Renr5009 07 00 All

RENR5009-07
August 2010
Troubleshooting
3500B and 3500C Marine Propulsion
Engines
M8A1-Up (Engine)
M8B1-Up (Engine)
S2D1-Up (Engine)
S2E1-Up (Engine)
S2F1-Up (Engine)
B5G1-Up (Engine)
MRG1-Up (Engine)
PAG1-Up (Engine)
MKH1-Up (Engine)
S2J1-Up (Engine)
S2K1-Up (Engine)
S2L1-Up (Engine)
S2M1-Up (Engine)
S2N1-Up (Engine)
S2S1-Up (Engine)
S2T1-Up (Engine)
S2W1-Up (Engine)
S2X1-Up (Engine)
S2Y1-Up (Engine)
SAFETY.CAT.COM
i03991620
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 identied 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.
A non-exhaustive list of operations that may cause product damage are identied 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. You must
not use this product in any manner different from that considered by this manual without rst
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specic rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specically 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 become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specications, 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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
cations including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5009-07 3
Table of Contents
Table of Contents MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open
circuit ................................................................... 64
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1
short .................................................................... 64
Troubleshooting Section MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open
circuit ................................................................... 64
Electronic Troubleshooting
System Overview .................................................... 6
short .................................................................... 65
Self-Diagnostics .................................................... 10
MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open
Electronic Service Tools ......................................... 11
circuit ................................................................... 65
Electronic Display Module .................................... 14
Engine Monitoring System .................................... 16
short .................................................................... 65
Programming Parameters
circuit ................................................................... 65
Programming Parameters ..................................... 21
Factory Passwords ............................................... 21
short .................................................................... 66
Factory Passwords Worksheet ............................. 21
Flash Programming .............................................. 22
circuit ................................................................... 66
System Conguration Parameters ........................ 23
Customer Parameters Worksheet ........................ 27
short .................................................................... 66
Replacing the ECM ............................................... 29
circuit ................................................................... 66
Troubleshooting without a Diagnostic Code
Symptoms ............................................................. 31
short .................................................................... 67
Air Starting Motor .................................................. 31
Alternator .............................................................. 32
circuit ................................................................... 67
Can Not Reach Top Engine RPM ......................... 32
Coolant in Engine Oil ............................................ 33
short .................................................................... 67
Coolant Temperature Is Too High ......................... 34
ECM Will Not Accept Factory Passwords ............. 35
circuit ................................................................... 67
ECM Will Not Communicate with Other Systems or
Display Modules .................................................. 35
short .................................................................... 68
Electronic Service Tool Will Not Communicate with
ECM .................................................................... 35
circuit ................................................................... 68
Engine Cranks but Will Not Start .......................... 36
Engine Has Early Wear ........................................ 38
short .................................................................... 68
Engine Misres, Runs Rough or Is Unstable ........ 38
Engine Oil in Cooling System ............................... 40
open circuit .......................................................... 68
Engine Stalls at Low RPM .................................... 40
Engine Will Not Crank ........................................... 41
short .................................................................... 69
Excessive Engine Oil Consumption ...................... 42
Excessive Black Smoke ........................................ 43
open circuit .......................................................... 69
Excessive White Smoke ....................................... 44
Exhaust Temperature Is Too High ......................... 45
short .................................................................... 69
Fuel Dilution of Engine Oil .................................... 45
Fuel in Cooling System ......................................... 46
open circuit .......................................................... 69
Intermittent Engine Shutdown ............................... 46
Intermittent Low Power or Power Cutout .............. 47
short .................................................................... 70
Low Engine Oil Pressure ...................................... 48
Low Power/Poor or No Response to Throttle ....... 49
open circuit .......................................................... 70
Mechanical Noise (Knock) in Engine .................... 50
Noise Coming from Cylinder ................................. 51
short .................................................................... 70
Poor Fuel Consumption ........................................ 51
Secondary ECM Assumes Control ....................... 52
open circuit .......................................................... 70
Secondary ECM Indicator Fault ............................ 53
Synchronizing Switch Not Functioning Properly ... 53
short .................................................................... 71
Too Much Valve Lash ............................................ 61
Too Much Vibration ............................................... 61
open circuit .......................................................... 71
Valve Rotocoil or Spring Lock Is Free ................... 62
short .................................................................... 71
Troubleshooting with a Diagnostic Code
Diagnostic Codes .................................................. 63
open circuit .......................................................... 71
4 RENR5009-07
Table of Contents
MID 036 - CID 0016 - FMI 06 Injector Cylinder 16 MID 036 - CID 0274 - FMI 04 Atmospheric Pressure
short .................................................................... 72 short to ground .................................................... 80
MID 036 - CID 0091 - FMI 08 Throttle Position signal MID 036 - CID 0275 - FMI 03 Right Turbo Inlet
abnormal ............................................................. 72 Pressure open/short to +batt .............................. 80
MID 036 - CID 0091 - FMI 13 Throttle Position MID 036 - CID 0275 - FMI 04 Right Turbo Inlet
calibration required ............................................. 72 Pressure short to ground .................................... 81
MID 036 - CID 0094 - FMI 03 Fuel Pressure MID 036 - CID 0276 - FMI 03 Left Turbo Inlet
open/short to +batt .............................................. 73 Pressure open/short to +batt .............................. 81
MID 036 - CID 0094 - FMI 04 Fuel Pressure short to MID 036 - CID 0276 - FMI 04 Left Turbo Inlet
ground ................................................................. 73 Pressure short to ground .................................... 81
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0277 - FMI 08 Timing Calibration
open/short to +batt .............................................. 73 signal abnormal ................................................... 81
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0279 - FMI 03 Aftercooler Temperature
short to ground .................................................... 73 open/short to +batt .............................................. 82
MID 036 - CID 0101 - FMI 03 Crankcase Pressure MID 036 - CID 0279 - FMI 04 Aftercooler Temperature
open/short to +batt .............................................. 74 short to ground .................................................... 82
MID 036 - CID 0101 - FMI 04 Crankcase Pressure MID 036 - CID 0289 - FMI 03 Unltered Fuel Pressure
short to ground .................................................... 74 open/short to +batt .............................................. 82
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0289 - FMI 04 Unltered Fuel Pressure
Temperature open/short to +batt ......................... 74 short to ground .................................................... 83
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature short to ground ............................... 74 inputs .................................................................. 83
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0337 - FMI 02 Incorrect Remote
High ..................................................................... 75 E-Stop Switch inputs ........................................... 83
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Low ..................................................................... 75 circuit ................................................................... 83
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
intermittent/erratic ............................................... 75 to ground ............................................................. 84
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0342 - FMI 02 Loss of Secondary
signal ................................................................... 75 Engine Speed signal ........................................... 84
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0342 - FMI 03 Secondary Engine
open/short to +batt .............................................. 76 Speed open/short to +batt .................................. 84
MID 036 - CID 0190 - FMI 07 Primary Speed Sensor MID 036 - CID 0342 - FMI 07 Secondary Speed
misinstalled ......................................................... 76 Sensor misinstalled ............................................. 84
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0342 - FMI 08 Secondary Engine
abnormal ............................................................. 76 Speed signal abnormal ....................................... 85
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0444 - FMI 05 Start Relay open
communicating .................................................... 76 circuit ................................................................... 85
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0444 - FMI 06 Start Relay short to
mismatch ............................................................. 77 ground ................................................................. 85
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
Module Error ....................................................... 77 open .................................................................... 85
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
calibration required ............................................. 77 short .................................................................... 86
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0542 - FMI 03 Unltered Engine Oil
Power Supply short to +batt ................................ 78 Pressure open/short to +batt .............................. 86
Power Supply short to ground ............................. 78 Pressure short to ground .................................... 86
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply MID 036 - CID 0827 - FMI 08 Left Exhaust
short to +batt ....................................................... 78 Temperature signal abnormal ............................. 86
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply MID 036 - CID 0828 - FMI 08 Right Exhaust
short to ground .................................................... 78 Temperature signal abnormal ............................. 87
MID 036 - CID 0268 - FMI 02 Check Programmable MID 036 - CID 1249 - FMI 08 Secondary Throttle
Parameters ......................................................... 79 Position signal abnormal ..................................... 87
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure MID 036 - CID 1249 - FMI 13 Secondary Throttle
above normal ...................................................... 79 Position calibration required ................................ 87
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure MID 036 - CID 1495 - FMI 02 Injector Trim Codes Not
open/short to +batt .............................................. 79 Programmed ....................................................... 88
MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure MID 047 - CID 0001 - FMI 05 Injector Cylinder 1 open
short to ground .................................................... 80 circuit ................................................................... 88
MID 036 - CID 0274 - FMI 03 Atmospheric Pressure MID 047 - CID 0001 - FMI 06 Injector Cylinder 1
open/short to +batt .............................................. 80 short .................................................................... 88
RENR5009-07 5
Table of Contents
MID 047 - CID 0002 - FMI 05 Injector Cylinder 2 open MID 047 - CID 0190 - FMI 08 Engine Speed signal
circuit ................................................................... 88 abnormal ............................................................. 96
MID 047 - CID 0002 - FMI 06 Injector Cylinder 2 MID 047 - CID 0342 - FMI 02 Loss of Secondary
short .................................................................... 89 Engine Speed signal ........................................... 96
MID 047 - CID 0003 - FMI 05 Injector Cylinder 3 open MID 047 - CID 0342 - FMI 08 Secondary Engine
circuit ................................................................... 89 Speed signal abnormal ....................................... 97
short .................................................................... 89 Troubleshooting with an Event Code
MID 047 - CID 0004 - FMI 05 Injector Cylinder 4 open Event Codes ........................................................ 98
circuit ................................................................... 89 E007 High Aftercooler Temperature Derate .......... 99
MID 047 - CID 0004 - FMI 06 Injector Cylinder 4 E008 High Aftercooler Temperature Shutdown .. 100
short .................................................................... 90 E009 High Altitude Derate .................................. 101
MID 047 - CID 0005 - FMI 05 Injector Cylinder 5 open E012 High Crankcase Pressure Derate .............. 101
circuit ................................................................... 90 E013 High Crankcase Pressure Shutdown ........ 102
MID 047 - CID 0005 - FMI 06 Injector Cylinder 5 E015 High Engine Coolant Temperature Derate .. 103
short .................................................................... 90 E016 High Engine Coolant Temperature
MID 047 - CID 0006 - FMI 05 Injector Cylinder 6 open Shutdown .......................................................... 104
circuit ................................................................... 90 E017 High Engine Coolant Temperature
MID 047 - CID 0006 - FMI 06 Injector Cylinder 6 Warning ............................................................. 104
short .................................................................... 91 E021 High Exhaust Temperature Derate ............ 105
MID 047 - CID 0007 - FMI 05 Injector Cylinder 7 open E031 Air Inlet Restriction Derate ........................ 106
circuit ................................................................... 91 E038 Low Engine Coolant Temperature
MID 047 - CID 0007 - FMI 06 Injector Cylinder 7 Warning ............................................................. 107
short .................................................................... 91 E040 Low Engine Oil Pressure Shutdown .......... 108
MID 047 - CID 0008 - FMI 05 Injector Cylinder 8 open E043 Low System Voltage Warning .................... 109
circuit ................................................................... 91 E048 Backup ECM Took Control ......................... 110
MID 047 - CID 0008 - FMI 06 Injector Cylinder 8 E095 Fuel Filter Restriction Warning ................... 111
short .................................................................... 92 E099 Engine Oil Filter Restriction Warning .......... 112
MID 047 - CID 0009 - FMI 05 Injector Cylinder 9 open E100 Low Engine Oil Pressure Warning .............. 112
circuit ................................................................... 92 E101 High Crankcase Pressure Warning ............ 113
MID 047 - CID 0009 - FMI 06 Injector Cylinder 9 E173 High Exhaust Temperature Warning ........... 114
short .................................................................... 92 E190 Engine Overspeed Warning ....................... 115
MID 047 - CID 0010 - FMI 05 Injector Cylinder 10 E272 Inlet Air Restriction Warning ....................... 116
open circuit .......................................................... 92 E279 High Aftercooler Temperature Warning ...... 116
short .................................................................... 93 Diagnostic Functional Tests
MID 047 - CID 0011 - FMI 05 Injector Cylinder 11 Air Shutoff System ............................................... 118
open circuit .......................................................... 93 Analog Sensor Supply ........................................ 125
MID 047 - CID 0011 - FMI 06 Injector Cylinder 11 CAN Data Link .................................................... 128
short .................................................................... 93 Cat Data Link ...................................................... 131
MID 047 - CID 0012 - FMI 05 Injector Cylinder 12 Digital Sensor Supply ......................................... 133
open circuit .......................................................... 93 Electrical Power Supply ...................................... 136
MID 047 - CID 0012 - FMI 06 Injector Cylinder 12 Emergency Stop Switch ...................................... 142
short .................................................................... 94 Emergency Stop Switch (Remote) ...................... 148
MID 047 - CID 0013 - FMI 05 Injector Cylinder 13 Engine Control Switch (ECS) .............................. 153
open circuit .......................................................... 94 Engine Sensor Open/Short Test ......................... 161
MID 047 - CID 0013 - FMI 06 Injector Cylinder 13 Engine Speed/Timing Sensor ............................. 170
short .................................................................... 94 Injector Solenoids ............................................... 175
MID 047 - CID 0014 - FMI 05 Injector Cylinder 14 Inspecting Electrical Connectors ........................ 182
open circuit .......................................................... 94 Prelubrication System ......................................... 187
MID 047 - CID 0014 - FMI 06 Injector Cylinder 14 Secondary ECM/Personality Module .................. 192
short .................................................................... 95 Starting Motor System ....................................... 197
MID 047 - CID 0015 - FMI 05 Injector Cylinder 15 Throttle Position Sensor ..................................... 202
open circuit .......................................................... 95
MID 047 - CID 0015 - FMI 06 Injector Cylinder 15 Calibration Procedures
short .................................................................... 95 Analog Sensor - Calibrate ................................... 208
MID 047 - CID 0016 - FMI 05 Injector Cylinder 16 Engine Speed/Timing Sensor - Calibrate ............ 209
open circuit .......................................................... 95 Throttle Position Sensor - Calibrate ..................... 211
short .................................................................... 96 Index Section
MID 047 - CID 0190 - FMI 02 Loss of Engine Speed
signal ................................................................... 96 Index ................................................................... 214
6 RENR5009-07
Troubleshooting Section
Troubleshooting Section The ECM is programmed at the factory which limits

the quantity of fuel that can be injected. The position
of the Fuel Ratio Control (FRC) controls the fuel
limit for exhaust smoke. The FRC is based on the
Electronic Troubleshooting maximum allowable ratio of fuel to air. The FRC fuel
position is increased when the ECM senses a higher
turbocharger compressor outlet pressure. This will
i01911288 allow more fuel into the cylinder.
System Overview The rated fuel position is a limit that is based on the
engine power rating. This is similar to the rack stops
SMCS Code: 1901-038; 1924 and the torque spring on a mechanically governed
engine. The rated fuel position limits the power curve
The engine is designed for electronic control of most and the torque curve for a specic engine family.
engine operating functions. The electronic system
consists of the following components: Electronic
Control Module (ECM), wiring harness, switches,
sensors, and electronic fuel injectors.
Electronic Controls
Electronic Control Module
The ECM controls the engine operation. The ECM
consists of two main components, the control
computer (hardware) and the personality module
(software). The control computer consists of
a microprocessor and electronic circuitry. The
personality module is the software for the control
computer which contains operating maps that dene
power and torque curves. The ECM monitors the
engine parameters during operation. The ECM
supplies signals to the electronic fuel injectors.
The ECM governs engine speed. Desired engine

speed is determined by the throttle position sensor
signal and certain sensor readings. Diagnostic codes
may derate the engine. Actual engine speed is
supplied to the ECM by the engine speed/timing
sensor.
Fuel Injection
The ECM controls the timing of the engine by varying
the signals to the electronic solenoids that control
fuel injection. Fuel is injected only while an injector
solenoid is energized by a 105 volt signal from the
ECM. By controlling the timing and duration of the
105 volt signal, the ECM controls the fuel injection
timing, the quantity of fuel and the desired engine
speed. Injection timing depends on desired engine
speed, load, and other operational factors.
The ECM limits engine power during cold mode

operation. The ECM may modify the injection timing
and the ECM may cut out certain engine cylinders.
This will increase startability and this will reduce warm
up time. Cold mode is activated whenever the engine
coolant temperature falls below a predetermined
value. Cold mode remains active until the engine has
warmed or a time limit is exceeded.
RENR5009-07 7
Engine Wiring Diagram
g00995630
Illustration 1
Typical example
8 RENR5009-07
Location of the Engine

Components
g01019029
Illustration 2
Left side view
(1) Unltered fuel pressure sensor (5) Secondary ECM connector J2 (8) Secondary engine speed/timing sensor
(2) Filtered fuel pressure sensor (6) Left exhaust temperature sensor (9) Primary engine speed/timing sensor
(3) Aftercooler temperature sensor (7) Left turbocharger compressor inlet (10) Secondary ECM connector J1
(4) Coolant temperature sensor pressure sensor (11) Secondary ECM
RENR5009-07 9

Components
g01019032
Illustration 3
Right side view
(12) Right turbocharger compressor inlet (13) Right exhaust temperature sensor
pressure sensor (14) Crankcase pressure sensor
10 RENR5009-07

