problem returns. The correct voltage measurement is at least +20 VDC. and AUTO positions from the engine control switch. Turn the engine control switch to the AUTO position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. If the engine control switch is faulty. I. Remove the probe from terminal 62 and insert the probe into terminal 64. replace the ECM. repair the harness. Turn the engine control switch to the START position and measure the voltage between terminal 69 and terminal 70 of the P1 connector. If the problem is not resolved. H. when possible. If the original problem is not resolved. Three of the slots are about 2. When the engine rotates in the normal direction. the sensor generates a signal that matches the pattern of the teeth. All 24 teeth pass the sliphead during one revolution of the camshaft or two revolutions of the crankshaft. the ECM will not initiate the ignition. Twenty-one of the slots are narrow. The timing ring is mounted on the rear of the left camshaft. The timing ring has 24 slots in the outer diameter.5 times wider than the rest of the slots. If there is a problem with the engine speed/timing sensor’s signal during start-up but no corresponding diagnostic code is active. the ECM retards the timing of the affected cylinders. The next likely cause is a problem with the engine speed/timing sensor. If detonation is detected in any of the cylinders. The ECM determines the desired ignition timing according to the engine speed and load. the ECM is able to calculate the positions of the pistons in the cylinders. the ECM will shut down the engine if the ECM detects a problem with the signal from the speed/timing sensor. The sensor is powered by the sensor supply (12 VDC) from the ECM. The ECM sends voltage pulses to the ignition transformers for firing the spark plugs according to the desired timing. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. As the teeth of the ring rotate past the sliphead of the sensor.281 Troubleshooting Section i01745104 Engine Speed/Timing Sensor SMCS Code: 1912-038 System Operation Description: Illustration 130 Speed/Timing sensor and timing ring g00893441 The speed/timing sensor provides information about engine speed and the position of the crankshaft to the Electronic Control Module (ECM). the slots pass the speed/timing sensor in the following order: The number one cylinder is at the top center position when the rising edge of the third narrow slot passes the center of the sliphead. The timing ring has a special tooth pattern that indicates the position of the camshaft and the direction of rotation. The least likely cause is a problem with the ECM. • 1 wide slot • 3 narrow slots • 2 wide slots • 18 narrow slots . The corresponding diagnostic code is not activated. A magnetic pickup is located in the plastic sliphead of the sensor. With the information from the engine speed/timing sensor. The engine will not start. The ECM will activate the corresponding diagnostic code. During engine operation. Turn the engine control switch to the OFF/RESET position. Check the torque of the Allen head screw for the ECM connector. a.282 Troubleshooting Section Logged diagnostic codes provide an historical record. . refer to Troubleshooting. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Before you begin this procedure. Thoroughly inspect the ECM J1/P1 connectors. Clear the diagnostic codes after the problem is resolved. Note: For the following steps. the terminal box J10/P10 connectors. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). “Inspecting Electrical Connectors”. Switch the 16 amp circuit breaker for the ECM OFF. and the connectors for the speed/timing sensor. Keep your mind on correcting the cause of the original diagnostic code. Inspect the Electrical Connectors and Wiring. The troubleshooting procedure may generate additional diagnostic codes. A. Illustration 132 g00893313 (1) ECM connectors J1/P1 (2) J10/P10 connectors for the harness from the speed/timing sensor B. Illustration 131 Schematic for the circuit of the speed/timing sensor g00893306 Test Step 1. and sockets are connected properly. Switch the 16 amp circuit breaker for the ECM OFF. Check the Sensor A. Illustration 136 (1) Speed/timing sensor g00893358 B. Test Step 2. pins.283 Troubleshooting Section c. STOP. Proceed to Test Step 2. Turn the engine control switch to the OFF/RESET position. if necessary. Illustration 134 Harness side of the P10 connector (T) +12 volt supply (U) Return (V) Signal g00893324 b. Illustration 137 Speed/timing sensor Illustration 135 Speed/timing sensor (1) Connector for the speed/timing sensor (2) Speed/timing sensor g00893337 g00893482 (2) Sliphead . Check the harness and wiring for abrasion and pinch points from the speed/timing sensor to the ECM. Illustration 133 Harness side of the ECM P1 connector (33) Signal (43) +12 volt supply (51) Return g00893339 • Not OK – The components are not in good condition and/or at least one connection is improper. and pinch points. The connectors and the wiring are free of corrosion. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the speed/timing sensor. Repair: Perform the necessary repairs and/or replace parts. Results: • OK – The components are in good condition with proper connections. Expected Result: All of the connectors. Remove the speed/timing sensor (1). abrasion. B. Results: • Not OK – The plastic sliphead is damaged and/or the tension of the sliphead is insufficient. Calibrate the sensor. The tension of the plastic sliphead is correct. Inspect the condition of the plastic sliphead (2). The maximum allowable clearance between the sliphead and a tooth on the timing ring is 0. “Engine Speed/Timing Sensor . Use the following steps to install the speed/timing sensor: a.02 inch). NOTICE The plastic sliphead must be fully extended when the speed/timing sensor is installed so that the sensor maintains the correct clearance with the timing ring. Do not install the sensor’s plastic sliphead between the teeth of the timing ring. the signal from the sensor will not be generated. Note: The plastic sliphead is designed to contact the tooth of the timing ring during installation. proceed to proceed to Test Step 3. d. Fully extend the sliphead. Turn the engine control switch to the STOP position. Coat the threads of the sensor with 4C-5597 Anti-Seize Compound. Use the “Active Diagnostic” screen on Cat ET. Turn the engine control switch to the STOP position. • 145-03 12 Volt DC Power Supply short to +batt • 145-04 12 Volt DC Power Supply short to ground Expected Result: None of the above codes are active. Ensure that a tooth on the timing ring is visible in the mounting hole for the sensor. Clean any debris from the plastic sliphead. c. the radial runout of the timing ring will push the plastic sliphead into the sensor body slightly. Proceed to Test Step 4. at least one of the codes is logged. Results: • No active codes – None of the above codes are active. This provides the plastic sliphead’s air gap with a self-adjusting function. Observe the “Engine Speed” parameter on the screen and turn the engine control switch to the START position. C.16 inch). At least 22 N (5 lb) of force is required to push in the plastic sliphead from the extended position. Switch the 16 amp circuit breaker for the ECM ON.284 Troubleshooting Section C. Damage to the plasic sliphead will result. Tighten the sensor to 40 ± 5 N·m (30 ± 4 lb ft). Repair: Install the sensor. B. Install the sensor. Continue to observe the screen and allow the engine rpm to stabilize at the normal cranking speed. If the condition is not resolved. ensure that a tooth of the ring is visible in the mounting hole for the sensor.5 mm (0. Check for Active Diagnostic Codes for the 12 Volt Sensor Supply A. Check the tension of the plastic sliphead (2). Test Step 4. b. • Active code – One of the above codes is active. 1. .Calibrate”. If the correct clearance is not maintained. Look for signs of wear and contaminants. Use Cat ET to Check the Engine RPM A. Refer to Troubleshooting. D. C. Expected Result: The sensor is in good condition. Crank the engine. Repair: Clear the logged codes. Test Step 3. Use the “Status . Look for the following codes: • OK – The sensor is not damaged. Proceed to Test Step 3. Then push back the plastic sliphead. However. Connect Cat ET to the service tool connector on the terminal box. Proceed to Test Step 5. Repair: Install a new sensor. As the timing ring begins to turn. Before installing the sensor. Gently extend the plastic sliphead for a minimum of 4 mm (0.Group 1” screen in order to observe “Engine Speed”. 0 VDC during cranking. D. “Engine Speed/Timing Sensor . The engine speed increases until the speed stabilizes at the normal cranking speed. Remove the wire from terminal “C” of the breakout t in order to isolate the sensor signal wire from the ECM terminal J1-33. the speed decreases back to “0”. Switch the 16 amp circuit breaker for the ECM OFF. Expected Result: The supply voltage is 12. B. Turn the engine control switch to the STOP position. Cat ET displayed the correct engine speed. B. Proceed to Test Step 8. Remove the breakout t. Proceed to Test Step 5. Calibrate the sensor. the voltage is less than 3. Install a 8T-8726 Adapter Cable As (3 Pin Breakout) in series with the connectors for the speed/timing sensor.285 Troubleshooting Section Expected Result: Before the engine is cranked. The voltage varied between 2. Install a new speed/timing sensor. Proceed to Test Step 6.0 VDC. • Not OK – The sensor is not producing the correct output signal. STOP. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. E.0 VDC. Refer to Troubleshooting. A 145-03 diagnostic code or a 145-04 diagnostic code is not active.0 VDC or the voltage is greater than 10. Repair: Refer to Troubleshooting. However. Turn the engine control switch to the OFF position. Make repairs. A 320-03 diagnostic code or a 320-08 diagnostic code was not activated. Cat ET did not display the correct engine speed or a 320-03 or a 320-08 diagnostic code was activated. • Not OK – The sensor is not receiving correct supply voltage or a 145-03 diagnostic code or a 145-04 diagnostic code is active. Leave the breakout t connected. Turn the engine control switch to the STOP position.5 ± 1. Repair: Remove the breakout t from the connectors for the speed/timing sensor.0 VDC and 4. Remove the breakout t from the connectors for the speed/timing sensor. Results: • OK – The engine started and the engine ran properly. Proceed to Test Step 7. Turn the engine control switch to the START position. Measure the supply voltage between Terminal “A” and terminal “B” of the breakout t. A 145-03 diagnostic code or a 145-04 diagnostic code is not active. STOP. The ECM is receiving a valid signal. • OK – The sensor is receiving correct supply voltage. the engine speed is “0”. Reconnect the connectors for the speed/timing sensor. • Not OK – The engine cranked but the engine did not start. Test Step 5. A 320-03 diagnostic code or a 320-08 diagnostic code is not activated.Calibrate”. Results: • OK – The sensor is producing the correct output signal. Repair: Turn the engine control switch to the OFF/RESET position. Crank the engine and measure the signal voltage between terminal “C” and terminal “B”. . Measure the Sensor Supply Voltage at the Sensor A. The speed/timing sensor is operating properly. “Engine Cranks But Will Not Start”. Isolate the Signal Voltage at the Sensor A. C. Ensure that the breakout t is connected in series with the connectors for the speed/timing sensor. • Not OK – The engine cranked. Turn the engine control switch to the OFF/RESET position. STOP. C. as needed. Expected Result: When the engine control switch is in the STOP position. Results: Test Step 6. When the engine is stopped. Measure the signal voltage between terminal “C” and terminal “B”. Test Step 8. The wiring and/or the connectors between the sensor and the ECM has an open circuit or the circuit has excessive resistance. Refer to Troubleshooting.286 Troubleshooting Section Test Step 7. Measure the Sensor Signal Voltage at the ECM Illustration 138 Harness side of the ECM P1 connector (33) Signal (43) +12 volt supply (51) Return g00893376 A. STOP. Repair: It is unlikely that the ECM has failed. Turn the engine control switch to the OFF/RESET position. replace the ECM.0 VDC. Measure the Sensor Supply Voltage at the ECM A. “Replacing the ECM”. Make the necessary repairs to the harness and/or connectors. Refer to Troubleshooting.5 ± 1. There may be a problem with the ECM. If the new ECM operates correctly and the original ECM does not operate correctly. perform the following steps: Temporarily install a new ECM. Switch the 16 amp circuit breaker for the ECM OFF. A 145-03 diagnostic code or a 145-04 diagnostic code is not active.0 VDC. Insert the probes into terminals 43 and 51 of the P1 connector. If the problem is resolved with the new ECM. Use two 7X-1710 Multimeter Probes. “Replacing the ECM”. STOP. • No – The ECM is not producing the correct sensor supply voltage or a 145-03 or a 145-04 diagnostic code is active. Repair: Turn the engine control switch to the OFF/RESET position. Results: • Yes – The sensor supply voltage at the ECM is 12. . A 145-03 diagnostic code or a 145-04 diagnostic code is not active. If the condition is not resolved.5 ± 1. B. install the original ECM and verify that the problem returns. C. Turn the engine control switch to the STOP position. Measure the supply voltage at the ECM. Exit this procedure and perform this procedure again. Turn the engine control switch to the OFF/RESET position. Expected Result: The voltage is 12. 287 Troubleshooting Section Repair: It is unlikely that the ECM has failed. Crank the engine and measure the signal voltage between terminal 33 and terminal 51 of the ECM P1 connector. The ECM sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. Make repairs. Turn the engine control switch to the START position. Use two 7X-1710 Multimeter Probes in order to measure the signal voltage between terminal 33 and terminal 51 of the ECM P1 connector. C. install the original ECM and verify that the problem returns. However. The following procedure tests whether the command signal for the flow of fuel and the information about the specific gravity of the gas is properly sent to the fuel metering valve by the ECM.0 VDC and 4. The valve works with the Electronic Control Module (ECM) in order to ensure the correct flow of gas in all conditions of engine operation. There may be a problem with the ECM. Refer to Troubleshooting. • Not OK – The signal voltage is not correct. the voltage is less than 3.0 VDC during cranking. Expected Result: When the engine control switch is in the STOP position. i01745508 Illustration 139 Harness side of the ECM P1 connector (33) Signal (51) Return g00893409 Fuel Metering Valve SMCS Code: 1741 S/N: 7EZ1-Up B. • OK – The signal voltage is correct. as needed. D. Repair: Refer to Troubleshooting. Turn the engine control switch to the STOP position. . Use a 151-6320 Wire Removal Tool to remove the wire from terminal 33 of the ECM P1 connector. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link.0 VDC or the voltage is greater than 10. There is an intermittent problem in the circuit for the speed/timing sensor. “Inspecting Electrical Connectors”. perform the following steps: Temporarily install a new ECM. “Replacing the ECM”. differential pressure of the valve. If the new ECM operates correctly and the original ECM does not operate correctly. STOP. STOP. CTW1-Up System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine. The position of the valve is compensated by these additional factors that are internal to the valve: a signal for absolute fuel pressure. The command signal is a 180 hertz PWM signal.0 VDC. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. The voltage varied between 2. Results: S/N: CSC1-Up. Refer to Troubleshooting. replace the ECM. If the problem is resolved with the new ECM. “Replacing the ECM”. If the condition is not resolved. the ECM is not reading the signal. and fuel temperature sensors. Exit this procedure and perform this procedure again. This troubleshooting procedure may generate additional diagnostic codes. Logged diagnostic codes provide an historical record. The next likely cause is a problem with the fuel metering valve. Switch the 16 amp circuit breaker for the ECM OFF. and fuel temperature. Before you begin this procedure. Illustration 140 Schematic for the circuit of the fuel metering valve g00894639 Test Step 1. differential pressure of the valve. “Inspecting Electrical Connectors”. This procedure tests whether the following information is properly sent to the ECM by the fuel metering valve: position of the fuel valve. . refer to Troubleshooting. Clear the diagnostic code after the problem is resolved. Turn the engine control switch to the OFF/RESET position. Inspect the Electrical Connectors and Wiring A. Note: For the following steps. Keep your mind on correcting the cause of the original diagnostic code. A diagnostic code is probably caused by a problem with a wiring harness or a connector. absolute fuel pressure. The least likely cause is a problem with the ECM. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file.288 Troubleshooting Section The fuel metering valve sends information to the ECM via the CAN Data Link. 289 Troubleshooting Section Illustration 143 Harness side of the P16 connector (A) +Battery (B) CAN Data Link + (C) CAN Data Link − (D) CAN shield (E) Signal for fuel flow (H) -Battery g00893631 Illustration 141 (1) ECM connectors J1/P1 (2) J16/P16 connectors for the fuel metering valve g00893557 B. Illustration 144 Harness side of the P24 connector (B) CAN high out (G) Signal in (K) Switched +Battery (L) −Battery (N) Can Data Link + (R) Switched +Battery (S) CAN low out (V) CAN Data Link − g00897164 b. Check the torque of the Allen head screw for the ECM connector. Illustration 142 Harness side of the P1 connector (34) (42) (50) (58) (63) (65) (67) (69) CAN Data Link − CAN shield CAN Data Link + PWM out 1 (fuel flow) -Battery -Battery -Battery -Battery g00893562 . The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Thoroughly inspect each of the following connectors: • ECM J1/P1 connectors • J16/P16 connectors on the terminal box a. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the fuel metering valve. pins. The connectors and the wiring are free of corrosion. abrasion. pins. Connect Cat ET to the service tool connector on the terminal box. The components are in good condition with proper connections. Proceed to Test Step 3. abrasion. Switch the 16 amp circuit breaker for the ECM ON. • Not OK (Active 1446-12) – The fuel metering valve has detected an internal malfunction. Check the Signal for the Fuel Flow A. The connectors and the wiring are free of corrosion. STOP. • OK – All of the connectors. Expected Result: All of the connectors. Proceed to Test Step 2. Proceed to Test Step 4. Look for these codes: • 1446-05 “Fuel Metering Module open circuit” • 1446-09 “Unable to communicate with Fuel Metering Module” • 1446-12 “Fuel Metering Module malfunction” • 1446-13 “Fuel Metering Module calibration required” Expected Result: None of the above codes are active. wait at least 30 seconds so that any codes may become activated. sockets are not connected properly. Turn the engine control switch to the OFF/RESET position. abrasion. Turn the engine control switch to the STOP position. Repair: Perform the necessary repairs and/or replace parts. “Inspecting Electrical Connectors”. STOP. STOP. . Check the harness and wiring for abrasion and pinch points from the fuel metering valve to the ECM. and/or pinch points. Test Step 2. and pinch points. Repair: Refer to Operation and Calibration Manual. or • Not OK (Active 1446-13) – The fuel metering valve requires calibration. pins. Check for Diagnostic Codes A. STOP. Results: • Not OK (Active 1446-05) – The ECM has detected an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. and sockets are connected properly. • Not OK (Active 1446-09) – The ECM has detected an open circuit or a short circuit for the circuit of the CAN Data Link between the ECM and the fuel metering valve. Repair: If you are troubleshooting an intermittent problem. B. Switch the 16 amp circuit breaker for the ECM OFF. Test Step 3. and sockets are connected properly.290 Troubleshooting Section C. “Tecjet Gas Control Valve”. Repair: Refer to Operation and Calibration Manual. c. if necessary. At least one of the connectors and the wiring has corrosion. • Not OK – At least one of the connectors. Observe the “Active Diagnostic ” screen on Cat ET. and pinch points. “Tecjet Gas Control Valve”. Results: • No active codes – None of the above codes are Illustration 145 (1) Fuel metering valve g00894648 active. refer to Troubleshooting. Proceed to Test Step 5. There is a problem with the fuel metering valve. and the frequency of the signal for the fuel flow is correct at the ECM P1 connector. Use a multimeter that is capable of measuring the frequency and the duty cycle. Illustration 146 ECM P1 terminals for the signal of the fuel flow (58) PWM out 1 (63) −Battery g00742506 B. Turn the engine control switch to the STOP position.291 Troubleshooting Section Test Step 4. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Turn the engine control switch to the OFF/RESET position. the duty cycle. The frequency is between 175 and 185 hertz. Results: Illustration 147 g00895462 Connectors for Data Link circuits that are external to the terminal box (1) P19 connector for the gauge panel (2) P5 connector for the integrated temperature sensing module (3) P7 connector (if equipped) (4) P9 Connector for the customer C. • Not OK – The voltage. The duty cycle is between 92 and 98 percent. Switch the 16 amp circuit breaker for the ECM OFF. Repair: Replace the fuel metering valve. the duty cycle. Measure the DC voltage. P7. the duty cycle. and P9 connectors from the terminal box. and the frequency of the signal for the fuel flow. Insert the first probe into terminal 58.7 and 15. and/or the frequency of the signal for the fuel flow is not correct at the ECM P1 connector. . Insert the second probe into terminal 63. Disconnect the P19. Expected Result: The DC voltage is between 13. P5. Disconnect the fuel metering valve J24/P24 connectors. • OK – The voltage. Check the Continuity of the Wiring Harness for the Circuit of the CAN Data Link A. Verify that the repair has eliminated the original problem. STOP. B. D.7. Switch the 16 amp circuit breaker for the ECM ON. Disconnect the ECM J1/P1 connectors. Connect the multimeter to the probes. C. Repair: Perform the necessary repairs to the wiring and/or connectors. The resistance of the terminals on the P24 connector is correct. If a “1446-09 Unable to communicate with Fuel Metering Module” diagnostic code is activated. J9/P9. Verify that the repair has eliminated the original problem. The continuity between the terminals and the ECM ground strap is open. If a 1446-09 diagnostic code is not activated. 2. Turn the engine control switch to the OFF/RESET position. Expected Result: The continuity of the circuits between the terminals is good. Disconnect the fuel metering valve J24/P24 connectors. The resistance of the terminals on the P24 connector is incorrect. Ensure that the connectors are properly engaged. troubleshoot the circuit that is external to the terminal box. Use a multimeter to check for continuity or resistance between the points that are listed in Table 24. Illustration 148 (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-34) Can Data Link − (P1-50) Can Data Link + (P24-V) Can Data Link − (P24-N) Can Data Link + (P24-S) CAN low out g00742693 • Not OK – At least one of the following conditions is found: There is an open circuit between the ECM P1 connector and the connector for the fuel metering valve. C. Switch the 16 amp circuit breaker for the ECM ON. J7/P7. B. Table 24 Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-34 P1-50 Connector and Terminal P24-V P24-N ECM ground strap ECM ground strap Points to Check for Resistance P24-B P24-S Test Step 5. The continuity of the circuit between the ECM P1 connector and the ECM ground strap is open. Observe the “Active Diagnostic Codes” screen of Cat ET as you reconnect the following connectors one at a time: J5/P5. Ensure that all of the seals are properly installed. The resistance between the P24-B terminal and the P24-S terminal is 120 ± 5 ohms. .292 Troubleshooting Section Repair: Perform the following steps: 1. and J19/P19. D. Results: • OK – The continuity of the circuit between the ECM P1 connector and the connector for the fuel metering valve is good. There is a short circuit between the ECM P1 connector and a component that is at ground potential. if necessary. Turn the engine control switch to the STOP position. Replace parts. Disconnect the ECM J1/P1 connectors. proceed to Test Step 6. STOP. Switch the 16 amp circuit breaker for the ECM OFF. Check the Continuity of the Circuit for the Fuel Flow A. Illustration 149 (P1) Connector for the ECM (P24) Connector for the fuel metering valve (P1-58) PWM out 1 (fuel flow) (P24-G) Signal in g00742757 D. Switch the 16 amp circuit breaker for the ECM OFF. Verify that the repair has eliminated the original problem. P7. Turn the engine control switch to the OFF/RESET position. Ensure that all of the seals are properly installed. Ensure that the ECM J1/P1 connectors are disconnected. The continuity between the terminal and the ECM ground strap is open. Expected Result: The continuity of the circuits between the terminals is good. The continuity of the circuit between the ECM and the ECM ground strap is open. Results: Illustration 150 g00895462 Connectors for Data Link circuits that are external to the terminal box (1) P19 connector for the gauge panel (2) P5 connector for the integrated temperature sensing module (3) P7 connector (if equipped) (4) P9 connector for the customer C. Use a multimeter to check the continuity of the circuits that are listed in Table 25: Table 25 • OK – The continuity of the circuit between the ECM and the fuel metering valve is good. Use a multimeter to check the continuity of the following circuits: • P1-58 and P24-G • P1-58 and the ECM ground strap Expected Result: The continuity of the circuits between the terminals is good. STOP. . There is a short circuit between the ECM and a component that is at ground potential. Points to Check for Continuity Connector and Terminal P1-42 P1-42 P1-42 P1-42 P1-42 P1-58 Connector and Terminal J5-D J7-H J9-a J16-D J19-R ECM ground strap • Not OK – One or both of the following conditions is found: There is an open circuit between the ECM and the fuel metering valve. Disconnect the P19. Ensure that the connectors are properly engaged. Test Step 6. and P9 connectors from the terminal box. Check the Wire Shield of the CAN Data Link A.293 Troubleshooting Section B. Replace parts. D. Proceed to Test Step 7. if necessary. Repair: Repair the wiring and/or connectors. The continuity between the terminal and the ECM ground strap is open. P5. Measure the resistance between terminal J24-G and terminal J24-L. STOP. B. Do not connect the P24 connector to the fuel metering valve. Illustration 151 J24 connector on the fuel metering valve (G) Signal in (L) −Battery g00897167 B. Ensure the following conditions: • The engine control switch is in the OFF/RESET position. • The fuel metering valve J24/P24 connectors are disconnected. Check the continuity again between the ECM P1-58 terminal and the ECM ground strap. STOP. and J19/P19 connectors on the terminal box. Ensure the following conditions: • The 16 amp circuit breaker in the terminal box for the ECM is OFF. If a short circuit is found between the ECM P1-58 terminal and the ECM ground strap.700 ± 500 ohms. There is a short circuit between the ECM P1-58 terminal and a component that is at ground potential. if necessary. Expected Result: The resistance between terminal J24-G and terminal J24-L is 12. Test Step 7. 2. Test Step 8. Repair: Perform the following steps: 1. Check the Supply Voltage to the Fuel Metering Valve A. Reconnect the P16 connector. Verify that the repair has eliminated the original problem. The continuity of the circuit between P1-58 and the ECM ground strap is open. Proceed to Test Step 8. Ensure that all of the seals are properly installed. Verify that the repair has eliminated the original problem. Check the Resistance of the Internal Circuit of the Fuel Metering Valve A. Reconnect the J5/P5. Results: • Not OK – One or both of the following conditions is found: At least one of the circuits of the wire shield for the CAN Data Link is open. replace the harness for the fuel metering valve. • The engine control switch is in the OFF/RESET position.294 Troubleshooting Section Results: • OK – The continuity of the circuits of the wire shield for the CAN Data Link is good. Repair: Replace the fuel metering valve.700 ± 500 ohms. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. If the circuit between the ECM P1-58 terminal and the ECM ground strap is still open. Repair: Repair the wiring and/or connectors. proceed to Test Step 8. • The fuel metering valve J24/P24 connectors are disconnected. • OK – The resistance between terminal J24-G and terminal J24-L is 12.700 ± 500 ohms. Replace parts. . • The 16 amp circuit breaker for the ECM is OFF. C. J9/P9. • Not OK – The resistance between terminal J24-G and terminal J24-L is not 12. J7/P7. Ensure that the connectors are properly engaged. differential pressure of the valve. P24 connector on the harness for the fuel metering valve D. However. The valve works with the ECM in order to ensure the correct flow of gas in all conditions of engine operation. STOP. differential pressure of the valve. Replace parts. • Not OK – The battery voltage to the P24 harness connector for the fuel metering valve is open or the voltage is shorted to a component that is at ground potential. absolute fuel pressure. The Electronic Control Module (ECM) sends a command signal for the flow of fuel and information about the specific gravity of the gas to the fuel metering valve. This procedure also tests whether the following information is properly sent to the ECM by the fuel metering valve: position of the fuel valve.295 Troubleshooting Section Note: The “1446-05 Fuel Metering Module open circuit” and “1446-09 Unable to communicate with Fuel Metering Module” diagnostic codes will be activated. Repair: Replace the fuel metering valve. and fuel temperature sensors. STOP. . Results: • OK – The battery voltage is good at the P24 harness connector for the fuel metering valve. The battery voltage between the P24-R and P24-L terminals is 24 ± 2 VDC. Information about the specific gravity of the gas is sent to the fuel metering valve via the CAN Data Link. Ensure that all of the seals are properly installed. Repair: Perform the necessary repairs for the wiring and/or the connectors. if necessary. the fuel metering valve is not communicating with the ECM. The following procedure tests whether the command signal for the flow of fuel and the information about the specific gravity of the gas is properly sent to the fuel metering valve by the ECM. Use a multimeter to measure the voltage between the following terminals of the P24 harness connector for the fuel metering valve: • P24-K and P24-L • P24-R and P24-L Expected Result: The battery voltage between the P24-K and P24-L terminals is 24 ± 2 VDC. Verify that the repair has eliminated the original problem. Verify that the repair has eliminated the original problem. and fuel temperature. The valve converts the command signal and the information into a valve position that directly corresponds to the desired gas flow. The fuel metering valve sends information to the ECM via the CAN Data Link. Ensure that the connectors are properly engaged. The position of the valve is compensated by these additional factors that are internal to the valve: a signal for absolute fuel pressure. i01749466 Fuel Metering Valve SMCS Code: 1741 S/N: CSC1-Up S/N: CFD1-Up Illustration 152 (K) +Battery (L) −Battery (R) +Battery g00743077 S/N: CME1-Up S/N: CEY1-Up System Operation Description: The fuel metering valve is an electronic gas valve that controls the flow of fuel to the engine. The command signal is a 180 hertz PWM signal. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Turn the engine control switch to the OFF/RESET position. • ECM J1/P1 connectors • J16/P16 connectors for the fuel metering valve a.296 Troubleshooting Section Illustration 153 Schematic for the circuit of the fuel metering valve g00897187 Test Step 1. Thoroughly inspect each of the following connectors: . Check the torque of the Allen head screw for the ECM connector. Note: For the following steps. Illustration 155 Harness side of the ECM P1 connector (34) (42) (50) (58) (60) (63) (65) (67) (69) CAN Data Link − CAN shield CAN Data Link + PWM out 1 (fuel flow) Return −Battery −Battery −Battery −Battery g00895632 Illustration 154 (1) ECM connectors J1/P1 (2) J16/P16 connectors for the fuel metering valve g00893557 B. Inspect the Electrical Connectors and Wiring A. “Inspecting Electrical Connectors”. refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel metering valve. if necessary. Check the wiring for abrasion and pinch points from the fuel metering valve to the ECM. Ensure that the connectors are properly engaged. and sockets are connected properly. STOP. Switch the 16 amp circuit breaker for the ECM ON. Check for Diagnostic Codes A. Ensure that all of the seals are properly installed. The connectors and the wiring are free of corrosion. Verify that the repair has eliminated the original problem. Results: • OK – The components are in good condition with Illustration 157 Harness side of the P24 connector (C) CAN Data Link + (F) CAN Data Link − (L) −Battery (M) Switched +battery (P) CAN Resistor + (R) CAN Resistor − (S) Signal for the fuel flow (T) Return g00897185 proper connections. abrasion. Proceed to Test Step 2. B. Use Cat ET to determine if any of the following diagnostic codes are active: . Test Step 2.297 Troubleshooting Section Illustration 156 Harness side of the P16 connector (A) Switched +Battery (B) CAN Data Link + (C) CAN Data Link − (D) CAN shield (E) Signal for the fuel flow (F) Return (H) −Battery g00895636 Illustration 158 (1) Fuel metering valve g00895657 c. and pinch points. Turn the engine control switch to the STOP position. pins. b. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. • Not OK – The components are not in good condition and/or at least one connection is improper. C. Expected Result: All of the connectors. Repair: Perform the necessary repairs and/or replace parts. Repair: Refer to Installation and Operation Manual. Illustration 159 ECM P1 terminals for the signal of the fuel flow (58) PWM out 1 (60) −Battery g00838477 • Not OK (Active 1446-05) – The ECM has detected an open circuit or a short circuit for the circuit of the fuel flow signal between the ECM and the fuel metering valve. Proceed to Test Step 3. Results: • OK – The voltage. frequency of the signal for the fuel flow is correct at the ECM P1 connector. Switch the 16 amp circuit breaker for the ECM OFF. C. Insert the second probe into terminal 60. “Inspecting Electrical Connectors”. the duty cycle. Use a multimeter that is capable of measuring the frequency and the duty cycle. Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Switch the 16 amp circuit breaker for the ECM ON. the duty cycle. “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. Proceed to Test Step 4. STOP. Repair: If you are troubleshooting an intermittent problem. Check the Signal for the Fuel Flow A. D. STOP. However.7. Repair: Refer to Installation and Operation Manual. and the frequency of the signal for the fuel flow. B. Expected Result: The DC voltage is between 13. The duty cycle is between 92 and 98 percent. Insert the first probe into terminal 58. Results: • OK – There are no active diagnostic codes. STOP. STOP.7 and 15. • 1446-12 “Fuel Metering Module malfunction” • 1446-13 “Fuel Metering Module calibration required” Test Step 3. There is a problem with the fuel metering valve. and the • Not OK (Active 1447-12) – There is a malfunction of the sensor module in the fuel metering valve.298 Troubleshooting Section • 1446-05 “Fuel Metering Module open circuit” • 1446-09 “Unable to communicate with Fuel Metering Module” Repair: Refer to Installation and Operation Manual. refer to Troubleshooting. Connect the multimeter to the probes. . • Not OK (Active 1446-12) – The fuel metering valve has detected an internal malfunction. • Not OK (Active 1446-13) – The fuel metering valve requires calibration. • Not OK (Active 1446-09) – The ECM has detected an open circuit or a short circuit for the circuit of the CAN Data Link between the ECM and the fuel metering valve. • 1447-12 “Fuel Metering Sensor Module malfunction” Expected Result: There are no active diagnostic codes. The frequency is between 175 and 185 hertz. Turn the engine control switch to the STOP position. Measure the DC voltage. “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. “Raptor Gas Regulation and Metering Valve/Actuator System for Caterpillar”. The signal and the communication between the ECM and the fuel metering valve appear to be OK at this time. diagnostic codes may be logged. Turn the engine control switch to the OFF/RESET position. The continuity between the terminals and the ECM ground strap is open. Verify that the repair has eliminated the original problem. • Not OK – The voltage. Test Step 4. Table 26 Points to Check for Continuity Connector and Terminal P1-34 P1-50 P1-34 P1-50 P24-P Connector and Terminal P24-F P24-C ECM ground strap ECM ground strap P24-R Expected Result: Illustration 160 g00897190 The continuity of the circuits between the terminals is good. Turn the engine control switch to the OFF/RESET position. P7. and P9 connectors from the terminal box. The continuity of the circuit between the plug for the ECM and the ECM ground strap is open. Switch the 16 amp circuit breaker for the ECM OFF. Disconnect the P19. Disconnect the fuel metering valve J24/P24 connectors. Disconnect the ECM J1/P1 connectors. Results: Connectors for Data Link circuits that are external to the terminal box (1) ECM ground strap (2) P19 connector for the gauge panel (3) P5 connector for the integrated temperature sensing module (4) J7 connector (if equipped) (5) J9 connector for the customer C. The continuity between the P24-P terminal and the P24-R terminal is good. Check the Continuity of the Wiring Harness for the Circuit of the CAN Data Link A.299 Troubleshooting Section Repair: Replace the fuel metering valve. Turn the engine control switch to the STOP position. • OK – The continuity of the circuits is good. The continuity between the P24-P terminal and the P24-R terminal is good. and/or the frequency of the signal for the fuel flow is not correct at the ECM P1 connector. P5. Repair: Perform the following steps: 1. B. Proceed to Test Step 5. STOP. the duty cycle. Switch the 16 amp circuit breaker for the ECM ON. Illustration 161 (P1) Plug for the ECM (P24) Plug for the fuel metering valve (P1-34) Can Data Link − (P1-50) Can Data Link + (P24-F) Can Data Link − (P24-C) Can Data Link + (P24-P) Jumper wire (P24-R) Jumper wire g00839621 D. . Use a multimeter to check for continuity between the points that are listed in Table 26. B. Switch the 16 amp circuit breaker for the ECM OFF. Ensure that the connectors are properly engaged. troubleshoot the circuit that is external to the terminal box. STOP. If a 1446-09 diagnostic code is not activated. Observe the “Active Diagnostic Codes” screen of Cat ET as you reconnect the following connectors one at a time: J5/P5. • Not OK – At least one of the following conditions is found: There is an open circuit between the plug for the ECM and the plug for the fuel metering valve. Repair: Repair the wiring and/or connectors. Illustration 162 (P1) Plug for the ECM (P24) Plug for the fuel metering valve (P1-58) PWM out 1 (fuel flow) (P1-60) Return (P24-S) PWM out 1 (fuel flow) (P24-T) Return g00838617 D. • P1-60 and P24-T Expected Result: The continuity of the circuits between the terminals is good. and J19/P19. If a “1446-09 Unable to communicate with Fuel Metering Module” diagnostic code is activated. Replace parts. Use a multimeter to check the continuity of the following circuits: • P1-58 and P24-S • P1-58 and the ECM ground strap Test Step 5. The continuity between the terminal and the ECM ground strap is open. Check the Continuity of the Circuit for the Fuel Flow A.300 Troubleshooting Section 2. STOP. C. There is a short circuit between the ECM and a component that is at ground potential. Disconnect the ECM J1/P1 connector. Ensure that all of the seals are properly installed. J7/P7. Repair: Perform the necessary repairs to the wiring and/or connectors. Results: • OK – The continuity of the circuit between the ECM and the fuel metering valve is good. proceed to Test Step 6. if necessary. if necessary. Proceed to Test Step 7. Disconnect the fuel metering valve J24/P24 connector. Ensure that all of the seals are properly installed. There is a short circuit between the plug for the ECM and a component that is at ground potential. Replace parts. Turn the engine control switch to the OFF/RESET position. The continuity between the P24-P terminal and the P24-R terminal is open. Verify that the repair has eliminated the original problem. . • Not OK – One or both of the following conditions is found: There is an open circuit between the ECM and the fuel metering valve. Ensure that the connectors are properly engaged. J9/P9. Verify that the repair has eliminated the original problem. The continuity of the circuit between the ECM and the ECM ground strap is open. 301 Troubleshooting Section Test Step 6. Ensure the following conditions: Points to Check for Continuity Connector and Terminal P1-42 P1-42 P1-42 P1-42 P1-42 P1-58 Connector and Terminal J5-D J7-H J9-a J16-D J19-R ECM ground strap • The engine control switch is in the OFF/RESET position. • Not OK – One or both of the following conditions Illustration 163 g00897190 Connectors for Data Link circuits that are external to the terminal box (1) ECM ground strap (2) P19 connector for the gauge panel (3) P5 connector for the integrated temperature sensing module (4) J7 connector (if equipped) (5) J9 connector for the customer is found: At least one of the circuits of the wire shield for the CAN Data Link is open. Results: • OK – The continuity of the circuits of the wire shield for the CAN Data Link is good. and P9 connectors from the terminal box. The continuity between the terminal and the ECM ground strap is open. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. The continuity of the circuit between P1-58 and the ECM ground strap is open. D. proceed to Test Step 8. 2. Use a multimeter to check the continuity of the circuits that are listed in Table 27: Table 27 Test Step 7. P7. • The fuel metering valve J24/P24 connectors are disconnected. Switch the 16 amp circuit breaker for the ECM OFF. Check the continuity again between the ECM P1-58 terminal and the ECM ground strap. Do not connect the J24/P24 connection on the fuel metering valve. There is a short circuit between the ECM P1-58 terminal and a component that is at ground potential. replace the harness for the fuel metering valve. If the circuit between the ECM P1-58 terminal and the ECM ground strap is still open. Ensure that all of the seals are properly installed. B. . If a short circuit is found between the ECM P1-58 terminal and the ECM ground strap. Check the Resistance of the Internal Circuit of the Fuel Metering Valve A. Reconnect the J16/P16 connection on the terminal box. P5. C. Replace parts. • The 16 amp circuit breaker in the terminal box for the ECM is OFF. STOP. Expected Result: The continuity of the circuits between the terminals is good. Ensure that the ECM J1/P1 connectors are disconnected. Disconnect the P19. Repair: Repair the wiring and/or connectors. Ensure that the connectors are properly engaged. Check the Wire Shield of the CAN Data Link A. if necessary. Verify that the repair has eliminated the original problem. 000 ± 5000 Ohms. Use a multimeter to measure the voltage between the following terminals of the P24 harness connector for the fuel metering valve: • P24-M and P24-L • Not OK – The resistance of the circuit between terminal J24-S and terminal J24-T is not 320. Results: Illustration 165 P24 plug on the harness for the fuel metering valve (K) Unswitched +Battery (M) Switched +Battery (L) −Battery g00838651 • OK – The resistance of the circuit between terminal J24-S and terminal J24-T is 320. Expected Result: The resistance of the circuit between terminal J24-S and terminal J24-T is 320. Verify that the repair has eliminated the original problem. . the fuel metering valve is not communicating with the ECM. • The 16 amp circuit breaker for the ECM is OFF. Repair: Replace the fuel metering valve. Repair: Replace the fuel metering valve.000 ± 5000 Ohms. and J19/P19 connectors on the terminal box. Reconnect the J5/P5. D. However. The battery voltage between the P24-K and P24-L terminals is 24 ± 2 VDC.302 Troubleshooting Section C. • The fuel metering valve J24/P24 connectors are disconnected. Ensure the following conditions: • OK – The battery voltage is good at the P24 plug for the fuel metering valve. Note: The “1446-05 Fuel Metering Module open circuit” and “1446-09 Unable to communicate with Fuel Metering Module” diagnostic codes will be activated. • The engine control switch is in the OFF/RESET position. J7/P7. Check the Supply Voltage to the Fuel Metering Valve A. B. Measure the resistance of the circuit between terminal J24-S and terminal J24-T. Illustration 164 J24 connector on the fuel metering valve (J24-S) Signal for the fuel flow (J24-T) Return g00897204 B. Proceed to Test Step 8. Switch the 16 amp circuit breaker for the ECM ON. J9/P9. STOP. Verify that the repair has eliminated the original problem. STOP. Results: Test Step 8.000 ± 5000 ohms. Turn the engine control switch to the STOP position. • P24-K and P24-L Expected Result: The battery voltage between the P24-M and P24-L terminals is 24 ± 2 VDC. • Not OK – The battery voltage to the P24 plug for the fuel metering valve is open or the voltage is shorted to a component that is at ground potential. 7-9. The signal goes to the high side of the primary circuits of the ignition transformers. Ignition Transformers Primary Circuit SMCS Code: 1561-038 System Operation Description: The Electronic Control Module (ECM) has internal circuit drivers for the transformers. On the other hand. The pairs of cylinders that are opposite by 360 degrees in the firing order reach Top Center simultaneously. 6-12. 2-4-6-10.303 Troubleshooting Section Repair: Perform the necessary repairs for the wiring and/or the connectors. If any cylinder’s high side has an open circuit. Before you begin this procedure. If multiple diagnostic codes are active for the primary ignition. Because of the diodes. Each following group of cylinders are coupled by an internal diode to one low side circuit driver: 1-3-5-9. The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. This means that a short circuit to the high side on any cylinder will also affect the cylinder that is opposite by 360 degrees. Internally. Verify that the repair has eliminated the original problem. The next likely cause is a problem with an ignition transformer. Each following pair of cylinders are supplied by one of the eight high side circuit drivers: 1-15. Ensure that the connectors are properly engaged. if necessary. Replace parts. 5-11. The transformers deliver high voltage (8000 to 37. and 8-10. 4-14. Because the circuits are in pairs or groups. a return short circuit to the −Battery side will affect only one cylinder. The least likely cause is a problem with the ECM. i01745958 Logged diagnostic codes provide an historical record. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. Ensure that all of the seals are properly installed. multiple diagnostic codes can be activated for a single problem. The circuit drivers send a signal of +108 volts through terminals that are in pairs. . Each of the circuits are connected via 16 diodes. These pairs of cylinders share the same high side circuit driver inside the ECM. and 8-12-14-16.000 volts) to the spark plugs. a return short circuit to the +Battery side can simultaneously affect all four return circuits in a single group. Note: The ECM has internal returns for the transformer’s circuits. these returns consist of individual terminals for each primary circuit. only that cylinder is affected. 2-16. these returns are grouped into four groups of four circuits. Externally. STOP. troubleshooting the circuits one at a time is an effective way to find the root cause. 3-13. 7-11-13-15. 304 Troubleshooting Section Illustration 166 g00719645 . a. refer to Troubleshooting. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit of the ignition system. b. Switch the 16 amp circuit breaker for the ECM OFF. Thoroughly inspect the ECM J2/P2 connectors. . The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Turn the engine control switch to the OFF/RESET position. Note: For the following steps. “Inspecting Electrical Connectors”.305 Troubleshooting Section Schematic for the ignition system Test Step 1. Illustration 168 Harness side of the ECM P2 connector (P2-1) Number 1 transformer’s circuit driver (P2-2) Number 1 transformer’s return (P2-3) Number 2 transformer’s circuit driver (P2-4) Number 2 transformer’s return (P2-24) Number 3 transformer’s circuit driver (P2-25) Number 3 transformer’s return (P2-26) Number 4 transformer’s circuit driver (P2-27) Number 4 transformer’s return (P2-14) Number 5 transformer’s circuit driver (P2-15) Number 5 transformer’s return (P2-16) Number 6 transformer’s circuit driver (P2-17) Number 6 transformer’s return (P2-5) Number 7 transformer’s circuit driver (P2-18) Number 7 transformer’s return (P2-52) Number 8 transformer’s circuit driver (P2-62) Number 8 transformer’s return (P2-32) Number 9 transformer’s circuit driver (P2-33) Number 9 transformer’s return (P2-34) Number 10 transformer’s circuit driver (P2-35) Number 10 transformer’s return (P2-48) Number 11 transformer’s circuit driver (P2-49) Number 11 transformer’s return (P2-50) Number 12 transformer’s circuit driver (P2-51) Number 12 transformer’s return (P2-58) Number 13 transformer’s circuit driver (P2-59) Number 13 transformer’s return (P2-60) Number 14 transformer’s circuit driver (P2-61) Number 14 transformer’s return (P2-40) Number 15 transformer’s circuit driver (P2-41) Number 15 transformer’s return (P2-42) Number 16 transformer’s circuit driver (P2-43) Number 16 transformer’s return g00893769 Illustration 167 ECM connectors J2/P2 g00893752 B. Inspect the Electrical Connectors and Wiring A. Check the torque of the Allen head screw for the ECM connector. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. attempt to repeat the condition that generated the code. Proceed to Test Step 5. Proceed to Test Step 3. Test Step 2. Run the engine to full operating temperature. The engine will not operate without the valve covers. Switch the 16 amp circuit breaker for the ECM ON. Results: Illustration 169 Bulkhead connector on the front housing g00719936 • Active “open circuit” – There is an open in the primary circuit. The transformers are grounded to the valve covers. B. D. Switch the 16 amp circuit breaker for the ECM OFF. Do not attempt to remove the valve covers when the engine is operating. Turn the engine control switch to the OFF/RESET position. Connect Cat ET to the service tool connector on the terminal box. Expected Result: All of the connectors. if necessary. Turn the engine control switch to the STOP position. condition and/or at least one connection is improper. Expected Result: None of the above diagnostic codes are active. Check the ignition harness and wiring for abrasion and pinch points from the bulkhead connector to the ECM. and sockets are connected properly. Determine if the following codes are active or logged: • 301-05 Cylinder 1 Transformer Primary open circuit through 316-05 Cylinder 16 Transformer Primary open circuit . Avoid contacting the ignition system components and wiring. Proceed to Test Step 2. Attempt to start the engine and use Cat ET. and pinch points. Inspect the bulkhead connector for the ignition harness. • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. Results: • Active “short” – There is a short in the primary circuit. pins.306 Troubleshooting Section • 301-06 Cylinder 1 Transformer Primary short through 316-06 Cylinder 16 Transformer Primary short Note: If a diagnostic code for the primary circuit is logged but not currently active. C. STOP. 1. The connectors and the wiring are free of corrosion. abrasion. • Logged only – There may be an intermittent problem in the ignition harness. Repair: Perform the following steps: Ignition systems can cause electrical shocks. Check for Diagnostic Codes for the Primary Circuit A. • OK – The components are in good condition with proper connections. Remove valve cover (1) for the suspect cylinder. B. “Inspecting Electrical Connectors”. and damage. exposed wires. . Test Step 3. Switch the 16 amp circuit breaker for the ECM OFF. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Inspect the harness and the 2-pin connector (3) of transformer (2). Avoid contacting the ignition system components and wiring.307 Troubleshooting Section Illustration 170 (1) (2) (3) (4) (5) Valve cover Transformer 2-pin connector Camshaft cover Ignition harness g00897228 Illustration 171 (1) Valve cover (2) Transformer (3) 2-pin connector g00897999 2. Refer to Troubleshooting. The transformers are grounded to the valve covers. STOP. Check the Transformer’s Primary Circuit and the Secondary Circuit Ignition systems can cause electrical shocks. C. The engine will not operate without the valve covers. Turn the engine control switch to the OFF/RESET position. A. Remove the valve cover (1) of the suspect cylinder. Remove camshaft cover (4) and inspect ignition harness (5) for abrasion. Visually inspect the 2-pin connector for corrosion and/or damage. 3. D. 4. Disconnect the 2-pin connector (3). Remove the transformer (2) from the cylinder head. Inspect the engine harness. Do not attempt to remove the valve covers when the engine is operating. Record the measurement.000 ohms. b. The other voltage measurement is infinite. Note: The resistance of the secondary coil will vary with the temperature.000 ohm scale.450 VDC. Expected Result: For the primary circuit. Record the measurement. Set the multimeter to the diode scale.14) of the 2-pin connector.Terminal (7) Flyback diode (8) Blocking diode (9) Primary coil of the transformer (10) Secondary coil of the transformer (11) Plug resistor (12) Spark plug gap g00898077 Schematic for the primary circuit and the secondary circuit E. Illustration 174 Resistance versus temperature (Y) Resistance in ohms (X) Temperature in degrees celsius (degrees fahrenheit) g00863850 a. Measure the voltage between the terminals. The polarity of the leads is not important. Measure the voltage between the terminals again. Measure the resistance of the secondary circuit. F. Illustration 172 (4) 2-pin connector for the transformer (5) + Terminal (6) . the correct resistance is between 21. Illustration 174 demonstrates the relationship between the secondary coil’s resistance and the temperature. Connect the multimeter leads to the terminals (13. Repair: Perform the following steps: .Terminal (15) Screw for the ground spring (16) Connector for the spark plug g00897988 Results: • OK – All three of the measurements are correct. Measure the primary circuit by checking the voltage of the blocking diode. Illustration 173 (13) + Terminal (14) . For the secondary circuit. one of the voltage measurements is approximately 0.308 Troubleshooting Section a. Measure the resistance between the screw for the ground spring (15) and the connector for the spark plug (16). Reverse the multimeter leads.000 and 23. the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance. A reading that is within 1000 ohms is acceptable. if the transformer’s temperature is 60 C (140 F). For example. Set the multimeter to the 40. If the problem stays with the suspect transformer. Shut OFF the fuel supply. the cylinders. 4. NOTICE The air inlet. Disconnect the ignition harness from the bulkhead connector. proceed to Test Step 5. The short circuit is in the ignition harness that is inside of the engine block. Proceed to Test Step 8. Clear any logged codes. Turn OFF the gas supply before you perform this step. NOTICE The air inlet. as needed. Turn the engine control switch to the OFF position. Operate the engine. the ignition system is disabled. The short circuit is probably located in the harness between the bulkhead connector and the ECM P2 connector. If the problem stays with the suspect cylinder. Do not attempt to remove the valve covers when the engine is operating. STOP. The unburned fuel can ignite unexpectedly and cause damage. Avoid contacting the ignition system components and wiring. A. and the engine is cranked. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. the ignition system is disabled. Turn OFF the gas supply before you perform this step. Turn the engine control switch to the OFF/RESET position. . Disregard the additional codes. If the condition is not corrected. and the exhaust system can be filled with fuel when the gas supply is ON. Note: Additional diagnostic codes will be generated during this test. • No – The original “short” code was not generated after the bulkhead connector was disconnected. Create an Open Circuit in the Ignition Harness There is a strong electrical shock hazard when the crankshaft is rotating. A. and the engine is cranked. Install the spark plug according to the instructions in Operation and Maintenance Manual. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. Check for a recurrence of the problem. Make repairs. Expected Result: The original “short” code is active when the bulkhead connector is disconnected. replace the transformer. Repair: Replace the ignition transformer. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Restart the engine. Shut OFF the fuel supply. Ignition systems can cause electrical shocks. The unburned fuel can ignite unexpectedly and cause damage. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Make sure that you use the correct transformer for the G3500B Engine. and the exhaust system can be filled with fuel when the gas supply is ON. Reset the control system. “Ignition System Spark Plugs Check/Adjust/Replace”. Install the valve covers. Install the transformers. Check for a Short Circuit Between the P2 Connector and the Bulkhead Connector Test Step 5. The transformers are grounded to the valve covers. Repair: Locate the short circuit. B. • Not OK – At least one of the three measurements is incorrect. proceed to Test Step 4. the cylinders. Refer to Troubleshooting. 2. Pay attention to the original “short” code. “Inspecting Electrical Connectors”. Results: • Yes – The original “short” code was generated after the bulkhead connector was disconnected. 3.309 Troubleshooting Section 1. Test Step 4. The engine will not operate without the valve covers. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Remove the jumper wire from the 2-pin connector of the ignition harness. Inspect the harness. C. • No – Cat ET displayed an active “short” diagnostic code after a short circuit was created in the ignition harness. Remove valve cover (1) for the suspect cylinder. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Look for the original “open circuit” code. 2. Switch the 16 amp circuit breaker for the ECM OFF. Expected Result: The original “open circuit” code is active. D. Repair: Perform the following steps: . Make sure that you use the correct transformer for the G3500B Engine. STOP. the cylinders. and the engine is cranked. 7. Results: • Yes – The original “open circuit” code was generated after a short circuit was created in the ignition harness. 4. “Inspecting Electrical Connectors”. 5.310 Troubleshooting Section There is a strong electrical shock hazard when the crankshaft is rotating. The harness and the ECM are OK. Turn the engine control switch to the OFF/RESET position. Thoroughly inspect the connectors for the transformer. 3. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. 1. turn the engine control switch to the OFF/RESET position. Clear all of the logged diagnostic codes. Switch the 16 amp circuit breaker for the ECM OFF. Replace the transformer. Connect the ignition harness to the transformer. Inspect the connectors of the harness and the transformer for damage and/or corrosion. and the exhaust system can be filled with fuel when the gas supply is ON. 6. The ECM did not detect the jumper wire. Illustration 175 (1) Valve cover (2) 2-pin connector for the ignition harness g00720019 B. Look for the original “open circuit” code. Proceed to Test Step 6. NOTICE The air inlet. Install a jumper wire into the terminals of the 2-pin connector on the ignition harness. If the original “open circuit” code is generated. The unburned fuel can ignite unexpectedly and cause damage. Disconnect the 2-pin connector (2). E. Turn OFF the gas supply before you perform this step. the ignition system is disabled. Refer to Troubleshooting. 