Components
g01019034
Illustration 4
Front and rear view
(4) Coolant temperature sensor (7) Left turbocharger compressor inlet (18) Atmospheric pressure sensor
(15) Filtered engine oil pressure sensor pressure sensor (19) Primary ECM connector J1
(16) Unltered engine oil pressure sensor (6) Left exhaust temperature sensor (20) Primary ECM
(3) Aftercooler temperature sensor (13) Right exhaust temperature sensor (21) Primary ECM connector J2
(17) Turbocharger compressor outlet (12) Right turbocharger compressor inlet
pressure sensor pressure sensor
i01977688 Event Code An event code is generated by the

detection of an abnormal engine operating condition.
Self-Diagnostics For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
SMCS Code: 1901-038 indicates the symptom of a problem.
The Electronic Control Module (ECM) has the ability The codes can have two different states:
to detect problems with the electronic system and
with engine operation. When a problem is detected, a Active
code is generated. An alarm may also be generated.
There are two types of codes: Logged
Diagnostic Active Code An active diagnostic code or an
active event code indicates that an active problem
Event has been detected. Active codes require immediate
attention. Always service active codes prior to
Diagnostic Code When a problem with the servicing logged codes.
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specic problem Logged Code Every generated code is stored in
with the electronic control system. the permanent memory of the ECM. The codes are
logged.
RENR5009-07 11
Logged codes may not indicate that a repair is Table 1

needed. The problem may have been temporary. The Service Tools
problem may have been resolved since the logging
of the code. If the system is powered, it is possible Pt. No. Description
to generate an active diagnostic code whenever a N/A 4 mm Allen Wrench
component is disconnected. When the component is
reconnected, the code is no longer active. Logged 151-6320 Wire Removal Tool (14-GA TO 18-GA,
codes may be useful to help troubleshoot intermittent RED)
problems. Logged codes can also be used to review 1U-5804 Crimp Tool (12AWG TO 18AWG)
the performance of the engine and of the electronic
system. 6V-2197 Transducer
7X-1171 Transducer Adapter
i04020509 7X-1695 Cable As
Electronic Service Tools 146-4080 Digital Multimeter Gp (RS232)
7X-1710 Multimeter Probes
SMCS Code: 1901-038
326-4904 Adapter Cable As (3-PIN BREAKOUT)
Service Tools 7X-1715 Adapter Cable As (40-PIN BREAKOUT)
134-5195 Harness (40-PIN)
Most of the tools that are listed in Table 1 are required For ADEM 2 ECM (two 40-pin
to enable a service technician to perform the test connectors)
procedures in this manual. Some of the devices are 208-0059 Adapter Cable As (70-PIN BREAKOUT)
specic to the type of Electronic Control Module For ADEM 3 ECM (two 70-pin
(ECM) that is being used. connectors) and for ADEM 4 ECM
(one 70-pin connector and one 120-pin
connector)
257-8718 Adapter Cable As (120-PIN BREAKOUT)
For ADEM 4 ECM (one 70-pin connector
and one 120-pin connector)
N/A Torque Wrench (capable of applying
1.5 Nm (13.3 lb in))
Repair Kits for Connectors
270-5051 Connector Repair Kit (AMPSEAL)
175-3700 Connector Repair Kit (DEUTSCH DT)
Bypass Harnesses for the ECM
129-2018 Power Cable
Stand alone cable for ADEM 2 ECM
217-0113 Wiring Harness (ECM BYPASS)
The bypass harness connects to the
battery. The bypass harness is used
with the following harnesses for different
types of electronic control modules.
328-2292 Harness (ENGINE ECM BYPASS)
For ADEM 3 ECM and ADEM 4 ECM
277-4734 Harness (ENGINE ECM BYPASS)
For A4:E2 ECM (Two 64-pin connectors)
Two short jumper wires are needed to check the

continuity of some wiring harness circuits by shorting
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the
continuity of some wiring harness circuits.
12 RENR5009-07
Optional Service Tools Once you have downloaded Cat ET onto your
PC, you will need a license from your Caterpillar
Table 2 lists the optional service tools that may be dealer in order to use the software. Various licenses
needed during testing or repair. are available for different users with different
requirements. Consult your Caterpillar dealer.
Table 2
Optional Service Tools Note: For more information regarding the use of
Cat ET and the PC requirements for Cat ET, refer to
Pt. No. Description the documentation that accompanies your Cat ET
198-4240 Digital Pressure Indicator software.
or or
1U-5470 Engine Pressure Group Connecting Cat ET
4C-4075 Crimp Tool (4AWG TO 10AWG)
Connecting the Communication Adapter
4C-4911(1) Battery Load Tester
5P-7277 Voltage Tester Table 4 lists the standard hardware that is required in
order to connect Cat ET.
6V-9130(2) Temperature Adapter (MULTIMETER)
8T-5319 Connector Tool Group Note: The 275-5120 Communication Adapter
Gp was canceled and replaced by the 317-7484
349-4199 AC/DC Current Probe Communication Adapter Gp. However, the 275-5120
348-5430 Multi-Tool Gp Communication Adapter Gp can still be used.
(1) Refer to Special Instructions, SEHS9249, Use of 4C-4911 Table 4
Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries and
Special Instructions, SEHS7633, Battery Test Procedure. Standard Hardware for the Use of Cat ET
(2) Refer to Special Instructions, SEHS8382, Use of the 6V-9130
Temperature Adapter Group. Part Number Description
N/A Personal Computer (PC)

Caterpillar Electronic Technician
Communication Adapter
(ET) 317-7484
Gp
Cat ET can be used by the technician to help perform Components of the 317-7484 Communication
the following procedures: Adapter Gp
Communication Adapter
317-7485
Diagnostic tests (3)
353-5083 Cable As (USB)
Calibrations
327-8981 Cable As (DATA LINK)
Flash programming Tool Operating Manual & Software CD ROM,
NETG5057, Communication Adapter 3
Conguration of the ECM
Cat ET can display the following information: Follow the instructions for the communication
adapter. Use the following procedure in order to
Parameters connect Cat ET and the communication adapter to
a PC.
Event codes
1. Remove the electrical power from the ECM.
Diagnostic codes
Engine conguration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Software, JEBD3003, CATERPILLAR

ELECTRONIC TECHNICIAN
RENR5009-07 13
Cat ET displays a message that indicates that

the rmware in the communications adapter is
old.
Dual Data Links
When the connection of the communication adapter

is complete, observe the communication adapter
and Cat ET. If the J1939 and the Cat Data Link
indicators are ashing and Cat ET does not display
a message that indicates Service tool support is
limited, Cat ET is communicating with the ECM on
both data links.
Refer to Troubleshooting, Electronic Service Tool

Does Not Communicate if the J1939 indicator and
the Cat Data Link indicator are not ashing. Both
indicators must be ashing.
Communicating with the Wireless Communication

Adapter
g02051513
Illustration 5
(1) PC
Table 5 lists the optional hardware that is needed
(2) 353-5083 Cable As (USB) in order to connect Cat ET by using a wireless
(3) 317-7485 Communication Adapter (3) connection.
(4) 327-8981 Cable As (DATA LINK)
Note: Some applications cannot use a wireless
2. Connect cables (2) and (4) to communication connection. Also, a dual data link cannot be used
adapter (3). with a wireless connection.
Note: The communication adapter will power up Table 5

when the adapter is connected to a PC or to an ECM Optional Hardware for the Use of Cat ET
that is powered up.
Part Number Description
3. Connect cable (2) to the USB port of the PC.
N/A Personal Computer (PC)
4. Connect cable (4) to a service tool connector.
5. Restore electrical power to the ECM. Verify that

the POWER indicator on the communication
adapter is illuminated. Make sure that the PC is
powered up.
6. Establish communication between Cat ET and the

ECM. If Cat ET indicates that there is more than
one ECM, select the engine ECM.
7. If Cat ET and the communication adapter

do not communicate with the ECM, refer to
Troubleshooting, Electronic Service Tool Will Not
Communicate with ECM.
Refer to Troubleshooting, Electronic Service Tool

Does Not Communicate if any of the following
conditions exist:
Cat ET displays a message that refers to a

communication problem. g01297379
Illustration 6
Cat ET displays Error #142 The interface (1) Personal computer (PC)
(7) 261-4867 Card (PCMCIA)
hardware is not responding. (8) 239-9955 Communication Radio Gp
(9) 259-3183 Data Link Cable As
14 RENR5009-07
Note: Items (7), (8), and (9) are part of the 261-3363
Wireless Communication Adapter Gp.
Use the following procedure in order to connect the

wireless communication adapter for use with Cat ET.
1. Remove the electrical power from the ECM.
2. Ensure that the computer has been correctly

congured for the 261-4867 Card. Verify that
the PC card is installed in the computer PCMCIA
expansion slot.
3. Connect cable (9) between communication radio

(8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET

and the communication radio do not communicate
with the ECM, refer to Troubleshooting, Electronic
Service Tool Will Not Communicate with ECM.
PL1000E Communication ECM (If

Equipped)
g01163897
Illustration 7
The PL1000E is an ECM that provides the i03158926

customer with the ability to integrate Caterpillar
engines into specic applications. The PL1000E Electronic Display Module
enables communication from a J1939 data link
to a Modbus. A PC with Cat ET installed can be SMCS Code: 1901-038
connected to the PL1000E through the RS232
serial port of the PC. The PL1000E contains an The control panel is the control station for the
embedded communications adapter that will allow engine. The control panel has the following controls
Cat ET to communicate with the engine over the on the front of the panel: Marine Power Display
J1939 data link. (MPD), Engine Control Switch (ECS), emergency
stop switch, and indicator lamps. The control panel
Refer to System Operation/Troubleshooting/Test and contains the following controls on the inside of
Adjust, RENR8091, PL1000E Communication ECM the panel: override switches, local/remote switch
for additional information. (throttle), control relays, and diodes.
RENR5009-07 15
Control Panel
g01316970
Illustration 8
Control panel
(1) Marine Power Display (11) Reset 1 relay (21) Overspeed indicator
(2) ECM Ready lamp (12) Stop 1 relay (22) Emergency stop lamp
(3) Pyrometer (13) Reset 2 relay (23) STE relay
(4) Override switch (crank) (14) Stop 2 relay (24) Run 1 relay
(5) Prelube override switch (15) Horn relay (25) STPE relay
(6) Marine override switch (16) Engine control switch (ECS) (26) Run 2 relay
(7) Torque limit switch (17) Speed Control (27) ECSIR relay
(8) Local/remote switch (throttle) (18) Emergency stop switch (28) SN relay
(9) Diodes D1 to D10 (19) ECM Active lamp
(10) RSR relay (20) Alarm (horn)
Power Distribution Panel

The power distribution panel distributes power to
the various systems on the engine. The power
distribution panel has two external connections for
the battery. The power distribution panel has multiple
breakers that are mounted externally. The power
distribution panel contains the following controls
on the inside of the panel: control relays, circuit
breakers, diodes, control switches, and timer.
16 RENR5009-07
g01621243
Illustration 9
Power distribution panel
(29) Circuit breaker for the primary ECM (20 (34) PPR2 relay (44) SD Notify relay
Amp) (35) Relay 4A (45) Starting motor magnetic switch 2
(30) Circuit breaker for the secondary ECM (36) Relay 4 (46) Starting motor magnetic switch 1
(20 Amp) (37) Relay 3A (47) PPR1 switch
(31) Circuit breaker for the prelube and air (38) Relay 3 (48) Air shutoff switch (ASOS)
shutoff circuits (40 Amp) (39) Relay 2A
(32) Marine Power Display (MPD) circuit (40) Relay 2
breaker (20 Amp) (41) Relay 1
(33) Starter and alternator circuit breaker (42) Air shutoff timer
(70 Amp) (43) General alarm relay
i01907886 Separate timers are used in the ECM for each

response that is associated with a parameter. Once
Engine Monitoring System the trip point is exceeded for an action, the timer for
that action is started. For example, if the high coolant
SMCS Code: 1901-038 temperature warning is set to 102 C (216 F) with a
ve seconds delay, the delay timer starts counting
The Electronic Control Module (ECM) monitors once the coolant temperature exceeds 102 C
engine parameters. If a parameter extends outside (216 F). If the coolant remained above 102 C
an acceptable range, the ECM will initiate action. The (216 F) for ve seconds, a warning would be issued.
ECM can cause a warning to occur. The ECM can
derate engine power. The ECM can cause an engine Use care when you program the trip point and the
shutdown to occur. Not all of the actions are available delay times. The resulting ECM response must be
for all parameters. correct for the application. If the acceptable range
is not exceeded, the engine monitoring system will
The Caterpillar Electronic Technician (ET) can be accept any setting.
used to select the ECM response. Cat ET can be
used to program the level of engine monitoring and If the trip point for a shutdown is lower than the trip
the delay times. point for a warning, the engine will shut down. The
warning will not be activated.
Once a parameter has exceeded the trip point the

parameter must drop a certain amount below the trip
point before the ECM response will end.
RENR5009-07 17
If a warning is programmed to 102 C (216 F), the

temperature must exceed the range in order for the
warning to activate. The temperature must decrease
below 99 C (210 F) for the warning to stop. The
variance is the hysteresis. The following table gives
the hysteresis for each parameter.
Table 6
Parameter Hysteresis
ECM Voltage 2 VDC
Oil Pressure 20 kPa (2.9 psi)
High Coolant Temperature 5 C (41 F)
Low Coolant Temperature 5 C (41 F)
Overspeed 100 rpm
Air Inlet Restriction 1.5 kPa (6.0 inch of H2O)
Altitude 0
High Exhaust Temperature 10 C (50 F)
Oil Filter Differential 10 kPa (1.5 psi)
Pressure
Fuel Filter Differential 10 kPa (1.5 psi)
Pressure
Crankcase Pressure 0.25 kPa
(1.0047 inch of H2O)
Aftercooler Water 3 C (37 F)
Temperature
High Transmission Oil 5 C (41 F)
Temperature
High Boost Pressure 0
Note: The following tables are examples. The values

may have changed. Use Cat ET to determine the
actual defaults and the specic conguration.
Table 7
Programmable Monitoring System

Parameter ECM Response Default Trip Point Default Limits
Delay
Time Range for Trip Point Delay Time
Low High
Low System On/Off
Voltage
Warning 20 VDC 10 20 VDC 22 VDC 1 to 30
Seconds seconds
Low Oil Pressure On/Off
(1)
Warning 4 Seconds N/A 1 to 15
seconds
(1)
Shutdown 9 Seconds N/A 1 to 15
seconds
(continued)
18 RENR5009-07
(Table 7, contd)
High Coolant On/Off
Temperature
Warning 102 C (216 F) 5 Seconds 90 C (194 F) 102 C 1 to 60
(216 F) Seconds
Derate 107 C (225 F) 30 90 C (194 F) 107 C 1 to 60
Seconds (225 F) Seconds
Shutdown 107 C (225 F) 5 Seconds 90 C (194 F) 107 C 1 to 60
(225 F) Seconds
Low Coolant On/Off
Temperature
Warning 80 C (176 F) 5 Seconds 63 C (145 F) 85 C (185 F) 1 to 60
Seconds
Engine On/Off
Overspeed
Warning Application 0 Seconds 1200 rpm 2400 rpm 0 to 5
Dependent Seconds
Shutdown Application 0 Seconds 1200 rpm 2400 rpm 0 to 5

Dependent Seconds
Air Filter On/Off

Restriction
Pressure Warning 7 kPa (1 psi) 5 Seconds 3 kPa (0.4 psi) 7 kPa (1 psi) 1 to 60
Seconds
Derate 7 kPa (1 psi) 5 Seconds 1 kPa 7 kPa (1 psi) 1 to 60
(0.14 psi) Seconds
Altitude On/Off
Derate 762 m (2500 ft) 0 250 m (820 ft) 4562 m 0 seconds
(14967 ft)
High Exhaust On/Off
Temperature
Warning 600 C (1112 F) 5 Seconds 500 C 800 C 1 to 60
(932 F) (1472 F) Seconds
Derate 750 C (1382 F) 5 Seconds 1 to 60
Seconds
Oil Filter On/Off
Differential
Pressure Warning 105 kPa (15 psi) 5 Seconds 70 kPa 105 kPa 1 to 60
(10 psi) (15 psi) Seconds
Fuel Filter On/Off
Differential
Pressure Warning 105 kPa (15 psi) 5 Seconds 70 kPa 105 kPa 1 to 60
Crankcase Off
Pressure
Warning 2 kPa (0.3 psi) 3 Seconds 0.5 kPa 6 kPa (0.9 psi) 1 to 60
(0.1 psi) Seconds
Derate 6 kPa (0.9 psi) 10 0.5 kPa 6 kPa (0.9 psi) 1 to 60
Seconds (0.1 psi) Seconds
Shutdown 3.5 kPa (0.5 psi) 3 Seconds 0.5 kPa 6 kPa (0.9 psi) 1 to 60
(0.1 psi) Seconds
(continued)
RENR5009-07 19
(Table 7, contd)
Aftercooler On/Off
Water
Temperature Warning 102 C (216 F) 5 Seconds 40 C (104 F) 102 C 1 to 60
(216 F) Seconds
Derate 107 C (225 F) 5 Seconds 40 C (104 F) 107C 1 to 60
(225 F) Seconds
Shutdown 107 C (225 F) 5 Seconds 40 C (104 F) 107 C 1 to 60
(225 F) Seconds
High Boost On/Off
Pressure
Derate 400 kPa (58 psi) 30 400 kPa 400 kPa 0 Seconds
Seconds (58 psi) (58 psi)
High On/Off
Transmission Oil
Temperature(2) Warning 99 C (210 F) 5 Seconds 20 C (68 F) 120 C 1 to 120
(248 F) Seconds
Low On/Off
Transmission
Oil Pressure(2) Warning 1500 kPa (218 psi) 5 Seconds 900 kPa 2900 kPa 1 to 60
Low Engine On/Off
Coolant Level(2)
Warning ON 10 ON ON 1 to 120
Seconds Seconds
(1) Refer to the oil pressure map.
(2) Optional equipment
Note: The engine monitoring system is enabled after

the engine is started. The ECM delays monitoring
some parameters at start-up. The delay is designed
to eliminate false warnings. The following parameters
have a delay at start-up.
The delay for low engine oil pressure is 10 seconds.

The delay for high transmission oil temperature is
30 seconds.
The delay for low transmission oil pressure is 30

seconds.
The delay for low engine coolant temperature is

600 seconds.
The delay for low engine coolant level is 60

seconds.
20 RENR5009-07
Oil Pressure Map
g01027393
Illustration 10
Oil pressure map
RENR5009-07 21
Programming Parameters Note: The old interlock code is required to change

the interlock code on a used Electronic Control
Module (ECM). A new interlock code is also required
i02549044 to change the interlock code on a used ECM.
Programming Parameters The Cat ET screen for factory passwords will display
the following parameters:
SMCS Code: 1901-038
Serial number of the ECM
Caterpillar Electronic Technician (ET) can be used to
view certain parameters that can affect the operation Engine serial number
of the engine. Cat ET can also be used to change
certain parameters. Some of the parameters are Serial number for Cat ET
protected from unauthorized changes by passwords.
Parameters that can be changed have a tattletale Reason code
number. The tattletale number shows if a parameter
has been changed. Interlock code
i02399101
Total tattletale
Factory Passwords Note: Factory passwords are only valid for the current
Cat ET screen. A different set of factory passwords
SMCS Code: 1901-038 will be required if you exit the current Cat ET screen.
A different set of passwords will be required to
change information on another Cat ET screen.
Passwords
Passwords are part of a security system that helps to Customer Passwords
prevent unauthorized changing of certain parameters.
Passwords prevent unauthorized erasing of logged Customer passwords allow the customer to restrict
events. Passwords allow the factory to control access access to parameters that can be changed by the
to engine calibration parameters. Passwords allow customer. The customer passwords cannot be longer
the customer to control access to certain engine than eight characters. The customer passwords may
parameters. consist of alphanumeric characters. The customer
has the option of entering one or two customer
passwords.
Factory Passwords
If customer passwords have been entered, then
Factory passwords are required to clear any event the customer passwords are required to change
code. Factory passwords are required to change any parameter that is customer programmable.
certain parameters such as Full Load Setting. Parameters that are customer programmable are
Factory passwords restrict changes to authorized those parameters that affect the engine speed
personnel. When the correct factory passwords have limits and the power rating within an engine family.
been entered, the changes can then be made. Refer to the diagnostic procedure Troubleshooting,
System Conguration Parameters for more detail
Note: Factory passwords are calculated on a on parameters that are customer programmable.
computer system that is only available to Caterpillar
dealers. Note: If the owner loses the owner's customer
passwords, the owner will not be able to change
In order to obtain the proper factory passwords, parameters that are protected by customer
certain information must be given to an authorized passwords. You must use factory passwords in order
Caterpillar dealer. Since the factory passwords to read the customer passwords. You may then use
contain alphabetic characters, the Caterpillar those customer passwords to change parameters
Electronic Technician (ET) can be used to perform that have been protected by customer passwords.
this function. In order to obtain the factory passwords,
proceed as if you already have the factory passwords.
At some point, if the factory passwords are actually i01562584
needed, Cat ET will request the factory passwords
and Cat ET will display the information that is required Factory Passwords Worksheet
to obtain the factory passwords.
SMCS Code: 1901-038
Note: A mistake in recording these parameters will

result in incorrect passwords.
22 RENR5009-07
Table 8 Programming a Flash File

Dealer Code
1. Establish communication between Cat ET and the
Customer's Name engine's ECM.
Address
2. Select WinFlash from the Utilities menu on Cat
ET.
Note: If WinFlash will not communicate with the

Telephone Number ECM, refer to troubleshooting without a diagnostic
Information From Engine Information Plate code Troubleshooting, Electronic Service Tool Will
Not Communicate with ECM.
Engine Serial Number
Full Load Setting 3. Program the ash le into the ECM.
Full Torque Setting a. Select the engine ECM under the Detected
Information From Engine Hour Meter ECMs.
Engine Hours b. Press the Browse button in order to select the
Information From Factory Password Entry name of the ash le that will be programmed
Screen on ET into the ECM.
Electronic Service Tool c. When the correct ash le is selected, press
Serial Number
the Open button.
d. Verify that the File Values match the
ECM Serial Number
application. If the File Values do not match
Total Tattletale the application, obtain the correct ash le.
Reason Code
e. When the correct ash le is selected, press
From Interlock(1) the Begin Flash button.
To Interlock(1)
f. Cat ET will indicate when ash programming
Factory Passwords has been successfully completed.
Factory Password (No. 1)
4. Start the engine and check for proper operation.
Factory Password (No. 2) Repair any active diagnostic or event codes.
(1) This parameter is required when the engine is being rerated.
This parameter is displayed only when the engine is being WinFlash Error Messages
rerated.
If you receive any error messages during ash
i02419726
programming, click on the Cancel button in order
to stop the process. Access the information about
Flash Programming the ECM Summary under the Information menu.
Make sure that you are ashing the correct le for
SMCS Code: 1901-038 your engine.
Flash Programming This is a method of

programming or updating the ash le in an engine's
Electronic Control Module (ECM).
Caterpillar Electronic Technician (ET) is used to ash

program a le into the memory of the engine's ECM.
If you do not have the ash le, use the Flash File
Search tool on the Service Technician Workbench
(STW) to obtain the ash le for your engine.
Alternatively, use the Service Software Files feature
on SIS Web to obtain the ash le for your engine.
You must have the engine serial number in order to
search for the ash le. After locating the correct
ash le, download the ash le to your PC. Write
down the name of the ash le for future reference.
RENR5009-07 23
i01908150 Engine Cooling System Conguration

System Conguration This parameter is used as a switch to toggle between
Parameters the SCAC cooling system or the JWAC cooling
system.
SMCS Code: 1901-038
Cold Cylinder Cutout
System conguration parameters are parameters
that affect emissions and power of the engine The cold cylinder cutout automatically stops fuel
applications. Default values for the parameters are injection to cylinders that are not ring. The fuel
programmed at the factory. Some parameters may injection is stopped to the cylinders until the engine
be changed by the customer in order to suit the reaches operating temperature.
needs of the specic application. Proper values for
these parameters are available on the electronic Cooldown Engine Speed
service tool. Certain conguration parameters are
also stamped on the engine information plate. This parameter denes the engine rpm level when
the Engine Control Switch (ECS) is placed in the
No password is required for programming a new STOP position.
Electronic Control Module (ECM) during the rst
100 hours of service life. This 100 hour free
conguration feature enables the customer to tailor Engine Cooldown Duration
the programmable setpoints to the requirements
This parameter denes engine operation at the
of the installation. Exceptions are Fuel Limit and
Personality Module Mismatch. cooldown speed. Programming this parameter to 0
will disable this function.
Note: If the parameters that are protected with
the factory passwords are changed, the Caterpillar Engine Prelube Duration
warranty may be voided.
This parameter sets the engine prelubrication timeout
period. Programming this parameter to 0 will disable
Parameter Descriptions this function.
Injector Codes Crank Duration

Note: The injector codes are not part of the The crank duration determines when the starting
Conguration screen on the electronic service tool. motors will be energized. The crank duration
Injector Codes Calibration can be found under determines when the starting motors will be
Calibrations in the Service menu on the electronic disengaged. Programming this parameter to 0 will
service tool. prevent the ECM from engaging the starting motors.
The injector code is a number that is found on each
of the unit injectors. The ECM uses this number to Maximum Number of Crank Cycles
compensate for manufacturing variations between
individual injectors. If you replace any of the unit This parameter is the total number of crank cycles
injectors, you must reprogram the code for the new that can be performed.
injectors. Also, if you replace the ECM, you must
reprogram all of the injector codes. Crank Terminate Speed
Fuel Ratio Control This parameter determines when the starting motor
will disengage.
The Fuel Ratio Control limit controls the amount
of fuel to air ratio by limiting the rack as a function Total Tattletale
of boost pressure, engine speed and altitude. The
Fuel Ratio Control function permits an offset to be The parameter counts the number of changes to
applied to the calculation for the altitude. The offset system parameters.
changes the fuel to the air ratio to a richer mixture
or a leaner mixture.
Rated Fuel Position

This parameter is used to limit the engine power. A
factory password is required to change this setting.
24 RENR5009-07
Parameter Table
Table 9
System Conguration Parameters

Parameter ECM Default Range Password
Fuel Ratio Control Primary 0 25 to +25 No
Offset
Rated Fuel Positon Primary Software Dependent Software Dependent Yes
(mm)
Engine Cooling Primary SCAC SCAC or JWAC Yes
System Conguration
Cold Cylinder Cutout Primary Enabled Enabled No
Disabled
Cooldown Engine Primary 600 300 to 1600 No
Speed (rpm
Engine Cooldown Primary 5 0 to 30 No
Duration (min)
Engine Prelube Primary 0 0 to 210 No
Duration (sec)
Crank Duration (sec) Primary 0 0 to 60 No
Maximum Number of Primary 0 0 to 10 No
Crank Cycles
Crank Terminate Primary 400 100 to 500 No
Speed (rpm)
Total Tattletale Primary 0 0 to 255 N/A
Secondary
Customer Parameters Personality Module Part Number
Equipment ID Personality Module Part Number is programmed

into the software.
Equipment ID allows the customer to enter a
description into the ECM in order to identify the Personality Module Release Date
vessel. A maximum of 17 characters may be entered
in the eld. This parameter is only for reference by Personality Module Release Date is programmed
the customer. This parameter is not required. into the software.
Engine Serial Number Engine Rotation

Engine Serial Number must be programmed to The Engine Rotation can be viewed only.
match the engine serial number that is stamped on
the engine information plate. If the ECM is replaced, Engine Location
the engine serial number must be programmed into
the new ECM. If multiple engines are installed, the parameter for the
engine location identies the locations of the engines.
Note: When you are requesting factory passwords,
always use the engine serial number that is resident
in the ECM.
Full Load Setting (FLS)
FLS is a number that represents the adjustment to
ECM Serial Number the fuel system that was made at the factory in order
to ne tune the fuel system. The correct value for
The ECM Serial Number is stored in the memory of this parameter is stamped on the engine information
the ECM. The ECM Serial Number can be accessed plate. Factory passwords are required.
by the use of the service tool.
RENR5009-07 25
Full Torque Setting (FTS)

FTS is similar to FLS. Factory passwords are
required.
High Idle Speed

The High Idle Speed is programmed into the
software.
Low Idle Speed

Low Idle Speed is the minimum allowable operating
speed for the engine.
Fuel Correction Factor

The Fuel Correction Factor is a parameter that
adjusts the calculation of fuel consumption. The fuel
correction factor is used to correct the estimated fuel
rate.
Coolant Level Sensor

The Coolant Level Sensor parameter can be set to
the following status: Not Installed, Data Link, and
Sensor. If the sensor is available via the EMS panel
in the engine control panel, set the status to the Data
Link. If the sensor is mounted on the engine, set the
status to the Sensor.
Torque Limit Enable Status

The Torque Limit Enable Status enables the torque
limit.
Maximum Engine Torque Limit

The Maximum Engine Torque Limit and the
range for the Maximum Engine Torque Limit is
programmed into the software.
Minimum Engine Torque Limit

The Minimum Engine Torque Limit and the range for
the Minimum Engine Torque Limit is programmed
into the software.
Coolant Warning Engine Load Enable

Threshold
The Coolant Warning Engine Load Enable
Threshold is programmed in order to set the setpoint
for low coolant.
Air Shutoff Status

This Air Shutoff Status enables the strategy for the
air shutoff.
26 RENR5009-07
Parameter Table
Table 10
Customer Parameters
Parameter ECM Default Range Password
Equipment ID Primary N/A 17 alphanumeric No
Secondary characters
Engine Serial Number Primary 8 alphanumeric No
Secondary characters
#AA#####
ECM Serial Number Primary ECM Serial Number ECM Serial Number N/A
Secondary
Personality Module Primary N/A
Part Number Secondary
Personality Module Primary Month N/A
Release Date Secondary Year
Engine Rotation Primary Forward Forward/Reverse N/A
Secondary
Engine Location Primary Center Port No
Center
Starboard
Full Load Setting Primary Not Programmed 128 to +127 Yes
(FLS) Secondary
Full Torque Setting Primary 0 128 to +127 Yes
(FTS) Secondary
Rated Engine Speed Primary Programmed at the Factory N/A
Factory
High Idle Speed (rpm) Primary Programmed at the Factory N/A
Factory
Low Idle Speed (rpm) Primary 600 300 to 900 No
Secondary
Fuel Correction Primary 0 64 to +63.5 No
Factor
Coolant Level Sensor Primary Installed Not Installed No
Data Link
Sensor
Torque Limit Enable Primary Not installed Installed No
Status Secondary Not Installed
Maximum Engine Primary Programmed at the Factory No
Torque Limit Secondary Factory
Minimum Engine Primary Programmed at the Factory No
Torque Limit Secondary Factory
Coolant Warning Primary 40% 5 to 95% No
Engine Load Enable
Threshold
Air Shutoff Status Secondary Enabled Enabled No
Disabled
RENR5009-07 27
i01908609 Table 13
Customer Parameters Customer Parameters
Worksheet Parameter
Equipment ID
SMCS Code: 1901-038
Table 11 ECM Serial Number
Parameter Worksheet
Personality Module Part
System Conguration Number
Fuel Ratio Control Offset Personality Module

Release Date
Rated Fuel Positon (mm)
Engine Rotation
Engine Cooling System
Conguration Engine Location
Cold Cylinder Cutout Full Load Setting (FLS)
Cooldown Engine Speed Full Torque Setting (FTS)

(rpm)
Rated Engine Speed
Engine Cooldown
High Idle Speed (rpm)
Duration (min)
Low Idle Speed (rpm)
Engine Prelube Duration
(sec) Fuel Correction Factor
Crank Duration (sec) Coolant Level Sensor
Maximum Number of Torque Limit Enable
Crank Cycles Status
Crank Terminate Speed Maximum Engine Torque
(rpm) Limit
Total Tattletale Minimum Engine Torque
Limit
Table 12 Coolant Warning Engine
Injector Codes Load Enable Threshold
Injector Code (1) Air Shutoff Status
Injector Code (2)

Injector Code (3)
Injector Code (4)
Injector Code (5)
Injector Code (6)
Injector Code (7)
Injector Code (8)
Injector Code (9)
Injector Code (10)
Injector Code (11)
Injector Code (12)
Injector Code (13)
Injector Code (14)
Injector Code (15)
Injector Code (16)
28 RENR5009-07
Table 14
Parameter Worksheet
Programmable Monitoring System
Warning Trip Warning Delay Derate Trip Derate Delay Shutdown Trip Shutdown
Point Time Point Time Point Delay Time
Low System
Voltage
Low Oil
Pressure
High Coolant
Temperature
Low Coolant
Temperature
Engine
Overspeed
Air Filter
Restriction
Pressure
Altitude
High Exhaust
Temperature
Oil Filter
Differential
Pressure
Fuel Filter
Differential
Pressure
Crankcase
Pressure
Aftercooler
Water
Temperature
High
Transmission
Oil
Temperature
Low
Transmission
Oil Pressure
RENR5009-07 29
i01908773
NOTICE
Replacing the ECM If the personality module and engine application are
not matched, engine damage may result.
SMCS Code: 1901-038
NOTICE Perform the following procedure in order to replace

Care must be taken to ensure that uids are contained the ECM.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 1. Connect the Cat ET to the service tool connector
collect the uid with suitable containers before open- for the engine.
ing any compartment or disassembling any compo-
nent containing uids. 2. Print the parameters from the Conguration
screen on Cat ET. If a printer is unavailable,
Refer to Special Publication, NENG2500, Caterpillar record all of the parameters. Record any logged
Tools and Shop Products Guide for tools and supplies diagnostic codes and logged event codes for
suitable to collect and contain uids on Caterpillar your records. Record the injector codes from the
products. Calibrations screen in the Service menu on
Cat ET.
Dispose of all uids according to local regulations and
mandates. Note: The injector trim code is a number that is found
on each of the unit injectors. The ECM uses this
number to compensate for manufacturing variations
NOTICE between individual injectors. If you replace any of the
Keep all parts clean from contaminants. unit injectors, you must reprogram the trim code for
the new injectors. Also, if you replace the ECM, you
Contaminants may cause rapid wear and shortened must reprogram all of the trim codes.
component life.
3. Use the Copy Conguration/ECM Replacement
The Electronic Control Module (ECM) contains no feature that is found under the Service menu on
moving parts. Replacement of the ECM can be Cat ET. Select Load from ECM in order to copy
costly. Replacement can also be a time consuming the conguration from the suspect ECM.
task. Follow the troubleshooting procedures in this
manual in order to be sure that replacing the ECM Note: If the Copy Conguration process fails and
will correct the problem. Verify that the suspect ECM the parameters were not obtained in Step 2, the
is the cause of the problem. parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
Note: Ensure that the ECM is receiving power plate, but most parameters must be obtained from
and that the ECM is properly wired to the negative the factory.
battery circuit before a replacement of the ECM is
attempted. Refer to the diagnostic functional test 4. Remove the ECM.
Troubleshooting, Electrical Power Supply.
a. Turn the engine control to the OFF position.
A spare ECM can be used to determine if the
ECM is faulty. Install a spare ECM in place of the b. Disconnect the ECM connectors J1/P1 and
suspect ECM. Transfer the personality module from J2/P2.
the suspect ECM to the spare ECM. Program the
parameters for normal operation. The parameters NOTICE
must match the parameters in the suspect ECM. Use a suitable container to catch any fuel that might
Refer to the following test steps for details. If the spill. Clean up any spilled fuel immediately.
spare ECM resolves the problem, reconnect the
suspect ECM. Verify that the problem returns. If the
problem returns, replace the ECM. NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Note: The replacement or the spare ECM must clean the area around a fuel system component that
have the same serial number sufx as the suspect will be disconnected. Fit a suitable cover over discon-
ECM. Ensure that the replacement ECM and nected fuel system component.
the interlock code for the personality module
match the suspect ECM. Be sure to record the c. Remove the fuel lines from the ECM (if
parameters from the replacement ECM. Use the equipped).
Copy Conguration/ECM Replacement feature that
is found under the Service menu on the Caterpillar d. Remove the mounting bolts from the ECM.
Electronic Technician (ET).
30 RENR5009-07
e. Disconnect the ECM ground strap from the 9. Calibrate the fuel injectors. Refer to the diagnostic
engine. functional test Troubleshooting, Injector Codes -
Calibrate.
5. Install the replacement ECM.
10. Calibrate the injection timing. Refer to the
a. Use the old mounting hardware to install the diagnostic functional test Troubleshooting,
replacement ECM. The mounting hardware Engine Speed/Timing Sensor - Calibrate.
should be free of damage.
11. Check for diagnostic codes and for event codes.
b. Reconnect the fuel lines (if equipped).
c. Ensure that the ECM mounting hardware is

installed correctly. The fuel lines should not
be putting tension on the ECM. The rubber
grommets are used to protect the ECM from
excessive vibration. The ECM should be able to
drift in the rubber grommets. If the ECM cannot
be moved slightly in the grommets, check that
the fuel lines are not pulling the ECM against
one side of the grommets.
d. Install the ECM ground strap on the engine.
e. Reconnect ECM connectors J1/P1 and

J2/P2. Tighten the allen head screws on the
connectors to the proper torque:
40-pin connector 2.25 Nm (20 lb in)

70-pin connector 6.0 Nm (53 lb in)
6. Flash program the personality module into
the ECM. Refer to the diagnostic procedure
Troubleshooting, Flash Programming for the
correct procedure.
7. Use Cat ET to match the engine application and

the interlock code if the replacement ECM was
used for a different application.
8. Congure the ECM.
a. If the Copy Conguration process from

Step 3 was successful, return to the Copy
Conguration/ECM Replacement screen on
Cat ET and select Program ECM. Proceed
to Step 10.
b. If the Copy Conguration process was

unsuccessful, program the ECM parameters.
The parameters must match the parameters
from Step 2.
Note: If the Copy Conguration process fails and

the parameters were not obtained in Step 2, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.
c. If necessary, program the engine monitoring

system.
RENR5009-07 31
Troubleshooting without a Determine if the logged diagnostic codes occur

at the same time as the symptoms.
Diagnostic Code
Determine if the logged diagnostic codes are
logged repeatedly.
i02554797
If these inspections do not reveal any problems, use
Symptoms the procedure that best describes the symptoms.
SMCS Code: 1000-038; 1901-038
i02400486
Some engine symptoms can be unrelated to the
electronic control system. Gather information about Air Starting Motor
the complaint that describes the symptoms. Verify
that the complaint is not due to normal engine SMCS Code: 1451-035
operation.
The probable root causes are listed below:
Perform the following steps in order to determine the
problem. Low air pressure
1. Repair all active diagnostic codes. Wiring
2. Gather operator information. Control valve
3. Verify that the complaint is not due to normal Relay valve
engine operation.
Motor
4. Perform a visual inspection of the engine. Inspect
the following items: 1. Charge the air system.
Wiring 2. Repair the wiring and/or replace the wiring.
Connectors 3. Repair the control valve and/or replace the control

valve.
Fuel level
4. Repair the relay valve and/or replace the relay
Fuel supply valve.
Engine oil level 5. Repair the motor and/or replace the motor.
Engine oil supply The Air Starting Motor has a loss of power.
Coolant level The probable root causes are listed below:
Intake air system Low air pressure
Air exhaust system Improper lubrication

5. Check the wiring and the connectors for the Worn parts
following problems:
Air leaks
Damage
1. If necessary, charge the air system. Check the air
Abrasion system for leaks. Check the air compressor for
correct operation.
Corrosion
2. Check the lubrication system.
Incorrect attachment
3. Inspect parts for wear. Replace any worn parts.
6. Check for any logged diagnostic codes.
a. Inspect the vanes for damage. If the width of
Determine if the logged diagnostic codes the vane is less than 32 mm (1.25 inch) at
correlate to probable causes. either end replace the vane.
32 RENR5009-07
b. Inspect the rotor bearings. If the bearings are 4. Inspect the drive belts. Install new drive belts.
loose or damaged replace the bearings. Loosen the drive pulley. Tighten the pulley. Refer
to the Specications manual. If the belt and the
c. Inspect the rotor for scoring. Attempt to remove pulley are misaligned, adjust the belt and the
the scoring with an emery cloth. If the scoring pulley. If the alternator bearings are worn, install
cannot be removed, replace the rotor. new bearings.
d. Inspect the cylinders for cracks and/or scoring. 5. If the problem is still present, refer to Special
If necessary, replace the cylinder. Instruction, REHS0354, Charging System
Troubleshooting.
4. Check for worn seals. Plug the exhaust and apply
205 kPa (30 psi) to the inlet. Place the unit in a
i02421020
nonammable liquid for 30 seconds. If bubbles
appear, replace the motor seals. Can Not Reach Top Engine
The pinion does not engage the ywheel. RPM
The probable root cause is a broken clutch and/or SMCS Code: 1000-038; 1901-038
other parts. Replace the clutch.
Note: If this problem occurs under load, refer to
The pinion engages the ywheel but the ywheel the diagnostic procedure Troubleshooting, Low
does not turn. Power/Poor Or No Response To Throttle.
The probable root cause is a broken shaft and/or Probable Causes

gear teeth. Inspect the shaft and teeth for damage.
Replace any damaged parts.
Derated engine
The pinion incorrectly engages the ywheel.
Cold mode
The probable root cause is a dry pinion shaft.
Remove the pinion and apply grease on the splines
Flash le
and the pinion.
Throttle signal
i01953472 Fuel supply
Alternator Air inlet restriction
SMCS Code: 1405-035 Exhaust restriction
The probable root causes are listed below: Leaks in air system
The alternator is not charging the battery. Valve adjustment
The battery charge is low. Injectors
The battery charge is high. Faulty accessory equipment
Noisy operation Recommended Actions
Perform the following checks:
Derate
1. Loosen the drive belts on the alternator. Adjust the
drive belt tension. Inspect all of the cables and the Connect Caterpillar Electronic Technician (ET) and
connections. Clean the connections and tighten check for an active derate event. A derate status
the connections. Replace faulty parts. Inspect the ag will appear on Cat ET if an active engine derate
rotor. Install a new rotor. is occurring. In order to view active events, go to
the Events menu under Diagnostics. Refer to
2. Inspect the rectier diodes. Replace the diode. Troubleshooting, Troubleshooting with an Event
Code for the specic events for this application.
3. Inspect the alternator for loose connections.
Tighten all connections to the alternator. Inspect
the regulator. If a replacement is required, the
alternator must be disassembled.
RENR5009-07 33
Cold Mode Valve Adjustment