2. Shut OFF the fuel supply. B. The external engine harness and the ECM are OK. the ignition system is disabled. Turn OFF the gas supply before you perform this step. Results: • Yes – When the jumper wire was installed into Illustration 176 g00720061 Terminals on the bulkhead connector of the ignition harness C. However. Turn the engine control switch to the OFF/RESET position. the cylinders. However.311 Troubleshooting Section Test Step 6. a “short” diagnostic code is generated for the suspect cylinder. and the exhaust system can be filled with fuel when the gas supply is ON. Switch the 16 amp circuit breaker for the ECM OFF. NOTICE The air inlet. The cylinders and the terminals are identified in Table 28 and Illustration 176. Disconnect the bulkhead connector. The internal ignition harness in the engine block has an open circuit. . Expected Result: The original “open circuit” diagnostic code is not active. the original “open circuit” diagnostic code was not active. and the engine is cranked. Install the ends of the jumper wire into the terminals of the connector on the external engine harness side of the bulkhead connector for the suspect cylinder. Turn the engine control switch to the OFF/RESET position. Check the Engine Harness for an Open Circuit Table 28 Cylinders and Corresponding Terminals of the Bulkhead Connector for the Ignition Harness Cylinder Terminals for the Circuit Driver A V C X E c G e J h N k L n S r Return Terminals B W D Z F d H f R j P m M p K s There is a strong electrical shock hazard when the crankshaft is rotating. A. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 D. Repair: Perform the following steps: 1. Look for the original “open circuit” diagnostic code. a “short” diagnostic code was generated for the suspect cylinder. The unburned fuel can ignite unexpectedly and cause damage. Remove the camshaft covers from the bank of the engine with the suspect cylinder. the harness. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. If you are troubleshooting an “open circuit” diagnostic code. Thoroughly inspect the connectors for corrosion. Disconnect the ECM J2/P2 connectors. exposed wires. NOTICE The air inlet. B. Turn the engine control switch to the OFF/RESET position. and the engine is cranked. Check the ECM There is a strong electrical shock hazard when the crankshaft is rotating. Turn OFF the gas supply before you perform this step. Repair the harness. if necessary. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Inspect the internal ignition harness for abrasion. if necessary. C. If the condition is not corrected. “Inspecting Electrical Connectors”. Switch the 16 amp circuit breaker for the ECM OFF. as needed. refer to Illustration 177 and Table 29. Make repairs. a. when possible. • No – When the jumper wire was installed into the external engine harness. and other damage. the cylinders. Illustration 177 g00720097 Note: For identification of the terminals. Use a 151-6320 Wire Removal Tool to remove wiring from the ECM P2 connector. The ECM did not detect the jumper wire. moisture. The removal of the wiring depends on the original diagnostic code. remove the wire from the terminal for the circuit driver of the suspect cylinder. or other damage. Be sure to inspect the harness inside the front of the engine.312 Troubleshooting Section 3. If you are troubleshooting a “short” diagnostic code. The open circuit is probably in the external engine harness. Replace the harness. A. and the exhaust system can be filled with fuel when the gas supply is ON. b. STOP. Make repairs. The unburned fuel can ignite unexpectedly and cause damage. Then install the ends of the jumper wire into the terminals for the removed wires. proceed to Test Step 7. Repair: Refer to Troubleshooting. the ignition system is disabled. . remove the wires from the terminal for the circuit driver AND from the return of the suspect cylinder. Test Step 7. the original “open circuit” diagnostic code was generated. install the valve covers. A “short” diagnostic code is generated for the circuit with the installed jumper wire. Expected Result: An “open circuit” diagnostic code is generated for the circuit after removal of the wire for the circuit driver. There is a problem with the ignition harness. There is a problem with the ECM. Remove the valve cover for the suspect cylinder. F. E. if necessary. Turn the engine control switch to the STOP position. Switch the 16 amp circuit breaker for the ECM OFF. exposed wires. C. the ignition system is disabled. Switch the 16 amp circuit breaker for the ECM OFF. The engine will not operate without the valve covers. Follow the instructions in Troubleshooting. or other damage. Avoid contacting the ignition system components and wiring. STOP. Switch the 16 amp circuit breaker for the ECM ON. The unburned fuel can ignite unexpectedly and cause damage. Switch the 16 amp circuit breaker for the ECM ON. The transformers are grounded to the valve covers. Disconnect the ignition harness from the transformer. Repair the harness. Inspect the ignition harness for abrasion. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. B.313 Troubleshooting Section Table 29 Cylinders and Corresponding Terminals of the ECM P2 Connector for the Ignition Harness Cylinder Terminals for the Circuit Driver 1 3 24 26 14 16 5 52 32 34 48 50 58 60 40 42 Return Terminals 2 4 25 27 15 17 18 62 33 35 49 51 59 61 41 43 Repair: Turn the engine control switch to the OFF/RESET position. when possible. E. Results: • Yes – A diagnostic code was generated according to the Expected Result. Turn the engine control switch to the OFF/RESET position. “Replacing the ECM”. If any valve covers were removed. and the engine is cranked. A. Turn the engine control to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Do not attempt to remove the valve covers when the engine is operating. the cylinders. Test Step 8. Turn OFF the gas supply before you perform this step. Check the Ignition Transformer for a Short Circuit Ignition systems can cause electrical shocks. D. Thoroughly inspect the 2-pin connector on the transformer. NOTICE The air inlet. Reconnect all of the connectors. The ECM is operating correctly. Replace the harness. and the exhaust system can be filled with fuel when the gas supply is ON. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 • No – A diagnostic code was NOT generated according to the Expected Result. Repair: Replace the ECM. . STOP. D. Turn the engine control switch to the STOP position. Ignition Transformers Secondary Circuit and Spark Plugs SMCS Code: 1561-038 System Operation Description: The ignition transformers initiate combustion by providing high voltage to the spark plugs. Repair: Perform the following steps: There is a strong electrical shock hazard when the crankshaft is rotating. The transformers are located underneath the valve covers. Do not touch the wires that are associated with the ignition system when the engine is cranking or when the engine is running. Thoroughly inspect the 2-pin connectors for the internal ignition harness and the transformer. The short circuit is in the internal ignition harness.314 Troubleshooting Section F. The unburned fuel can ignite unexpectedly and cause damage. STOP. Switch the 16 amp circuit breaker for the ECM OFF. and the exhaust system can be filled with fuel when the gas supply is ON. Repair: Perform the following steps: 1. Expected Result: An “open circuit” diagnostic code is generated for the circuit with the disconnected transformer. Switch the 16 amp circuit breaker for the ECM OFF. 2. Turn OFF the gas supply before you perform this step. 6. The positive output from the secondary circuit of the transformer is at the connection for the terminal of the transformer and the terminal of the spark plug. Do not reconnect the transformer. Each transformer is grounded to a valve cover via a ground spring. Turn the engine control switch to the OFF/RESET position. Remove the camshaft covers from the bank of the engine with the suspect cylinder. Refer to Troubleshooting. Inspect the internal ignition harness for abrasion. . Replace the harness. • Yes – An “open circuit” diagnostic code was • No – An “open circuit” diagnostic code was not generated for the circuit with the disconnected transformer. Replace the transformer. exposed wires. the cylinders. Switch the 16 amp circuit breaker for the ECM ON. the ignition system is disabled. and the engine is cranked. STOP. If the “short circuit” code is generated again. 3. 2. Clear all of the logged diagnostic codes. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. when possible. Make sure that you use the correct transformer for the G3500B Engine. Reconnect the internal ignition harness to the transformer. Switch the 16 amp circuit breaker for the ECM OFF. if necessary. or other damage. 1. turn the engine control switch to the OFF/RESET position. 4. “Inspecting Electrical Connectors”. Results: 5. Turn the engine control switch to the OFF/RESET position. NOTICE The air inlet. 3. Turn the engine control switch to the START position and observe the “Active Diagnostic” screen of Cat ET while you crank the engine. Repair the harness. i01755380 generated for the circuit with the disconnected transformer. a megohmmeter must be used. Connect Cat ET to the service tool connector on the terminal box.315 Troubleshooting Section Note: Ignition transformers from Electronic Ignition Systems (EIS) are not interchangeable with the transformers in this engine. Logged diagnostic codes provide an historical record. Most ignition systems are not affected by resistance in the secondary circuit.000 to 37. Test Step 1.000 volts to the spark plug. Switch the 16 amp circuit breaker for the ECM ON. The total duration of the spark is approximately 400 microseconds. Caterpillar spark plugs are high voltage devices with internal resistors. these conditions may lead to misfire which can cause lugging of the engine. use the Caterpillar Electronic Technician (ET) to print the logged codes to a file. This voltage ionizes the spark plug gap. Use eight of the following labels for parameters on each Status screen: Illustration 178 Ignition transformer and spark plug (1) Ground spring (2) 2-pin connector (3) secondary spark plug terminal (4) Extension (5) O-ring seal (6) Hole in the spark plug’s precombustion chamber g00893879 The secondary circuit of the transformer provides an initial 8. B. However. The spark plugs operate at a voltage that is greater than 5. D. Check the Status Screen of Cat ET for the Output of the Secondary Circuits of the Transformers A. Secondary open circuits and short circuits will not directly shut down the engine. This voltage is then reduced to about 1000 volts. A low voltage multimeter will not provide a reliable reading of the resistance because oxidation of the spark plug’s internal components will affect the readings of those meters. Before you begin this procedure. Switch the 16 amp circuit breaker for the ECM OFF.000 volts. Lugging of the engine can cause a shutdown. The Electronic Control Module (ECM) can diagnose the primary circuit of the ignition transformers for open circuits and/or for short circuits. C. . Set up two Status screens for Cat ET. If a measurement of the resistance is desired. Turn the engine control switch to the STOP position. Turn the engine control switch to the OFF/RESET position. Do not pull on the wiring harness. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. C. NOTICE Pulling on the wiring harness may break the wires. B. Proceed to Test Step 2. Repair: Investigate other possible root causes of the problem. Start the engine. Apply the normal load at rated speed. Troubleshoot the symptom. The transformers are grounded to the valve covers. STOP. The ignition system components are operating properly. Refer to Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. Turn the engine control switch to the OFF/RESET position. . Remove the valve cover of the suspect cylinder. Remove the transformer from the engine. Results: Illustration 179 (1) Valve cover (2) 2-pin connector g00893893 • OK – The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent. Allow the engine to warm up to normal operating temperature. “Troubleshooting Without A Diagnostic Code”.316 Troubleshooting Section Table 30 • Not OK – At least one of the outputs displayed Screen 1 Group 8 Screen 2 Group 9 “Cylinder #2 Transformer Secondary Output Voltage Percentage” “Cylinder #4 Transformer Secondary Output Voltage Percentage” “Cylinder #6 Transformer Secondary Output Voltage Percentage” “Cylinder #8 Transformer Secondary Output Voltage Percentage” “Cylinder #10 Transformer Secondary Output Voltage Percentage” “Cylinder #12 Transformer Secondary Output Voltage Percentage” “Cylinder #14 Transformer Secondary Output Voltage Percentage” “Cylinder #16 Transformer Secondary Output Voltage Percentage” Parameters for the Status Screens on Cat ET a value of 0 percent or a value that is greater than 90 percent. E. Expected Result: The displayed value of the output for the secondary circuit of each transformer is between 1 and 90 percent. F. The ignition system components require maintenance. Observe the value of the output for the secondary circuit of each transformer. Do not attempt to remove the valve covers when the engine is operating. “Cylinder #1 Transformer Secondary Output Voltage Percentage” “Cylinder #3 Transformer Secondary Output Voltage Percentage” “Cylinder #5 Transformer Secondary Output Voltage Percentage” “Cylinder #7 Transformer Secondary Output Voltage Percentage” “Cylinder #9 Transformer Secondary Output Voltage Percentage” “Cylinder #11 Transformer Secondary Output Voltage Percentage” “Cylinder #13 Transformer Secondary Output Voltage Percentage” “Cylinder #15 Transformer Secondary Output Voltage Percentage” Test Step 2. Avoid contacting the ignition system components and wiring. Inspect the Transformer Ignition systems can cause electrical shocks. A. The engine will not operate without the valve covers. Disconnect the ignition harness from the ignition transformer. Expected Result: The transformer is in good condition. Illustration 181 (1) (2) (3) (4) (5) (6) (7) (8) (9) 2-pin connector for the transformer + Terminal . • Not OK – An inspection found a problem with the transformer.Terminal Flyback diode Blocking diode Primary coil of the transformer Secondary coil of the transformer Plug resistor Spark plug gap g00898121 Schematic for the primary circuit and the secondary circuit A. E. F. Be sure to use the correct transformer for the G3500B Engine. if necessary. Reset the control system. Clear the logged codes. Verify that the screws for the ground spring are secure. Clean any deposits from the inside of the extension. Replace the transformer. . H. NOTICE The extension can be scratched and damaged with a wire brush. Repair: Repair the transformer. when possible. Proceed to Test Step 3. Use a 6V-7093 Brush with isopropyl alcohol. Restart the engine. STOP. Results: • OK – The transformer appears to be in good condition. Inspect the secondary terminal for the spark plug (4) inside the extension for corrosion and/or damage. Measure the primary circuit by checking the voltage of the blocking diode.317 Troubleshooting Section I. Illustration 180 (1) (2) (3) (4) (5) (6) Screw Ground spring Spacer secondary terminal for the spark plug Extension O-ring seal g00715304 Test Step 3. Check for a secure connection between the transformer and the spark plug. Inspect the O-ring seal inside the extension for damage. Check the Primary Circuit and the Secondary Circuit D. Do not use a wire brush on the extension. Check the extension near the spacer for signs of punch through (pin holes) and/or arcing. Note: Punch through is caused by misfire in the engine that does not generate a diagnostic code. Inspect the body of the transformer and the ground spring for corrosion and/or damage. G. The other voltage measurement is infinite.318 Troubleshooting Section Illustration 183 Resistance versus temperature (Y) Resistance in ohms (X) Temperature in degrees celsius (degrees fahrenheit) g00863850 Illustration 182 (10) + Terminal (11) . • Not OK – At least one of the measurements is incorrect.11) of the 2-pin connector. Reverse the multimeter leads. one of the voltage measurements is approximately 0. the correct resistance is between 21.Terminal (12) Screw for the ground spring (13) Secondary terminal for the spark plug g00898124 a.000 ohm scale. Make sure that you use the correct transformer for the G3500B Engine. Replace the ignition transformer. Connect the multimeter leads to the terminals (10. Measure the voltage between the terminals again. Note: The resistance of the secondary coil will vary with the temperature.450 VDC. Measure the resistance of the secondary circuit. Measure the resistance between the screw for the ground spring (12) and the connector for the spark plug (13). For example. Record the measurement.000 and 23. . A reading that is within 1000 ohms is acceptable. if the transformer’s temperature is 60 C (140 F). Results: a. Expected Result: For the primary circuit. Set the multimeter to the 40. • OK – All three of the measurements are correct. Measure the voltage between the terminals. Illustration 183 demonstrates the relationship between the secondary coil’s resistance and the temperature. the resistance between the screw for the ground spring and the connector for the spark plug is within the acceptable tolerance. B. Record the measurement. b. Check the Spark Plug A. Proceed to Test Step 4.000 ohms. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF. Set the multimeter to the diode scale. For the secondary circuit. STOP. Test Step 4. Switch the 16 amp circuit breaker for the ECM OFF. The polarity of the leads is not important. Reset the control system. B. Inspect the spark plug. C. Clear the logged codes. Install the transformers. Isolate the Spark Plug and the Transformer A. c. B. Install a new spark plug according to the instructions in the engine’s Operation and Maintenance Manual. Results: • Not OK – A diagnostic code is generated. Start the engine and operate the engine in order to generate the diagnostic code again. b. Test Step 6. Reset the control system. STOP. Expected Result: The diagnostic code is generated for the suspect transformer. Proceed to Test Step 5. Reset the control system. . STOP. Clear any logged diagnostic codes. Install the spark plug according to the instructions in the engine’s Operation and Maintenance Manual. Expected Result: A diagnostic code is not generated. Proceed to Test Step 6. Results: Illustration 184 Spark plug that has a precombustion chamber g00837850 • OK – A diagnostic code is not generated. a. • Not OK – The spark plug is not in good condition. Install the valve covers. • OK – The spark plug is in good condition. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF. Install the transformer and the valve cover. “Ignition System Spark Plugs . Make sure that you use the correct transformer for the G3500B Engine.Check/Adjust/Replace”. Remove the spark plug from the cylinder head. Reset the control system. Switch the suspect transformer with a transformer from a different cylinder that is known to be good. Clear any logged diagnostic codes. Repair: Make sure that the engine control switch to the OFF/RESET position and the 16 amp circuit breaker for the ECM is OFF.319 Troubleshooting Section D. Note: For a spark plug with a precombustion chamber. The minimum service life of a spark plug with a precombustion chamber is approximately 3000 service hours. Results: • Yes – The diagnostic code is generated for the suspect transformer. the resistance cannot be measured. Repair: Discard the spark plug. Reset the control system. C. Install a new spark plug according to the instructions in Operation and Maintenance Manual. Operate the Engine A. Test Step 5. Clear any logged diagnostic codes. Start the engine and operate the engine in order to generate the diagnostic code again. Restart the engine. Proceed with normal operation. STOP. • No – The diagnostic code is generated for the original cylinder. Perform the following procedures according to the instructions in the engine’s Operation and Maintenance Manual. Clean the spark plug. Replace the faulty transformer. Clear any logged diagnostic codes. Expected Result: The spark plug is in good condition. The spark plug may be good for a considerable period beyond 3000 service hours. B. Experience at the particular site will help to determine the proper interval for replacement of the spark plug. STOP. 320 Troubleshooting Section i01746137 Inspecting Electrical Connectors SMCS Code: 1901-038 System Operation Description: Many of the troubleshooting procedures direct you to a specific electrical connector. The pins and the sockets are soldered to the electrical wires. The solder connections are usually protected by a chemical potting which prevents access to the solder point. Sometimes. The pins and the sockets are crimped onto the electrical wires. simply disconnecting a connector and then reconnecting the connector can solve a problem. repair the connector and verify that the problem is corrected. These connectors are repairable without cutting the wires. . check for codes again. The connector has a locking mechanism in order to hold the pins and the sockets. If a problem is found in a connector. Illustration 185 g00700045 The MS Connectors have a metal housing. If this occurs. Use the following test steps to help determine whether the connector is the cause of the problem. Always check for an active diagnostic code before you open any connection. Intermittent electrical problems are often caused by poor connections. the following conditions are likely causes: Illustration 186 g00700064 • Loose terminals • Bent terminals • Improperly crimped terminals • Improperly mated connectors • Moisture • Corrosion Deutsch connectors have a plastic housing. Immediately after you reconnect the connector. Switch the 16 amp circuit breaker for the ECM OFF. make sure that the orange wedge is used in order to lock the pins. Make sure that the receptacle is turned fully in the clockwise direction. make sure that the receptacle is turned fully in the clockwise direction. A. Check that the receptacle has clicked into the locked position. Results: Test Step 1. Make sure that the two halves cannot be pulled apart. Reconnect all of the connectors. B. Test Step 2. Always turn the engine control switch to the OFF/RESET position before you inspect electrical conductors. When you connect the 70-pin connector to the Electronic Control Module (ECM). do not exceed 6 ± 1 N·m (55 ± 9 lb in) of torque on the screw. Verify that the receptacle is clicked into the locked position. B. STOP. Be careful not to overtighten the screw and break the screw. D. Check that the threading is properly aligned and securely mated. • OK – Proceed to test step 2. For the Deutsch HD connectors. . make sure that the plug and the receptacle are aligned properly with the index markings. Expected Result: The ECM connector is secure and the allen head screw is properly torqued. For the MS connectors. C.321 Troubleshooting Section Illustration 187 g00700442 Use the following test steps in order to thoroughly inspect the connectors and determine if the connectors are the cause of the problem. Check the Connectors. Ensure that the allen head screw is properly tightened. Check the Allen Head Screw on the ECM Connector. For the Deutsch DT style. Expected Result: All connectors are properly mated and free of damage. • Not OK Repair: Repair the connectors and/or replace the connectors. A. Make sure that the two halves cannot be pulled apart. Expected Result: • OK – Proceed to Test Step 3. Perform a Pull Test on Each Wire Connection. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector. C. Monitor the Electronic Service Tool While the Wiring and the Connectors Are Being Pulled. If the harness is being pulled and the engine has a speed burp or a power cutout. Then start the engine. Use the 1U-5804 Crimp Tool. Monitor the “Active Diagnostic Code” screen on Cat ET while you pull on all harnesses and connectors for the circuit with the active code. Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. b. • Not OK Repair: Repair the circuit. b. B. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the DT connectors. Turn the engine control switch to the “STOP” position. There is a strong electrical shock hazard when the crankshaft is rotating. The DT connectors use an orange wedge to lock the terminals in place. If the harness is being pulled and the reading changes erratically. Run the engine under normal operating conditions. STOP. • Not OK Repair: Repair the connector or replace the connector. A. STOP. Switch the 16 amp circuit breaker for the ECM ON. Do not touch wires that are associated with the ignition transformer circuit when the engine is cranking or running. d. there is a problem in the wiring or the connector. component status. If there are no active diagnostic codes and there are complaints about intermittent changes in speed or power cutouts. Results: • OK – Proceed to Test Step 4. . Run the engine under normal operating conditions. Test Step 3. Listen for speed burps or power cutouts while the wiring and/or the connectors are pulled. If there are no active diagnostic codes that pertain to the circuit. Monitor the “Display Status” screen on Cat ET while you pull on all harnesses and connectors for the circuit. Do not solder terminals. Pulling on the harness and the connectors has no effect on the active diagnostic code. Run the engine under normal operating conditions. Switch the 16 amp circuit breaker for the ECM OFF. Test Step 4. there could be a problem in the wiring or the connector. there is a problem in the wiring or the connector. If there is an active diagnostic code that pertains to the circuit. The problem appears to be external to the harnesses and connectors. b. c. Turn the engine control switch to the OFF/RESET position. perform the following test: a. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. Note: Terminals should ALWAYS be crimped onto the wires by using a Crimp Tool. perform the following steps: a. Verify that the repair eliminates the problem. or engine performance. B.322 Troubleshooting Section Results: A. perform the following test: a. Verify that the repair eliminates the problem. Expected Result: Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body. as required. If the harness is being pulled and the active diagnostic code disappears. • Not OK Repair: Repair the wires or replace the wires. If any of the seals or plugs are missing. • Not OK Repair: Turn the engine control switch to the OFF/RESET position. Also. Turn the engine control switch to the “OFF/RESET” position. . replace the seal or plug. Check all of the wiring harnesses in order to verify that the harness does not make a sharp bend out of a connector. Ensure that the connector seals and the white sealing plugs are in place. STOP. Results: A. or cuts. Allow the engine to coast to a stop. Check the Connectors for Moisture or Corrosion. STOP. • OK – Proceed to Test Step 5. nicks. as required. If necessary. Carefully inspect each wire for signs of abrasion. Test Step 5. replace the connector. Thoroughly inspect ECM J1/P1 and J2/P2 connectors for evidence of moisture entry. • OK – Proceed to Test Step 6. Illustration 189 g00690568 B. Verify that the repair eliminates the problem. Switch the 16 amp circuit breaker for the ECM OFF. Expected Result: The wires are free of abrasion. Verify that the repair eliminates the problem. Check all of the hold down clamps for the harness in order to verify that the harness is properly clamped. Pull back the harness sleeves in order to check for flattening of the wires by the clamps.323 Troubleshooting Section Results: Test Step 6. Switch the 16 amp circuit breaker for the ECM OFF. or cuts and the harness is properly clamped. nicks. Repair the circuit. B. A. Turn the engine control switch to the “STOP” position. Check Wires for Nicks or Abrasion in the Insulation. check all of the hold down clamps in order to verify that the harness is not compressed by the clamps. C. This will deform the connector seal and this will create a path for the entrance of moisture. The following areas are likely locations: Illustration 188 g00690571 • Places with exposed insulation • Points with wiring that rubs against the engine • Places with wiring that rubs against a sharp point D. it may be necessary to replace the wires that have moisture. STOP.1. The following list includes likely paths for the entrance of moisture: Verify that the repair eliminates the problem by running the engine for several minutes and by checking again for moisture. Inspect the Connector Terminals. the source of the moisture entry must be found and the source of the moisture entry must be repaired. STOP. Expected Result: The terminals are properly aligned and the terminals appear undamaged. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. as required. The harness and the wiring is free of corrosion. Results: • OK – Proceed to Test Step 7. If the repair is not made. These wires may have moisture that is trapped inside the insulation. Simply drying the connector will not fix the problem. • Not OK Repair: Repair the circuit. Use a cotton swab or a soft brush to remove the corrosion. the moisture is wicking into the connector. Verify that the terminals are not damaged. • Not OK Repair: Repair the terminals and/or replace the terminals. Verify that the repair eliminates the problem.324 Troubleshooting Section Note: It is normal to see some minor seal abrasion on the ECM connector seals. Note: If corrosion is evident on the pins. and pinch points. . use only denatured alcohol to remove the corrosion. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector. Verify that the repair eliminates the problem. the problem will recur.1 trichloro-ethylene because 1. Expected Result: Test Step 7. thoroughly check all connectors and wires on the harness that connects to the ECM. Even if the moisture entry path is repaired. If moisture reappears. If moisture or corrosion is evident in the connector. Results: • OK – Proceed to Test Step 7. If moisture is found in the ECM connector. The ECM is not the source of the moisture. sockets or the connector. Do not use any cleaners that contain 1. • Missing seals or plugs • Improperly installed seals or plugs • Nicks in exposed insulation • Improperly mated connectors Moisture can also wick from one connector through the inside of a wire to the ECM connector.1. All of the connectors are completely coupled and all of the seals are completely inserted. abrasion. Minor seal abrasion will not allow the entry of moisture.1 trichloro-ethylene may damage the connector. Do not replace an ECM if moisture is found in either ECM connector. Verify that the socket holds the pin when the connector hangs freely. Repair: Repair any bad pins and sockets. STOP. Logged diagnostic codes provide an historical record. Clear the diagnostic codes after the problem is resolved. Results: • High inlet temperature to the turbocharger turbine • High outlet temperature from the turbocharger turbine A diagnostic code is generated by the ITSM for the circuit of any thermocouple that is shorted to the +Battery side. Replace the wiring. Before you begin this procedure. i01754840 Integrated Temperature Sensing Module (ITSM) SMCS Code: 1901-038 System Operation Description: The Integrated Temperature Sensing Module (ITSM) monitors K type thermocouples at each cylinder exhaust port and at the inlets and outlets for both turbochargers. Make sure that the pin is properly gripped by the socket. or open. • Not OK – The pins and sockets do not mate properly. Temperature readings of the thermocouples are available over the CAT Data Link for use by the Electronic Control Module (ECM) and other modules. insert a new socket onto each pin. if necessary. The temperatures can be viewed on the Caterpillar Electronic Technician (ET). B. The ITSM can also calculate the average temperature for each cylinder bank (left and right). if necessary. Replace the connectors. Do not FLASH any software with a personality module date code that is dated after March 1998 into the 141-1957 Electronic Control. Note: The 141-1957 Electronic Control (ITSM) will not function properly with a personality module date code that is dated after March 1998. . Keep your mind on correcting the cause of the original diagnostic code. Check the Individual Retention of the Pins and Sockets. Make sure that the pin is properly gripped by the socket. This troubleshooting procedure may generate additional diagnostic codes. • OK – The pins and sockets mate properly. One at a time. Verify that the repair eliminates the problem. use Cat ET to print the logged codes to a file. insert a new pin into each socket. STOP. Expected Result: Each socket firmly grips each pin. shorted to ground. The ITSM generates event codes for each of the following programmable conditions: Illustration 190 g00690572 • High exhaust temperature • High deviation of an exhaust port temperature • Low deviation of an exhaust port temperature Note: This is especially important for intermittent problems. A. One at a time.325 Troubleshooting Section Test Step 8. The J1/P1 and J5/P5 connectors are not shown. . For the actual wiring. refer to the schematic for the engine electrical system.326 Troubleshooting Section Illustration 191 Schematic for the circuit of the ITSM g00897802 The ECM is connected to the ITSM via the J1/P1 connectors and the terminal box J5/P5 connectors. The proper torque is 6 ± 1 N·m (53 ± 9 lb in). and J9/P9 (if equipped) connectors on the terminal box Illustration 192 G3516 Engine cylinders (A) Inlet valve (B) Exhaust valve (C) Flywheel g00741742 a. Inspect the Electrical Connectors and Wiring A. Check the torque of the Allen head screw for the ECM connector. Turn the engine control switch to the OFF/RESET position. Thoroughly inspect each of the following connectors: • ECM J1/P1 connectors • J5/P5. Switch the 16 amp circuit breaker for the ECM OFF. . “Inspecting Electrical Connectors”. refer to Troubleshooting.327 Troubleshooting Section Test Step 1. Illustration 195 Harness side of the ECM P1 connector (8) CAT data link + (9) CAT data link − g00894447 Illustration 193 Terminal box (1) ECM connectors J1/P1 (2) J5/P5 connectors for the ITSM (3) J7 connector (if equipped) (4) J9/P9 connector for the customer (if equipped) g00894400 b. Illustration 194 g00754888 B. J7 (if equipped). Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the ITSM. Note: For the following steps. 328 Troubleshooting Section Illustration 196 Harness and thermocouples g00754942 Illustration 197 Harness and connectors for the thermocouples (P40) Connector for the harness to the ITSM (1 through 16) Cylinders (17) Outlet for the right turbine (18) Outlet for the left turbine (19) Right turbine inlet (20) Left turbine inlet g00754950 Illustration 198 Connectors for the ITSM g00894405 (1) J18/P18 connectors for the harness to the terminal box (2) J40/P40 connectors for the harness to the thermocouples . Expected Result: All of the connectors. D. and sockets are connected properly. . Check the harnesses and wiring for abrasion and pinch points from each component to the ECM. condition and/or at least one connection is improper. STOP. Results: • OK – The components are in good condition with proper connections. Access the “ITSM Configuration Parameter” screen. • Not OK – The components are not in good Illustration 200 Terminal box (1) ECM connectors J1/P1 (2) J5/P5 connectors for the ITSM (3) J7 connector for the Versatile Control Module (if equipped) (4) J9/P9 connector for the customer (if equipped) g00894400 Repair: Perform the necessary repairs and/or replace parts. and pinch points. if necessary. Note that all of the wiring for the thermocouples must be K type. Turn the engine control switch to the STOP position. Connect Cat ET to the service tool connector on the terminal box. abrasion. Test Step 2. Disconnect the terminal box J7/P7 and J9/P9 connectors (if equipped).329 Troubleshooting Section Illustration 199 Connectors for the harness from the ITSM to the terminal box (1) P5 connector to the terminal box (2) P18 connector to the ITSM g00894459 c. Expected Result: “V16. Carefully inspect the connectors for each of the thermocouples. pins. B. Thoroughly inspect the J18/P18 connectors and the J40/P40 connectors. Select the ITSM under the “File/Select ECM” menu of Cat ET. Switch the 16 amp circuit breaker for the ECM ON. Use Cat ET to Check the Communications from the ITSM A. C.2 Turbos” is displayed in the “Value” column of the “ITSM Application Type”. The connectors and the wiring are free of corrosion. Observe the display. Proceed to Test Step 2. . Switch the 16 amp circuit breaker for the ECM OFF. This is normally only needed for a replacement ITSM. Follow the instructions in Troubleshooting. If the ITSM cannot be selected. The ITSM is not communicating normally. perform the following procedure in order to make sure that the CAT Data Link is OK: 1. troubleshoot the circuits of the CAT Data Link that are external to the terminal box. Check the Continuity of the CAT Data Link A. Repair: Perform the following Steps: 1. Results: If no 1042-09 diagnostic code is generated. Reconnect the terminal box J9/P9 connectors (if equipped). Refer to the schematic of the engine electrical system and Troubleshooting. Table 31 D. If the original problem is not resolved. proceed to Test Step 3. Select “Change” in the lower left corner of the “Configuration” screen. Access the “Service/Configuration” screen of Cat ET. proceed to Test Step 3. • OK – “V16. Check Cat ET again for an active 1042-09 diagnostic code. Select “V16. Reconnect the terminal box J7/P7 connectors (if equipped). If the voltage supply is good but the ITSM does not communicate. Repair: If the original problem is not resolved. replace the ITSM. B. 2.2 Turbos” is displayed in the “Value” column of the “ITSM Application Type”.330 Troubleshooting Section Results: Test Step 3. The ITSM seems to be communicating properly. For instructions on flash programming of the ITSM. Turn the engine control switch to the OFF/RESET position. The terminals are listed in Table 31. “Replacing the ITSM”. The continuity of the circuits between the terminals and the engine block are open. Use a multimeter to check for continuity of the circuits that are listed in Table 32: Table 32 Check for Continuity Connector and Terminal P1-8 Connector and Terminal P18-J J23-D P18-J P1-9 J23-D P18-N J23-E P18-N J23-D J23-E J23-E Engine block J7/P7 and J9/P9 Connections for the CAT Data Link Terminal P7-E P9-c P7-M P9-g Function CAT Data Link + CAT Data Link − Expected Result: The continuity of the circuits between the terminals is good. If either connection activates the 1042-09 diagnostic code. ensure that the flash programming of the ITSM has been performed.2 Turbos” for a “New Value”. Disconnect the ECM J1/P1 connectors. • OK – The continuity of the circuits between the terminals is good. Disconnect the ITSM J18/P18 connectors. verify that voltage is supplied to the ITSM P18-A and P18-B terminal.2 Turbos” is not displayed in the “Value” column of the “ITSM Application Type”. 2. The continuity of the circuits between the terminals and the engine block are open. “Replacing the ITSM”. • Not OK – “V16. C. “Electrical Power Supply”. refer to Troubleshooting. STOP. Check Cat ET for an active “1042-09 Unable to communicate with ITSM” diagnostic code. Repair: Before you continue. refer to Troubleshooting. Reconnect the thermocouple’s connectors and check for an active short circuit diagnostic code. Turn the engine control switch to the STOP position. 5. C. • Active “short to ground” or “short to +batt” – At least one “short to ground” or “short to +batt” diagnostic code is active. If the short circuit diagnostic code becomes active again. Determine if any of the following diagnostic codes for the thermocouples are active: There is an active “open circuit” diagnostic code for the disconnected thermocouple. Verify that the repair has eliminated the original problem. 3. If necessary. there may be an intermittent condition that is causing the codes to be generated. Repair: Perform the following procedure: 1. If the engine is not running properly. Test Step 4. 4. There is a short circuit to the engine block. Results: • Yes – There is an active “open circuit” diagnostic code for the disconnected thermocouple. Access the “Active Diagnostic” screen for the ITSM on Cat ET. D. • No Active Codes – None of the above diagnostic codes for the thermocouples are active. replace the wiring and/or connectors. Switch the 16 amp circuit breaker for the ECM OFF. Test Step 5. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. there is a problem with the thermocouple. Clear the logged diagnostic codes. Do not install the thermocouple into the engine yet. Ensure that all of the seals are properly installed. Proceed to Test Step 6. Access the “Active Diagnostic” screen for the ITSM on Cat ET. STOP. Allow a minimum of 30 seconds for any diagnostic codes to be generated. the service tool J23 connector. Thoroughly inspect the thermocouple’s connectors. and the ITSM P18 connector is open. Verify the Active Diagnostic Codes A. Disconnect the connector for the thermocouple with the short circuit diagnostic code.331 Troubleshooting Section • Not OK – One or both of the following conditions are found: The continuity of any circuit between the ECM P1 connector. Create an Open Circuit A. Results: • 1489-03 through 1492-03 (“short to +batt”) • 1489-04 through 1492-04 (“short to ground”) • 1489-05 through 1492-05 (“open circuit”) • 1531-03 through 1546-03 (“short to +batt”) • 1531-04 through 1546-04 (“short to ground”) • 1531-05 through 1546-05 (“open circuit”) Expected Result: None of the above diagnostic codes for the thermocouples are active. 2. STOP. The ITSM and the harness are OK. Proceed to Test Step 5. If the diagnostic code is not generated with the good thermocouple. “Troubleshooting Without a Diagnostic Code”. STOP. Switch the 16 amp circuit breaker for the ECM ON. . Expected Result: Repair: Repair the wiring and/or the connectors. Repair: If any of the codes are logged. Install the good thermocouple. remove the suspect thermocouple from the engine. B. Turn the engine control switch to the OFF/RESET position. Ensure that the connectors are properly engaged. Ensure that the connectors and the seals are in good condition. Check for an active short circuit diagnostic code. • Active “open circuit” – At least one “open circuit” diagnostic code is active. Switch the 16 amp circuit breaker for the ECM ON. When the jumper wire was removed. G. There is a short circuit between the harness for the thermocouple and the ITSM. Observe the “Active Diagnostic” screen. • Yes – When the jumper wire was installed. Only pay attention to the diagnostic codes for the suspect thermocouple. remove the suspect thermocouple from the engine. Disconnect the P40 plug from the ITSM. Check for an active open circuit diagnostic code. Check the ITSM A. Install the jumper wire into terminal A and terminal B on the harness connector from the ITSM. Test Step 7. Proceed to Test Step 7. Turn the engine control switch to the STOP position. 3. 5. the “open circuit” diagnostic code recurred. 4. Install the good thermocouple. Repair: Remove the jumper wire. D. This is normal. Repair: Perform the following procedure: 1. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Observe the “Active Diagnostic” screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Disconnect the connector for the thermocouple with the open circuit diagnostic code. Proceed to Test Step 7. E. Note: When the J40/P40 connectors are disconnected. 2. Do not install the good thermocouple into the engine yet. B. When the jumper wire was removed. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Expected Result: When the jumper wire was installed. D. Thoroughly inspect the J40/P40 connectors. There is probably an open circuit in the harness between the ITSM and the connector for the thermocouple. If the open circuit diagnostic code becomes active again. Disconnect the suspect thermocouple and connect a thermocouple that is known to be good. Turn the engine control switch to the STOP position. The ITSM and the harness are OK. B. C. If the diagnostic code is not generated with the good thermocouple. Create a Short Circuit A. Reconnect the thermocouple’s connectors and check for an active open circuit diagnostic code. an active “open circuit” diagnostic code will be generated for all of the thermocouples that are associated with the ITSM. Switch the circuit breaker for the ECM OFF. E. Ensure that the connectors and the seals are in good condition. the “open circuit” diagnostic code recurred. Turn the engine control switch to the OFF/RESET position. Remove the jumper wire and observe the “Active Diagnostic” screen. Test Step 6. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Switch the 16 amp circuit breaker for the ECM ON. a “short circuit” diagnostic code was generated. a “short circuit” diagnostic code was generated. F. Switch the 16 amp circuit breaker for the ECM OFF. . Thoroughly inspect the thermocouple’s connectors. C. Ensure that the connectors are in good condition. Access the “Active Diagnostic” screen for the ITSM on Cat ET. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch terminals on both ends. there is a problem with the thermocouple. STOP. the “open circuit” diagnostic code recurred. Results: • No – When the jumper wire was installed.332 Troubleshooting Section • No – There is not an active “open circuit” diagnostic code for the disconnected thermocouple. Clear the logged diagnostic codes. Fabricate a jumper wire that is approximately 100 to 150 mm (4 to 6 inches) long with Deutsch terminals on both ends. Turn the engine control switch to the OFF/RESET position. Results: 4. Observe the “Active Diagnostic” screen. an “open circuit” diagnostic code was generated for the suspect sensor. Replace the harness. “Replacing the ITSM”. Repair the harness. See Troubleshooting. 3. Oxygen Sensor Buffer Supply SMCS Code: 1901-038 System Operation Description: The oxygen buffer uses an oxygen sensor in order to measure the concentration of oxygen in the engine exhaust. H. See Troubleshooting. Repair: Remove the jumper wire. refer to Illustration 191. G. Install the jumper wire into the terminals for the suspect sensor on the J40 connector. Turn the engine control switch to the STOP position. This keeps the voltage between the positive VS terminal and negative VS terminal relatively constant. Observe the “Active Diagnostic” screen. Allow a minimum of 30 seconds for any diagnostic codes to be generated. Switch the circuit breaker for the ECM ON. an “open circuit” diagnostic code was not generated for the suspect sensor. Verify that no diagnostic codes are generated with the good ITSM. Expected Result: When the J40/P40 connectors were disconnected. Turn the engine control switch to the OFF/RESET position. Clear the logged diagnostic codes and verify that the problem is resolved. STOP. Switch the 16 amp circuit breaker for the ECM OFF.5 amperes and 10. There is a problem in the harness between the ITSM and the connector for the suspect thermocouple. When the jumper wire was installed. when possible. Disconnect the P18 connector from the ITSM. Allow a minimum of 30 seconds for any diagnostic codes to be generated. a “short circuit” diagnostic code was not generated. STOP. This signal is supplied to terminal 67 of the ECM J2/P2 connector. The buffer converts the current to a Pulse Width Modulated signal (PWM) with a nominal frequency of 500 Hz. if necessary. The buffer provides a power supply of 1. Remove the jumper wire. 6. “Replacing the ITSM”. Switch the circuit breaker for the ECM OFF. Turn the engine control switch to the STOP position.5 volts between the positive VH and negative VH terminals in order to power a resistive type of heater in the oxygen sensor. 7. i01747684 • Yes – When the J40/P40 connectors were disconnected. When the jumper wire was installed. an “open circuit” diagnostic code was generated for the suspect sensor. Verify that the diagnostic code recurs with the original ITSM. a “short circuit” diagnostic code was generated. Repair: Perform the following procedure: 1. Turn the engine control switch to the OFF/RESET position. . The oxygen buffer receives power from terminal 13 of the J2/P2 connector on the ECM. Make sure that the good ITSM has the correct flash programming. the buffer regulates the current from the positive IP terminal to the negative IP terminal. Connect an ITSM that is known to be good to the P18 plug from the terminal box. Turn the engine control switch to the OFF/RESET position. Reconnect the P40 plug to the original ITSM. • No – Either of the following results or both of the results occurred: When the J40/P40 connectors were disconnected. Connect the P40 plug to the good ITSM.333 Troubleshooting Section F. For identification of the terminals. The return circuit is through terminal 23 of the J2/P2 connector. 8. The ITSM is OK. a “short circuit” diagnostic code was generated. The current will vary from 0 mA at 0 percent of oxygen to approximately 8. Switch the 16 amp circuit breaker for the ECM ON. Switch the circuit breaker for the ECM OFF. The oxygen buffer measures this current. Reconnect the original ITSM to the P18 plug from the terminal box. When the jumper wire was installed. 2. 9. 5. Replace the ITSM. The amount of current is a measure of the concentration of oxygen in the exhaust gases.7 mA at 21 percent of oxygen. After this heater raises the temperature of the sensing element to 700 C (1292 F). 25 in order to obtain the reading that is displayed on Cat ET. This will cause the PWM signal from the oxygen buffer to change to a duty cycle of approximately 15 percent. The ECM will generate a diagnostic code that can be viewed with the Caterpillar Electronic Technician (ET). The wet reading is multiplied by a conversion factor of approximately 1. the buffer assumes that the oxygen sensor has failed or the sensor is disconnected from the oxygen buffer. The oxygen buffer is equipped with a diagnostic circuit that detects the current which is provided to the heating element of the oxygen sensor.334 Troubleshooting Section The duty cycle of the PWM signal has a range of 30 to 65 percent. These values vary slightly between different buffers and sensors. Problems with the circuit for the oxygen signal must be repaired as soon as possible because of the effects on engine performance and emissions. Calibration of the buffer is also required after every 1500 service hours. • Maintain desired emissions levels. The ECM uses the signal of the percent of oxygen for two functions: • Make corrections for variation of fuel BTU. The 30 percent corresponds to 0 percent of oxygen and the 65 percent corresponds to 21 percent of oxygen. Some applications may require more frequent calibration or less frequent calibration. If this current is too low. . This allows oxygen readings from Cat ET to be compared to dry readings from an emissions analyzer. The ECM interprets this condition as a diagnostic condition. a diagnostic code is activated and compensation for fuel quality is disabled. The sensor provides a wet reading that is slightly lower than a dry reading. Calibration is required for every new buffer. If an incorrect signal is detected by the ECM. Illustration 202 g00894811 Note: For the following steps. Turn the engine control switch to the OFF/RESET position. Inspect the Electrical Connectors and Wiring During operation. (1) ECM connectors J2/P2 (2) J10/P10 connectors for the harness from the oxygen buffer B.335 Troubleshooting Section Illustration 201 Schematic of the circuit for the oxygen buffer and the oxygen sensor g00894718 Test Step 1. Do not touch the sensor during engine operation. Check the torque of the Allen head screw for the ECM connector. Switch the 16 amp circuit breaker for the ECM OFF. the oxygen sensor may reach temperatures that exceed 700 C (1292 F). refer to Troubleshooting. A. Severe personal injury and property damage will result from contact with a hot oxygen sensor. or testing. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Thoroughly inspect the following connections: • ECM J2/P2 connectors • J10/P10 connectors on the terminal box a. calibration. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. Allow the sensor to cool before moving the sensor. . “Inspecting Electrical Connectors”. Make sure that the connections are properly fastened. Expected Result: All of the connectors. STOP. . Ensure that all of the seals are properly installed. and sockets are connected properly.336 Troubleshooting Section Illustration 203 Harness side of the ECM P2 connector (13) +24 Volt supply for the buffer (23) Return (53) Shield (67) Oxygen signal (PWM) g00894825 Illustration 205 g00894840 (1) Oxygen sensor (2) Connectors for the oxygen sensor (3) Oxygen buffer (4) J651/P651 connectors for the harness from the terminal box (5) J652/P652 connectors for the harness to the oxygen sensor c. The connectors and the wiring are free of corrosion. Verify that the repair has eliminated the problem. Proceed to Test Step 2. Results: Illustration 204 Harness side of the P10 connector (K) +24 Volt supply for the buffer (H) Shield (L) Return (M) Oxygen signal (PWM) g00894829 • OK – The components are in good condition with proper connections. abrasion. • Not OK – The components are not in good condition and/or at least one connection is improper. b. if necessary. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen buffer. pins. Repair: Perform the necessary repairs and/or replace parts. and pinch points. Disconnect the P651 connector from the oxygen buffer. the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. E. Note: After you exit the “Override Parameters” screen. Switch the 16 amp circuit breaker for the ECM ON. Check the Supply Voltage for the Oxygen Buffer A. Select a “New Value” of “On” and then select “OK”. STOP. Select “Oxygen Sensor Override” under the “Description” column. Turn the engine control switch to the STOP position. D. Access the “Diagnostic Override” screen of Cat ET. F. Allow a minimum of ten seconds for the diagnostic codes to be activated. The oxygen buffer is now ON. G. The status of the “Oxygen Sensor Override” should change to “On”. Results: Illustration 206 (1) P651 connector g00894874 B. • Logged 1088-06 diagnostic code – The supply for • No codes – The supply for the buffer is OK. Select “Change” in the lower left corner of the screen. If the following codes are logged. A popup window with the title “Change Parameter Value” will appear. Connect Cat ET to the service tool connector on the terminal box. E. Select a “New Value” of “On” and then select “OK”. the buffer has a short circuit to ground. • Logged 1088-05 diagnostic code – The supply for the buffer has an open circuit or a short circuit to the +Battery side. Switch the 16 amp circuit breaker for the ECM OFF. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Proceed to Test Step 5. Switch the 16 amp circuit breaker for the ECM ON. Access the “Diagnostic Override” screen of Cat ET. Select “Change” in the lower left corner of the screen. Turn the engine control switch to the STOP position. F.337 Troubleshooting Section Test Step 2. C. Turn the engine control switch to the OFF/RESET position. . the “Value” of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. Note: After you exit the “Override Parameters” screen. Access the “Logged Diagnostic Codes” screen again. Proceed to Test Step 3. Access the “Logged Diagnostic Codes” screen on Cat ET. clear the codes: Test Step 3. The oxygen buffer is now ON. • 1088-05 Oxygen Sensor Power Supply open circuit • 1088-06 Oxygen Sensor Power Supply short to ground C. Look for the 1088-05 or 1088-06 diagnostic codes again. D. Wait for 65 seconds. B. Expected Result: A 1088-05 or 1088-06 diagnostic code is logged. The “Value” of the “Oxygen Sensor Override” should change to “On”. Check for Diagnostic Codes for the Oxygen Buffer A. Follow the instructions in Troubleshooting. Check the Voltage at the Terminal Box Illustration 207 P651 harness connector for the oxygen buffer (A) +24 Volt supply (B) Return g00897352 G. The buffer is receiving the correct supply voltage.338 Troubleshooting Section Test Step 4. Expected Result: The supply voltage for the oxygen buffer is greater than 18 VDC. Results: Illustration 208 g00894848 • OK – The supply voltage for the oxygen buffer is greater than 18 VDC. “Oxygen Sensor Calibrate”. Proceed to Test Step 4. Illustration 209 Side view of the terminal box and the J10 connector g00894854 B. • Not OK – The supply voltage is less than 18 VDC. After you replace the buffer. calibrate the oxygen sensor. Repair: Reconnect the connectors. Replace the oxygen buffer. . If the problem is not resolved. STOP. (1) P10 connector for the harness from the oxygen buffer A. Measure the voltage between terminals “K” and “L” on the J10 connector. Measure the voltage between terminal “A” and terminal “B” of the P651 connector on the harness. turn the engine control switch to the OFF/RESET position and switch the 16 amp circuit breaker for the ECM OFF. Expected Result: The voltage is greater than 18 VDC. Determine whether the diagnostic code recurs. Disconnect the P10 connector from the terminal box. 339 Troubleshooting Section Results: • OK – The voltage is greater than 18 VDC. There is a problem with the harness between the terminal box and the oxygen buffer. Repair: Repair the harness, when possible. Replace the harness, if necessary. STOP. The oxygen buffer is now ON. The status of the “Oxygen Sensor Override” should change to “On”. Wait for 65 seconds. Note: After you exit the “Override Parameters” screen, the status of the oxygen sensor is automatically changed to “OFF” when the engine control switch is not in the START position. H. Access the “Logged Diagnostic Codes” screen again. Look for the 1088-06 diagnostic code. Expected Result: There is a logged 1088-06 diagnostic code. Results: • Not OK – The voltage is less than 18 VDC. Proceed to Test Step 6. Test Step 5. Disconnect the Oxygen Buffer and Check for a Short to Ground A. Turn the engine control switch to the OFF/RESET position. • Yes – The supply for the buffer still has a short circuit. Proceed to Test Step 7. • No – The supply for the buffer does not have a short circuit when the buffer is disconnected. The harness to the buffer is OK. Repair: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Inspect the buffer J651 connector for corrosion and/or damage. Make repairs, as needed. If the condition is not resolved, replace the buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, “Oxygen Sensor - Calibrate”. STOP. Illustration 210 (1) P651 connector g00894874 Test Step 6. Create a Short Circuit in the Harness A. Turn the engine control switch to the OFF/RESET position. B. Disconnect the P651 connector from the oxygen buffer. C. Turn the engine control switch to the STOP position. D. Access the “Logged Diagnostic Codes” screen on Cat ET. If a 1088-06 diagnostic code is logged, clear the code. E. Access the “Diagnostic Override” screen of Cat ET. Select “Diagnostics/Diagnostic Tests/Override Parameters”. F. Select “Change” in the lower left corner of the screen. G. Select a “New Value” of “On” and then select “OK”. Wait for a minimum of 65 seconds. 340 Troubleshooting Section The oxygen buffer is now ON. The status of the “Oxygen Sensor Override” should change to “On”. Wait for 65 seconds. Note: After you exit the “Override Parameters” screen, the status of the oxygen sensor is automatically changed to “OFF” when the engine control switch is not in the START position. I. Access the “Logged Diagnostic Codes” screen again. Look for the 1088-05 diagnostic code. Expected Result: The 1088-05 diagnostic code is not logged when the circuit for the supply to the buffer is shorted by the jumper wire. Results: • OK – The 1088-05 diagnostic code is not logged Illustration 211 (1) P651 connector g00894874 when the circuit for the supply to the buffer is shorted by the jumper wire. The harness and the ECM are OK. Repair: Perform the following steps: 1. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 2. Inspect the J651 connector on the oxygen buffer for corrosion and other damage. Make repairs, as needed. B. Disconnect the P651 connector from the oxygen buffer. Illustration 212 P651 harness connector for the oxygen buffer (A) +24 volt supply (B) Return g00894897 If the condition is not resolved, replace the oxygen buffer. Be sure to calibrate the oxygen sensor after you replace the buffer. Refer to Troubleshooting, “Oxygen Sensor - Calibrate”. STOP. C. Install the ends of a jumper wire into terminals “A” and “B” of the P651 connector. D. Turn the engine control switch to the STOP position. E. Access the “Logged Diagnostic Codes” screen on Cat ET. If a 1088-05 diagnostic code is logged, clear the code. F. Access the “Diagnostic Override” screen of Cat ET. Select “Diagnostics/Diagnostic Tests/Override Parameters”. G. Select “Change” in the lower left corner of the screen. H. Select a “New Value” of “On” and then select “OK”. Wait for 65 seconds. • Not OK – The 1088-05 diagnostic code is logged when the circuit for the supply to the buffer is shorted by the jumper wire. The ECM does not detect the short circuit. Proceed to Test Step 7. Test Step 7. Check the Supply for the Oxygen Buffer at the ECM A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. 341 Troubleshooting Section Note: After you exit the “Override Parameters” screen, the status of the oxygen sensor is automatically changed to “OFF” when the engine control switch is not in the START position. Illustration 213 Harness side of the ECM P2 connector (13) Supply for the buffer (23) Return g00894970 Illustration 214 g00894979 B. Use a 151-6320 Wire Removal Tool to remove terminals (P2-13) and (P2-23) of the ECM P2 connector. This will create an open circuit between the buffer and the ECM. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. D. Access the “Logged Diagnostic Codes” screen on Cat ET. If a 1088-05 or 1088-06 diagnostic code is logged, clear the code. E. Access the “Diagnostic Override” screen of Cat ET. Select “Diagnostics/Diagnostic Tests/Override Parameters”. F. Select “Change” in the lower left corner of the screen. G. Select a “New Value” of “On” and then select “OK”. Wait for a minimum of 65 seconds. The oxygen buffer is now ON. The status of the “Oxygen Sensor Override” should change to “On”. Wait for 65 seconds. Harness side of the ECM P2 connector (2) Jumper wire (13) Supply for the buffer (23) Return H. Install a jumper wire (2) into terminals (P2-13) and (P2-23). Pull on the jumper wire in order to verify proper installation. This will create a short circuit between the supply and the return of the buffer circuit. I. Access the “Logged Diagnostic Codes” screen again. Allow a minimum of ten seconds for any diagnostic codes to be activated. Look for the 1088-05 or 1088-06 diagnostic code. Expected Result: When an open circuit was created, a 1088-05 diagnostic code was activated. When a short circuit was created, a 1088-06 diagnostic code was activated. 342 Troubleshooting Section Results: i01748331 • Yes – When an open circuit was created in the P2 connector, a 1088-05 diagnostic code was activated. When a short circuit was created with the jumper wire in the P2 connector, a 1088-06 diagnostic code was activated. The ECM is OK. There is a problem in the harness between the ECM and the oxygen buffer. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. Repair the harness, when possible. Replace the harness, if necessary. STOP. Oxygen Sensor Signal SMCS Code: 1901-038 System Operation Description: The oxygen sensor is used by the oxygen buffer in order to measure the concentration of oxygen in the engine exhaust. The oxygen buffer receives power from terminal 13 of the J2/P2 connector on the Electronic Control Module (ECM). The return circuit is through terminal 23 of the J2/P2 connector. The buffer provides a power supply of 1.5 amperes and 10.5 volts between the positive VH and negative VH terminals in order to power a resistive type of heater in the oxygen sensor. After this heater raises the temperature of the sensing element to 700 C (1292 F), the buffer regulates the current from the positive IP terminal to the negative IP terminal. This keeps the voltage between the positive VS terminal and negative VS terminal relatively constant. The amount of current is a measure of the concentration of oxygen in the exhaust gases. The current will vary from 0 mA at 0 percent of oxygen to approximately 8.7 mA at 21 percent of oxygen. The oxygen buffer measures this current. The buffer converts the current to a Pulse Width Modulated signal (PWM) with a nominal frequency of 500 Hz. This signal is supplied to terminal 67 of the ECM J2/P2 connector. The duty cycle of the PWM signal has a range of 30 to 60 percent. The 30 percent corresponds to 0 percent of oxygen and the 60 percent corresponds to 21 percent of oxygen. These values vary slightly between different buffers and sensors. Calibration is required for every new buffer. Calibration of the buffer is also required after every 1500 service hours. Some applications may require more frequent calibration or less frequent calibration. The oxygen buffer is equipped with a diagnostic circuit that detects the current which is provided to the heating element of the oxygen sensor. If this current is too low, the buffer assumes that the oxygen sensor has failed or the sensor is disconnected from the oxygen buffer. This will cause the PWM signal from the oxygen buffer to change to a duty cycle of approximately 15 percent. The ECM interprets this condition as a diagnostic condition. The ECM will generate a diagnostic code that can be viewed with the Caterpillar Electronic Technician (ET). • No – The ECM did not detect an open circuit and/or a short circuit. There may be a problem with the ECM. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. Reinstall the terminals into P2-12 and P2-23. Pull on the wires in order to verify proper installation of the terminals. It is unlikely that the ECM has failed. Exit this procedure and perform this procedure again. If the problem is not resolved, perform the following steps: Temporarily install a new ECM. Refer to Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM, install the original ECM and verify that the problem returns. If the new ECM operates correctly and the original ECM does not operate correctly, replace the original ECM. Refer to Troubleshooting, “Replacing the ECM”. STOP. 343 Troubleshooting Section The sensor provides a wet reading that is slightly lower than a dry reading. The wet reading is multiplied by a conversion factor of approximately 1.25 in order to obtain the reading that is displayed on Cat ET. This allows oxygen readings from Cat ET to be compared to dry readings from a meter such as a Teledyne meter. The ECM uses the signal of the percent of oxygen for two functions: • Make corrections for variation of fuel BTU. • Maintain desired emissions levels. If an incorrect signal is detected by the ECM, a diagnostic code is generated and compensation for fuel quality is disabled. Problems with the circuit for the oxygen signal must be repaired as soon as possible because of the effects on engine performance and emissions. Illustration 215 Schematic of the circuit for the oxygen sensor and the oxygen buffer g00894718 Test Step 1. Inspect the Electrical Connectors and Wiring A. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Note: For the following steps, refer to Troubleshooting, “Inspecting Electrical Connectors”. During operation, the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Severe personal injury and property damage will result from contact with a hot oxygen sensor. Do not touch the sensor during engine operation, calibration, or testing. Allow the sensor to cool before moving the sensor. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. 344 Troubleshooting Section Illustration 218 Harness side of the P10 connector (K) +24 volt supply for the buffer (H) Return (L) Return (M) Oxygen signal Illustration 216 g00894811 g00894829 (1) ECM connectors J2/P2 (2) J10/P10 connector for the harness from the oxygen buffer b. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen sensor. B. Thoroughly inspect the following connections: • ECM J2/P2 connectors • J10/P10 connectors on the terminal box a. Check the torque of the Allen head screw for the ECM connector. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Illustration 219 g00894840 Illustration 217 Harness side of the ECM P2 connector (13) +24 volt supply for the buffer (23) Return (53) Return (67) Oxygen signal g00894825 (1) Oxygen sensor (2) Connectors for the oxygen sensor (3) Oxygen buffer (4) J651/P651 connectors for the harness from the terminal box (5) J652/P652 connectors for the harness to the oxygen sensor c. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM. 345 Troubleshooting Section Expected Result: All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. Results: D. Access the “Diagnostic Override” screen of Cat ET. Select “Diagnostics/Diagnostic Tests/Override Parameters”. E. Select “Change” in the lower left corner of the screen. F. Select a “New Value” of “On” and then select “OK”. The oxygen buffer is now ON. The status of the “Oxygen Sensor Override” should change to “On”. Wait for 65 seconds. Note: After you exit the “Override Parameters” screen, the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. • OK – All of the connectors, pins, and sockets are connected properly. The connectors and the wiring are free of corrosion, abrasion, and pinch points. The components are in good condition with proper connections. Proceed to Test Step 2. • Not OK – At least one of the connectors, pins, or sockets are not connected properly. At least one of the connectors and/or the wiring has corrosion, abrasion, and/or pinch points. Repair: Perform the necessary repairs and/or replace parts, if necessary. STOP. Test Step 2. Measure the Supply Voltage for the Heater at the Connector for the Oxygen Sensor A. Connect Cat ET to the service tool connector on the terminal box. Illustration 221 Harness connector for the oxygen sensor (A) VH+ (B) VH- g00895047 G. Measure the voltage between terminals “A” and “B” on the harness connector for the oxygen buffer. Expected Result: Illustration 220 (1) Connector for the oxygen sensor g00895028 The voltage is greater than 9 VDC. Results: B. Disconnect the oxygen sensor from the engine harness. C. Switch the 16 amp circuit breaker for the ECM ON. Turn the engine control switch to the STOP position. • OK – The voltage is greater than 9 VDC. The correct supply voltage for the heater of the oxygen sensor is present at the harness connector. Proceed to Test Step 3. Select “Diagnostics/Diagnostic Tests/Override Parameters”.Calibrate”. Expected Result: At least one of the above diagnostic codes are logged. Note: After you exit the “Override Parameters” screen. Be sure to calibrate the oxygen sensor after you replace the buffer. The supply voltage for the heater of the oxygen sensor is not present at the harness connector. D. Repair: Refer to Troubleshooting. The oxygen buffer is now ON. Switch the 16 amp circuit breaker for the ECM OFF. 2. J2/P2. • Logged 1086-09 – A 1086-09 diagnostic code is active. 3. • Logged 1088-05 or 1088-06 Diagnostic Code – There is a problem with the supply voltage for the oxygen buffer. Test Step 4. Proceed to Test Step 4. If the connectors and the harness appear to be OK. Make repairs. “Oxygen Sensor . STOP. “Oxygen Sensor Buffer Supply”. as needed. STOP. clear the codes: • 1086-09 Oxygen Sensor Element not communicating on link • 1087-03 Oxygen Buffer Module short to +batt • 1087-08 Oxygen Buffer Module noisy signal • 1088-05 Oxygen Sensor Power Supply open circuit • 1088-06 Oxygen Sensor Power Supply short to ground B. B. Select a “New Value” of “On” and then select “OK”. 1087-08. “Inspecting Electrical Connectors”. the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. Access the “Diagnostic Override” screen of Cat ET. Access the “Logged Diagnostic Codes” screen again. Check for Diagnostic Codes A. The status of the “Oxygen Sensor Override” should change to “On”. Disconnect the following connectors: J1/P1. E. Turn the engine control switch to the OFF/RESET position. Refer to Troubleshooting. install an oxygen sensor that is known to be good. 1. Test Step 3. Turn the engine control switch to the OFF/RESET position. Verify that the condition is resolved with the new oxygen sensor. Select “Change” in the lower left corner of the screen. If the condition is not resolved.346 Troubleshooting Section • Not OK – The voltage is less than 9 VDC. Thoroughly inspect all of the connectors for corrosion and/or moisture. Inspect the connections and the harness from the oxygen buffer to the oxygen sensor. Proceed to Test Step 6. Check the Harness for Open Circuits and Short Circuits A. replace the oxygen buffer. STOP. and 1088-06. Make repairs. Refer to Troubleshooting. Repair: Perform the following steps: . if necessary. and J651/P651. Calibrate the oxygen sensor. 1088-05. Look for corrosion and other damage. 4. Wait for 65 seconds. • No Codes – The circuit for the oxygen sensor is OK. “Oxygen Sensor . Results: • Logged 1087-03 or 1087-08 Diagnostic Code – The PWM signal is noisy or the signal is missing. Access the “Logged Diagnostic Codes” screen on Cat ET.Calibrate”. C. Look for the following diagnostic codes again: 1086-09. Refer to Troubleshooting. 1087-03. If the following codes are logged. Switch the 16 amp circuit breaker for the ECM OFF. 000 ohms.000 ohms. Check for a short circuit. if necessary. Replace the harness. Reconnect the J1/P1. Use an ohmmeter to check for continuity between the terminals that are listed in Table 33. Remove the jumper wire from the P651 connector. Illustration 224 g00895873 . Expected Result: The resistance between terminals 67 and 23 of the P2 connector is less than 2 ohms. J2/P2. Test Step 5. Results: • OK – The resistance between terminals 67 and 23 of the P2 connector is less than 2 ohms. All of the other ohmmeter readings are greater than 20. Isolate the Oxygen Signal and Check the Signal at the ECM A. Install the ends of a jumper wire into terminals “B” and “C” of the P651 connector. STOP. Table 33 Points to Check P2-67 Signal (1) P2-67 Signal (2) P2-23 Return J1-69 −battery terminal Engine block P2-13 supply All of the remaining terminals in the P2 connector (1) (2) Illustration 223 g00895866 Check for continuity. B. Use a 151-6320 Wire Removal Tool to remove terminal P2-67 from the ECM P2 connector. All of the other ohmmeter readings are greater than 20.347 Troubleshooting Section Illustration 222 (B) Return (C) Oxygen signal g00895813 P651 harness connector for the terminal box to the oxygen buffer C. Repair: Repair the harness. and J651/P651 connectors. D. when possible. • Not OK – There is a problem with the harness between the terminal box and the oxygen buffer. Proceed to Test Step 5. replace the oxygen sensor. D. Connect one lead of the multimeter to terminal that was removed from P2-67. Turn the engine control switch to the OFF/RESET position. G.348 Troubleshooting Section C. Install an oxygen buffer that is known to be good. Reinstall the wire into terminal 67 of the ECM P2 connector. Measure the signal between the wire that was removed from terminal 67 and terminal 23 (return) of the ECM P2 connector. Reinstall the wire into terminal 67 of the ECM P2 connector. Select “Change” in the lower left corner of the screen. Remove the 7X-1710 Multimeter Probe from terminal P2-23. However. Wait for 65 seconds. Note: Do not remove the wire from terminal 23 of the P2 connector. If either of the codes are present. Pull on the wire in order to verify proper installation of the terminal. . Test Step 6. 4. Repair: Perform the following steps: 1. Use a 7X-1710 Multimeter Probe to make contact with terminal 23. F. Verify that the condition has been resolved. Turn ON the oxygen buffer. 4. • Not OK – The harness is OK. 3. “Oxygen Sensor . “Replacing the ECM”. Connect the other multimeter lead to the 7X-1710 Multimeter Probe. 5. E. the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. Be sure to calibrate the oxygen sensor after you replace the buffer and/or the sensor. Refer to Troubleshooting. 3. Note: After you exit the “Override Parameters” screen. • OK – A valid oxygen signal is present at the loose wire. Turn the engine control switch to the STOP position. Remove the 7X-1710 Multimeter Probe from terminal P2-23. The signal for the frequency is between 375 and 625 Hz. The status of the “Oxygen Sensor Override” should change to “On”. Turn the engine control switch to the STOP position. the Repair: Perform the following steps: oxygen signal is not present at the loose wire. I. The oxygen buffer is now ON. Access the “Diagnostic Override” screen of the Cat ET. 5. If the condition is not resolved.Calibrate”. STOP. Clear all of the logged diagnostic codes. H. Pull on the wire in order to verify proper installation of the terminal. Insert a 7X-1710 Multimeter Probe along terminal P2-23 of the ECM P2 connector. J. Select “Diagnostics/Diagnostic Tests/Override Parameters”. STOP. Measure the Supply Voltage for the Heater at the Oxygen Buffer A. Results: 2. Use Cat ET to check for logged 1087-03 and 1087-08 diagnostic codes. 1. Expected Result: The signal for the duty cycle is between 20 and 90 percent. 2. replace the ECM according to Troubleshooting. Turn the engine control switch to the OFF/RESET position. Select a “New Value” of “On” and then select “OK”. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. Use a multimeter that is capable of measuring the duty cycle and the frequency. 6. Switch the 16 amp circuit breaker for the ECM ON. Check the Supply Voltage for the Oxygen Buffer A. • Not OK – The voltage is less than 9 VDC. D. when possible. . F. Note: After you exit the “Override Parameters” screen. the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position.349 Troubleshooting Section Illustration 225 g00895063 Illustration 226 J652 connector on the oxygen buffer (A) VH+ (B) VH− g00895067 (1) P652 connector for the harness to the oxygen sensor B. if necessary. Expected Result: The voltage is greater than 9 VDC. Select a “New Value” of “On” and then select “OK”. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Replace the harness. E. C. The oxygen buffer is now ON. Test Step 7. Select “Change” in the lower left corner of the screen. Turn the engine control switch to the OFF/RESET position. The correct supply voltage for the heater of the oxygen sensor is not present at the oxygen buffer. Repair: Repair the harness. The correct supply voltage for the heater of the oxygen sensor is present at the oxygen buffer. STOP. The status of the “Oxygen Sensor Override” should change to “On”. Access the “Diagnostic Override” screen of Cat ET. Results: • OK – The voltage is greater than 9 VDC. Turn the engine control switch to the STOP position. Measure the voltage between terminals J652-A and J652-B on the oxygen buffer. G. Proceed to Test Step 7. Disconnect the P652 connector from the oxygen buffer. Wait for 65 seconds. There is a problem with the harness for the oxygen sensor. g00894897 Illustration 228 P651 harness connector for the oxygen buffer (A) +24 volt supply (B) Return . Repeat Test Step 2. Turn the engine control switch to the STOP position. replace the oxygen buffer. If the condition is not resolved. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Select a “New Value” of “On” and then select “OK”. the buffer is not sending the supply to the heater for the oxygen sensor. the status of the “Oxygen Sensor Override” is automatically changed to “OFF” when the engine control switch is not in the START position. Access the “Diagnostic Override” screen of Cat ET. Illustration 227 (1) P651 connector g00895883 • Not OK – The oxygen buffer is not receiving the correct supply voltage for the heater in the oxygen sensor. Repair: Perform the following procedures: Reconnect the J651/P651 connectors for the oxygen buffer.350 Troubleshooting Section G. Disconnect the P651 connectors from the oxygen buffer. Expected Result: The voltage is greater than 18 VDC. B. Test Step 8. E. Select “Change” in the lower left corner of the screen. The oxygen buffer is now ON. Wait for 65 seconds. Disconnect the P10 connector from the terminal box. The status of the “Oxygen Sensor Override” should change to “On”. Results: • OK – The oxygen buffer is receiving the correct supply voltage for the heater in the oxygen sensor. Proceed to Test Step 8. Note: After you exit the “Override Parameters” screen. D. However. C. Be sure to calibrate the oxygen sensor after you replace the buffer. Measure the voltage between terminals “A” and “B” of the P651 connector on the harness. Check the Supply for the Oxygen Buffer at the ECM Illustration 229 g00894848 (1) P10 connector for the harness from the oxygen buffer A. F. • Not OK – The voltage is less than 18 VDC. Wait for 65 seconds. The oxygen buffer is now ON. D. Measure the voltage between terminals “K” and “L” on the J10 connector. STOP. The status of the “Oxygen Sensor Override” should change to “On”. Disconnect the P651 connector from the oxygen buffer. Create a Short Circuit in the Harness A. Turn the engine control switch to the OFF/RESET position. • OK – The voltage is greater than 18 VDC. Select “Change” in the lower left corner of the screen. G. if necessary. There is a problem with the harness between the terminal box and the oxygen buffer. Select a “New Value” of “On” and then select “OK”. C. Wait for 65 seconds. H. Replace the harness. Select “Diagnostics/Diagnostic Tests/Override Parameters”. E. Illustration 232 P651 harness connector for the oxygen buffer (A) +24 volt supply (B) Return g00894897 Repair: Repair the harness.351 Troubleshooting Section Illustration 230 Side view of the terminal box and the J10 connector g00894854 Illustration 231 (1) P651 connector g00894874 B. Access the “Logged Diagnostic Codes” screen on Cat ET. . Expected Result: The voltage is greater than 18 VDC. Results: B. Access the “Diagnostic Override” screen of Cat ET. clear the code. Proceed to Test Step 9. F. If a 1088-05 diagnostic code is logged. when possible. Test Step 9. Install the ends of a jumper wire into terminals “A” and “B” of the P651 connector. Turn the engine control switch to the STOP position. Refer to Troubleshooting. If a 1088-05 or 1088-06 diagnostic code is logged. Access the “Logged Diagnostic Codes” screen again. Expected Result: The 1088-05 diagnostic code is not logged when the circuit for the supply to the buffer is shorted by the jumper wire. Access the “Diagnostic Override” screen of Cat ET. F. The ECM does not detect the short circuit. Switch the 16 amp circuit breaker for the ECM OFF. Switch the 16 amp circuit breaker for the ECM OFF. “Oxygen Sensor . Inspect the J651 connector on the oxygen buffer for corrosion and other damage. Results: • OK – The 1088-05 diagnostic code is not logged when the circuit for the supply to the buffer is shorted by the jumper wire. Look for the 1088-05 diagnostic code. Repair: Perform the following steps: 1. the status of the oxygen sensor is automatically changed to “OFF” when the engine control switch is not in the START position. If the condition is not resolved. STOP. Be sure to calibrate the oxygen sensor after you replace the buffer. Turn the engine control switch to the OFF/RESET position. The status of the “Oxygen Sensor Override” should change to “On”. Select a “New Value” of “On” and then select “OK”. Access the “Logged Diagnostic Codes” screen on Cat ET. Check the Supply for the Oxygen Buffer at the ECM A. Turn the engine control switch to the STOP position. Make repairs. Use a 151-6320 Wire Removal Tool to remove terminals (P2-13) and (P2-23) from the ECM P2 connector. C. 2. Wait for a minimum of 65 seconds.Calibrate”. . Turn the engine control switch to the OFF/RESET position. D. I. G.352 Troubleshooting Section Note: After you exit the “Override Parameters” screen. Wait for 65 seconds. Test Step 10. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Select “Change” in the lower left corner of the screen. The oxygen buffer is now ON. replace the oxygen buffer. This will create an open circuit between the buffer and the ECM. E. • Not OK – The 1088-05 diagnostic code is logged when the circuit for the supply to the buffer is shorted by the jumper wire. Proceed to Test Step 10. The harness and the ECM are OK. Illustration 233 Harness side of the ECM P2 connector (13) +24 volt supply (23) Return g00894970 B. clear the code. as needed. Switch the 16 amp circuit breaker for the ECM ON. “Replacing the ECM”. H. Allow a minimum of ten seconds for any diagnostic codes to be activated. Switch the 16 amp circuit breaker for the ECM OFF. It is unlikely that the ECM has failed. Pull on the jumper wire in order to verify proper installation. Reinstall the terminals into P2-12 and P2-23. There may be a problem with the ECM. Refer to Troubleshooting. if necessary. when possible. Install a jumper wire (2) into terminals (P2-13) and (P2-23). Expected Result: When an open circuit was created. a 1088-06 diagnostic code was activated. a 1088-05 diagnostic code was activated. Access the “Logged Diagnostic Codes” screen again. Exit this procedure and perform this procedure again. Look for the 1088-05 or 1088-06 diagnostic code. If the problem is resolved with the new ECM. Refer to Troubleshooting. There is a problem in the harness between the ECM and the oxygen buffer. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. Repair the harness. STOP. perform the following steps: Temporarily install a new ECM. Pull on the wires in order to verify proper installation of the terminals. “Replacing the ECM”. the status of the oxygen sensor is automatically changed to “OFF” when the engine control switch is not in the START position. Results: • Yes – When an open circuit was created in the P2 connector. If the new ECM operates correctly and the original ECM does not operate correctly. • No – The ECM did not detect an open circuit and/or a short circuit. a 1088-06 diagnostic code was activated. When a short circuit was created. Pull on the wires in order to verify proper installation of the terminals. This will create a short circuit between the supply and the return of the buffer circuit. When a short circuit was created with the jumper wire in the P2 connector. . Reinstall the terminals into P2-12 and P2-23. Switch the 16 amp circuit breaker for the ECM OFF. install the original ECM and verify that the problem returns. STOP. Replace the harness. The ECM is OK. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. a 1088-05 diagnostic code was activated.353 Troubleshooting Section Note: After you exit the “Override Parameters” screen. I. Illustration 234 Harness side of the ECM P2 connector (2) Jumper wire (13) +24 volt supply (23) Return g00894979 Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. If the problem is not resolved. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector. replace the original ECM. the prelubrication is disabled. the ECM monitors the engine oil pressure sensor in order to determine whether lubrication has occurred. The ECM uses the input from the prelube pressure switch in order to monitor the lubrication pressure. During the prestart. the prelube pump is energized until the prelube pressure switch closes: For the prelube system to work. • The emergency stop switch is open. “ECM Start/Stop Output”. see Troubleshooting. The pump will operate until one of these conditions occur: J1-30 and J1-31 are connected to the prelube pressure switch via the J12/P12 connectors on the terminal box. For the actual wiring. the Electronic Control Module (ECM) can energize the prelube pump before cranking the engine in order to provide lubrication to the engine bearings. the prelube pump can continue to operate for a programmable period of time (“Engine Pre-Lube Time Out Period”). Under the following circumstances. The range for the “Engine Pre-Lube Time Out Period” is 30 to 300 seconds. J1-56 is connected to the manual prelube switch via the J9/P9 connectors on the terminal box. The J12/P12 and J9/P9 connectors are not shown. Closure of the prelube pressure switch indicates that the lubrication pressure is acceptable. Illustration 235 Schematic of the prelube system g00895116 • The manual prelube switch is closed.3 ± 0. The engine will crank without the prelubrication. refer to the schematic for the engine electrical system. Check the “Service/Configuration” screen on the Caterpillar Electronic Technician (ET). The “A” and “B” contacts of the prelube pressure switch open at a pressure of 7 kPa (1 psi). Closure of the pressure switch indicates that sufficient oil pressure has been achieved. • The engine speed is zero. The pump is de-energized when the process of prelubrication is completed. If the prelube pressure switch is closed before the prestart. The “A” and “B” contacts of the prelube pressure switch close at a pressure of 9 ± 3 kPa (1. If the ECM does not detect closure of the pressure switch within the programmed period of time. the “Engine Pre-Lube Time Out Period” must be programmed for a time period between 30 and 300 seconds. After the pressure switch closes. . If the prelubrication does not occur. The starting sequence is terminated. • The manual prelube switch opens.354 Troubleshooting Section i01748491 Prelubrication System SMCS Code: 1319-038 System Operation Description: The prelube system is an option.4 psi). If the “Engine Pre-Lube Time Out Period” is not programmed for a time period between 30 and 300 seconds or if the engine is not equipped with the prelubrication function. an “E233 Low Engine Prelube Pressure” event code is generated. the prelube pump will run for the programmed “Engine Pre-Lube Time Out Period”. Test Step 1. Verify that the time that is programmed for the “Engine Pre-Lube Time Out Period” parameter is between 30 and 300 seconds. Check the Programming of the ECM and Check for the Proper Hardware A. Closure of the manual prelube switch selects the operation of the prelube system. • The prelube pressure switch closes. • The emergency stop switch closes. The following codes cannot be generated: • E233 Low Engine Prelube Pressure • 338-05 Pre-Lube Relay open circuit • 338-06 Pre-Lube Relay short to ground • 339-05 Engine Pre-Lube Pressure Switch open circuit Note: To troubleshoot the circuit for the prelube relay. STOP. All of the components are installed. Program the “Engine Pre-Lube Time Out Period” for zero seconds. Repair: The engine is not equipped for the prelube system. Note: For the following steps. Proceed to Test Step 2. Switch the 16 amp circuit breaker for the ECM OFF. • OK – The “Engine Pre-Lube Time Out Period” parameter is programmed for a time period between 30 and 300 seconds. “Inspecting Electrical Connectors”. Turn the engine control switch to the OFF/RESET position. The wiring is installed. The wiring is installed. The prelube system is an option that can be added. All of the components are installed. Expected Result: The “Engine Pre-Lube Time Out Period” parameter is programmed for a time period between 30 and 300 seconds. • Not OK – The “Engine Pre-Lube Time Out Period” parameter is programmed for a time period between 30 and 300 seconds. Test Step 2. refer to Troubleshooting. Inspect the Electrical Connectors and Wiring A. Repair: Program the “Engine Pre-Lube Time Out Period” for a time period between 30 and 300 seconds. STOP. The wiring is installed.355 Troubleshooting Section B. . None of the components are installed and/or the wiring is not installed. Verify that the following components are installed: Results: • Prelube pump • Prelube pump relay • Prelube pressure switch • Manual prelube switch • Not OK – The “Engine Pre-Lube Time Out Period” parameter is not programmed for a time period between 30 and 300 seconds. All of the components are installed. Illustration 236 Harness sides of the P1 and P2 connectors (P1-30) (P1-31) (P1-56) (P2-12) (P2-22) Prelube pressure switch Digital return Manual prelube switch Prelube relay Return g00895120 C. Verify that the wiring is present in the terminals that are shown in Illustration 236. The connectors and the wiring are free of corrosion.356 Troubleshooting Section Table 34 Terminals for the Wiring of the Prelube System P1-30 Pressure switch P1-56 Manual switch P1-31 Return P2-12 Relay P2-22 Return J9-D Manual switch J12-R Return J12-T Pressure switch J15-A J15-B Illustration 237 (1) ECM connectors J2/P2 (2) ECM connectors J1/P1 (3) J15/P15 connectors for the prelube pump’s solenoid (4) J12/P12 connectors for the prelube pressure switch (5) J9/P9 connectors for the manual prelube switch g00895134 c. STOP. and sockets are connected properly. Check the terminals for the prelube pressure switch and the manual prelube switch. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Switch the 16 amp circuit breaker for the ECM ON. B. pins. and J15/P15 connectors on the terminal box a. abrasion. Check the harness and wiring for abrasion and pinch points from the prelube pressure switch and the manual prelube switch to the ECM. Results: B. Turn the engine control switch to the STOP position. Check the torque of the Allen head screw for the ECM connector. Repair: Perform the necessary repairs and/or replace parts. Connect Cat ET to the service tool connector on the terminal box. • Not OK – The components are not in good condition and/or at least one connection is improper. if necessary. and pinch points. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the prelube system. Observe the “Logged Diagnostic” screen on Cat ET. b. Expected Result: Neither of the codes are logged. Thoroughly inspect each of the following connectors: • ECM J1/P1 and J2/P2 connectors • J9/P9. Test Step 3. • OK – The components are in good condition with proper connections. Expected Result: All of the connectors. J12/P12. Proceed to Test Step 3. . Look for these codes: 338-05 Pre-Lube Relay open circuit and 338-06 Pre-lube Relay short to ground. The wires are listed in Table 34. Use Cat ET to Check for Logged Diagnostic Codes A. C. Check the Prelube Pressure Switch A. Measure the resistance between the terminals of the prelube pressure switch. Disconnect the wires from the terminals of the prelube pressure switch. STOP. “ECM Start/Stop Output”. Measure the resistance of the prelube pressure switch. E. The contacts of the prelube pressure switch are stuck in the closed position or the open position. C. D. Test Step 4. Turn the engine control switch to the OFF/RESET position. Proceed to test Step 5. • Not OK – The resistance is not correct. Measure the resistance of the prelube pressure switch.357 Troubleshooting Section Results: • E269 Customer Shutdown Requested • E270 Driven Equipment Shutdown Requested A. Expected Result: When the prelube pump is OFF. Reinstall the terminal and clear the codes after the test: • 336-02 Incorrect ECS Switch inputs . Use a 151-6320 Wire Removal Tool to remove terminals P1-30 and P1-31. Test Step 5. Measure the resistance between the terminals of the prelube pressure switch. E. the resistance is greater than 2000 ohms. Make sure that the prelube pump is ON. Turn the manual prelube switch ON. B. Reconnect the wires to the terminals of the prelube pressure switch. Replace the prelube pressure switch. Turn the manual prelube switch ON. F. Repair: Refer to Troubleshooting. When the prelube pump is ON. Make sure that the prelube pump is ON. the resistance is greater than 2000 ohms. Turn the engine control switch to the STOP position. The codes are caused by removing the P1-31 terminal. Check the Circuit of the Prelube Pressure Switch Note: The following diagnostic codes and event codes may be logged during this test. Connect a multimeter to the terminals that were removed from the P1 connector. When the prelube pump is ON. the resistance is less than 2 ohms. Results: Illustration 238 Harness side of the P1 connector (30) Prelube pressure switch (31) Return g00895145 • OK – The resistance is correct. Repair: Turn the engine control switch to the OFF position. G. • Not OK – One of the codes is logged. Proceed to Test Step 4. Turn the engine control switch to the STOP position. • OK – Neither of the codes are logged. Expected Result: When the prelube pump is OFF. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. the resistance is less than 2 ohms. B. STOP. D. reduce the pressure in order to avoid activation of false diagnostic codes. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position.0 ± 0. If the pressure is actually too high. Keep your mind on correcting the cause of the original diagnostic code. Clear the diagnostic codes after the problem is resolved. the code will be generated. The ECM is not reading the circuit for the prelube pressure switch correctly. “Replacing the ECM”. measure the absolute pressure with a pressure gauge before you troubleshoot the sensor. Although there is not a problem with the sensor. Although there is not a problem with the sensor. STOP. Turn the engine control switch to the OFF position. If the actual inlet manifold air pressure is greater than approximately 338 kPa (49 psi). Pull on the wires in order to verify that the terminals are fully inserted into the connector. Pull on the wires in order to verify that the terminals are fully inserted into the connector. There is a short circuit or an open circuit in at least one of the wires for the prelube pressure switch. • Not OK – The resistance is not correct. This troubleshooting procedure may generate additional diagnostic codes. i01754772 PWM Sensor SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) supplies 8. print the logged codes to a file. Before you begin this procedure. Repair the harness.5 VDC to the humidity sensor (if equipped). Switch the 16 amp circuit breaker for the ECM OFF.358 Troubleshooting Section Results: Note: Excessive pressure can generate false “noisy signal” diagnostic codes. Replace the harness.8 VDC to the following sensors: • Engine coolant pressure (outlet) • Inlet manifold air pressure • Atmospheric pressure (if equipped) The ECM supplies 5. if necessary. a “109-08 Engine Coolant Outlet Pressure Sensor noisy signal” diagnostic code will be generated. If a “106-08” or “109-08” diagnostic code is generated. Insert terminals 30 and 31 into the P1 connector. Repair: Perform the following procedure: Turn the engine control switch to the OFF/RESET position. a “106-08 Air Inlet Pressure Sensor noisy signal” diagnostic code will be generated. . Replace the ECM according to the instructions in Troubleshooting. the code will be generated. • OK – The resistance is correct. Insert terminals 30 and 31 into the P1 connector. Logged diagnostic codes provide an historical record. when possible.0 ± 0. STOP. If the actual engine coolant pressure is greater than approximately 444 kPa (64 psi). Note: For the following steps. refer to Troubleshooting. Turn the engine control switch to the OFF/RESET position. “Inspecting Electrical Connectors”. Illustration 240 (1) ECM connectors J2/P2 (2) ECM connectors J1/P1 (3) J12/P12 connectors for the PWM sensors g00896222 . Switch the 16 amp circuit breaker for the ECM OFF. Inspect the Electrical Connectors and Wiring A.359 Troubleshooting Section Illustration 239 Schematic of the circuit for the PWM sensors g00896182 Test Step 1. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the PWM sensors.360 Troubleshooting Section B. Thoroughly inspect the following connectors: • ECM J1/P1 connectors • ECM J2/P2 connectors • J12/P12 connectors on the terminal box a. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). Illustration 242 Harness sides of the ECM P2 connector (68) Signal for engine coolant pressure (outlet) g00896241 Illustration 244 (1) Sensor for engine coolant pressure (outlet) (2) Sensor for inlet manifold air pressure g00896380 . Illustration 243 Harness side of the P12 connector (A) +5 volt supply (C) Return (D) Signal for atmospheric pressure (G) Signal for humidity (L) +8 volt supply (M) Signal for inlet manifold air pressure (N) Return (P) Signal for engine coolant pressure (outlet) g00896248 Illustration 241 Harness sides of the ECM P1 connector (2) + 5 volt supply (3) Return (4) +8 volt supply (5) Return (10) Signal for inlet manifold air pressure (11) Signal for humidity (12) Signal for atmospheric pressure g00896239 b. Check the torque of the Allen head screw for the ECM connector. • Not OK – The components are not in good Repair: Perform the necessary repairs and/or replace parts. B. Results: C. if necessary. abrasion. Check for Active “8 Volt DC Supply” Diagnostic Codes and “5 Volt Sensor DC Supply” Diagnostic Codes A. Switch the 16 amp circuit breaker for the ECM ON. Look for these codes: • 41-03 8 Volt DC Supply short to +batt • 41-04 8 Volt DC Supply short to ground • 262-03 5 Volt Sensor DC Supply short to +batt • 262-04 5 volt Sensor DC Supply short to ground Expected Result: There are no active “8 Volt DC Supply” diagnostic codes or “5 Volt Sensor DC Supply” diagnostic codes. This procedure will not work when this type of code is active. Repair: Refer to Troubleshooting. or Troubleshooting.361 Troubleshooting Section Illustration 245 (3) Sensor for humidity (4) Sensor for atmospheric pressure g00896276 c. Expected Result: All of the connectors. Connect the Caterpillar Electronic Technician (ET) to the service tool connector on the terminal box. STOP. Proceed to Test Step 2. • Active code – There is an active diagnostic code for a power supply. Results: • OK – The components are in good condition with proper connections. Test Step 2. Observe the “Active Diagnostic” screen on Cat ET. and sockets are connected properly. Proceed to Test Step 3. “+5 V Sensor Voltage Supply”. “+8 V Sensor Voltage Supply”. Check the harness and wiring for abrasion and pinch points from each of the PWM sensors to the ECM. Turn the engine control switch to the STOP position. The connectors and the wiring are free of corrosion. and pinch points. condition and/or at least one connection is improper. STOP. pins. • No codes – There are no active diagnostic codes for the power supplies. . Allow a minimum of thirty seconds for any codes to activate. “Inspecting Electrical Connectors”. Replace any faulty wiring and/or connectors. Refer to Troubleshooting. Disconnect the suspect sensor. . there may be an intermittent problem in the harness that is causing the codes to be logged. Repair any faulty wiring and/or connectors. Determine if any of these diagnostic codes are active: C. B. Verify the Supply Voltage to the Sensor A. refer to Troubleshooting. If the engine is running properly at this time. If you are troubleshooting the humidity sensor. or in the engine harness. The wiring problem may be inside the terminal box. • Not OK – The voltage is not within the specification. Check for Active Diagnostic Codes for the PWM Sensors A.5 VDC. The correct voltage is not present at the sensor connector. • 106-03 Air Inlet Pressure Sensor open/short to +batt • 106-08 Air Inlet Pressure Sensor noisy signal • 109-03 Engine Coolant Outlet Pressure open/short to +batt Illustration 246 Harness connector for the PWM sensors (A) +8 volt supply or +5 volt supply (B) Return g00896288 • 109-08 Engine Coolant Outlet Pressure noisy signal • 1758-03 Specific Humidity Sensor open/short to +batt D. “Troubleshooting Without a Diagnostic Code”. Turn on the “Active Diagnostic” screen on Cat ET. Repair: Verify that the wiring and/or connectors are OK.0 ± 0. the voltage is +5. Turn the engine control switch to the STOP position. • No – None of the above codes are active. Results: • 1758-08 Specific Humidity Sensor noisy signal • 1759-03 Exhaust Back Pressure Sensor open/short to +batt • 1759-08 Exhaust Back Pressure Sensor noisy signal Expected Result: One of the above codes is active. • Yes – At least one of the above diagnostic codes is active. Refer to Troubleshooting. Proceed to Test Step 5. Turn the engine control switch to the OFF/RESET position.0 ± 0.4 VDC. if necessary. The correct voltage is present at the sensor connector. Repair: If any of the above codes are logged and the engine is not running properly. Results: • OK – The voltage is within the specification.362 Troubleshooting Section Test Step 3. when possible. STOP. “Inspecting Electrical Connectors”. Test Step 4. Expected Result: The voltage between terminal “A” and terminal “B” is +8. Proceed to Test Step 4. The correct voltage must be present at the sensor connector in order to continue this procedure. measure the voltage between terminal “A” and terminal “B”. STOP. At the harness connector for the suspect sensor. At the harness connector for the suspect sensor. B. E. If the duty cycle and the frequency of the sensor signal are incorrect.0 and 8. Connect the multimeter to terminal “B” and terminal “C” of the breakout t. • OK – The voltage is between 7. when possible. Expected Result: The voltage is between 7. if necessary. STOP. Results: • OK – The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor. The signal wire is probably shorted to ground between the sensor and the ECM. Check the duty cycle and the frequency of the sensor signal again. Results: A. turn the engine control switch to the OFF/RESET position. D.0 and 8.363 Troubleshooting Section Test Step 5. Replace the harness. Test Step 6. The +Battery voltage is not present in the signal wire.0 volts. the inlet manifold pressure sensor. Verify that +Battery Voltage is Not Present in the Signal Wire C. measure the voltage between terminal “B” and terminal “C”. 5. Switch the 16 amp circuit breaker for the ECM OFF. Turn the engine control switch to the OFF/RESET position. STOP. 6. Measure the duty cycle and the frequency of the suspect sensor. the inlet manifold pressure sensor. Repair: Turn the engine control switch to the OFF/RESET position. Proceed to Test Step 7. Turn the engine control switch to the OFF/RESET position. Illustration 247 Harness connector for the PWM sensors (B) Return (C) Signal g00896299 Expected Result: The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor. • Not OK – The voltage is approximately 0 volts. Allow a minimum of 30 seconds for any codes to activate. when possible. 3. Disconnect the sensor. Thoroughly inspect the connector for the sensor according to Troubleshooting. “Inspecting Electrical Connectors”. Turn the engine control switch to the STOP position. Repair the harness. Proceed to Test Step 6.0 volts. The signal wire is probably shorted to the +Battery between the sensor and the ECM. Do not install the new sensor into the engine yet. or the atmospheric pressure sensor. or the atmospheric pressure sensor. 2. The duty cycle is between 10 and 90 percent for the humidity sensor. Check the Signal at the Sensor A. The duty cycle is between 10 and 90 percent for the humidity sensor. Install a 8T-8726 Adapter Cable As (Three-Pin Breakout) at the harness connector for the suspect sensor. Repair: Perform the following steps: 1. • Not OK – The voltage is approximately equal to the Battery voltage. Repair the harness. Replace the harness. Use a multimeter that is capable of measuring both the duty cycle and the frequency. . • Not OK – The duty cycle or the frequency is incorrect. A valid signal is produced by the sensor. if necessary. The sensor is receiving the correct supply voltage but the sensor is not producing a valid signal. 4. The frequency is between 400 and 600 Hz. The frequency is between 400 and 600 Hz. Switch the 16 amp circuit breaker for the ECM OFF. Repair: Turn the engine control switch to the OFF/RESET position. Turn the engine control switch to the STOP position. Connect a sensor that is known to be good. . Turn the engine control switch to the STOP position. Check for an active diagnostic code. Results: • OK – The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor. Table 35 Terminals for the Connection of the Probes Suspect Sensor Engine coolant pressure (outlet) Inlet manifold air pressure Atmospheric pressure Humidity Connector and Terminals J2-68 and J1-5 J1-10 and J1-5 J1-12 and J1-5 J1-11 and J1-3 Test Step 7. D. Check the Signal at the ECM A. Turn the engine control switch to the OFF/RESET position. install the sensor into the engine. 3. 2. The duty cycle is between 10 and 90 percent for the humidity sensor. Check “Status Screen Group 2” on Cat ET. or the atmospheric pressure sensor. Repair: Perform the following steps: Illustration 248 Harness side of the ECM P1 and P2 connectors (1) P1 connector (2) P2 connector (P1-3) Return (P1-5) Return (P1-10) Signal for inlet manifold air pressure (P1-11) Signal for humidity (P1-12) Signal for atmospheric pressure (P2-68) Signal for engine coolant pressure (outlet) g00896482 1. Insert two 7X-1710 Multimeter Probes into the terminals that are appropriate for the suspect sensor. If the code is not active for the new sensor. The ECM is receiving a valid signal from the sensor. Turn the engine control switch to the STOP position. the inlet manifold pressure sensor.364 Troubleshooting Section 7. B. The duty cycle is between 10 and 90 percent for the humidity sensor. Expected Result: The duty cycle is between 5 percent and 95 percent for the engine coolant pressure sensor. or the atmospheric pressure sensor. E. Switch the 16 amp circuit breaker for the ECM OFF. Use a multimeter that is capable of measuring both the duty cycle and the frequency. the inlet manifold pressure sensor. Switch the 16 amp circuit breaker for the ECM ON. Connect the multimeter to the probes. Switch the 16 amp circuit breaker for the ECM ON. Look for a valid signal. Clear any logged diagnostic codes. C. Turn the engine control switch to the OFF/RESET position. Switch the 16 amp circuit breaker for the ECM OFF. The terminals for the connection of the probes are identified in Table 35. Measure the duty cycle and the frequency of the suspect sensor. The frequency is between 400 and 600 Hz. STOP. Otherwise. the 1440-05 diagnostic code can occur if the low side wire is shorted to ground. The next likely cause is an open circuit inside the actuator solenoid. verify that the ECM is receiving the correct voltage. The 1440-05 diagnostic code is probably caused by a problem with an electrical connector or an open circuit in a harness. adjust the derivative gain and the fuel quality in order to make the engine more stable at low idle. “Electrical Power Supply”. Refer to Troubleshooting.7 kPa (3. The next likely cause is a short circuit inside the actuator solenoid. Verify that the problem is resolved. STOP. • Not OK – The duty cycle or the frequency is incorrect. install a known good ECM according to Troubleshooting. The least likely cause is a problem with the ECM. Under certain circumstances. Refer to Troubleshooting. “Replacing the ECM”. The sensor is producing a valid signal but the signal does not reach the ECM.365 Troubleshooting Section It is possible that the actual air inlet pressure is less than the pressure that can be measured by the sensor during low idle operation (26. The 1440-06 diagnostic code is probably caused by a short circuit in a harness or a problem with an electrical connector. If the condition is not resolved. There is a problem in the harness between the sensor and the ECM. if necessary. when possible. “System Configuration Parameters”. Repair: Repair the harness.87 psi)). i01748742 Throttle Actuator Solenoid SMCS Code: 1901-038 System Operation Description: The Electronic Control Module (ECM) controls the throttle actuator by adjusting current flow through the actuator’s solenoid. This causes the ECM to set the 106-03 diagnostic code although there is no short circuit to the +Battery side. Replace the harness. . The least likely cause is a problem with the ECM. STOP. In this case. “Inspecting Electrical Connectors”. Check the torque of the Allen head screw for the ECM connector. a. Switch the 16 amp circuit breaker for the ECM OFF. Inspect the Electrical Connectors and Wiring Note: This Test Step is important for troubleshooting a problem with instability. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). refer to Troubleshooting.366 Troubleshooting Section Illustration 249 Schematic of the circuit for the throttle actuator g00895170 Test Step 1. Note: For the following steps. A. Illustration 251 Harness side of the ECM P2 connector Illustration 250 g00895184 g00895195 (1) ECM connectors J2/P2 (2) J10/P10 connector for the harness from the throttle actuator (3) 16 amp circuit breaker (63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator B. Turn the engine control switch to the OFF/RESET position. Thoroughly inspect the following connectors: • J2/P2 ECM connectors • J10/P10 connectors on the terminal box . Proceed to Test Step 3. Expected Result: All of the connectors and terminals are connected properly. If you are troubleshooting a 1440-05 diagnostic code. The connectors and the wiring are free of corrosion. Be sure to wiggle the harnesses near each of the connectors. if necessary. There is a problem with a connector and/or the wiring for the solenoid. Illustration 252 Harness side of the P10 connector (C) High side wire for the throttle actuator (D) Low side wire for the throttle actuator g00895202 b. • OK – The components are in good condition with • Not OK – The resistance is higher than 20.6 proper connections. Proceed to Test Step 6. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the throttle actuator.6 ohms. Check the Solenoid and Harnesses for an Open Circuit A. Expected Result: The resistance is between 5. or the ECM may have a problem. Thoroughly inspect the connectors (J518/P518) for the throttle actuator for moisture and contamination. or the solenoid may have a problem. Test Step 2. Switch the 16 amp circuit breaker for the ECM OFF. B.6 ohms. If you are troubleshooting a 1440-06 diagnostic code. During this measurement. Check the harness and wiring for abrasion and pinch points from the throttle actuator to the ECM.367 Troubleshooting Section • Not OK – The components are not in good condition and/or at least one connection is improper. Results: • OK – The resistance is between 5. Measure the resistance between P2 terminal (63) and terminal (64). The connectors are free of moisture and corrosion. ohms. The solenoid and wiring appear to be OK.0 and 20. STOP. Repair: Perform the necessary repairs and/or replace parts. . Disconnect connector P2 from the ECM. The low side wire may have a short to ground. Turn the engine control switch to the OFF/RESET position.0 and 20. Illustration 254 ECM side of connector P2 (P2-63) High side wire for the throttle actuator (P2-64) Low side wire for the throttle actuator g00895192 g00895267 Illustration 253 (4) Throttle actuator (5) J518/P518 connectors for the throttle actuator c. proceed to Test Step 2. proceed to Test Step 8. and pinch points. wiggle the harnesses in order to check for an intermittent problem with the harness. abrasion. Results: C. Check All of the Low Side Wiring for a Short to Ground A. Measure the resistance between the ground strap for the ECM and P2 terminal (64). Verify that harness connector P2 is disconnected from the ECM.000 ohms.000 ohms. Results: • OK – The resistance measurement is greater than 20. During this measurement. Test Step 4.000 ohms. Proceed to Test Step 12. The low side wire for the throttle actuator appears to be OK. Disconnect connector P10 from the terminal box. • Not OK – The resistance measurement is less than 20. Check the Low Side Wiring inside the Engine Harness for a Short to Ground Illustration 256 g00894848 (1) P10 connector for the harness from the throttle actuator A. Proceed to Test Step 4.368 Troubleshooting Section Test Step 3. Be sure to wiggle the harnesses near each of the connectors. Illustration 255 ECM side of connector P2 (1) Ground strap for the ECM (P2-64) Low side wire for the throttle actuator g00895270 B. . wiggle the harnesses in order to check for an intermittent problem with the harness. There is a problem with the low side wire for the throttle actuator. Expected Result: The resistance is greater than 20. Results: B. The low side wire inside the engine harness may have a problem. Repair: Repair the harness and/or the connector. Check the Engine Harness and the Solenoid for an Open Circuit A. The solenoid has an internal short circuit. Replace the harness. Disconnect connector P518 from the throttle actuator. Refer to Operation and Maintenance Manual. when possible. Illustration 258 Throttle actuator (1) Shell (2) J518-B g00895288 B. The low side wire inside the terminal box may have a problem. . The solenoid does not have an internal short circuit. STOP.000 ohms. • OK – The resistance measurement is greater than 20. The low side wire inside the engine harness has a short to ground. During this measurement. Illustration 257 Harness connector P10 (1) Ground Strap for the ECM (P10-D) Low side wire for the throttle actuator g00895280 Expected Result: The resistance is greater than 20.000 ohms. wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Measure the resistance between terminal J518-B and the connector’s shell. Proceed to Test Step 5. Expected Result: The resistance is greater than 20. when possible. “Electrohydraulic Actuator .000 ohms. There may be a problem with a connector. Check the Solenoid for an Internal Short Circuit A. Test Step 5. Measure the resistance between the ground strap for the ECM and terminal P10-D.Recondition”. Test Step 6. STOP. Replace the harness.369 Troubleshooting Section • Not OK – The resistance measurement is less than 20. or there may be a problem with the solenoid. Disconnect connector P10 from the terminal box. The low side wire inside the engine harness appears to be OK. STOP. if necessary. Repair: Repair the engine harness or connectors. • Not OK – The resistance is less than 20.000 ohms. Repair: Replace the solenoid.000 ohms. if necessary.000 ohms. Results: • OK – The resistance is greater than 20. 0 and 20. Results: • OK – The resistance of the solenoid is between 5. when possible. There may be a problem with a connector.3 ohms. . Check all of the Wiring and the Solenoid for a Short Circuit A. • Not OK – The resistance of the solenoid is higher than 10. Repair: Repair the engine harness or connectors. The wiring inside the terminal box or the terminal box’s connectors may have a problem. if necessary.3 ohms. STOP.6 ohms. The resistance of the solenoid is incorrect. Proceed to Test Step 7. • Not OK – The resistance is greater than 20.370 Troubleshooting Section Illustration 259 Harness connector P10 (P10-C) High side wire for the throttle actuator (P10-D) Low side wire for the throttle actuator g00895298 Illustration 260 Throttle actuator (1) J518-A (2) J518-B g00895313 B. Expected Result: The resistance is between 5. Expected Result: The resistance is between 5. Repair: Repair the wiring and/or connectors. Disconnect connector P2 from the ECM. The engine harness and the solenoid appear to be OK.0 and 10. Test Step 8. wiggle the harnesses in order to check for an intermittent problem with the harness.3 ohms. There is an open circuit in the engine harness. The solenoid has an open circuit. Refer to Operation and Maintenance Manual.6 ohms. Results: B. Test Step 7. Repair: Replace the solenoid. Measure the resistance between terminals (A) and (B) on the throttle actuator’s connector.Recondition”. The solenoid does not have an open circuit. when possible. if necessary. Be sure to wiggle the harnesses near each of the connectors. Replace the wiring. • OK – The resistance is between 5. Replace the harness. Disconnect connector P518 from the throttle actuator.6 ohms. Check the Solenoid for an Open Circuit A. “Electrohydraulic Actuator . Measure the resistance between P10 terminal (C) and terminal (D). There is a problem with the engine harness or the solenoid. STOP.0 and 10. STOP. During this measurement.0 and 20. Check the Solenoid for a Short Circuit A. Proceed to Test Step 10. • Not OK – The resistance is lower than 5. There may be a problem with a connector.0 ohms. Expected Result: The resistance is between 5. Proceed to Test Step 9.0 and 20. The wiring inside the terminal box has a problem. Disconnect connector P10 from the terminal box. wiggle the harnesses in order to check for an intermittent problem with the harness. Measure the resistance between harness connector P10 terminal (C) and terminal (D). Check the Engine Harness and the Solenoid for a Short Circuit A. Be sure to wiggle the harnesses near each of the connectors. or the solenoid has a problem. Proceed to Test Step 11. Expected Result: The resistance is between 5. The solenoid and wiring do not have a short circuit. Test Step 10. During this measurement.6 ohms. There is a problem with a connector and/or the wiring.6 ohms. if necessary. . Disconnect connector P518 from the throttle actuator. Replace the harness.0 and 20. when possible. Measure the resistance between P2 terminal (63) and terminal (64).371 Troubleshooting Section Illustration 261 ECM side of connector P2 (P2-63) High side wire for the throttle actuator (P2-64) Low side wire for the throttle actuator g00895267 Illustration 262 Harness connector P10 (P10-C) High side wire for the throttle actuator (P10-D) Low side wire for the throttle actuator g00895298 B. wiggle the harnesses in order to check for an intermittent problem with the harness. Test Step 9. There is a problem with the engine harness or the solenoid. Results: B. Be sure to wiggle the harnesses near each of the connectors. Results: • OK – The resistance is between 5.6 ohms.6 • Not OK – The resistance is less than 5. ohms. During this measurement. Repair: Repair the wiring and/or the connector. • OK – The resistance is between 5.0 and 20.0 ohms. STOP. The engine harness and the solenoid appear to be OK.0 and 20. Then turn the engine control switch to the STOP position. B. Harness side of the ECM P2 connector (63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator C. G.0 and 10. Observe the “Active Diagnostic” screen on the Caterpillar Electronic Technician (ET). if necessary.372 Troubleshooting Section Illustration 263 Throttle actuator (1) J518-A (2) J518-B g00895313 B.Recondition”. . Expected Result: • Not OK – The resistance of the solenoid is lower than 5. Replace the harness. “Electrohydraulic Actuator .3 ohms. Repair: Repair the engine harness or connectors. clear the code. A 1440-05 diagnostic code is activated. Allow a minimum of 30 seconds for the generation of any codes. The engine harness appears to have a short circuit.0 ohms. when possible. Expected Result: The resistance is between 5. Measure the resistance between terminals (A) and (B) on the throttle actuator’s connector. Repair: Replace the solenoid. Results: Illustration 264 g00895195 • OK – The resistance of the solenoid is between 5.0 and 10. Prevent fuel from entering the engine. The solenoid does not have a problem. Turn the engine control switch to the START position and crank the engine. D. Create an Open Circuit and Check the Operation of the ECM A.3 ohms. Look for a 1440-05 diagnostic code. This will replace the wiring for the throttle actuator with an open circuit. E. Switch the 16 amp circuit breaker for the ECM ON. Verify that the gas supply to the engine is OFF. Test Step 11. STOP. Use a 151-6320 Wire Removal Tool to remove terminal (63) and terminal (64) from harness connector P2. F. The resistance of the solenoid is incorrect. If a 1440-05 diagnostic code and/or a 1440-06 diagnostic code is logged. STOP. Refer to Operation and Maintenance Manual. Verify that the 16 amp circuit breaker for the ECM is OFF. Verify that the engine control switch is in the OFF/RESET position. The ECM may have a problem. Follow the instructions in Troubleshooting. Switch the 16 amp circuit breaker for the ECM OFF. Insert the other end of the jumper wire into the open terminal 64 of the P2 connector. Look for a 1440-06 diagnostic code. STOP. Exit this procedure and perform this procedure again. Repair: Perform the following procedure: Turn the engine control switch to the OFF position. Insert one end of the jumper wire into the open terminal 63 of the P2 connector. D. The initial diagnostic code was probably caused by a poor electrical connection. H. Test Step 12. Observe the “Active Diagnostic” screen on Cat ET. Use a 151-6320 Wire Removal Tool to remove terminal (63) and terminal (64) from harness connector P2. Verify that the socket is making contact with pin 64 in the J2 connector. a 1440-05 diagnostic code was activated. If the problem is resolved with a new ECM. Verify that the problem is resolved. “Replacing the ECM”. Switch the 16 amp circuit breaker for the ECM ON. F. a 1440-05 diagnostic code was not activated. perform the following procedure: Temporarily install a new ECM. This will replace the wiring for the throttle actuator with a short circuit. Illustration 265 Harness side of the ECM P2 connector (63) High side wire for the throttle actuator (64) Low side wire for the throttle actuator g00895195 C. STOP. Prevent fuel from entering the engine. Create a Short Circuit and Check the Operation of the ECM A. Repair: It is unlikely that the ECM has failed. B. Verify that the socket is making contact with pin 63 in the J2 connector. • Not OK – When an open circuit was created.373 Troubleshooting Section Results: • OK – When an open circuit was created. Fabricate a jumper wire with Deutsch sockets on the ends. Verify that the engine control switch is in the OFF/RESET position. If a 1440-05 diagnostic code and/or a 1440-06 diagnostic code is logged. Verify that the gas supply to the engine is OFF. . Then turn the engine control switch to the STOP position. G. The ECM is operating correctly. Refer to Troubleshooting. replace the original ECM. Turn the engine control switch to the START position and crank the engine. clear the code. Verify that the 16 amp circuit breaker for the ECM is OFF. “Replacing the ECM”. If the problem is not resolved. If the new ECM operates correctly and the original ECM does not operate correctly. E. I. Reinstall the terminals that were removed from connector P2. install the original ECM and verify that the problem returns. Allow a minimum of 30 seconds for the generation of any codes. Pull on the wires in order to verify proper installation of the terminals. Reconnect all of the connectors. The problem appears to be resolved. Results: • OK – When the wiring for the throttle actuator was replaced with a short circuit. a 1440-06 diagnostic code is not activated by the ECM. Switch the 16 amp circuit breaker for the ECM OFF. If the problem is resolved with a new ECM. STOP. “Replacing the ECM”. Repair: It is unlikely that the ECM has failed. replace the original ECM. a 1440-06 diagnostic code was activated by the ECM. The ECM may have a problem. Follow the instructions in Troubleshooting. If the new ECM operates correctly and the original ECM does not operate correctly. perform the following procedure: Temporarily install a new ECM. • Not OK – When the wiring for the throttle actuator is replaced with a short circuit. Exit this procedure and perform this procedure again. Repair: Perform the following procedure: Turn the engine control switch to the OFF position. Remove the jumper wire from the P2 connector. If the problem is not resolved. The ECM is operating correctly. STOP. Refer to Troubleshooting. Reconnect all of the connectors. “Replacing the ECM”. Verify that the problem is resolved.374 Troubleshooting Section Expected Result: A 1440-06 diagnostic code is activated. install the original ECM and verify that the problem returns. The problem appears to be resolved. Pull on the wires in order to verify proper installation of the terminals. . Reinstall the terminals that were removed from connector P2. The initial diagnostic code was probably caused by a poor electrical connection. 375 Troubleshooting Section Calibration Procedures i01746763 Engine Speed/Timing Sensor Calibrate SMCS Code: 1912-038 System Operation Description: The Electronic Control Module (ECM) has the ability to calibrate the mechanical differences between the Top Center (TC) of the flywheel and the TC of the timing gear on the left rear camshaft gear. . • The timing gear and/or the rear gear train have been adjusted. Note: The “261-13 Engine Timing calibration required” diagnostic code is generated only for an ECM that has never performed a timing calibration. The calibration procedure is initiated with the Caterpillar Electronic Technician (ET). The engine speed/timing sensor signals the TC of the timing gear to the ECM. Any offset between the TC of the flywheel and the TC of the timing gear is stored into memory. • The speed/timing sensor has been replaced. A magnetic transducer signals the TC of the flywheel to the ECM when the TC hole on the flywheel passes beneath the transducer. Calibration of the timing is required only after the following circumstances: • The ECM has been replaced. • The timing gear and/or the rear gear train have been replaced. 376 Troubleshooting Section Test Step 1.04 inch) away from the surface of the flywheel. NOTICE The timing hole in the flywheel must not be aligned with the hole for the transducer. The transducer will be damaged on engine start-up if the transducer is installed through both holes. Make sure that the hole in the flywheel housing for the transducer is not aligned with the timing hole in the flywheel. Always confirm that the holes are not aligned. D. . Insert the transducer into the adapter until the transducer contacts the surface of the flywheel. Tighten the nut on the adapter in order to secure the transducer in place. Connect the other end of the cable to connector P50 inside of the terminal box. C. Remove the timing calibration plug from either the left side or the right side of the flywheel housing. Rotate the flywheel for more than 10 degrees before or after the TC position in order to move the flywheel hole away from the hole for the transducer. Install the 6V-3093 Transducer Adapter into the hole. Install the Transducer Illustration 266 (1) P50 connector (2) 6V-3093 Transducer Adapter (3) 6V-2197 Magnetic Transducer (4) 7X-1695 Cable g00894217 A. Turn the engine control switch to the OFF position. Connect the one end of the 7X-1695 Cable to the transducer. B. Remove the protective end cap from the 6V-2197 Magnetic Transducer. Move the transducer 1 mm (0. Turn the engine control switch to the STOP position. The surrounding air is assumed to be clean with approximately 20. the ECM reads the percent of oxygen in the surrounding air. Test Step 2. STOP. However. If the calibration is still unsuccessful. Select “Calibrations” from the menu. Connect Cat ET to the service tool connector on the terminal box. The ECM energizes the heater in the sensor for five minutes. D. Verify that there are no active diagnostic codes which can prevent the calibration. “Electrical Connectors and Functions”. The calibration offset and the calibration range are determined from these two points. the Electronic Control Module (ECM) first establishes the reference for zero percent of oxygen by reading the sensor after the sensor has cooled for two minutes. the new timing reference is programmed into the permanent memory of the ECM. Start Cat ET.95 percent oxygen. verify that the engine rpm was stable during the calibration (± 50 rpm). • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen. Expected Result: After a few moments. STOP. Repeat the calibration procedure.. Results: • OK – The timing calibration was successful. Repair: If the calibration failed in the first step. The reference is based on the signals from the transducer and the speed/timing sensor. Continue to the next test step. The calibration was unsuccessful. B. Cat ET will display “The ECM has calculated the Timing Reference” and “Choose the Continue button to program the Timing Reference”. Next. Start the engine. Operate the engine at the rated speed and load. Use either of the following methods in order to initiate the calculation of the new timing reference: • Not OK – The calibration was completed successfully. Last. Repair: Replace the ECM according to the instructions in Troubleshooting.Calculating the new Timing Reference”. The sensor must be placed in uncontaminated air in order to calibrate the sensor. Select “Service” from the main menu on Cat ET. Check the 7X-1695 Cable for continuity. The engine must be stopped and the sensor must be removed. The new timing reference is calculated first.. For instructions. • Press the space bar on the keyboard of the PC.377 Troubleshooting Section E. Select “Timing Calibration”. STOP. check the installation of the tools and check the operation of the tools. See the Operation And Maintenance Manual for the maintenance interval schedule. Cat ET will display “CALIBRATION SUCCESSFUL”. • Click the left mouse button on the “Continue” button in the lower left corner of the Cat ET screen. During the calibration. . refer to Troubleshooting. After a few moments. The air must be free of exhaust. or shorted internally. A. open. the “261-13 Engine Timing calibration required” diagnostic code is still active. Use either of the following methods in order to program the new timing reference: Oxygen Sensor . • Not OK – Cat ET displayed “COULD NOT CALIBRATE”.Calibrate SMCS Code: 1901-038 System Operation Description: Periodic calibration of the oxygen sensor is required in order to ensure accurate readings and optimum engine performance. Cat ET will indicate “Please wait. Repeat the calibration procedure. Excessive backlash in the gear train will cause inconsistent timing. i01746774 • Press the space bar on the keyboard of the PC. “Replacing the ECM”. Calibration Note: A two-step process is used to calibrate the signal for the speed/timing sensor. Verify that the transducer is not bent. C. Refer to Disassembly and Assembly for identifying and repairing a gear train problem. Turn the engine control switch to the OFF/RESET position. Thoroughly inspect the following connectors: • ECM J2/P2 connectors • J10/P10 connectors on the terminal box a. Switch the 16 amp circuit breaker for the ECM OFF. refer to Troubleshooting. The proper torque is 6 ± 1 N·m (55 ± 9 lb in). “Inspecting Electrical Connectors”. Wear gloves that resist heat. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. Severe personal injury and property damage will result from contact with a hot oxygen sensor.378 Troubleshooting Section Illustration 267 Schematic of the circuit for the oxygen sensor and the oxygen buffer g00894265 Test Step 1. (1) ECM connectors J2/P2 (2) J10/P10 connectors for the harness from the oxygen buffer B. calibration. . Do not touch the sensor during engine operation. or testing. Inspect the Electrical Connectors and Wiring During operation. A. Allow the sensor to cool before moving the sensor. the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Check the torque of the Allen head screw for the ECM connector. Illustration 268 g00894279 Note: For the following steps. and sockets are connected properly. pins. . and pinch points. Illustration 270 Harness side of the P10 connector (H) Return for the shield (K) +24 Volt supply for the buffer (L) Oxygen signal (PWM) (M) Return g00894295 Illustration 272 g00894309 (1) Oxygen sensor (2) Oxygen buffer (3) J651/P651 connectors for the harness from the terminal box (4) J652/P652 connectors for the oxygen sensor c. Expected Result: All of the connectors. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the oxygen buffer. abrasion. The connectors and the wiring are free of corrosion.379 Troubleshooting Section Illustration 269 g00894288 Illustration 271 (A) VH+ (B) VH− (C) IP+ (D) IP− (E) VS+ (F) VS+ g00720459 Terminals of the circuit for the oxygen buffer on the harness side of the ECM P2 connector (13) +24 Volt supply for the buffer (23) Return (53) Return for the shield (67) Oxygen signal (PWM) J652/P652 connectors for the oxygen sensor to the oxygen buffer b. Check the harness and wiring for abrasion and pinch points from the oxygen sensor to the ECM. If the humidity is 90 percent or more. do not calibrate the sensor. do not calibrate the sensor. c. if necessary. Use Table 36 to determine whether your relative humidity is within the permissible range for calibration of the oxygen sensor. .380 Troubleshooting Section Results: • OK – The components are in good condition with proper connections. B. Proceed to Test Step 2. If your relative humidity is equal to the humidity or greater than the humidity that is listed in the Table. Determine the ambient temperature. STOP. and barometric pressure. If the temperature is less than 12 C (54 F). Find the row for your ambient temperature. relative humidity. abrasion. Repair: Perform the necessary repairs and/or replace parts. • Not OK – At least one of the connectors. If the temperature is more than 38 C (100 F). At least one of the connectors or the wiring has corrosion. Find the relative humidity in the cell that intersects your column and your row. b. Find the column for your barometric pressure. a. and/or pinch points. pins. Test Step 2. or sockets are not connected properly. do not calibrate the sensor. Check the Atmospheric Conditions A. use the 12 C (54 F) row. Turn ON the “Oxygen Sensor Override”. The ambient relative humidity is within the permissible range for calibration of the oxygen sensor. Proceed to Test Step 3. Access the “Logged Diagnostic Codes” screen on the Caterpillar Electronic Technician ET. • 1088-05 Oxygen Sensor Power Supply open circuit • 1088-06 Oxygen Sensor Power Supply short to ground C.5 psi) 109 kPa (15. 1086-13.6 psi) 102 kPa (14. Repair: Do not calibrate the sensor until the humidity is acceptable. 1087-03. If the following codes are logged. Look for the following diagnostic codes again: 1086-09. STOP. Test Step 3. Access the “Diagnostic Override” screen of Cat ET. and Relative Humidity for Calibration of the Oxygen Sensor Ambient Temperature Barometric Pressure 96 kPa (13. 1088-05. Access the “Logged Diagnostic Codes” screen again.4 psi) 101 kPa (14. Switch the 16 amp circuit breaker for the ECM ON. Allow a minimum of 90 seconds for any diagnostic codes to be generated. • Not OK – The humidity is not acceptable. B. .7 psi) 99 kPa (14.2 psi) 107 kPa (15. Expected Result: • 1086-09 Oxygen Sensor Element not communicating on link None of the above diagnostic codes are logged. Select “Diagnostics/Diagnostic Tests/Override Parameters”. clear the codes: E. Barometric Pressure. F. and 1088-06.9 psi) 97 kPa (14. D. Check for Diagnostic Codes A.2 psi) 113 kPa (16. Results: • 1086-13 Oxygen Sensor Element calibration required • 1087-03 Oxygen Buffer Module short to +batt • 1087-08 Oxygen Buffer Module noisy signal • OK – The ambient conditions are acceptable.381 Troubleshooting Section Table 36 Ambient Temperature.8 psi) 110 kPa (16 psi) 112 kPa (16. Turn the engine control switch to the STOP position.4 psi) Relative Humidity 12 C (54 F) 14 C (57 F) 16 C (61 F) 18 C (64 F) 20 C (68 F) 22 C (72 F) 24 C (75 F) 26 C (79 F) 28 C (82 F) 30 C (86 F) 32 C (90 F) 34 C (93 F) 36 C (97 F) 38 C (100 F)                   90 85 75 65 60 50 45 40 35 35 30 25 25 20 90 85 75 65 60 50 45 40 35 35 30 25 25 25 90 85 75 65 60 55 45 40 40 35 30 30 25 25 90 85 75 70 60 55 50 45 40 35 30 30 25 25 90 90 80 70 60 55 50 45 40 35 30 30 25 25 90 90 80 70 65 55 50 45 40 35 30 30 25 25 90 90 80 70 65 55 50 45 40 35 35 30 25 25 90 90 80 75 65 60 50 45 40 35 35 30 25 25 90 90 85 75 65 60 50 45 40 35 35 30 25 25 90 90 85 75 65 60 55 45 40 40 35 30 30 25 90 90 85 75 65 60 55 50 45 40 35 30 30 25 90 90 85 75 70 60 55 50 45 40 35 30 30 25 Expected Result: The temperature is less than 38 C (100 F). 1087-08.8 psi) 104 kPa (15 psi) 105 kPa (15. Turn the engine control switch to the STOP position. Repair: Troubleshoot the diagnostic code. Check the connectors for the oxygen sensor and the oxygen buffer. Repair: Refer to Troubleshooting. B. • OK – The calibration was successful. Turn ON the “Oxygen Sensor Override” parameter. . calibration. B. Allow the sensor to cool before you install the sensor.382 Troubleshooting Section Results: Expected Result: Successful calibration is indicated by Cat ET. the oxygen sensor may reach temperatures that exceed 700 C (1292 F). Switch the circuit breaker for the ECM ON. Switch the circuit breaker for the ECM OFF. Proceed to Test Step 5. obtain a new oxygen sensor and repeat the calibration procedure. • Logged 1088-05 or 1088-06 Diagnostic Code – There is a problem with the supply voltage for the oxygen buffer. Use Cat ET to start the calibration. Severe personal injury and property damage will result from contact with a hot oxygen sensor. Verify the Calibration of the Sensor A. D.95 percent in about 30 seconds. or testing. • Not OK – The calibration was not successful. Wear gloves that resist heat. Test Step 4. “Oxygen Sensor Signal”. E. Repair: Repeat the calibration procedure. C. Allow the sensor to cool sufficiently for removal. STOP. Allow the sensor to cool before moving the sensor. Suspend the sensor in uncontaminated air. STOP. F. STOP. During operation. STOP. Approximately 12 minutes are required for the calibration. If the procedure is not successful after three attempts. Repair: Refer to Troubleshooting. Access the “Diagnostic Override” screen of Cat ET. “Oxygen Sensor Buffer Supply”. Results: • No Codes – The circuit for the oxygen sensor is OK. Do not place the sensor on or near any flammable material or any surface that can be damaged by high temperatures. Then remove the sensor from the exhaust system. Test Step 5. 1087-03 or 1087-08 – A 1086-09 1087-03 or 1087-08 diagnostic code is active. Select “Diagnostics/Diagnostic Tests/Override Parameters”. Disconnect the oxygen sensor from the oxygen buffer. Results: • OK – The calibration of the oxygen sensor is verified. Turn the engine control switch to the OFF/RESET position. Expected Result: The “Actual Oxygen” reading stabilizes to approximately 20. Access the “Service/Calibrations/Oxygen Sensor” screen of Cat ET. Repeat the calibration procedure. STOP. • Logged 1086-09. Connect the oxygen sensor to the oxygen buffer. Proceed to test Step 4. Do not touch the sensor during engine operation. Cat ET will display a diagnostic code. • Not OK – The calibration of the oxygen sensor is not verified. Calibrate the Oxygen Sensor A. .. E096 High Fuel Pressure ......... E242 Engine Overload ........................................................ E231 Fuel Quality Out of Range................................. 154 155 155 155 155 156 156 156 156 157 157 157 157 158 158 159 159 159 160 160 161 161 161 161 162 162 162 162 163 163 163 163 164 164 164 164 165 165 165 165 166 166 166 166 167 167 167 168 168 168 169 .............................. E020 High Engine Oil Temperature Warning..................... E243 High Left Turbo Turbine Outlet Temperature.............................. 28 D Desired Speed Input (4 .................................... E050 High System Voltage Warning .................... E413 Cylinder #13 Detonation............................... E253 Detonation Derate Requested.................. E403 Cylinder #3 Detonation............................. E026 High Inlet Air Temperature Shutdown .. E025 High Inlet Air Temperature Derate......................................... E268 Unexpected Engine Shutdown .......................................................... E270 Driven Equipment Shutdown Requested ...... E402 Cylinder #2 Detonation....................................................................................................... E423 Cylinder #3 Detonation Shutdown........... 193 +8V Sensor Voltage Supply............................................................................... E016 High Engine Coolant Temperature Shutdown......................................... 213 C Calibration Procedures ............ E127 Engine Oil Filter Diff Pressure Low Warning ..................... E422 Cylinder #2 Detonation Shutdown.............. E427 Cylinder #7 Detonation Shutdown......... E038 Low Engine Coolant Temperature Warning ....................... E415 Cylinder #15 Detonation. E410 Cylinder #10 Detonation............................ 71 Diagnostic Functional Tests........................................................................................................................................ E411 Cylinder #11 Detonation.......................................................................... E247 Low Left Turbo Turbine Outlet Temperature.............................................................................. 41 Recommended Repairs ............ E100 Low Engine Oil Pressure Warning .................................................................... 42 Detonation Sensors .... E244 High Right Turbo Turbine Outlet Temperature................................................................................................. E407 Cylinder #7 Detonation....... E405 Cylinder #5 Detonation.................................. E019 High Engine Oil Temperature Shutdown ................ E408 Cylinder #8 Detonation... E245 High Right Turbo Turbine Inlet Temperature........................................................................... E424 Cylinder #4 Detonation Shutdown.................................. E246 High Left Turbo Turbine Inlet Temperature.......... E425 Cylinder #5 Detonation Shutdown................... E254 No Detonation Derate Action Taken.................... E015 High Engine Coolant Temperature Derate............................................ E406 Cylinder #6 Detonation........................ E128 Engine Oil Filter Diff Pressure Low Shutdown....... E224 High Jacket Water Inlet Pressure........................................................ E404 Cylinder #4 Detonation.......... 43 Recommended Repairs ............................................... 71 Logged Diagnostic Codes..................... E401 Cylinder #1 Detonation.................................................... E249 Low Right Turbo Turbine Inlet Temperature........................ E414 Cylinder #14 Detonation............................. E233 Low Engine Pre-Lube Pressure .. E017 High Engine Coolant Temperature Warning ................ E426 Cylinder #6 Detonation Shutdown.. 149 149 149 150 150 150 151 151 151 151 152 152 152 153 153 153 153 154 154 E129 Engine Oil Filter Diff Pressure High Warning ........................................... E421 Cylinder #1 Detonation Shutdown....... 41 Probable Causes ..................................................... 228 Diagnostic Codes .............................................. E264 Emergency Stop Activated .............................. E043 Low System Voltage Warning ............................................. E269 Customer Shutdown Requested ......20 mA)....... E226 Driven Equipment Not Ready..................... E040 Low Engine Oil Pressure Shutdown............................................. E130 Engine Oil Filter Diff Pressure High Shutdown..................................... 70 Active Diagnostic Codes ..................................... E248 Low Right Turbo Turbine Outlet Temperature............................. E230 Fuel Energy Content Setting High.. E053 Low Fuel Pressure Warning .............................. E250 Low Left Turbo Turbine Inlet Temperature .................................................. 193 Driven Equipment ......... E223 High Gas Temperature ............................ E027 High Inlet Air Temperature Warning ... E135 Low Jacket Water Pressure Shutdown.... 204 A Analog Sensor Signal ....... 222 Detonation .. E337 High Engine Oil to Engine Coolant Diff Temp .................................................................................... E409 Cylinder #9 Detonation.................................. E266 Low Hydrax Oil Pressure ...... E225 Engine Overcrank ................. 43 E E004 Engine Overspeed Shutdown ...................... 43 Probable Causes ........................................................ E412 Cylinder #12 Detonation............ 375 Customer Passwords....... E229 Fuel Energy Content Setting Low ... E416 Cylinder #16 Detonation............... E042 Low System Voltage Shutdown.....................................383 Index Section Index Numerics +5V Sensor Voltage Supply............................. .. 48 Probable Causes ... 50 ........... E846 Cyl #6 Exhaust Port Temp Deviating Low ................................................... 47 Recommended Repairs .............. E823 Cyl #3 Exhaust Port Temp Deviating High................. Runs Rough or Is Unstable ............ 43 Recommended Repairs ........... E835 Cyl #15 Exhaust Port Temp Deviating High ................ 268 ECM Will Not Accept Factory Passwords................................... 11 Harness Wire Identification ..................................................... E810 Cylinder #10 High Exhaust Port Temp .. 46 Engine Coolant Temperature (Low) ...................... 47 Probable Causes ........................ 236 ECM Output Circuit (Prelubrication Oil Pump) ..................... 9 Engine Coolant Temperature (High) ................................. 47 Recommended Repairs ........... E833 Cyl #13 Exhaust Port Temp Deviating High ................................ 20 Electronic Troubleshooting ................... E806 Cylinder #6 High Exhaust Port Temp .................. 50 Recommended Repairs .............. 48 Recommended Repairs ... 12 Electrical Power Supply......... 189 E855 Cyl #15 Exhaust Port Temp Deviating Low........................... 18 Caterpillar Electronic Technician (ET)............................. 21 Changing the Settings of the Monitoring System ... 26 Engine Oil Filter Differential Pressure .... E815 Cylinder #15 High Exhaust Port Temp ....... E807 Cylinder #7 High Exhaust Port Temp ....... E822 Cyl #2 Exhaust Port Temp Deviating High............................................ 191 E868 Gas Flow Control Valve Malfunction ........................................... E816 Cylinder #16 High Exhaust Port Temp ....................................................... E805 Cylinder #5 High Exhaust Port Temp .... 23 Engine Power Derating .......... E824 Cyl #4 Exhaust Port Temp Deviating High.............................................. E802 Cylinder #2 High Exhaust Port Temp .............384 Index Section E428 Cylinder #8 Detonation Shutdown...................................................................................................... E843 Cyl #3 Exhaust Port Temp Deviating Low ........................................... E849 Cyl #9 Exhaust Port Temp Deviating Low ............................ E814 Cylinder #14 High Exhaust Port Temp .. E851 Cyl #11 Exhaust Port Temp Deviating Low................. E850 Cyl #10 Exhaust Port Temp Deviating Low........... 11 Sensors.... E832 Cyl #12 Exhaust Port Temp Deviating High . E841 Cyl #1 Exhaust Port Temp Deviating Low .......................................... E836 Cyl #16 Exhaust Port Temp Deviating High .... 21 Default Settings of the Monitoring System...... E831 Cyl #11 Exhaust Port Temp Deviating High ............. 45 Recommended Repairs .................. 47 Engine Misfires.......................... 50 Recommended Repairs ......................... 43 Recommended Repairs ............................................................... E436 Cylinder #16 Detonation Shutdown...... 190 E864 Low Gas Fuel Differential Pressure .. 45 Probable Causes ..... E834 Cyl #14 Exhaust Port Temp Deviating High ....................................................... 23 Monitoring Parameters.... E828 Cyl #8 Exhaust Port Temp Deviating High.............. E853 Cyl #13 Exhaust Port Temp Deviating Low. E435 Cylinder #15 Detonation Shutdown...... 43 Electrical Connectors and Functions... 43 Probable Causes .. 190 E856 Cyl #16 Exhaust Port Temp Deviating Low...... E848 Cyl #8 Exhaust Port Temp Deviating Low ......................................................... 44 Electronic Service Tool Will Not Communicate with ECM (The Caterpillar Electronic Technician (ET) Will Not Communicate With the Electronic Control Module (ECM) and/or the Integrated Temperature Sensing Module (ITSM))......................... E804 Cylinder #4 High Exhaust Port Temp .... E829 Cyl #9 Exhaust Port Temp Deviating High...................................................... E431 Cylinder #11 Detonation Shutdown................................................. 247 ECM Output Circuit (Starting Motor) .... 22 Programmable Parameters of the Integrated Temperature Sensing Module ............... E803 Cylinder #3 High Exhaust Port Temp .... 50 Probable Causes ................ 258 ECM Status Indicator Output.................................................................. 169 169 169 170 170 170 171 171 171 171 172 172 173 173 173 174 174 174 175 175 176 176 176 177 177 178 178 179 179 179 180 180 181 181 181 182 182 183 183 183 184 184 185 185 185 186 186 187 187 187 188 188 189 189 E854 Cyl #14 Exhaust Port Temp Deviating Low.......... E433 Cylinder #13 Detonation Shutdown.............................................................. 50 Probable Causes ....... 45 Probable Causes .............................. E845 Cyl #5 Exhaust Port Temp Deviating Low . 50 Engine Oil Pressure (Low)....................... E821 Cyl #1 Exhaust Port Temp Deviating High......... 191 E866 Low Gas Fuel Flow Rate ... E826 Cyl #6 Exhaust Port Temp Deviating High............. 274 Electrohydraulic System Oil Pressure (Low) ...... E432 Cylinder #12 Detonation Shutdown. E811 Cylinder #11 High Exhaust Port Temp .......... 191 E867 Improper Gas Flow Control Valve Response..................... E429 Cylinder #9 Detonation Shutdown........................... 45 Recommended Repairs ................................................................ E434 Cylinder #14 Detonation Shutdown......................................................... E827 Cyl #7 Exhaust Port Temp Deviating High...................... E813 Cylinder #13 High Exhaust Port Temp .. 47 Probable Causes ............. E842 Cyl #2 Exhaust Port Temp Deviating Low . E430 Cylinder #10 Detonation Shutdown........................................ E852 Cyl #12 Exhaust Port Temp Deviating Low..... 47 Engine Cranks but Will Not Start ................................................ 45 Electronic Service Tools . E801 Cylinder #1 High Exhaust Port Temp ............................................ 48 Engine Monitoring System ......................................... 43 Probable Causes .. E844 Cyl #4 Exhaust Port Temp Deviating Low ...... E825 Cyl #5 Exhaust Port Temp Deviating High.................................. 192 ECM Output Circuit (Fuel Control)...................... E830 Cyl #10 Exhaust Port Temp Deviating High . E808 Cylinder #8 High Exhaust Port Temp ............................................................ E847 Cyl #7 Exhaust Port Temp Deviating Low .......................... 13 Terminal Box .......................................................... 191 E865 High Gas Fuel Differential Pressure.......................... E809 Cylinder #9 High Exhaust Port Temp ......................................................................................... E812 Cylinder #12 High Exhaust Port Temp ........... .. 53 Recommended Repairs ............................................................................................. Probable Causes ................. 54 Engine Shutdown (Unexpected)............. 62 MID 036 ..... 