Use Cat ET to verify that the engine has exited Check the valve lash setting.
cold mode. A status ag will appear if the engine is
operating in cold mode. This may limit engine speed. Injectors
Flash File Use Cat ET to determine if any active diagnostic
codes are present for the injector solenoids. Perform
Verify that the correct ash le has been installed. the Injector Solenoid Test. Observe that the injector
solenoids are being energized on Cat ET. Perform
Throttle Signal the Cylinder Cutout Test. Locate the misring
cylinder. Refer to the diagnostic functional test
Use Cat ET in order to monitor the status of the Troubleshooting, Injector Solenoids.
throttle. Observe the throttle position. Verify that the
throttle position is smooth from low idle to high idle. Faulty Accessory Equipment
The throttle position should reach 100 percent at
high idle. Check attached accessory equipment. Ensure that
the accessory equipment is not lugging down the
Fuel Supply engine.
Check fuel lines for the following problems: i02549176

restrictions, collapse, and pinched line. Repair the
lines and/or replace the lines. Coolant in Engine Oil
1. Check the fuel tank for foreign objects which may SMCS Code: 1300-038; 1901-038
block the fuel supply. Check for air leaks in the
suction line of the fuel pump. Prime the fuel system
after you perform the following procedures: Probable Causes
Replacing the fuel lters Failure of the oil cooler core
Working on the low pressure fuel supply circuit Failure of cylinder head gasket
Replacing fuel injectors Crack in cylinder head
2. Cold weather adversely affects the characteristics Cracked cylinder liner

of the fuel. Refer to the Operation and
Maintenance Manual for information on improving Cylinder liner seals
the characteristics of the fuel during cold weather
operation. Water pump
3. Check the fuel pressure during engine cranking. Recommended Actions

Check the fuel pressure after the fuel lter. Refer
to the Systems Operation/Testing and Adjusting Failure of Oil Cooler Cores
manual for the correct pressure values. If the fuel
pressure is low, replace the fuel lters. If the fuel Inspect the oil cooler for leaks. Make repairs, as
pressure is still low, check the following items: fuel needed. Drain the crankcase. Rell the crankcase
transfer pump, fuel transfer pump coupling, and with clean lubricant. Change the oil lters.
fuel pressure regulating valve.
Failure of Cylinder Head Gasket
Air Inlet Restriction
Check the cylinder head gasket.
Replace plugged air lters and/or clean the lters.
Leaks in the air inlet manifold system can lower Inlet
manifold pressure. Crack in Cylinder Head
Check for cracks in the cylinder head. Repair the
Exhaust Restriction cylinder head and/or replace the cylinder head.
Tighten the bolts that hold the cylinder head
Check the exhaust system for restrictions and/or for according to the Specications manual.
leaks.
34 RENR5009-07
Cracked Cylinder Liner Low Coolant Level

Check the cylinder liner for cracks. Use a borescope 1. Verify that the cooling system is lled to the proper
to check the cylinder liner. level. If the coolant level is too low, air will get into
the cooling system. Air in the cooling system will
Cylinder Liner Seals cause a reduction in coolant ow and bubbles in
the coolant. Air bubbles will keep coolant away
Check the liner water seals in the spacer plate. from the engine parts, which will prevent the
Check the bottom seals on the liner for damage. transfer of heat to the coolant. Low coolant level is
caused by leaks or incorrectly lling the radiator.
Water Pump 2. Check the mixture of antifreeze and water. The
mixture should be approximately 50 percent water
Check the weep hole in the water pump for blockage.
and 50 percent antifreeze with 3 to 6 percent
Check the water pump seals for leakage. coolant conditioner. Refer to Operation and
Maintenance Manual. If the coolant mixture is
i02433524 incorrect, drain the system. Put the correct mixture
of water, antifreeze and coolant conditioner in the
Coolant Temperature Is Too cooling system.
High 3. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
SMCS Code: 1350-038; 1901-038
common causes of air in the cooling system are
the incorrect lling of the cooling system and
Probable Causes combustion gas leakage into the cooling system.
Combustion gas can get into the system through
Faulty temperature regulator inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket.
Radiator
4. Check the cooling system hoses and clamps.
Low coolant level Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during
Faulty jacket water coolant pump operation. The soft areas of the hose can become
kinked or crushed during operation. These areas
Faulty engine cooling fan (if equipped) of the hose can restrict the coolant ow. Hoses
become soft and/or get cracks after a period of
Faulty pressure relief valve time. The inside of a hose can deteriorate, and the
loose particles of the hose can restrict the coolant
Recommended Actions ow.
Faulty Temperature Regulator Faulty Jacket Water Coolant Pump
Check the water temperature regulator. A water Inspect the impeller vanes at the jacket water pump
temperature regulator that does not open, or a water for damage and/or for erosion. Repair impeller vanes
temperature regulator that only opens part of the way and/or replace the impeller vanes.
can cause overheating.
Faulty Engine Cooling Fan (if equipped)
Radiator
1. If the fan is belt driven, check for loose drive belts.
1. Check the cooling ns on the radiator for dirt A loose fan drive belt will cause a reduction in the
and/or for debris. Remove the dirt and/or debris. air ow across the radiator. Check the fan drive
belt for proper belt tension. Adjust the tension of
Inspect the cooling ns on the radiator for damage. the fan drive belt, if necessary. Refer to Operation
Refer to the Systems Operation/Testing and and Maintenance Manual.
Adjusting manual.
2. Check the fan clutch, if equipped. A fan clutch
2. Check the radiator for internal blockage. Check or a hydraulic driven fan that is not turning at
the temperature difference between the top and the correct speed can cause improper air speed
the bottom of the radiator. across the radiator core. The lack of proper air ow
across the radiator core can cause the coolant not
to cool to the proper temperature differential.
RENR5009-07 35
Faulty Pressure Relief Valve i02561478
Check operation of the pressure relief valve and the ECM Will Not Communicate
radiator cap. If necessary, clean the pressure relief with Other Systems or Display
valve and/or the radiator cap. Check that the seating
surface of the valve is clean and undamaged. If Modules
necessary, install new parts.
SMCS Code: 1901-038
i02826488
Probable Causes
ECM Will Not Accept Factory
Electronic Control Module (ECM)
Passwords
Connector or wiring problem
SMCS Code: 1901-038
Cat Data Link
Probable Causes
CAN data link (if applicable)
One of the following items may not be recorded
correctly on the Caterpillar Electronic Technician Recommended Actions
(ET):
Passwords ECM
Connect Caterpillar Electronic Technician (ET). If the
Serial numbers ECM does not communicate with the Cat ET, perform
the diagnostic functional test Troubleshooting,
Total tattletale Electronic Service Tool Will Not Communicate With
ECM.
Reason code
Connectors or Wiring
Recommended Actions
Check for correct installation of the ECM connectors.
1. Verify that the correct passwords were entered. Check any machine connector or the customer
Check every character in each password. Remove connector in the circuit for correct installation. Refer
the electrical power from the engine for 30 to the diagnostic functional test Troubleshooting,
seconds and then retry. Inspecting Electrical Connectors.
2. Verify that Cat ET is displaying the Enter Factory
Passwords dialog box. Cat Data Link
3. Use Cat ET to verify that the following information Verify that the Cat Data Link does not have an open
has been entered correctly: or short circuit. Refer to the diagnostic functional test
Troubleshooting, Cat Data Link.
Engine serial number
CAN data link (if applicable)
Serial number for the electronic control module
Verify that the CAN data link does not have an open
Serial number for Cat ET or short circuit. Refer to the diagnostic functional test
Troubleshooting, CAN Data Link.
Total tattletale
i02561494
Reason code
For additional information, refer to Troubleshooting,
Electronic Service Tool Will
Factory Passwords. Not Communicate with ECM
SMCS Code: 1901-038
Probable Causes
Conguration for the communications adapter
36 RENR5009-07
Electrical connectors 2. Disconnect the communication adapter and the

cables from the service tool connector. Reconnect
Communication adapter and/or cables the communication adapter to the service tool
connector.
Electrical power supply to the service tool
connector 3. Verify that the correct cable is being used between
the communication adapter and the service tool
Caterpillar Electronic Technician (ET) and related connector. Refer to Troubleshooting, Electronic
hardware Service Tools.
Electrical power supply to the Electronic Control Electrical Power Supply to the Service
Module (ECM)
Tool Connector
Flash le Verify that battery voltage is present between
terminals A and B of the service tool connector. If the
Cat Data Link communication adapter is not receiving power, the
display on the communication adapter will be blank.
Recommended Actions
Cat ET and Related Hardware
Start the engine. If the engine starts, but the ECM
will not communicate with Cat ET, continue with In order to eliminate Cat ET and the related hardware
this procedure. If the engine will not start, refer to as the problem, connect Cat ET to a different engine.
Troubleshooting, Engine Cranks but Will Not Start. If the same problem occurs on a different engine,
If the engine will not crank, refer to Troubleshooting, check Cat ET and the related hardware in order to
Engine Will Not Crank. determine the cause of the problem.
Conguration for the Communications Electrical Power Supply to the Electronic

Adapter Control Module (ECM)
1. Access Preferences under the Utilities menu Check power to the ECM. Refer to Troubleshooting,
on Cat ET. Electrical Power Supply.
2. Verify that the correct Communications Interface Note: If the ECM is not receiving battery voltage, the
Device is selected. ECM will not communicate.
3. Verify that the correct port is selected for use by
the communication adapter. Flash File
Note: The most commonly used port is COM 1. Ensure that the correct ash le is properly installed
in the ECM.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any Note: The new ECM does not have a ash le.
devices are congured to use the same port, exit The engine will not start and the engine will not
or close the software programs for that device. communicate with Cat ET until the ash le has
been installed. Refer to Troubleshooting, Flash
Programming.
Electrical Connectors
Check for correct installation of the J1/P1 and J2/P2 Cat Data Link
ECM connectors and of the service tool connector.
Refer to Troubleshooting, Inspecting Electrical Troubleshoot the Cat Data Link for possible problems.
Connectors. Refer to Troubleshooting, Cat Data Link.
Communication Adapter and/or Cables i02399199
1. If you are using a Communication Adapter II, Engine Cranks but Will Not
ensure that the rmware and software for the
communication adapter are the most current les
Start
that are available. If the rmware and software do SMCS Code: 1000-038; 1901-038
not match, the communication adapter will not
communicate with Cat ET. The probable root causes are listed below:
RENR5009-07 37
Electrical power supply b. Purge air from the low pressure fuel supply
circuit with the hand priming pump and by
Low fuel level cranking the engine in 30 second cycles. After
you crank the engine, stop for two minutes.
Fuel supply This will allow the starting motor to cool.
Loosen the vent plug for the fuel return line.
Starting aids (if applicable) The plug is located on the rear upper left side of
the engine block. Hand prime the engine again
Cranking speed if air in fuel continues. A sight glass in the low
pressure supply line is helpful in diagnosing air
Shutdown switch in the fuel.
Active engine shutdown c. Check fuel quality. In temperatures below

0 C (32 F), check for solidied fuel (wax).
Electrical connectors Refer to Special Publication, SEBD0717,
Diesel Fuels And Your Engine. Check the fuel
Circuit breakers pressure while the engine is cranking. Check
the fuel pressure at the lter. If the pressure
Personality module is low, check for plugged fuel lters. If the fuel
pressure is still low, check the following items:
Engine speed/timing sensor fuel transfer pump, fuel transfer pump coupling,
and fuel pressure regulating valve.
Injector solenoid
4. If equipped, check the operation of the ether
Air shutoff (if applicable) starting aids. Replace the ether canister if the
ether is low. Refer to the diagnostic functional test
Perform the following checks: Troubleshooting, Ether Injection System.
1. Measure the voltage at the connector of the 5. Check the cranking speed of the starter.
Electronic Control Module (ECM). If the ECM is
not receiving battery voltage, the ECM will not 6. The shutdown switch should be in the OFF
power up. Refer to the diagnostic functional test position. Connect the Caterpillar Electronic
Troubleshooting, Electrical Power Supply. Technician (ET). Use Cat ET in order to verify
the status of the shutdown switch. If the Cat ET
2. Visually check the fuel level. If necessary, add will not communicate with the ECM, refer to the
fuel. Ensure the proper operation of the jacket diagnostic procedure Troubleshooting, Electronic
water heater. Repair the jacket water heater Service Tool Will Not Communicate with ECM.
and/or replace the jacket water heater. Check for When a shutdown occurs, the keyswitch must
the presence of solidied fuel (wax). be turned to the OFF position. The keyswitch
must then be turned to the ON position before the
3. Check the fuel system. Check fuel lines for the engine will start.
following problems: restrictions, collapse, pinched
line, and loose ttings. Repair the lines and/or 7. Use Cat ET to determine if any active shutdowns
replace the lines. are present. If a Shutdown is ACTIVE, determine
the reason. After you correct the problem, turn
a. Check the fuel tank for foreign objects which the keyswitch to the OFF position for at least 15
may block the fuel supply. Check for air in seconds before you try to restart the engine.
the low pressure fuel supply system after you
perform the following procedures: 8. Check for correct installation of the following
components: ECM connectors J1/P1 and
Replacing the fuel lters J2/P2, customer connector, connector for the
engine speed/timing sensor, and fuel injector
Working on the low pressure fuel supply connectors. Refer to the diagnostic functional
circuit test Troubleshooting, Inspecting Electrical
Connectors.
Replacing fuel injectors
9. The circuit breakers may exceed the trip point due
to overheating. Check the circuit breakers on the
machine. Reset the circuit breakers if the circuit
breakers are tripped.
10. If the diagnostic code 253-02 is present, program

with the correct ash le.
38 RENR5009-07
11. Crank the engine and observe the engine Contaminated Engine Oil
rpm on Cat ET. If engine rpm is 0, refer to
the diagnostic functional test Troubleshooting, Drain the crankcase and rell the crankcase with
Engine Speed/Timing Sensor. clean engine oil. Install new engine oil lters. Refer to
the engine's Operation and Maintenance Manual.
a. Ensure that the timing reference gear is
installed correctly. The engine will not start if If the oil lter bypass valve is open, the oil will not be
the gear was installed backward. Check for ltered. Check the oil lter bypass valve for a weak
proper orientation between the crankshaft and spring or for a broken spring. If the spring is broken,
camshaft drive gears. Correct the orientation replace the spring. Refer to the engine's Disassembly
and/or replace the drive gear. Refer to and Assembly manual. Make sure that the oil bypass
Disassembly and Assembly Manual. valve is operating correctly.
12. Perform the Injector Solenoid Test. Verify Low Oil Pressure
that the ECM is energizing all the injector
solenoids. Refer to the diagnostic functional test When some components of the engine show bearing
Troubleshooting, Injector Solenoids. wear in a short time, the cause can be a restriction in
a passage for engine oil.
13. Verify that both of the air shutoff valves are open
and that both of the air shutoffs are in the starting An indicator for the engine oil pressure may indicate
position. sufcient pressure, but a component is worn due
to a lack of lubrication. In such a case, look at the
14. Check for a problem with the combustion system. passage for the engine oil supply to the component.
i03506600 Leaks in Air Intake System

Engine Has Early Wear A leak in the air intake system may allow unltered
air into the engine. Inspect the air intake system for
SMCS Code: 1000-038; 1901-038 streaks which may indicate a leakage of unltered air.
Inspect all of the gaskets and the connections. Repair
Probable Causes any leaks. Refer to Systems Operation, Testing and
Adjusting for more information.
Engine Oil Inspect the air lter. Replace the air lter, if necessary.
Incorrect maintenance intervals
Inspect the Fuel Filters for Contamination
Contaminated engine oil
1. Remove the fuel lters. Inspect the fuel lters for
Low oil pressure contamination. Install new fuel lters. Refer to the
Operation and Maintenance Manual. Determine
the cause of the contamination.
Contaminated Air
2. Contaminants in the fuel such as hydrogen sulde
Leaks in air intake system and sulfur can lead to the formation of acids in the
crankcase. Obtain a fuel analysis.
Contaminated Fuel
Inspect the fuel lters for contamination. i02526054
Engine Misres, Runs Rough

Recommended Actions
or Is Unstable
Incorrect Maintenance Intervals SMCS Code: 1000-038; 1901-038
Use engine oil that is recommended and change the Note: If the symptom is intermittent and the symptom
engine oil at the interval that is recommended by the cannot be repeated, refer to Troubleshooting,
engine's Operation and Maintenance Manual. Intermittent Low Power or Power Cutout. If the
symptom is consistent and the symptom can be
repeated, continue with this procedure.
RENR5009-07 39
Probable Causes 3. Check the fuel pressure during engine operation.

Diagnostic codes to the Systems Operation/Testing and Adjusting
Electrical connectors pressure is low, replace the fuel lters. If the fuel
pressure is still low, check the following items: fuel
Fuel supply transfer pump, fuel transfer pump coupling, and
Cold mode operation and cold cylinder cutout
Cold Mode Operation and Cold Cylinder
Throttle signal Cutout
Unit injectors Use Cat ET in order to verify that the engine has
exited cold mode. During cold mode, fuel injection
Air inlet and exhaust system timing is modied. When the engine is in cold mode,
the cold cylinder cutout strategy may be active.
Recommended Actions Cold mode cylinder cutouts may cause variations
in vibration and available power. This is normal
Note: If the symptom only occurs under certain operation.
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under Throttle Signal
those conditions. Troubleshooting the symptom
under other conditions can give misleading results. Monitor the throttle signal on Cat ET. Verify that the
throttle signal is smooth from the low idle position
Diagnostic Codes to the high idle position.
Check for active diagnostic codes on Caterpillar Unit Injectors

Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure. 1. Use Cat ET to determine if there are any active
diagnostic codes for the unit injectors.
2. Perform the Injector Solenoid Test on Cat ET in
Check for correct installation of the J1/P1 and J2/P2 order to determine if all of the injector solenoids
Electronic Control Module (ECM) connectors and the are being energized by the ECM.
unit injector connectors. Refer to Troubleshooting,
Inspecting Electrical Connectors. 3. Perform the Cylinder Cutout Test on Cat ET in
order to identify any misring cylinder(s). Refer
Fuel Supply to Troubleshooting, Injector Solenoids for more
information.
Check the fuel level in the fuel tank. Ensure that
adequate fuel is available for the application. Air Inlet and Exhaust System
Check fuel lines for the following problems: 1. Check for an air lter restriction. Clean plugged air
restrictions, collapse, and pinched line. Repair the lters or replace plugged air lters. Refer to the
lines and/or replace the lines. Operation and Maintenance Manual.
1. Check the fuel tank for foreign objects which may 2. If air shutoff valves are installed, verify that the air
block the fuel supply. Check for air leaks in the shutoff valves are fully opened.
after you perform the following procedures: 3. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to the Systems
Replacing the fuel lters Operation/Testing and Adjusting for information on
the air inlet and exhaust system.
Working on the low pressure fuel supply circuit
2. Cold weather adversely affects the characteristics
Maintenance Manual for information on improving
operation.
40 RENR5009-07
i02549498 Recommended Actions

Engine Oil in Cooling System Unit Injectors
SMCS Code: 1350-038; 1901-038
1. Check for correct installation of the J1/P1 and
J2/P2 connectors for the Electronic Control
Probable Causes Module (ECM). Check for correct installation
of the connectors for the unit injectors. Refer
Engine oil cooler core to Troubleshooting, Inspecting Electrical
Connectors.
Cylinder head gasket
2. Perform the Injector Solenoid Test with the
Water pump Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being
Recommended Actions energized by the ECM.
3. Perform the Cylinder Cutout Test with Cat ET

Engine Oil Cooler Core in order to identify any injectors that might be
misring. Refer to Troubleshooting, Injector
1. Inspect the engine oil cooler core for leaks. If a Solenoids for the proper procedure.
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
Fuel Supply
2. Drain the crankcase and rell the crankcase with
clean engine oil. Install new engine oil lters. 1. Check the fuel pressure. Refer to the Systems
Refer to Operation and Maintenance Manual. Operation/Testing and Adjusting manual for the
correct procedure.
Cylinder Head Gasket 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
1. Remove the cylinder head. Refer to Disassembly problems are found with the fuel lines, repair the
and Assembly. lines and/or replace the lines.
2. Check the cylinder liner projection. Refer to 3. Check the fuel tank for foreign objects which may
Systems Operation/Testing and Adjusting. block the fuel supply.
3. Install a new cylinder head gasket and new water
seals in the spacer plate. Refer to Disassembly NOTICE
and Assembly. Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Water Pump
Check the weep hole in the water pump for blockage. 4. Prime the fuel system if any of the following
Check the water pump seals. procedures have been performed:
i02385598
Replacement of the fuel lters
Engine Stalls at Low RPM Service on the low pressure fuel supply circuit
SMCS Code: 1000-038; 1901-038 Replacement of unit injectors
Note: A sight glass in the fuel supply line is helpful in
Probable Causes diagnosing air in the fuel.
Unit injectors 5. Cold weather adversely affects the characteristics
of the fuel. Refer to the applicable Operation and
Fuel supply Maintenance Manual for information on improving
Air shutoff valves (if applicable) or blocked air operation.
supply
Low engine idle

Accessory equipment
RENR5009-07 41
6. Check the fuel pressure after the fuel lter while The secondary ECM is not connected to the
the engine is being cranked. Refer to the Systems Battery. The yellow SECONDARY ECM READY
Operation/Testing and Adjusting manual for the indicator on the panel for the Marine Power
correct pressure values. If the fuel pressure is low, Display (MPD) does not illuminate and the red
replace the fuel lters. If the fuel pressure is still OVERSPEED indicator illuminates upon an
low, check the following items: fuel transfer pump, attempt to start the engine.
fuel transfer pump coupling, and fuel pressure
regulating valve. Recommended Actions
Air Shutoff Valves (if applicable) Batteries and/or Battery Cables
1. Verify that the air shutoff valves are open.
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
2. Check for restrictions in the air inlet system. Refer for corrosion. If the battery cables are corroded,
to the Systems Operation/Testing and Adjusting
remove the battery cables and clean the battery
manual for information on the air inlet system.
cables. Tighten any loose connections.
Low Idle 2. Inspect the batteries.
Check the low idle setting. a. Charge the batteries. Refer to Special
Instruction, SEHS7633, Battery Test
Accessory Equipment Procedure.
Check all accessory equipment for problems that b. Load test the batteries. Refer to Special
may create excessive load on the engine. Repair Instruction, SEHS9249, Use of 4C-4911
any damaged components or replace any damaged Battery Load Tester for 6, 8 and 12 Volt Lead
components. Acid Batteries.
i02854965
Starting Motor Solenoid or Starting
Circuit
Engine Will Not Crank
1. Check the operation of the engine start switch.
SMCS Code: 1000-038; 1901-038 Monitor the engine start switch on Caterpillar
Probable Causes Refer to the appropriate troubleshooting test that
is applicable to your engine if repairs are required.
Batteries
2. Test the operation of the starting motor solenoid.
Battery cables
3. Check the wiring to the starting motor solenoid.
Starting circuit
Starting motor solenoid Starting Motor or Flywheel Ring Gear
Starting motor 1. Test the operation of the starting motor.
Shutdown switch 2. Inspect the solenoid on the starter and the

ywheel ring gear for damage.
Prelubrication system (if applicable)
Prelubrication System (if applicable)
Faulty crank enable switch (if applicable)
If equipped, inspect the prelubrication system for
Flywheel ring gear proper operation.
Transmission (if applicable) Shutdown Switch

Engine accessories Use Cat ET to monitor the status of the engine. Check
the status of engine shutdowns that are ACTIVE
Hydraulic cylinder lock due to shutdown switches. Determine the cause for
the engine shutdown and take the necessary action
Internal engine problem in order to resolve the shutdown.
42 RENR5009-07
Crank Enable Switch (if applicable) The Secondary ECM is Not Connected to
the Battery
Ensure that the crank enable switch is not faulty.
If the yellow SECONDARY ECM READY indicator
Transmission or Engine Accessories (if on the panel for the MPD does not illuminate and
applicable) the red OVERSPEED indicator illuminates upon
an attempt to start the engine, perform the following
1. If the engine's application has a transmission procedure.
neutral switch, test the operation of the
transmission neutral switch. Ensure that the 1. At the power distribution panel, open the 20 Amp
machine is in neutral gear before attempting to circuit breaker for the panel for the MPD. The
start the engine. MPD will turn off.
2. Ensure free movement of the driveline. 2. Reset the air shutoffs (if equipped). Cycle the
power to the ECM.
3. Ensure that the timing pin was not left in the
ywheel housing. 3. Start the engine.
4. Remove any engine accessories that may lock up 4. At the power distribution panel, close the 20 Amp
the engine and inspect any engine accessories circuit breaker for the panel for the MPD. The
that may lock up the engine. MPD will turn on.
The following list illustrates examples of engine Determine the reason for the secondary ECM to be
accessories that may lock up the engine: disconnected from battery power. The secondary
ECM can be connected to battery power and
Hydraulic pump that is driven from the rear gear the engine will continue running. The yellow
group SECONDARY ECM READY indicator will illuminate
on the panel for the MPD.
Air compressor
i02549516
Engine oil pump
Excessive Engine Oil
Other components that are driven by the engine Consumption
Hydraulic Cylinder Lock SMCS Code: 1300-038; 1901-038
Check for uid in the cylinders (hydraulic cylinder
lock) by removing the individual unit injectors. Probable Causes
Note: Drain the fuel from the cylinder head. Fuel will Oil leaks
ow from the cylinder head into the cylinders when
the unit injector is removed. Oil level
Internal Engine Problem Engine oil cooler
Disassemble the engine. Refer to the Disassembly Turbocharger

and Assembly manual. Inspect the internal
components for the following conditions: Valve guides
Seizure Piston rings
Broken components Incorrect installation of the compression ring and/or

the intermediate ring
Bent components
Recommended Actions
Oil Leaks
Locate all oil leaks. Repair the oil leaks. Check for
dirty crankcase breathers.
RENR5009-07 43
Oil Level Air Inlet and Exhaust System

Inspect the engine oil level. Remove any extra oil 1. Check the air inlet system for restrictions and/or
from the engine. Recheck all uid levels. for leaks.
Engine Oil Cooler a. Check for an air lter restriction.
Check for leaks in the engine oil cooler. Check for oil b. Check for derates and for alarms.
in the engine coolant. If necessary, repair the engine
oil cooler. c. Perform a visual inspection of the system for
restrictions and/or for leaks.
Turbocharger 2. Check the exhaust system for restrictions.
Check the air inlet manifold for oil. Check for oil 3. Repair any leaks that were found. Remove
leakage past the seal rings in the impeller end of
any restrictions that were found. Replace any
the turbocharger shaft. If necessary, repair the
damaged components that were found.
turbocharger.
Fuel Injector
Valve Guides
Check that the injector trim codes have been entered.
If the valve guides are worn, reconditioning of the
Perform the Cylinder Cutout Test. Use similar
cylinder head is required.
conditions for the test that were experienced during
operation. Refer to the diagnostic functional test
Piston Rings Troubleshooting, Injector Solenoids.
Inspect the internal engine components. Replace any Turbocharger

worn components.
Verify that the turbocharger has not failed. Periodic
i02304643 inspection and cleaning is recommended for the
turbocharger compressor housing (inlet side).
Excessive Black Smoke
Atmospheric Pressure Sensor
SMCS Code: 1000-038; 1901-038
1. Check the atmospheric pressure sensor for dirt
Probable Causes and/or for debris. Remove the dirt and/or the
debris. The atmospheric pressure should be
Air shutoff (if applicable) between 50 kPa (7.2 psi) and 100 kPa (14.5 psi).
The atmospheric pressure will vary depending
Air inlet and exhaust system on your altitude. If there is an active diagnostic
code, perform the diagnostic functional test
Fuel injector Troubleshooting, Engine Sensor Open/Short
Test.
Turbocharger
2. Verify that the crankshaft and the camshaft drive
Atmospheric pressure sensor gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
Fuel Position and/or FRC Fuel Limit
Turbocharger Compressor Outlet
Flash le Pressure Sensor, Fuel Position, and/or
Fuel quality FRC Fuel Limit
Valve adjustment 1. Monitor the status of Fuel Position and Rated

Fuel Limit while the engine is operating under full
load. If Fuel Position equals Rated Fuel Limit
Recommended Actions and Fuel Position is less than FRC Fuel Limit,
the electronics are operating correctly. Otherwise,
Air Shutoff (if applicable) proceed to the next Step.
Check that both the air shutoffs are open.

44 RENR5009-07
2. Verify that there are no active diagnostic codes Component wear

for the turbocharger compressor outlet pressure
sensor. Cooling system
3. Monitor the status of Turbocharger compressor Recommended Actions
outlet pressure and Atmospheric Pressure for
normal operation on the Caterpillar Electronic
Technician (ET). When the engine is not running, Starting Aids (if applicable)
Turbocharger compressor outlet pressure should
be 0 kPa (0 psi). 1. If equipped, check for proper operation of installed
starting aids.
Note: A problem with the FRC will only cause black
smoke during acceleration. A problem with the FRC a. Ensure that the ether canister is not empty
will not cause black smoke during steady state and/or low. Replace the ether canister if the
operation. ether canister is empty and/or low.
b. Actuate the system manually after start-up

Flash File and observe results. The ether system will
not operate if the coolant temperature is too
Verify that the correct ash le is installed. Refer
high. Refer to the diagnostic functional test
to Troubleshooting, Flash Programming for more Troubleshooting, Ether Injection System.
information.
Coolant Temperature Sensor
Fuel Quality
1. Use the Caterpillar Electronic Technician (ET) to
Cold weather adversely affects the characteristics of
verify that the engine has exited cold mode.
the fuel. Refer to Operation and Maintenance Manual
for information on improving the characteristics of the
2. Compare the coolant temperature from Cat ET to
fuel during cold weather operation.
the coolant temperature that is obtained from the
6V-9130 Temperature Adapter (MULTIMETER).
Valve Adjustment
Water Temperature Regulators
Check the valve adjustment. Refer to the Systems
Operation/Testing and Adjusting manual for more
Check the water temperature regulators for correct
information.
operation. Verify that the engine reaches full
operating temperature. If the engine does not reach
i02536795 full operating temperature, a water temperature
regulator may be stuck open. Remove the water
Excessive White Smoke temperature regulator and inspect the water
temperature regulator. If necessary, repair the
SMCS Code: 1000-038; 1901-038 water temperature regulator and/or replace the
coolant temperature regulator. Refer to the Systems
Note: Some white smoke may be present during Operation/Testing and Adjusting manual for the
cold start-up conditions when the engine is operating proper procedure.
normally. If the white smoke persists, there may be
a problem. Engine Speed/Timing
Probable Causes Check the calibration of the engine speed/timing
sensor. Refer to Troubleshooting, Engine
Starting aids (if applicable) Speed/Timing Sensor - Calibrate.
Coolant temperature sensor Unit Injectors

Water temperature regulators Perform the Cylinder Cutout Test on Cat ET in order
to try to isolate any injectors that might be misring.
Engine speed/timing sensor Refer to Troubleshooting, Injector Solenoids.
Unit injectors Flash File

Flash le Verify that the correct ash le is installed.
Fuel supply
RENR5009-07 45
Fuel Supply Air Inlet and Exhaust System

Check the fuel quality. Low cetane fuel can create 1. Check the air inlet manifold pressure. Check for
white smoke. If necessary, replace the fuel with a air inlet restrictions and/or leaks. Refer to the
higher cetane fuel. Cold weather adversely affects the Systems Operation/Testing and Adjusting manual
characteristics of the fuel. Refer to the Operation and for more information.
the characteristics of the fuel during cold weather 2. Check for leaks between the exhaust manifold and
operation. the turbocharger. Check for exhaust restrictions.
Refer to the Systems Operation/Testing and
Check the fuel level in the fuel tank. Ensure that Adjusting manual for more information.
adequate fuel is available for the application.
i02119587
Component Wear
Fuel Dilution of Engine Oil
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner SMCS Code: 1300-038; 1901-038
wear, and reduced compression pressure.
Probable Causes
Cooling System
Leaking seals on the case of the unit injector or on
Check for proper operation of the jacket water heater. the barrel of the unit injector
Repair the jacket water heater or replace the jacket
water heater. Check for an internal coolant leak into Leaking seals on the fuel line adapter for the
the cylinder and/or the exhaust. Refer to the Systems cylinder head
Operation/Testing and Adjusting manual for more
information. Excessive leakage from the unit injector tip or
breakage of the unit injector tip
i02405574
Cracked fuel supply manifold
Exhaust Temperature Is Too
High Leaking seal on the fuel transfer pump
SMCS Code: 1050-038; 1901-038 Recommended Actions
Probable Causes Leaking Seals on the Case of the Unit

Injector or on the Barrel of the Unit
Diagnostic codes Injector
Air inlet and exhaust system Look for signs of damage to the seals for the unit
injectors. Replace any seals that are leaking.
Air leak
Leaking Seals on the Fuel Line Adapter
Recommended Actions for the Cylinder Head
Diagnostic Codes Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
Connect Caterpillar Electronic Technician (ET) in lines or components and/or replace any leaking fuel
order to determine if any diagnostic codes for the lines or components.
injector solenoids are present. Check that the injector
trim codes have been entered. Perform the Injector Excessive Leakage from the Unit Injector
Solenoid Test. Observe that the injector solenoids
are being energized on Cat ET. Perform the Cylinder Tip or Breakage of the Unit Injector Tip
Cutout Test. Locate the misring cylinder. Refer
to the diagnostic functional test Troubleshooting, Look for signs of damage to the unit injectors. If
Injector Solenoids. necessary, repair the unit injectors or replace the unit
injectors.
46 RENR5009-07
Cracked Fuel Supply Manifold Engine Speed/Timing Sensor

Look for signs of damage to the fuel supply manifold. If the following diagnostic codes are applicable,
check Cat ET for any logged diagnostic codes for
Leaking Fuel Transfer Pump Seal the primary engine speed/timing sensor: 190-02,
190-03, and 190-08. If the engine is equipped with
Ensure that the weep hole is not plugged. If a secondary engine speed/timing sensor, check for
necessary, repair the fuel transfer pump or replace any of the following logged diagnostic codes: 342-02,
the fuel transfer pump. 342-03, and 342-08. Refer to the diagnostic functional
test Troubleshooting, Engine Speed/Timing Sensor.
i02281012
Fuel in Cooling System 1. Check Cat ET for the following logged diagnostic
SMCS Code: 1350-038; 1901-038 codes: 168-01 and 168-02. Follow the battery
wires from the ECM back to the battery
The probable root cause is a damaged O-ring seal compartment. Refer to the electrical system
for a fuel injector. schematic. Inspect the wires and the power relay.
Check the power to the ECM and to the ground
Perform the following procedure: connections. Refer to the diagnostic functional
test Troubleshooting, Electrical Power Supply.
Remove the valve cover. Remove the fuel supply.
Disconnect the fuel return line from the cylinder head. 2. Check for correct installation of the J1/P1
Cap the fuel return connector and apply 700 kPa and J2/P2 Electronic Control Module (ECM)
(102 psi) maximum air pressure to the fuel supply connectors. Refer to Troubleshooting, Inspecting
connector. Check for fuel leakage around each fuel Electrical Connectors.
injector. If leakage is present, remove the leaking fuel
injector. Install a new O-ring seal onto the injector. 3. Inspect the battery wires from the ECM back to
Install the injector. Connect the fuel return line. Install the battery compartment. Refer to the Electrical
the valve cover. Verify that the problem is resolved. System Schematic. Inspect the wires and the
power relay. Check the power and ground
connections to the ECM. Refer to Troubleshooting,
i02526655 Electrical Power Supply for more information.
Intermittent Engine Shutdown Fuel Supply
SMCS Code: 1000-038; 1901-038
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted.
Check fuel lines for the following problems:
Probable Causes lines and/or replace the lines.
Engine start switch 1. Check the fuel tank for foreign objects which may
Engine speed/timing sensor(s) suction line of the fuel pump. Prime the fuel system
after you perform the following procedures:
Electrical connections
Replacing the fuel lters
Fuel supply
Engine shutdown switch (if applicable)
Crank without injection input (if applicable)
Recommended Actions of the fuel. Refer to the Operation and
Engine Start Switch operation.
Check the engine start switch on Cat ET. Look for
an intermittent problem in the wiring for the engine
start switch.
RENR5009-07 47
3. Check the fuel pressure during engine operation. Recommended Actions

to the Systems Operation/Testing and Adjusting Note: If the problem only occurs under certain
manual for the correct pressure values. If the fuel conditions, test the engine under those conditions.
pressure is low, replace the fuel lters. If the fuel Examples of certain conditions are high engine
pressure is still low, check the following items: fuel speed, full load and engine operating temperature.
transfer pump, fuel transfer pump coupling, and Troubleshooting the symptoms under other
fuel pressure regulating valve. conditions can give misleading results.
Engine Shutdown Switch (if applicable) Fuel Supply