59 Probable Causes .....................CID 0017 ............................................. 148 Logged Event Codes ............................CID 0017 ...... Recommended repairs..........FMI 12 Fuel Shutoff Valve malfunction . 67 Recommended Repairs .................. Gas Fuel Flow Rate (Low) ......... 71 MID 036 ................... 57 Recommended Repairs .................................................. 52 Recommended Repairs ...... 67 Probable Causes ................... 57 Engine Speed/Timing Sensor........................................................ 62 Recommended Repairs ..................... 320 Integrated Temperature Sensing Module (ITSM).............. 51 Probable Causes ....... 66 Recommended Repairs ............................................................................ 55 Probable Causes ........... 66 Probable Causes ...................................... 64 Probable Causes ................................................................................................................................ Probable Causes ...................................................................385 Index Section Engine Oil Temperature (High) ............. 62.............................................. 29 Flash Programming ................ 67 Probable Causes ............................................................... I Ignition Transformers Primary Circuit ..... 57 Probable Causes ............................. 149 Operator Information........................... 56 Recommended Repairs ................................................... 51 Recommended Repairs ..........CID 0041 ........................ Gas Temperature (High) ................................................... 51 Probable Causes ................. 53 Engine Overspeed............ 58 Engine Will Not Crank ............................................................... 60 Recommended Repairs ......................................... 29 Flash Programming................................................................................................................................. 72 MID 036 ............................... 72 ............................................................................................................. 314 Important Safety Information ...... 147 Active Event Codes............... 54 Probable Causes ..... 54 Recommended Repairs .......................................................... 58 Probable Causes ......... Probable Causes ................ Recommended Repairs ..................................................................... 148 Troubleshooting....................................................................................... 54 Engine Shutdown ........ Gas Fuel Differential Pressure (Low) ................................................ 148 Exhaust Port Temperature (High) ......................... 59 Event Codes ....................................................... 64 Recommended Repairs . 52 Probable Causes .................................................. Recommended Repairs .............................. 148 Other Symptoms ........................... 375 Engine Starts but Stalls Immediately................. 56 Probable Causes .......................... 287........................ 58 Recommended Repairs ...............................................................................................................................FMI 03 8 Volt DC Supply short to +batt. Recommended Repairs .... 61 Recommended Repairs .................................................................................... 53 Probable Causes ............................................................................ 65 Inspecting Electrical Connectors .................................................................. 66 Jacket Water Pressure (Low)............... 61 Recommended Repairs ................... 52 Engine Overload..........................CID 0017 .................................................................................................................................... 62 G Gas Fuel Differential Pressure (High)................................................. 53 Probable Causes .......... 60 Probable Causes .......... 55 Recommended Repair .................................. 60 Exhaust Port Temperature (Low) ..... 53 Recommended Repairs ... 72 MID 036 ............................................................................................................................................. 61 Probable Causes ................................ 65 J Jacket Water Inlet Pressure (High)..................... 325 Intermittent Engine Shutdown .............. Probable Causes ................................. 51 Recommended Repairs ........ 29 Factory Passwords Worksheet ................................................... 67 Recommended Repairs ...................................................................FMI 05 Fuel Shutoff Value open circuit ................................................................................................................................... 57 Engine Timing Does Not Match Programmed Timing ................ 55 Engine Shutdown without a Diagnostic Code................................ 61 Fuel Metering Valve....................................................................... 62 Recommended Repairs ..... 281 Engine Speed/Timing Sensor ................................... 67 Jacket Water to Engine Oil Differential Temperature (Low)........................... 61 Probable Causes ...... 295 Probable Causes ................................................................................................................................................. 51 Engine Overcrank......................................... 67 M 62 62 62 63 63 63 63 63 63 64 64 64 Factory Passwords ............FMI 06 Fuel Shutoff Valve short to ground.................................. 303 Ignition Transformers Secondary Circuit and Spark Plugs.. 148 Diagnostic Codes and Event Codes ..Calibrate ............ 2 Inlet Air Temperature (High) . 61 F Fuel Pressure ................................................................ 59 Recommended Repairs ........................... 30 Fuel Energy Content............ 53 Engine Pre-Lube Pressure (Low) ........................................................................................ 65 Recommended Repairs .................................... 62 Probable Causes ......................................... 65 Probable Causes .................... ........ 74 MID 036 . 82 MID 036 ...................... 75 MID 036 ... 80 MID 036 .................................................Transformer Primary open circuit......CID 0172 .Transformer Primary open circuit.FMI 06 Cylinder 12 Transformer Primary short ................................................FMI 03 Warning Lamp short to +batt..........................Transformer Primary short ................. 82 MID 036 ....... 85 MID 036 .FMI 05 Cylinder 8 ..........FMI 05 Cyinder 6 ........... 88 MID 036 ......................... 93 MID 036 ..FMI 06 Cylinder 8 ........ 94 MID 036 ....FMI 04 Engine Oil Pressure short to ground .... 73 MID 036 ......... 77 MID 036 ...... 95 .......CID 0304 .............CID 0303 .....................CID 0309 .... 81 MID 036 ...CID 0304 .....FMI 05 Pre-Lube Relay open circuit .......CID 0100 .................... 76 MID 036 ..................... 84 MID 036 ..................................CID 0311 .....CID 0145 ................FMI 03 Air Inlet Pressure Sensor short to +batt ....................... 87 MID 036 ................................CID 0302 .................FMI 03 Coolant Outlet Pressure open/short to +batt ............................FMI 06 Cylinder 15 Transformer Primary short ....FMI 05 Cylinder 10 Transformer Primary open circuit...........CID 0307 .. 87 MID 036 .......FMI 03 Intake Manifold Air Temp open/short to +batt..................................FMI 06 Cylinder 5 ............. 89 MID 036 .........FMI 03 12 Volt DC Power Supply short to +batt ...........CID 0339 ......FMI 06 Cylinder 4 ............CID 0145 ..... 83 MID 036 .........FMI 05 Cylinder 7 ......FMI 02 Incorrect ECS Switch inputs .CID 0041 ..............CID 0316 .....CID 0175 .....................386 Index Section MID 036 ................... 93 MID 036 ...............CID 0305 ..........Transformer Primary open circuit........... 77 MID 036 ..................... 85 MID 036 ....CID 0316 ........Transformer Primary short ...................................................................FMI 05 Cylinder 3 ..CID 0320 .......CID 0168 ..........FMI 04 5 Volt Sensor DC Power Supply short to ground .. 90 MID 036 .............FMI 03 Engine Oil Temperature open/short to +batt ...............CID 0313 ...CID 0301 ..........FMI 03 Engine Coolant Temperature open/short to +batt ................CID 0308 .FMI 05 Cylinder 16 Transformer Primary open circuit........................FMI 05 Cylinder 4 ........................CID 0306 ......CID 0262 .CID 0320 .........CID 0401 ..........FMI 06 Cylinder 13 Transformer Primary short .................... 86 MID 036 .Transformer Primary short ............... 82 MID 036 ...................................FMI 05 Cylinder 12 Transformer Primary open circuit......... 83 MID 036 ............Transformer Primary short ..................Transformer Primary open circuit.............................................CID 0100 .... 85 MID 036 ....................CID 0312 ................... 84 MID 036 ....................................FMI 06 Cylinder 2 ......FMI 05 Cylinder 5 .............CID 0309 ..........FMI 04 Intake Manifold Air Temp short to ground................. 73 MID 036 ..FMI 06 Cylinder 7 ........FMI 05 Cylinder 2 .......FMI 04 Engine Coolant Temperature short to ground ................CID 0310 ......FMI 08 Engine Coolant Outlet Pressure Sensor noisy signal .CID 0338 ....CID 0110 .......................CID 0175 ...CID 0308 ........................CID 0106 ..................FMI 04 8 Volt DC Supply short to ground.......... 89 MID 036 . 93 MID 036 .........................................................................CID 0336 .....CID 0307 ............CID 0106 ...............................................................CID 0302 ..... 81 MID 036 ....... 79 MID 036 .............................CID 0303 ............................FMI 05 Engine Pre-lube Pressure Switch open circuit ..............................FMI 06 Cylinder 6 ...................FMI 03 5 Volt Sensor DC Power Supply short to +batt ..FMI 06 Cylinder 11 Transformer Primary short ........CID 0323 ..........FMI 05 Cylinder 13 Transformer Primary open circuit.................................... 90 MID 036 ...............................................CID 0110 ...... 74 MID 036 ....................CID 0306 .........................FMI 13 Engine Timing calibration required ...CID 0301 .............. 92 MID 036 ..........FMI 05 Cylinder 11 Transformer Primary open circuit...FMI 06 Cylinder 3 ......................FMI 05 Cylinder 15 Transformer Primary open circuit............................................ 88 MID 036 ......CID 0262 ..CID 0314 ......................................................................CID 0109 ..Transformer Primary open circuit..........CID 0311 ....CID 0312 ..................................CID 0324 .................... 86 MID 036 .............. 75 MID 036 .....FMI 05 Cylinder 1 .....Transformer Primary short ...........................Transformer Primary short .........................................................................CID 0313 ..........Transformer Secondary open circuit ....CID 0305 ......... 84 MID 036 .... 76 MID 036 .................FMI 05 Cylinder 14 Transformer Primary open circuit..FMI 02 System Voltage intermittent/erratic..FMI 05 Cylinder 9 ..Transformer Primary short ...............CID 0109 ....................FMI 06 Cylinder 16 Transformer Primary short .......Transformer Primary open circuit.................... 80 MID 036 .... 90 MID 036 .......FMI 04 Engine Oil Temperature short to ground ...........Transformer Primary open circuit.....................Transformer Primary open circuit..........CID 0310 ......FMI 06 Cylinder 10 Transformer Primary short ............ 74 MID 036 ............FMI 08 Air Inlet Pressure Sensor noisy signal..FMI 03 Speed/Timing Sensor short to +batt ..CID 0172 .FMI 06 Cylinder 9 .. 78 MID 036 ............................ 91 MID 036 ..... 94 MID 036 . 94 MID 036 ...........FMI 05 Cylinder 1 ................. 91 MID 036 ........CID 0338 .............Transformer Primary short .......Transformer Primary open circuit.CID 0314 ............ 79 MID 036 ............................... 78 MID 036 .........FMI 04 12 Volt DC Power Supply short to ground ..FMI 06 Cylinder 1 ..... 95 MID 036 ...................... 81 MID 036 .......................... 76 MID 036 .......... 87 MID 036 .......FMI 08 Engine Speed/Timing signal abnormal ...........CID 0261 ...........FMI 03 Engine Oil Pressure open/short to +batt ... 88 MID 036 ..... 79 MID 036 ..FMI 03 Shutdown Lamp short to +batt.............................FMI 06 Pre-Lube Relay short to ground.......... 91 MID 036 ........................CID 0315 ..................... 92 MID 036 ...........FMI 06 Cylinder 14 Transformer Primary short ...............Transformer Primary short .....CID 0315 ................. 75 MID 036 ...... ..........FMI 06 Cylinder 7 ..Transformer Secondary open circuit ............ 113 MID 036 .......... 107 MID 036 ...............CID 0406 .................FMI 06 Cylinder 2 ......Transformer Secondary short to ground ........................FMI 13 Oxygen Sensor Element calibration required ...CID 0414 ..FMI 06 Start Relay short to ground....CID 1506 .Transformer Secondary short to ground ..... 95 MID 036 ...................................................CID 0406 ........................FMI 05 Fuel Metering Module open circuit ........................... 113 MID 036 ...........FMI 05 Cylinder 5 ....................... 111 MID 036 ..................CID 1042 ..FMI 05 Cylinder 10 Transformer Secondary open circuit .........Transformer Secondary open circuit ......387 Index Section MID 036 .............CID 0402 ..............CID 1086 .................FMI 06 Cylinder 11 Transformer Secondary short to ground . 110 MID 036 ...FMI 05 Cylinder 8 .CID 0412 ...........CID 0404 ...........FMI 03 Cylinder #1 Detonation Sensor open/short to +batt .....FMI 04 Cylinder #6 Detonation Sensor short to ground ............................. 105 MID 036 ............................... 107 MID 036 ....................CID 1440 .....CID 0444 .....CID 1509 .........CID 1440 .......FMI 04 Desired Engine Speed Sensor short to ground ...CID 0402 ... 106 MID 036 .............CID 0413 ........CID 1086 ............ 115 MID 036 ........... 98 MID 036 .......FMI 13 Fuel Metering Module calibration required ....Transformer Secondary short to ground ............. 116 MID 036 ......CID 1505 ..FMI 06 Cylinder 3 ...............................CID 0542 .....CID 0407 ........ 117 MID 036 ......FMI 05 Cylinder 6 ..................CID 0443 ...................CID 0411 ...Transformer Secondary short to ground ........FMI 06 Oxygen Sensor Power Supply short to ground .......................CID 1087 ... 110 MID 036 ....Transformer Secondary open circuit ...FMI 05 Start Relay open circuit ......Transformer Secondary short to ground .FMI 06 Cylinder 8 .. 96 MID 036 ...FMI 06 Cylinder 9 ......FMI 09 Oxygen Sensor Element not communicating on link .............................CID 1446 .. 104 MID 036 ...CID 0524 ............................ 105 MID 036 ......FMI 05 Throttle Actuator Driver open circuit .....CID 0404 ...FMI 03 Crank Terminate Relay short to +batt ..............FMI 06 Cylinder 14 Transformer Secondary short to ground .FMI 06 Cylinder 15 Transformer Secondary short to ground ....................CID 0415 ......................... 97 MID 036 ...............FMI 04 Cylinder #5 Detonation Sensor short to ground ... 98 MID 036 .......................CID 0405 .... 108 MID 036 . 100 MID 036 .......... 115 MID 036 .CID 1088 ..........FMI 04 Cylinder #1 Detonation Sensor short to ground ..CID 0407 .................FMI 03 Cylinder #5 Detonation Sensor open/short to +batt ......CID 1447 ........FMI 05 Cylinder 11 Transformer Secondary open circuit .FMI 06 Cylinder 1 ........ 103 MID 036 ..............Transformer Secondary open circuit .............................FMI 06 Cylinder 5 .........FMI 05 Cylinder 2 ........................Transformer Secondary short to ground ..... 117 MID 036 ..CID 0405 . 106 MID 036 .......................Transformer Secondary short to ground .............................................CID 0410 ... 117 MID 036 ...........CID 1501 ...CID 1446 ..... 111 MID 036 . 99 MID 036 ....CID 1446 ....FMI 05 Cylinder 15 Transformer Secondary open circuit ....................................................FMI 06 Cylinder 10 Transformer Secondary short to ground ... 97 MID 036 ............CID 1506 ...CID 1502 ..................Transformer Secondary short to ground ....FMI 03 Unfiltered Engine Oil Pressure open/short to +batt .FMI 06 Cylinder 6 ......................FMI 05 Cylinder 14 Transformer Secondary open circuit . 101 MID 036 ..............................CID 0412 ...... 112 MID 036 ..... 110 MID 036 ..Transformer Secondary open circuit ....FMI 03 Cylinder #9 Detonation Sensor open/short to +batt ... 116 MID 036 .... 103 MID 036 ...............CID 1502 ..FMI 08 Oxygen Sensor Buffer Module noisy signal .........CID 0408 .............FMI 12 Fuel Metering Sensor Module malfunction.... 100 MID 036 ......FMI 05 Cylinder 16 Transformer Secondary open circuit ...CID 1088 .............FMI 06 Throttle Actuator Driver short to ground .FMI 05 Cylinder 7 ............................CID 0416 ......... 116 MID 036 ..... 109 MID 036 ............... 118 ..... 109 MID 036 ...FMI 04 Cylinder #2 Detonation Sensor short to ground ................ 102 MID 036 ..........FMI 05 Cylinder 3 ... 97 MID 036 ....................................... 102 MID 036 ......FMI 12 Fuel Metering Module malfunction .......................................Transformer Secondary open circuit .. 103 MID 036 .......... 112 MID 036 ..........FMI 05 Cylinder 4 ..... 107 MID 036 .. 101 MID 036 ..FMI 05 Cylinder 12 Transformer Secondary open circuit ....................CID 0409 ..........CID 0401 .CID 0444 .................. 114 MID 036 ...........CID 0408 .....CID 0416 .......Transformer Secondary open circuit .....................CID 0403 .... 96 MID 036 ........FMI 09 Unable to communicate with ITSM......................................... 112 MID 036 ............. 104 MID 036 ..........................................CID 0410 .....CID 0445 ..........FMI 06 Cylinder 16 Transformer Secondary short to ground ................................FMI 03 Desired Engine Speed Sensor short to +batt .FMI 03 Oxygen Sensor Buffer Module short to +batt......................CID 0411 ...............FMI 05 Cylinder 9 .................. 108 MID 036 ............. 104 MID 036 ..................CID 1087 .................CID 0414 ......... 114 MID 036 .....CID 1505 ........FMI 03 Run Relay short to +batt.....CID 1501 ........FMI 06 Cylinder 13 Transformer Secondary short to ground .....CID 0403 ....................CID 0415 .... 114 MID 036 ....Transformer Secondary open circuit ...............FMI 03 Cylinder #6 Detonation Sensor open/short to +batt ........FMI 04 Unfiltered Engine Oil Pressure short to ground ......CID 0413 ..............CID 1446 ..............................................................FMI 03 Cylinder #2 Detonation Sensor open/short to +batt .FMI 06 Cylinder 12 Transformer Secondary short to ground ...........Transformer Secondary short to ground ...... 108 MID 036 ...............FMI 09 Unable to communicate with Fuel Metering Module ......... 115 MID 036 ...................... 113 MID 036 ........ 99 MID 036 ........ 100 MID 036 ..............CID 0409 .....FMI 06 Cylinder 4 ...CID 0524 ..FMI 05 Oxygen Sensor Power Supply open circuit .CID 0542 .......... 99 MID 036 ..FMI 05 Cylinder 13 Transformer Secondary open circuit ........................ 118 MID 036 ........................................... 109 MID 036 ..... ...............FMI 05 Rt Turbo Turbine In Temp Sens open circuit .......................... 121 MID 036 .............. 129 MID 111 . 130 MID 111 ........................FMI 04 Cyl #2 Exhaust Port Temp Sensor short to ground ............FMI 04 Cyl #6 Exhaust Port Temp Sensor short to ground .........CID 1758 ....FMI 04 Cylinder #13 Detonation Sensor short to ground ....................... 120 MID 036 ......CID 1490 ...... 137 MID 111 ................................. 128 MID 111 .....FMI 04 Cylinder #9 Detonation Sensor short to ground ..............CID 1542 ...FMI 03 Exhaust Back Pressure Sensor open/short to +batt ...CID 1490 . 128 MID 111 ........FMI 04 Cyl #4 Exhaust Port Temp Sensor short to ground ................................... 124 MID 111 .........CID 1541 .........FMI 03 Cyl #6 Exhaust Port Temp Sensor short to +batt ..CID 1759 ........ 135 MID 111 ..CID 1542 ...CID 1531 ............CID 1491 .........FMI 05 Cyl #5 Exhaust Port Temp Sensor open circuit ............... 123 MID 111 ................CID 1539 ...CID 1540 ....CID 1513 .......... 133 MID 111 .....................................................CID 1539 .. 131 MID 111 ..................CID 1542 ..........................FMI 03 Rt Turbo Turbine In Temp Sens short to +batt..FMI 04 CYL #9 Exhaust Port Temp Sensor short to ground .................................................... 122 MID 111 .CID 1758 ......FMI 03 Left Turbo Turbine In Temp Sens short to +batt......................CID 1540 ............................ 119 MID 036 ...........CID 1535 ............CID 1510 . 138 MID 111 .............................CID 1492 ......................CID 1535 ............CID 1509 ......................FMI 04 Cyl #5 Exhaust Port Temp Sensor short to ground ........... 135 MID 111 ........................ 130 MID 111 ..................CID 1537 ............. 136 MID 111 .............. 119 MID 036 ........FMI 04 Cyl #1 Exhaust Port Temp Sensor short to ground .....CID 1759 .........FMI 05 Cyl #8 Exhaust Port Temp Sensor open circuit ......FMI 04 Cyl #10 Exhaust Port Temp Sensor short to ground .........CID 1514 ......CID 1534 ............ 140 MID 111 ..CID 1533 .......CID 1489 ...CID 1489 . 119 MID 036 ........FMI 05 Cyl #1 Exhaust Port Temp Sensor open circuit ...........FMI 04 Cyl #11 Exhaust Port Temp Sensor short to ground ..FMI 03 Cylinder #13 Detonation Sensor open/short to +batt ........... 126 MID 111 ...............FMI 05 Cyl #11 Exhaust Port Temp Sensor open circuit ...FMI 05 Cyl #4 Exhaust Port Temp Sensor open circuit ............... 137 MID 111 ..................CID 1538 ..FMI 03 Cylinder #14 Detonation Sensor open/short to +batt .........FMI 04 Cylinder #14 Detonation Sensor short to ground ..........................CID 1538 ........ 132 MID 111 ........CID 1532 .CID 1541 ................... 137 MID 111 ...... 134 MID 111 ... 126 MID 111 ....................... 123 MID 111 ......................CID 1532 ......... 125 MID 111 ...............FMI 04 Left Turbo Turbine Out Temp Sens short to ground ........................ 128 MID 111 ...................FMI 03 Cyl #9 Exhaust Port Temp Sensor short to +batt ....CID 1492 .... 121 MID 036 ..............CID 1532 ....................... 122 MID 111 ................ 127 MID 111 ........FMI 04 Cyl #12 Exhaust Port Temp Sensor short to ground . 120 MID 036 .CID 1489 ....CID 1538 ...........FMI 03 Cyl #10 Exhaust Port Temp Sensor short to +batt ..FMI 12 EEPROM checksum fault or ECM not programmed.........FMI 03 Cyl #3 Exhaust Port Temp Sensor short to +batt ............CID 1534 ................................ 124 MID 111 ............................................FMI 03 Cyl #1 Exhaust Port Temp Sensor short to +batt .....FMI 04 Cyl #3 Exhaust Port Temp Sensor short to ground ..FMI 03 Cyl #11 Exhaust Port Temp Sensor short to +batt ...........................................CID 1537 ...............FMI 04 Cyl #8 Exhaust Port Temp Sensor short to ground ....... 132 MID 111 ............FMI 05 Cyl #7 Exhaust Port Temp Sensor open circuit ..... 123 MID 111 ............CID 1490 . 133 MID 111 ....CID 1531 .......FMI 04 Cylinder #10 Detonation Sensor short to ground ......FMI 04 Rt Turbo Turbine In Temp Sens short to ground .. 139 MID 111 .CID 1491 . 134 MID 111 . 138 MID 111 ...... 122 MID 036 ....................... 125 MID 111 ................. 127 MID 111 ........CID 1531 ............................................................... 136 MID 111 ........................................ 118 MID 036 ...FMI 08 Exhaust Back Pressure Sensor signal abnormal.........CID 1539 ........................CID 1536 ...........FMI 05 Left Turbo Turbine Out Temp Sens open circuit ............CID 1513 .FMI 05 Cyl #2 Exhaust Port Temp Sensor open circuit ..................................CID 1492 ..............CID 1536 .......CID 1540 ..FMI 03 Cyl #8 Exhaust Port Temp Sensor short to +batt ........ 140 MID 111 ..CID 1514 ....CID 1534 ...FMI 03 Cylinder #10 Detonation Sensor open/short to +batt .........CID 1541 ......FMI 03 Rt Turbo Turbine Out Temp Sens short to +batt....CID 1533 ............. 129 MID 111 .......FMI 05 Cyl #9 Exhaust Port Temp Sensor open circuit ....... 130 MID 111 ....... 141 ................ 125 MID 111 .....CID 1537 ....CID 1536 .388 Index Section MID 036 .......FMI 08 Specific Humidity Sensor signal abnormal... 132 MID 111 ......FMI 05 Cyl #12 Exhaust Port Temp Sensor open circuit .......... 120 MID 036 ..........................................FMI 05 Cyl #10 Exhaust Port Temp Sensor open circuit .FMI 03 Cyl #5 Exhaust Port Temp Sensor short to +batt ... 131 MID 111 ...CID 0591 ...FMI 03 Cyl #4 Exhaust Port Temp Sensor short to +batt .. 124 MID 111 ..........................FMI 03 Left Turbo Turbine Out Temp Sens short to +batt....................FMI 05 Cyl #3 Exhaust Port Temp Sensor open circuit .......FMI 05 Cyl #6 Exhaust Port Temp Sensor open circuit ..... 133 MID 111 ........FMI 03 Cyl #2 Exhaust Port Temp Sensor short to +batt ..FMI 04 Cyl #7 Exhaust Port Temp Sensor short to ground ..............CID 1533 .FMI 03 Cyl #12 Exhaust Port Temp Sensor short to +batt ....FMI 04 Left Turbo Turbine In Temp Sens short to ground ...........CID 1491 ......... 135 MID 111 ..........................FMI 04 Rt Turbo Turbine Out Temp Sens short to ground ........CID 1510 ...........................FMI 05 Rt Turbo Turbine Out Temp Sens open circuit ..FMI 03 Specific Humidity Sensor open/short to +batt ......... 139 MID 111 .......... 126 MID 111 ... 139 MID 111 .CID 1535 .....................FMI 05 Left Turbo Turbine In Temp Sens open circuit .FMI 03 Cyl #7 Exhaust Port Temp Sensor short to +batt . ...............................CID 1543 ...........................................CID 1546 .. 10 Engine Speed Governing............................................. 69 .......................FMI 03 Cyl #14 Exhaust Port Temp Sensor short to +batt ..... Symptoms................CID 1544 ............................................ Timing Control................................................ 69 Recommended Repairs ................CID 1546 ........... Information for the Electronic Control Module (ECM)................ Operator Information..................................................................................... 143 MID 111 ......................................FMI 03 Cyl #15 Exhaust Port Temp Sensor short to +batt ............ 377 Oxygen Sensor Buffer Supply ......................... 365 Troubleshooting Data Sheet ........ 333 Oxygen Sensor Signal. 40 Troubleshooting Section ........................ 10 41 41 41 41 30 32 31 36 36 33 35 32 System Overview.........CID 1544 .........FMI 03 Cyl #13 Exhaust Port Temp Sensor short to +batt ...................................................................... 9 Introduction ................................FMI 04 Cyl #13 Exhaust Port Temp Sensor short to ground .................................... 68 T Table of Contents.................................................................. 9 Engine Monitoring and Protection......... 28 PWM Sensor .........................................................Calibrate ... Start/Stop Control Parameters.......FMI 05 Cyl #16 Exhaust Port Temp Sensor open circuit . 68 Recommended Repairs .......... 38 S Self-Diagnostics........... 68 Recommended Repairs .................................... Override Parameters......................CID 1543 ........ 147 Troubleshooting without a Diagnostic Code ......... 142 MID 111 ................... 39 Report the Service Information................................... 9 Ignition Control..................................CID 1546 ........ 10 System Voltage................................................ 68 Turbocharger Turbine Temperature (Low).. 141 MID 111 .... Air/Fuel Ratio Control..................................FMI 05 Cyl #14 Exhaust Port Temp Sensor open circuit ............................. 143 MID 111 ......................................................................................... 145 O Oxygen Sensor ..FMI 04 Cyl #16 Exhaust Port Temp Sensor short to ground ...................... 145 MID 111 ....................................... 9 Air/Fuel Ratio Control........................................................................ Speed Control ...................... 68 Probable Causes ................ 68 Probable Causes ........................ 342 P Prelubrication System ....................................................................................FMI 05 Cyl #13 Exhaust Port Temp Sensor open circuit ........FMI 05 Cyl #15 Exhaust Port Temp Sensor open circuit ...................................CID 1545 ................... Diagnostic Codes and Event Codes .. 3 Throttle Actuator Solenoid ..CID 1545 ............. System Configuration Parameters................ 41 Turbocharger Turbine Temperature (High)................... 36 Replacing the ITSM ..................... “Monitoring and Protection” ........................................................ 70 Troubleshooting with an Event Code ......................... 9 Troubleshooting with a Diagnostic Code ......................................CID 1545 .................................... 69 Probable Causes ................... 144 MID 111 .....CID 1544 .......................................... 358 R Replacing the ECM.......... 142 MID 111 ..................... 143 MID 111 ......FMI 04 Cyl #14 Exhaust Port Temp Sensor short to ground .................CID 1543 ......... 354 Programming Parameters................................. 145 MID 111 ........................................................ Other Symptoms ...............FMI 03 Cyl #16 Exhaust Port Temp Sensor short to +batt .......................... 144 MID 111 ........................ 141 MID 111 ..................................... 9 Start/Stop Sequencing...................................FMI 04 Cyl #15 Exhaust Port Temp Sensor short to ground ..........................................389 Index Section MID 111 . 390 Index Section . 391 Index Section . S.A.©2002 Caterpillar All Rights Reserved Printed in U. .