Use Cat ET to monitor the status of the engine. Check Check the fuel level in the fuel tank. Ensure that
for active shutdowns due to the engine shutdown adequate fuel is available for the application.
switch. Determine the cause for the active shutdown
and make any repairs necessary. Check fuel lines for the following problems:
Crank Without Injection Input (if lines and/or replace the lines.
applicable) 1. Check the fuel tank for foreign objects which may
If equipped, verify that the plug is installed for the
crank without injection input. Ensure that the plug
for the crank without injection input is installed
securely. Refer to the diagnostic functional test
Troubleshooting, Crank without Injection Input. Replacing the fuel lters
i02526753
Intermittent Low Power or
Power Cutout of the fuel. Refer to the Operation and
SMCS Code: 1000-038; 1901-038
operation.
Note: Use this procedure only if the engine does not
shut down completely.
3. Check the fuel pressure during engine operation.
Probable Causes to the Systems Operation/Testing and Adjusting
Fuel supply pressure is low, replace the fuel lters. If the fuel
Derates transfer pump, fuel transfer pump coupling, and
Throttle signal
Derate
Engine speed/timing sensor(s)
Connect Caterpillar Electronic Technician (ET) and
Turbocharger check for an active derate event. A derate status ag
will appear on Cat ET if an active engine derate is
Rated fuel position occurring. In order to view active events, go to the
Events menu under Diagnostics.
Air inlet and exhaust restrictions
Power supply for the Electronic Control Module Throttle Signal
(ECM)
Use Cat ET in order to monitor the status of the
throttle. Observe the throttle position. Verify that the
Fuel position multiplier (if applicable) throttle position is smooth from low idle to high idle.
high idle.
48 RENR5009-07
Engine Speed/Timing Sensor(s) Fuel Position Multiplier (if applicable)

If the following diagnostic codes are applicable, If equipped, use Cat ET to verify that the fuel position
check Cat ET for any logged diagnostic codes for multiplier is not affecting the available fuel rack. Refer
the primary engine speed/timing sensor: 190-02, to the diagnostic procedure Troubleshooting, Fuel
190-03, and 190-08. If the engine is equipped with Position Multiplier.
a secondary engine speed/timing sensor, check for
any of the following logged diagnostic codes: 342-02,
i02304699
342-03, and 342-08. Refer to the diagnostic functional
test Troubleshooting, Engine Speed/Timing Sensor. Low Engine Oil Pressure
Turbocharger SMCS Code: 1300-038; 1901-038
Ensure that the turbocharger is operating correctly. NOTICE

Periodic inspection and cleaning is recommended for Do not operate engine with low oil pressure. Engine
the turbocharger compressor housing (inlet side). damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is
Rated Fuel Position corrected.
Operate the engine under full load. Use Cat ET in

order to monitor the following values: turbocharger Probable Causes
compressor outlet pressure, fuel position, rated fuel
position, and Fuel Ratio Control (FRC). The fuel Low engine oil level
position should equal the rated fuel position. The
FRC fuel position should be greater than the rated Dirty engine oil lters
fuel position.
Restriction at engine oil pump
If any of the above values are changing rapidly for
no apparent reason, there may be an intermittent Restriction in engine oil cooler(s)
problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, Inspecting Electrical Fuel dilution of engine oil
Connectors.
Camshaft and/or camshaft bearings
Air Inlet and Exhaust Restrictions
Crankshaft bearings
Check the air inlet system for the following problems:
restrictions, collapse, and pinched line. Repair the Recommended Actions
lines and/or replace the lines.
Check for an air lter restriction indicator. Replace

Engine Oil Level
plugged air lters and/or clean lters. Repair any
Inspect the engine oil level. If engine oil is low add
leaks.
engine oil.
ECM Power Supply Oil Filter
1. Inspect the circuit between the ECM and
Inspect the engine oil lter. If the engine oil lter
the batteries. Refer to the Electrical System
is dirty, install a new engine oil lter. Check the
Schematic. Inspect the wires, the connectors,
operation of bypass valve for the lter. Clean the
and the components in the circuit. Refer to
bypass valve and the housing. If necessary, install
Troubleshooting, Electrical Power Supply for
new parts.
more information.
2. Inspect the circuit between the ECM and Engine Oil Pump
the keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors, Check for blockage of the inlet screen in the engine
and the components in the circuit. Refer to oil pump. Examine the engine oil pump for excessive
Troubleshooting, Electrical Power Supply for wear.
more information.
RENR5009-07 49
Oil Cooler Check fuel lines for the following problems:

Inspect the engine's oil cooler. Clean the engine oil lines and/or replace the lines.
cooler core(s) and/or install new engine oil cooler
core(s). 1. Check the fuel tank for foreign objects which may
Fuel Dilution of Engine Oil suction line of the fuel pump. Prime the fuel system
Check for presence of fuel in lubricating oil. Refer
to the diagnostic procedure Troubleshooting, Fuel Replacing the fuel lters
Dilution of Engine Oil.
Camshaft and/or Crankshaft
Inspect the camshaft and/or camshaft bearings.
Check the components for excessive wear. Excessive
wear is an indication of a blocked oil passage. Inspect Maintenance Manual for information on improving
the crankshaft and/or crankshaft bearings. Check the
components for excessive wear.
operation.
i02526779 3. Check the fuel pressure during engine operation.

Low Power/Poor or No to the Systems Operation/Testing and Adjusting
Response to Throttle pressure is low, replace the fuel lters. If the fuel
SMCS Code: 1000-038; 1901-038
transfer pump, fuel transfer pump coupling, and
Probable Causes
Derate Mode
Fuel supply
Connect Cat ET and check for logged derate events.
Derate mode A derate status ag will appear on Cat ET if an
active engine derate is occurring. The engine speed
Cold mode operation and cold cylinder cutout might be limited due to one of the following possible
causes: altitude, high exhaust temperatures, air lter
Throttle signal restriction, high coolant temperature, aftercooler
water temperature, and crankcase pressure.
Electrical connectors
Injector Cold Mode Operation and Cold Cylinder
Cutout
Fuel Ratio Control Limit (FRC)
Use the Caterpillar Electronic Technician (ET) in
Air inlet restriction order to verify that the engine has exited cold mode.
During cold mode, fuel injection timing is modied.
Exhaust restrictions When the engine is in cold mode, the cold cylinder
cutout strategy may be active. Cold mode cylinder
Electronic Control Module (ECM) cutouts may cause variations in vibration and
available power. This is normal operation.
Fuel position multiplier (if applicable)
Throttle Signal
Air shutoff valve (if applicable)
Use Cat ET in order to monitor the status of the
Recommended Actions throttle. Observe the throttle position. Verify that the
throttle position is smooth from low idle to high idle.
Fuel Supply high idle.
50 RENR5009-07
Electrical Connector Fuel Position Multiplier (if applicable)

Check for the correct installation of the ECM If equipped, use Cat ET to verify that the fuel position
connector(s) J1/P1 and/or J2/P2. Check for multiplier is not affecting the available fuel rack.
correct installation of the applicable fuel Injector Refer to Troubleshooting, Fuel Position Multiplier
connectors. Refer to the diagnostic functional test if a problem is suspected with the input for the fuel
Troubleshooting, Inspecting Electrical Connectors. position multiplier.
Injector Air Shutoff Valve (if applicable)

Use Cat ET to determine if any active diagnostic Check that both of the air shutoffs are open.
codes are present. Check that the injector trim codes
have been entered. Use Cat ET to determine if any
i02549632
logged diagnostic codes are present. Perform the
Injector Solenoid Test. Observe that the solenoids
for the injectors are being energized on Cat ET.
Mechanical Noise (Knock) in
Perform the Cylinder Cutout Test. Locate the Engine
misring cylinder. Refer to the diagnostic functional
test Troubleshooting, Injector Solenoids. SMCS Code: 1000-038; 1901-038
Fuel Ratio Control Limit (FRC) Probable Causes

Operate the engine under full load. Use Cat ET in Faulty accessory
order to monitor the following values: turbocharger
compressor outlet pressure, fuel position, rated fuel Damage to valve train components
position, and Fuel Ratio Control (FRC). The fuel
position should equal the rated fuel position. The Failure of connecting rod bearing
FRC fuel position should be greater than the rated
fuel position. Crankshaft bearings
If any of the above values are changing rapidly for
no apparent reason, there may be an intermittent
Recommended Actions
problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, Inspecting Electrical Faulty Accessory
Connectors.
Isolate the source of the noise. Remove the suspect
Air Inlet Restriction engine accessories. Inspect the suspect engine
accessories. Repair the engine accessories and/or
Check for an air lter restriction indicator. Replace replace the engine accessories.
plugged air lters and/or clean the lters. Repair any
leaks. Damage to Valve Train Components
Check the air inlet system for the following problems: Remove the valve cover from the suspect cylinder(s).
restrictions, collapse, pinched line, and loose ttings. Check the following items for damage: camshaft,
Repair the lines and/or replace the lines. valve rotocoil, valve springs, lifters, pushrods,
bridges, and injectors. Check for valves that do not
move freely. Remove the cylinder head and inspect
Exhaust Restrictions
the valves. Replace any damaged parts. If damage
Check the exhaust system for the following problems: has occurred, clean the following components:
cylinder liner, piston, and exhaust system. Replace
restrictions, collapse, pinched line, and loose ttings.
Repair the lines and/or replace the lines. any damaged parts.
Electronic Control Module (ECM) Failure of Connecting Rod Bearing
If you have replaced the ECM, check the read/change Inspect the connecting rod bearings and the bearing
surfaces (journals) on the crankshaft. Check the
system conguration parameters. Verify that the
parameters match the information on the engine piston pin for excessive wear. Replace any damaged
information plate. Verify that the correct ash le has parts.
been installed.
RENR5009-07 51
Crankshaft Bearings Injector

Check the crankshaft and/or crankshaft bearings. Use Caterpillar Electronic Technician (ET) to
Check the components for excessive wear. determine if any diagnostic codes for the injector
solenoids are present. Perform the Injector Solenoid
Test. Observe that the injector solenoids are being
i02421025
energized on Cat ET. Perform the Cylinder Cutout
Noise Coming from Cylinder Test. Locate the misring cylinder. Refer to the
diagnostic functional test Troubleshooting, Injector
SMCS Code: 1000-038; 1290-038 Solenoids.
Not Enough Lubrication

Probable Causes
Check the lubrication in the valve compartment.
Low quality fuel Check for sufcient lubrication between the injector
tappet and the rocker arm buttons. Check for blocked
Engine speed/timing sensor oil passages. Oil passages must be clean. Ensure
that the oil passages that send oil to the cylinder
Electrical connectors heads are clean.
Injector
Valve Lash
Not enough lubrication
Check the valve lash. Refer to the diagnostic
Too much valve lash procedure Troubleshooting, Too Much Valve Lash.
Damage to valve train components Damage to Valve Train Components

Failure of connecting rod bearing Remove the valve cover from the suspect cylinder(s).
Check the following items for damage: camshaft,
valve rotocoil, valve springs, lifters, pushrods, and
Recommended Actions bridges. Check for valves that do not move freely.
Remove the cylinder head. Inspect the valves.
Low Quality Fuel Replace any damaged parts.
Refer to Operation and Maintenance Manual for
information on the proper characteristics of the fuel.
Failure of Connecting Rod Bearing
Obtain a fuel analysis.
Inspect the connecting rod bearings and the bearing
surfaces (journals) on the crankshaft. Check the
Engine Speed/Timing Sensor piston pin for excessive wear. Replace any damaged
parts.
Calibrate the engine speed/timing sensor if a
CID-FMI 261-13 Engine Timing calibration required
diagnostic code is active. Refer to the calibration i02526831
procedure Troubleshooting, Engine Speed/Timing
Sensor - Calibrate. Poor Fuel Consumption
SMCS Code: 1000-038; 1901-038
Check for the correct installation of the connector(s) Probable Causes
for the Electronic Control Module (ECM) J1/P1 and/or
J2/P2. Check for correct installation of the applicable Engine speed/timing sensor(s)
fuel injector connectors. Repair the connector
and/or replace the connector. Refer to the diagnostic Electrical connectors
functional test Troubleshooting, Inspecting Electrical
Connectors. Injector
Fuel supply
Air inlet restrictions
Exhaust restrictions
52 RENR5009-07
Accessory equipment 3. Check the fuel pressure during engine operation.

to the Systems Operation/Testing and Adjusting
Recommended Actions manual for the correct pressure values. If the fuel
pressure is low, replace the fuel lters. If the fuel
Engine Speed/Timing Sensor(s) pressure is still low, check the following items: fuel
transfer pump, fuel transfer pump coupling, and
Check the calibration of the engine speed/timing fuel pressure regulating valve.
sensor if a CID-FMI 261-13 Engine Timing calibration
required diagnostic code is active. Refer to the
calibration procedure Troubleshooting, Engine
Air inlet Restrictions
Speed/Timing Sensor - Calibrate.
Inspect the engine air cleaner. Replace plugged air
lters and/or clean the lters. Check the air inlet
Electrical Connectors systems for restrictions and for leaks.
Check for the correct installation of the connectors
for the Electronic Control Module (ECM) J1/P1
Exhaust Restrictions
and/or J2/P2. Check for the correct installation
Check the exhaust systems for restrictions and for
of the applicable fuel injector connectors. Repair
leaks.
the connector and/or replace the connector. Refer
to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors. Accessory Equipment
Injector Check attached accessory equipment. Ensure that

the accessory equipment is not lugging down the
engine.
Check for active diagnostic codes that are associated
with the circuits for the fuel injector. Check that the
injector trim codes have been entered. Perform i02048525
the Injector Solenoid Test. Verify that the ECM is
energizing all the injector solenoids. Refer to the Secondary ECM Assumes
diagnostic functional test Troubleshooting, Injector
Solenoids.
Control
SMCS Code: 1901-038
Fuel Supply
adequate fuel is available for the application. Battery voltage to the primary Electronic Control
Module (ECM)
Check fuel lines for the following problems:
restrictions, collapse, and pinched line. Repair the Open circuit and/or short circuit condition
lines and/or replace the lines.
Primary ECM personality module
1. Check the fuel tank for foreign objects which may
block the fuel supply. Check for air leaks in the Injector solenoid
after you perform the following procedures: Circuit breaker
Replacing the fuel lters 1. Turn the Engine Control Switch (ECS) to the
OFF/RESET position. Wait for 15 seconds. Start
Working on the low pressure fuel supply circuit the engine. Observe the status screen on the
Caterpillar Electronic Technician (ET). Verify the
Replacing fuel injectors position of the ECS. If the position is indicated
incorrectly, perform the diagnostic functional test
2. Cold weather adversely affects the characteristics Troubleshooting, Engine Control Switch (ECS).
Maintenance Manual for information on improving 2. Check the connectors and wiring for the following
the characteristics of the fuel during cold weather problems: damage, abrasion, corrosion, and
operation. incorrect attachment. Refer to the diagnostic
functional test Troubleshooting, Inspecting
Electrical Connectors.
RENR5009-07 53
3. Refer to the diagnostic functional test i01912685

Troubleshooting, Secondary ECM/Personality
Module. Synchronizing Switch Not
Functioning Properly
4. Use Cat ET to determine if any active diagnostic
codes are present for the injector solenoids. Use SMCS Code: 1000-038
Cat ET to determine if any logged diagnostic codes
are present for the injector solenoids. Perform the In order to synchronize the throttle control on multiple
Injector Solenoid Test. Observe that the injector engines, the Electronic Control Module (ECM)
solenoids are being energized on Cat ET. Perform receives four input signals to the ECM. One of the
the Cylinder Cutout Test. Locate the misring inputs is the primary throttle signal. Another one of the
cylinder. Refer to the diagnostic functional test inputs is the secondary throttle signal. The other two
Troubleshooting, Injector Solenoids. inputs are from the engine synchronization switch.
These four inputs can be used to synchronize the
5. Check the circuit breaker for the ECM. Reset the throttle signals from multiple engines. The response
circuit breaker. from the ECM to the four input values depends on the
values in the following programmable parameters.
i02048574
Number of synchronized engines
Secondary ECM Indicator Fault
Engine location
SMCS Code: 1901-038
Secondary throttle
The probable causes are listed below:
The logic and wiring for synchronization is dependent
Voltage to the secondary Electronic Control Module upon the number of engines that are being
(ECM) synchronized. The ECM response is dependent on
the programmed engine location. Refer to Table 15
Secondary ECM personality module for the engine locations that are valid for a given
number of engines.
Open and/or short circuit condition
Table 15
Circuit breaker for the ECM Number of Valid Engine Secondary
Synchronized Locations Throttle
1. Turn the Engine Control Switch (ECS) to the Engines
OFF/RESET position. Wait for 15 seconds. Start none Port Enabled
the engine. Observe the status screen on the Starboard Disabled
Caterpillar Electronic Technician (ET). Verify the Center
position of the ECS. If the position is indicated Engine #n
incorrectly, perform the diagnostic functional test
Troubleshooting, Engine Control Switch (ECS). 2 Port unavailable
Starboard
2. Refer to the diagnostic functional test 3 Port unavailable
Troubleshooting, Secondary ECM/Personality Starboard
Module. Center
4 or more Engine #n unavailable
3. Check the connectors and wiring for the following
problems: damage, abrasion, corrosion, and
incorrect attachment. Perform the diagnostic In a single engine installation, there could be up to
functional test Troubleshooting, Inspecting two throttle inputs. One of the inputs is the primary
Electrical Connectors. throttle signal. Another one of the inputs is the
secondary throttle signal. The secondary throttle is
4. Check the circuit breaker for the ECM. Reset the activated with a single switch. Illustration 11 shows
circuit breaker. the wiring for a single engine installation.
54 RENR5009-07
g00996411
Illustration 11
Wiring for the throttle in a single engine installation
Table 16 shows the logic for a single engine

installation. If the primary throttle will be used, disable
the secondary throttle by setting the parameter for
the secondary throttle to the disabled position.
Table 16
Engine Synchronization Input Active Throttle Synchronization
Status
1 2
Open Open Primary unavailable
Open Low Secondary unavailable
Low Open Primary unavailable
Low Low Primary unavailable
In a twin engine installation, the ECM will assume that

one engine is on the port side of the boat and that the
other engine is on the starboard side of the boat. The
ECM will label the engines as the port engine and as
the starboard engine on the service tool and on the
display. The operator can synchronize both engines
in order to be controlled with either the port throttle or
the starboard throttle. The operator could choose to
not synchronize the engine throttles at all. Illustration
12 shows the wiring for twin engine installations.
g00996414
Illustration 12
Wiring for the throttle in a twin engine installation
The logic for Illustration 12 is shown in Table 17.

RENR5009-07 55
Table 17
Synchronization No Synchronization Synchronization Synchronization
Status Port Side Starboard Side
Port Engine Open Low Open
Synchronization
Input
1
Engine Open Open Low
Synchronization
Input
2
Active Throttle Primary Primary Secondary
Starboard Engine Open Open Low
Synchronization
Input
1
Engine Open Low Open
Synchronization
Input
2
Active Throttle Primary Secondary Primary
Table 18 shows the logic for the Port side control in a

twin engine installation.
Table 18
Engine Synchronization Input Active Throttle Port ECM

Synchronization
1 2 Status
Open Open Primary No
Synchronization
Open Low Secondary Synchronization
on the Starboard
side
Low Open Primary Synchronization
on the Port side
Low Low Primary Invalid
Table 19 shows the logic for the Starboard side

control in a twin engine installation.
Table 19
Engine Synchronization Input Active Throttle Starboard ECM
Synchronization
1 2 Status
Synchronization
on the Port side
on the Starboard
side
56 RENR5009-07
When there are three engines in an installation,

the engines will be arranged in a master-slave
conguration. The user must designate the master
throttle control. The user must synchronize throttle
control to the master throttle control only. The user
can add a fourth throttle control. The fourth throttle
control can be used as the master throttle control.
Illustration 13 shows the wiring for an installation of

three engines. Illustration 13 shows the center engine
as the master throttle control.
g00996416
Illustration 13
Wiring for the throttle in a triple engine installation (center as master throttle)

RENR5009-07 57
Table 20
Engine Synchronization Input No Synchronization Synchronization
Port Engine Synchronization Open Open
Input
1
Engine Synchronization Open Low
Input
2
Active Throttle Primary Secondary
Starboard Engine Synchronization Open Open
Input
1
Input
2
Active Throttle Primary Primary
Center Engine Synchronization Open Low
Input
1
Engine Synchronization Open Open
Input
2

three engines. Illustration 14 shows the port engine
g00996417
Illustration 14
Wiring for the throttle in a triple engine installation (Port as master throttle)

58 RENR5009-07
Table 21
Synchronization No Synchronization Synchronization
Status
Port Engine Synchronization Open Low
Input
1
Input
2
Input
1
Input
2
Center Engine Synchronization Open Open
Input
1
Input
2

three engines. Illustration 15 shows the starboard
engine as the master throttle control.
g00996418
Illustration 15
Wiring for the throttle in a triple engine installation (starboard as master throttle)

RENR5009-07 59
Table 22
Status
Input
1
Input
2
Starboard Engine Synchronization Open Low
Input
1
Input
2
Input
1
Input
2

three engines. Illustration 16 shows the fourth throttle
g00996419
Illustration 16
Wiring for the throttle in a triple engine installation (fourth throttle as master throttle)

60 RENR5009-07
Table 23
Status
Input
1
Input
2
Input
1
Input
2
Input
1
Input
2
Table 24 shows the logic for the ECM in a triple

engine installation. Use the logic in Table 24 in order
to synchronize multiple engines to a single throttle
control.
Table 24
Engine Synchronization Input Active Throttle Port

Starboard
1 2 Center
Synchronization
Status
(same for all)
Synchronization
If you are experiencing problems with the Vessel wiring

synchronization of the throttle controls, verify that
the wiring matches the congurations for your Faulty synchronizing switch
application. Verify that the following parameters are
programmed in order to match the congurations for Check the wiring for the following problems:
your application. damage, abrasion, corrosion, and incorrect
attachments.
Number of synchronized engines
1. Check the wiring for continuity or shorts between
Engine location the synchronizing switch and the ECM.
Secondary throttle 2. Check the wiring for continuity or shorts between

the throttle position sensor and the ECM.
RENR5009-07 61
3. Check the wiring for continuity or shorts between Not Enough Lubrication
the ECM connectors.
Check the lubrication in the valve compartment.
Check the synchronizing switch for proper Check for sufcient lubrication between the injector
operation. tappet and the rocker arm buttons.
1. Disconnect the wiring from the synchronizing Worn Bridges for Valves
switch.
Check the bridges for signs of wear. Adjust the
2. Use a voltmeter to check the resistance across bridges and/or replace the bridges. If there is too
the contacts of the synchronizing switch as much wear, install new parts. Adjust the valve lash.
the synchronizing switch is turned to different
positions.
Worn Pushrods
i02549667 Inspect the pushrods for signs of wear. If there is too
much wear, install new pushrods. Adjust the valve
Too Much Valve Lash lash.
SMCS Code: 1000-038; 1901-038 Worn Valve Lifters

Probable Causes Clean the valve train. Install new valve lifters.
Rocker arm Worn Camshaft

Not enough lubrication Check the camshaft for wear.
Worn rocker arm Worn Valve Stem

Worn bridges for valves Check the valve stem for signs of wear. Check for
free movement of valves. Check for a bent valve
Worn pushrods stem. Adjust the valve lash.
Worn valve lifters
Loose Retaining Bolt(s) for Rocker Shaft
Worn camshaft
Repair the retaining bolt for the rocker shaft and/or
Worn valve stem replace the retaining bolt.
Incorrect valve lash Worn Valve Springs

Loose retaining bolt(s) for rocker shaft Check the valve springs for damage or for signs of
wear. If there is too much wear, install new springs.
Worn valve springs Adjust the valve lash.
Valve seats Valve Seats

Recommended Actions Check the valve seats for signs of wear. If there is
too much wear, install new valve seats. Adjust the
Rocker Arm valve lash.
Check for proper installation of the rocker arm i02304874

adjustment screw locknut. If the rocker arm
adjustment screw locknut is loose, adjust the valve Too Much Vibration
lash.
SMCS Code: 1000-038; 1901-038
Check the rocker arms for signs of wear. If there is
too much wear, install new parts or rocker arms.
Adjust the valve lash.
Probable Causes
Vibration damper
Loose engine supports
62 RENR5009-07
Fan blade Recommended Actions

Misring cylinder Valve Rotocoil
Alignment and balance Determine the cause of the cracked rotocoil. Install
new parts.
Recommended Actions
Spring Locks
Vibration damper
Check the locks. A broken lock can cause the valve
Check the vibration damper for damage. Tighten to fall into the cylinder.
the bolts. Check the vibration damper bolt holes for
damage and/or wear. Valve Spring(s)
Loose engine supports Install the new valve spring(s). Replace the valve
and/or other damaged parts.
Run the engine. Check the engine for the following
problems: loose mounts, broken mounts, loose
brackets, and broken brackets. Tighten all mounting
bolts.
Fan blade
Check the fan blade for damage. Ensure that the fan
blade is balanced.
Misring cylinder
Check for a misring cylinder. Perform the Cylinder
Cutout Test. Refer to the diagnostic functional test
Troubleshooting, Injector Solenoids.
Alignment and balance

Check alignment and the balance. If the symptom
remains refer to the diagnostic procedure
Troubleshooting, Engine Misres, Runs Rough or
Is Unstable.
i02549674
Valve Rotocoil or Spring Lock

Is Free
SMCS Code: 1109-038
Probable Causes
Cracked inlet valve rotocoil
Broken spring locks
Broken valve spring(s)
RENR5009-07 63
Troubleshooting with a
Diagnostic Code
i01914069
Diagnostic Codes
SMCS Code: 1901-038
Diagnostic codes alert the operator that a problem

exists. Diagnostic codes indicate the nature of the
problem to the service technician. Diagnostic codes
consist of the following identiers: module identier
(MID), component identier (CID), and failure mode
identier (FMI). The MID indicates the electronic
module that generated the diagnostic code. The MID
for the engine's Primary Electronic Control Module
(ECM) is 36. The MID for the engine's Secondary
Electronic Control Module (ECM) is 47. The CID
indicates the component in the system. The FMI
indicates the failure mode that is present. Diagnostic
codes may be viewed on the Caterpillar Electronic
Technician (ET). Do not confuse diagnostic codes
with diagnostic events.
Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct this problem as
soon as possible. When an active diagnostic code is
generated, a display module such as the Electronic
Monitoring System (EMS) may produce a warning.
g00740986
Illustration 17
Typical example
Illustration 17 indicates a typical output voltage from

the coolant temperature sensor. The Cat ET can be
used to monitor the output voltage and temperature
of any sensor. The Cat ET will display diagnostic
codes that are associated with a sensor. As you look
at Illustration 17, notice the output voltage of the
sensor. A diagnostic code is generated when the
ECM detects an abnormal output voltage from the
sensor.
Note: Always clear logged diagnostic codes after

investigating and correcting the problem which
generated the code.
64 RENR5009-07
Logged Diagnostic Codes i01954439
When the ECM generates a diagnostic code the MID 036 - CID 0001 - FMI 06
ECM logs the code in permanent memory. The Injector Cylinder 1 short
ECM has an internal diagnostic clock. The ECM
will record the hour of the rst occurrence of the SMCS Code: 1290-038
diagnostic code. The ECM will record the hour of the
last occurrence of the diagnostic code. The ECM will Conditions Which Generate This Code:
record the number of occurrences of the code. This
information is a valuable indicator for troubleshooting The Electronic Control Module (ECM) detects a short
intermittent problems. Some diagnostic codes may circuit or short to ground in the No. 1 cylinder injector
log occurrences that did not result in complaints. solenoid.
The most likely cause of an intermittent problem is a
faulty connection or damaged wiring. The next likely System Response:
cause is a component failure. The least likely cause
is the failure of the ECM. Diagnostic codes that are The CID-FMI is logged in memory. The ECM will
logged repeatedly may indicate a problem that needs continue to operate all injectors.
special investigation.
Perform the following diagnostic procedure: Injector
If the symptoms continue, use the proper procedure Solenoids
for troubleshooting the symptoms that have been
experienced by the operator. Results:
i01954438 OK STOP.
MID 036 - CID 0001 - FMI 05 REPAIRED, OK STOP.
Injector Cylinder 1 open circuit
i01954440
SMCS Code: 1290-038
MID 036 - CID 0002 - FMI 05
Conditions Which Generate This Code: Injector Cylinder 2 open circuit
The Electronic Control Module (ECM) detects an SMCS Code: 1290-038
open circuit or short to battery voltage in the No. 1
cylinder injector solenoid. Conditions Which Generate This Code:
System Response: The Electronic Control Module (ECM) detects an
The CID-FMI is logged in memory. The ECM will cylinder injector solenoid.
continue to operate all injectors.
System Response:
Solenoids The CID-FMI is logged in memory. The ECM will
Results:
OK STOP. Solenoids
REPAIRED, OK STOP. Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 65
i01954441 i01954484
MID 036 - CID 0002 - FMI 06 MID 036 - CID 0003 - FMI 06
Injector Cylinder 2 short Injector Cylinder 3 short
SMCS Code: 1290-038 SMCS Code: 1290-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a short
circuit or short to ground in the No. 2 cylinder injector circuit or short to ground in the No. 3 cylinder injector
solenoid. solenoid.
System Response: System Response:
The CID-FMI is logged in memory. The ECM will The CID-FMI is logged in memory. The ECM will
continue to operate all injectors. continue to operate all injectors.
Perform the following diagnostic procedure: Injector Perform the following diagnostic procedure: Injector
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
REPAIRED, OK STOP. REPAIRED, OK STOP.
i01954483 i01954486
Injector Cylinder 3 open circuit Injector Cylinder 4 open circuit
The Electronic Control Module (ECM) detects an The Electronic Control Module (ECM) detects an
open circuit or short to battery voltage in the No. 3 open circuit or short to battery voltage in the No. 4
cylinder injector solenoid. cylinder injector solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
66 RENR5009-07
i01954487 i01954491
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954489 i01954493
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
RENR5009-07 67
i01954496 i01954500
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954498 i01954501
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
68 RENR5009-07
i01954503 i01954506
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954504 i01954507
Injector Cylinder 9 open circuit Injector Cylinder 10 open
SMCS Code: 1290-038
circuit
SMCS Code: 1290-038
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects an
cylinder injector solenoid.
System Response:
The CID-FMI is logged in memory. The ECM will System Response:

The CID-FMI is logged in memory. The ECM will
Perform the following diagnostic procedure: Injector continue to operate all injectors.
Solenoids
Results: Solenoids
Results:
OK STOP.
REPAIRED, OK STOP. OK STOP.
REPAIRED, OK STOP.
RENR5009-07 69
i01954508 i01954510
The Electronic Control Module (ECM) detects a short The Electronic Control Module (ECM) detects a
circuit or a short to ground in the No. 10 cylinder short circuit or short to ground in the No. 11 cylinder
injector solenoid. injector solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954509 i01954511
Injector Cylinder 11 open Injector Cylinder 12 open
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
70 RENR5009-07
i01954513 i01954515
The Electronic Control Module (ECM) detects a The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 12 cylinder short circuit or short to ground in the No. 13 cylinder
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954514 i01954517
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
RENR5009-07 71
i01954518 i01954522
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01954519 i01954523
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
72 RENR5009-07
i01954525 i01915026
Injector Cylinder 16 short Throttle Position calibration
SMCS Code: 1290-038 required
SMCS Code: 1913-038
The Electronic Control Module (ECM) detects a
short circuit or short to ground in the No. 16 cylinder
injector solenoid. The Electronic Control Module (ECM) detects the
following condition:
System Response:
The duty cycle for the throttle position sensor signal
is less than 5 percent or more than 95 percent.
This diagnostic code indicates that the throttle stops
are improperly set.
Solenoids
System Response:
Results:
OK STOP.
REPAIRED, OK STOP.
i01954590
MID 036 - CID 0091 - FMI

08 Throttle Position signal
abnormal
SMCS Code: 1913-038
g00764010
Illustration 18
The ECM sets the desired engine speed to
The Electronic Control Module (ECM) has been programmed low idle while this diagnostic code is
powered up for three seconds. The diagnostic codes active. The Caterpillar Electronic Technician (ET)
263-03 and 263-04 are not active. The sensor will indicate a throttle position of 0 percent while this
frequency is greater than 1000 Hz or less than 150 diagnostic code is active.
Hz for two seconds. The duty cycle is greater than 95
percent or less than 5 percent for one second. Possible Performance Effect:
System Response: The desired engine speed will return to low idle while
this diagnostic code is active.
The throttle position is set to a default value of 0
percent (low idle) by the ECM. The CID-FMI is logged Troubleshooting:
in memory when the engine has been running for
three seconds and the engine is not cranking. Perform the following diagnostic procedure: Throttle
Position Sensor - Calibrate
Perform the following diagnostic procedure: Throttle
Position Sensor Results:
Results: OK STOP.
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 73
i01936028 i01954600
MID 036 - CID 0094 - FMI 03 MID 036 - CID 0100 - FMI
Fuel Pressure open/short to 03 Engine Oil Pressure
+batt open/short to +batt
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second. voltage that is greater than 4.8 VDC for one second.
The ECM has been powered for three seconds. The The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. diagnostic codes 262-03 and 262-04 are not active.
The code is logged. The ECM ags ltered fuel The CID-FMI is logged in memory. The ECM ags
pressure as invalid data and a default value of engine oil pressure as invalid data and a default
500 kPa (73 psi) is used. value of 500 kPa (73 psi) is used.
Perform the following diagnostic procedure: Engine Perform the following diagnostic procedure: Engine
Sensor Open/Short Test Sensor Open/Short Test
Results: Results:
OK STOP. OK STOP.
i01936029 i01954601
Fuel Pressure short to ground Engine Oil Pressure short to
SMCS Code: 1901-038
ground
SMCS Code: 1924-038
The Electronic Control Module (ECM) reads signal Conditions Which Generate This Code:
voltage that is below 0.2 VDC for one second. The
The Electronic Control Module (ECM) reads signal
ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. voltage that is below 0.2 VDC for one second. The
diagnostic codes 262-03 and 262-04 are not active.
System Response:
System Response:
The code is logged. The ECM ags ltered fuel
pressure as invalid data and a default value of
500 kPa (73 psi) is used. The CID-FMI is logged in memory. The ECM ags
engine oil pressure as invalid data and a default
value of 500 kPa (73 psi) is used.
Perform the following diagnostic procedure: Engine
Sensor Open/Short Test
Results:
Results:
OK STOP.
REPAIRED, OK STOP.
74 RENR5009-07
i01954609 i01954615
MID 036 - CID 0101 - FMI MID 036 - CID 0110 - FMI 03
03 Crankcase Pressure Engine Coolant Temperature
open/short to +batt open/short to +batt
voltage that is greater than 4.8 VDC for one second. voltage that is greater than 4.8 VDC for one second.
The CID-FMI is logged in memory. The ECM ags The CID-FMI is logged in memory. The ECM ags
crankcase pressure as invalid data. The engine coolant temperature as invalid data and a default
monitoring system is disabled for crankcase pressure. value of 40 C (40 F) is used.
Results: Results:
OK STOP. OK STOP.
i01954610 i01954616
Crankcase Pressure short to Engine Coolant Temperature
ground short to ground
voltage that is less than 0.2 VDC for one second. voltage that is less than 0.2 VDC for one second.
The CID-FMI is logged in memory. The ECM ags The CID-FMI is logged in memory. The ECM ags
crankcase pressure as invalid data. The engine coolant temperature as invalid data and a default
monitoring system is disabled for crankcase pressure. value of 40 C (40 F) is used.
Results: Results:
OK STOP. OK STOP.
RENR5009-07 75
i01954667 i01954671
MID 036 - CID 0168 - FMI 00 MID 036 - CID 0168 -

System Voltage High FMI 02 System Voltage
SMCS Code: 1401-038 intermittent/erratic
SMCS Code: 1401-038
The Electronic Control Module (ECM) has been
powered for three seconds. The engine is not
cranking. The battery voltage is greater than 32 VDC The engine is running but not cranking. One of the
following conditions exist. The battery voltage is less
for two seconds.
than 9 VDC for at least 0.06 seconds. Three times in
System Response: the last seven seconds, the battery voltage was less
than 9 VDC.
The CID-FMI is logged in memory.
System Response:
Perform the following diagnostic procedure:
Electrical Power Supply
Results:
OK STOP. Results:
REPAIRED, OK STOP.
OK STOP.
i01954670 REPAIRED, OK STOP.
MID 036 - CID 0168 - FMI 01
i01935913
System Voltage Low
MID 036 - CID 0190 - FMI 02
SMCS Code: 1401-038
Loss of Engine Speed signal
SMCS Code: 1912-038
powered for three seconds. The engine is not
cranking. The battery voltage is less than 9 VDC for
two seconds. The primary engine speed signal cannot be detected.
The timing gear pattern returns within one second
before being lost and the battery voltage is greater
System Response:
than 9 VDC for the last two seconds. The code is
logged only if the engine has been running for three
seconds. The code will be active and logged if the
Perform the following diagnostic procedure: Electronic Control Module (ECM) detects an incorrect
signal for one second. The battery voltage is greater
than 9 VDC for the last two seconds.
Results:
System Response:
OK STOP. The code is logged. On engines with a secondary
engine speed/timing sensor, the secondary engine
REPAIRED, OK STOP. speed/timing signal will be used if the primary engine
speed/timing signal is lost.

Speed/Timing Sensor
Results:
OK STOP.
76 RENR5009-07
REPAIRED, OK STOP. i01954685
MID 036 - CID 0190 - FMI 08

i01954681
Engine Speed signal abnormal
MID 036 - CID 0190 - FMI 03
SMCS Code: 1912-038
Engine Speed open/short to
+batt Conditions Which Generate This Code:
SMCS Code: 1912-038 The diagnostic code will become active if the
following conditions exist. The engine speed is
Conditions Which Generate This Code: greater than 0 rpm. The primary engine speed/timing
signal is incorrect.
A wire on the primary engine speed/timing sensor is
disconnected and/or broken. There is a short circuit System Response:
to the +Battery terminal.
The code will become logged if the following
System Response: conditions exist. The engine speed is greater than 0
rpm. The engine speed/timing signal is incorrect for
The CID-FMI is logged in memory. On engines ve seconds. The engine speed/timing signal returns
with a secondary engine speed/timing sensor, the for ve seconds.
secondary engine speed/timing signal will be used if
the primary engine speed/timing signal is lost. On engines with a secondary engine speed/timing
sensor, the secondary engine speed/timing signal
Perform the following diagnostic procedure: Engine will be used if the primary engine speed/timing signal
Speed/Timing Sensor is abnormal.
Results: Perform the following diagnostic procedure: Engine

Speed/Timing Sensor
OK STOP.
Results:
REPAIRED, OK STOP.
OK STOP.
MID 036 - CID 0190 - FMI
07 Primary Speed Sensor i02168582
misinstalled MID 036 - CID 0248 - FMI 09 Cat

Data Link not communicating
SMCS Code: 1912-038
SMCS Code: 1901-038
The primary engine speed/timing sensor is connected
to the harness connector for the secondary engine The battery voltage to the Electronic Control Module
speed/timing sensor. (ECM) has been above 9 VDC for the last two
seconds. The engine is not cranking. Communication
System Response: was lost for two or more seconds.
The CID-FMI is logged in memory. System Response:
Perform the following diagnostic procedure: Engine The CID-FMI is logged in memory.
Speed/Timing Sensor
Perform the following diagnostic procedure: Cat
Results: Data Link
OK STOP. Results:

REPAIRED, OK STOP.
RENR5009-07 77
i02399280 i01902426
Personality Module mismatch Electronic Control Module
SMCS Code: 1901-038 Error
SMCS Code: 1901-038
The personality module that is used for replacement
is for a different engine family or a different engine
application. The Electronic Control Module (ECM) has detected
an internal fault.
Note: The personality module is a ash le. The
personality module is installed into the Electronic System Response:
Control Module (ECM) by ash programming.
The ECM will log the diagnostic code. Engine power
System Response: and engine performance may be affected. Any
normal ECM function may be affected.
The ECM will not log the diagnostic code. The engine
will not start. The Caterpillar Electronic Technician Possible Performance Effect:
(ET) will not be able to reset the diagnostic code.
Engine misres
Possible Performance Effect:
Low power
The engine will not start.
Reduced engine speed (rpm)
Troubleshooting:
Engine shutdown
A. Check the part number of ECM ash le. Ensure
Troubleshooting:
that the ash le part number agrees with the
original engine arrangement.
Replace the ECM. Ensure that the new ECM serial
number ends with the same two characters as the
Expected Result:
original ECM serial number. Refer to Troubleshooting,
The correct ash le is installed in the ECM. Replacing the ECM before replacing the ECM.
Results:
Results:
OK The correct ash le is installed in the ECM. OK STOP.
Repair: The diagnostic code 253-02 must be i01935923

cleared if the correct ash le has been installed.
Clearing this diagnostic code requires factory MID 036 - CID 0261 - FMI 13
passwords. The personality module code must
also be reset to zero.
Engine Timing calibration
required
STOP.
SMCS Code: 1905-038
Not OK The correct ash le is not installed in
the ECM. Conditions Which Generate This Code:
Repair: Reprogram the ECM with the correct The engine speed/timing sensor has not been
ash le. Refer to Troubleshooting, Flash calibrated.
Programming.
Note: This will not keep the engine from running. The
STOP. fuel injection timing may be out of adjustment.
78 RENR5009-07
The code is logged. The CID-FMI is logged in memory. The analog

sensors are set to the default values.
Speed/Timing Sensor - Calibrate Perform the following diagnostic procedure: Analog
Sensor Supply
Results:
Results:
OK STOP.
OK STOP.
REPAIRED, OK STOP.
REPAIRED, OK STOP.
i01954690
i01954692
MID 036 - CID 0262 - FMI 03 5
Volt Sensor DC Power Supply MID 036 - CID 0263 - FMI 03
short to +batt Digital Sensor Supply short to
+batt
SMCS Code: 1408-038-NS
The Electronic Control Module (ECM) reads an
analog sensor supply voltage above 5.2 VDC for two The Electronic Control Module (ECM) reads a
or more seconds. The ECM has been powered for digital sensor supply voltage above 8.5 VDC for
three seconds. two seconds. The ECM has been powered for three
seconds.
Note: Normal voltage is 5.0 0.2 VDC.
Note: Normal voltage is 8.0 0.4 VDC.
System Response:
System Response:
The CID-FMI is logged in memory. Analog sensors
are set to the default values. The CID-FMI is logged in memory.
Perform the following diagnostic procedure: Analog Perform the following diagnostic procedure: Digital
Sensor Supply Sensor Supply
Results: Results:
OK STOP. OK STOP.
i01954691 i01954694
MID 036 - CID 0262 - FMI 04 5 MID 036 - CID 0263 - FMI 04
Volt Sensor DC Power Supply Digital Sensor Supply short to
short to ground ground
SMCS Code: 1408-038-NS SMCS Code: 1408-038-NS
The Electronic Control Module (ECM) reads an The Electronic Control Module (ECM) reads a
analog sensor supply voltage below 4.8 VDC for digital sensor supply voltage below 7.5 VDC for two
two seconds. The ECM has been powered for three seconds. The ECM has been powered for three
seconds. seconds.
Note: Normal voltage is 5.0 0.2 VDC. Note: Normal voltage is 8.0 0.4 VDC.
RENR5009-07 79
System Response: i02385805
The CID-FMI is logged in memory. MID 036 - CID 0273 - FMI 00

Turbo Outlet Pressure above
Perform the following diagnostic procedure: Digital
Sensor Supply normal
Results: SMCS Code: 1052-038
OK STOP. Conditions Which Generate This Code:
REPAIRED, OK STOP. The Electronic Control Module (ECM) reads

turbocharger outlet pressure above 200 kPa (29 psi).
The engine speed is within 50 rpm of low idle for
i01923504 ve seconds. The diagnostic codes 262-03, 262-04,
273-03, and 273-04 are not active.
MID 036 - CID 0268 - FMI
02 Check Programmable System Response:
Parameters The diagnostic code is logged in memory. The ECM
ags turbocharger outlet pressure as invalid data and
SMCS Code: 1901-038 a default value of 0 kPa (0 psi) is used.
Conditions Which Generate This Code: Possible Performance Effect:
One or more of the following programmable Low power
parameters have not been programmed:
Troubleshooting:
Engine serial number
Full Load Setting (FLS) Sensor Open/Short Test
Full Torque Setting (FTS) Results:
Rated fuel position OK STOP.
System Response:
REPAIRED, OK STOP.
The code is logged. The engine performance and/or
system operation may be affected. i01936079
A. Check for parameters that have not been MID 036 - CID 0273 - FMI
programmed. 03 Turbo Outlet Pressure
Results: open/short to +batt
OK A parameter has not been programmed. SMCS Code: 1052-038
Repair: Program the missing parameter. Refer to Conditions Which Generate This Code:
the diagnostic procedure Troubleshooting, System
Conguration Parameters. The Electronic Control Module (ECM) reads signal
voltage that is greater than 4.8 VDC for one second.
STOP. The ECM has been powered for three seconds. The
System Response:
The code is logged. The ECM ags turbocharger

compressor outlet pressure as invalid data and a
default value of 0 kPa (0 psi) is used.

80 RENR5009-07
Results: Results:
OK STOP. OK STOP.
i01936089 i01954760
Turbo Outlet Pressure short to Atmospheric Pressure short to
ground ground
The Electronic Control Module (ECM) reads signal The Electronic Control Module (ECM) reads an
voltage that is less than 0.2 VDC for one second. atmospheric pressure signal voltage below 1.7 VDC
The ECM has been powered for three seconds. The for one second. The ECM has been powered for
diagnostic codes 262-03 and 262-04 are not active. three seconds. The diagnostic codes 262-03 and
262-04 are not active.
System Response:
System Response:
The code is logged. The ECM ags turbocharger
compressor outlet pressure as invalid data and a The CID-FMI is logged in memory. The turbocharger
default value of 0 kPa (0 psi) is used. compressor inlet pressure sensor (if equipped) is
used as a backup for atmospheric pressure. The
Perform the following diagnostic procedure: Engine atmospheric pressure is set to a default value of
Sensor Open/Short Test 45 kPa (7 psi).
Results: Perform the following diagnostic procedure: Engine

OK STOP.
Results:
REPAIRED, OK STOP.
OK STOP.
i01954758
REPAIRED, OK STOP.
MID 036 - CID 0274 - FMI
03 Atmospheric Pressure i01935990
open/short to +batt MID 036 - CID 0275 - FMI 03

SMCS Code: 1923-038
Right Turbo Inlet Pressure
open/short to +batt
SMCS Code: 1052-038
voltage that is greater than 4.8 VDC for one second. Conditions Which Generate This Code:
The ECM has been powered for three seconds. The
diagnostic codes 262-03 and 262-04 are not active. The Electronic Control Module (ECM) reads signal
System Response: The ECM has been powered for three seconds. The
The CID-FMI is logged in memory. The turbocharger
compressor inlet pressure sensor (if equipped) is
used as a backup for atmospheric pressure.

RENR5009-07 81
The code is logged. The right turbocharger The code is logged. The left turbocharger compressor
compressor inlet pressure is set to a default value of inlet pressure is set to a default value of 45 kPa
45 kPa (7 psi). (6.5 psi).
Results: Results:
OK STOP. OK STOP.
i01954762 i01936097
Right Turbo Inlet Pressure Left Turbo Inlet Pressure short
short to ground to ground
voltage that is less than 0.2 VDC for one second. voltage that is less than 0.2 VDC for one second.
The CID-FMI is logged in memory. The turbocharger The code is logged. The turbocharger compressor
compressor inlet pressure is set to a default value of inlet pressure is set to a default value of 45 kPa
45 kPa (7 psi). (7 psi).
Results: Results:
OK STOP. OK STOP.
i02174525 i01915091
03 Left Turbo Inlet Pressure Timing Calibration signal
open/short to +batt abnormal
SMCS Code: 1052-038 SMCS Code: 1408-038-NS
The Electronic Control Module (ECM) reads signal The engine speed is above low idle. The signal for
voltage that is greater than 4.8 VDC for one second. Top Center is 30 degrees.
82 RENR5009-07
System Response: i01954877
The CID-FMI is logged in memory. MID 036 - CID 0279 - FMI 04

Aftercooler Temperature short
Speed/Timing Sensor - Calibrate to ground
Results: SMCS Code: 1063-038
REPAIRED, OK STOP. The Electronic Control Module (ECM) reads an

output voltage that is 0.2 VDC or less for one second.
i01954871 CID-FMI 262-03 and/or the CID-FMI 262-04 are not
active.
MID 036 - CID 0279 - FMI
03 Aftercooler Temperature System Response:
open/short to +batt The CID-FMI is logged in memory. The ECM no
longer optimizes engine operation according to
SMCS Code: 1063-038 aftercooler temperature. The ECM ags aftercooler
temperature as invalid data. The engine monitoring
Conditions Which Generate This Code: system is disabled for aftercooler temperature.
The Electronic Control Module (ECM) reads an Perform the following diagnostic procedure: Engine
output voltage that is 4.8 VDC or more for one Sensor Open/Short Test
second. The ECM has been powered for three
seconds. The CID-FMI 262-03 and/or the CID-FMI Results:
262-04 are not active.
System Response:
OK STOP.
The CID-FMI is logged in memory. The ECM no

REPAIRED, OK STOP.
longer optimizes engine operation according to
aftercooler temperature. The ECM ags aftercooler i01954880
temperature as invalid data. The engine monitoring
system is disabled for aftercooler temperature. MID 036 - CID 0289 - FMI
03 Unltered Fuel Pressure
Sensor Open/Short Test open/short to +batt
Results: SMCS Code: 1261-038-NS
REPAIRED, OK STOP. The Electronic Control Module (ECM) reads signal

System Response:
The CID-FMI is logged in memory. The ECM ags

fuel pressure as invalid data. The engine monitoring
system for this feature will be disabled.

Results:
OK STOP.
RENR5009-07 83
REPAIRED, OK STOP. i01954888
MID 036 - CID 0337 - FMI

i01954883
02 Incorrect Remote E-Stop
MID 036 - CID 0289 - FMI 04 Switch inputs
Unltered Fuel Pressure short
SMCS Code: 1901-038
to ground
One line for the customer shutdown switch is open
Conditions Which Generate This Code: and one line is low.
The Electronic Control Module (ECM) reads signal System Response:
ECM has been powered for three seconds. The The CID-FMI is logged in memory.
System Response: Emergency Stop Switch (Remote)
The CID-FMI is logged in memory. The ECM ags Results:
unltered fuel pressure as invalid data. The engine
monitoring system is disabled for unltered fuel
pressure.
OK STOP.

REPAIRED, OK STOP.
i01954889
Results:
MID 036 - CID 0338 - FMI 05
OK STOP. Pre-Lube Relay open circuit
REPAIRED, OK STOP. SMCS Code: 1319-038
i01954884
MID 036 - CID 0336 - FMI 02 The Electronic Control Module (ECM) detects an
open circuit at the prelube relay. The ECM detects a
Incorrect ECS Switch inputs short to battery voltage at the prelube relay.
SMCS Code: 1901-038 System Response:
Conditions Which Generate This Code: The CID-FMI is logged in memory.
One line for the Engine Control Switch (ECS) is open Perform the following diagnostic procedure:
and one line is low. Prelubrication System
System Response: Results:
The CID-FMI is logged in memory. The Electronic
Control Module (ECM) will ag the ignition switch as
OK STOP.
invalid data.
REPAIRED, OK STOP.
Control Switch (ECS)
Results:
OK STOP.
REPAIRED, OK STOP.
84 RENR5009-07
i01954893 i01954901
06 Pre-Lube Relay short to Secondary Engine Speed
ground open/short to +batt
The Electronic Control Module (ECM) detects a short A wire on the secondary engine speed/timing sensor
circuit at the prelube relay. is disconnected and/or broken. There is a short circuit
to the +Battery terminal.
System Response:
System Response:
Prelubrication System Perform the following diagnostic procedure: Engine
Speed/Timing Sensor
Results:
Results:
OK STOP.
OK STOP.
REPAIRED, OK STOP.
REPAIRED, OK STOP.
i01954895
i01954905
MID 036 - CID 0342 - FMI 02
Loss of Secondary Engine MID 036 - CID 0342 - FMI 07
Speed signal Secondary Speed Sensor
misinstalled
SMCS Code: 1912-038
SMCS Code: 1912-038
The engine rpm signal can not be detected. The
timing gear pattern returns within one second of The secondary engine speed/timing sensor is
being lost and battery voltage is greater than 9 VDC connected to the harness connector for the primary
for the last two seconds. The fault is logged only if engine speed/timing sensor.
the engine has been running for three seconds. The
fault will be active and logged if the Electronic Control System Response:
Module (ECM) detects an incorrect signal for one
second and the primary sensor signal is nominal. The CID-FMI is logged in memory.
The primary sensor detects an engine speed that is
greater than 100 rpm. The battery voltage is greater Perform the following diagnostic procedure: Engine
than 9 VDC for the last two seconds. Speed/Timing Sensor
System Response: Results:
The CID-FMI is logged in memory. OK STOP.

Perform the following diagnostic procedure: Engine REPAIRED, OK STOP.
Speed/Timing Sensor
Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 85
i01954917 i01954914
Secondary Engine Speed Start Relay short to ground
signal abnormal SMCS Code: 1426-038
SMCS Code: 1912-038
The Electronic Control Module (ECM) detects a short
circuit to ground condition.
The diagnostic code will become active if the following
conditions exist. The engine speed is greater than 0
System Response:
rpm. The engine speed/timing signal is incorrect. The
code will become logged if the following conditions The CID-FMI is logged in memory.
exist. The engine speed is greater than 0 rpm. The
engine speed/timing signal is incorrect. The engine
Perform the following diagnostic procedure: Starting
speed/timing signal returns after ve seconds. Motor System
System Response:
Results:
OK STOP.
Speed/Timing Sensor REPAIRED, OK STOP.
Results: i01954915
OK STOP. MID 036 - CID 0446 - FMI 05 Air

Shutoff Relay open
REPAIRED, OK STOP.
SMCS Code: 1078-038
i01954916
MID 036 - CID 0444 - FMI 05
Start Relay open circuit open circuit and/or a short circuit to battery condition.
The ECM can only detect this condition when the air
SMCS Code: 1426-038
shutoff relay is not energized.
Conditions Which Generate This Code: System Response:
open circuit and/or a short circuit to battery condition.
Perform the following diagnostic procedure: Air
System Response:
Shutoff System
Results:
Perform the following diagnostic procedure: Starting
Motor System OK STOP.
Results: REPAIRED, OK STOP.
OK STOP.
REPAIRED, OK STOP.
86 RENR5009-07
i01954913 i01954910
MID 036 - CID 0446 - FMI 06 Air MID 036 - CID 0542 - FMI 04
Shutoff Relay short Unltered Engine Oil Pressure
SMCS Code: 1078-038 short to ground
SMCS Code: 1924-038
The Electronic Control Module (ECM) detects a
short circuit to ground. The ECM can only detect this
condition when the air shutoff relay is not energized. The Electronic Control Module (ECM) reads signal
System Response:
System Response:
Perform the following diagnostic procedure: Air
Shutoff System
oil pressure as invalid data and a default value of
Results: 500 kPa (73 psi) is used.

OK STOP. Sensor Open/Short Test
REPAIRED, OK STOP. Results:
i01954911 OK STOP.
MID 036 - CID 0542 - FMI 03 REPAIRED, OK STOP.
Unltered Engine Oil Pressure
open/short to +batt i01954909
SMCS Code: 1924-038

MID 036 - CID 0827 - FMI 08 Left
Exhaust Temperature signal
abnormal
SMCS Code: 1919-038
diagnostic codes 262-03 and 262-04 are not active. Conditions Which Generate This Code:

System Response:
powered for three seconds. The diagnostic codes
263-03 and 263-04 are not active. The sensor
frequency is greater than 1000 Hz or less than 150
oil pressure as invalid data and a default value of
500 kPa (73 psi) is used. Hz. The duty cycle is greater than 90 percent or less
than 10 percent.
Sensor Open/Short Test System Response:
The CID-FMI is logged in memory. The status screen

Results:
on Caterpillar Electronic Technician (ET) will show
the parameter as invalid data.
OK STOP.
REPAIRED, OK STOP. Sensor Open/Short Test
Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 87

MID 036 - CID 0828 - FMI 08
i02660210
Right Exhaust Temperature
signal abnormal MID 036 - CID 1249 - FMI 13
Secondary Throttle Position
SMCS Code: 1919-038
calibration required
SMCS Code: 1439-038; 1913-038-SE
powered for three seconds. The diagnostic codes Conditions Which Generate This Code:
262-03 and 262-04 are not active. The sensor
frequency is greater than 1000 Hz or less than 150 The Electronic Control Module (ECM) detects the
Hz. The duty cycle is greater than 95 percent or less following condition:
than 5 percent.
The duty cycle for the throttle position sensor signal
System Response: is less than 5 percent or more than 95 percent.
The code is logged. The status screen on the This diagnostic code indicates that the throttle stops
Caterpillar Electronic Technician (ET) will show the are improperly set.
parameter as invalid data.
System Response:
Results:
OK STOP.
REPAIRED, OK STOP.
i02660170
MID 036 - CID 1249 - FMI 08

Secondary Throttle Position
signal abnormal Illustration 19
g00764010
SMCS Code: 1439-038; 1913-038-SE The ECM sets the desired engine speed to
programmed low idle while this diagnostic code is
Conditions Which Generate This Code: active. The Caterpillar Electronic Technician (ET)
will indicate a throttle position of 0 percent while this
The Electronic Control Module (ECM) has been diagnostic code is active.
powered up for three seconds. The sensor frequency
is greater than 1000 Hz or less than 150 Hz for two Possible Performance Effect:
seconds. The duty cycle is greater than 95 percent or
less than 5 percent for one second. The desired engine speed will return to low idle while
this diagnostic code is active.
System Response:
Troubleshooting:
The throttle position is set to a default value of 0
percent (low idle) by the ECM. The CID-FMI is logged Perform the following diagnostic procedure: Throttle
in memory when the engine has been running for Position Sensor - Calibrate
three seconds and the engine is not cranking.
Results:
Perform the following diagnostic procedure: Throttle
Position Sensor OK STOP.
Results:
OK STOP.
88 RENR5009-07
i01954907 System Response:

MID 036 - CID 1495 - FMI The CID-FMI is logged in memory. The ECM will
02 Injector Trim Codes Not continue to operate all injectors.
Programmed Perform the following diagnostic procedure: Injector

Solenoids
SMCS Code: 1901-038
Results:
OK STOP.
The Electronic Control Module (ECM) detects that
one or more of the injector trim codes has not been REPAIRED, OK STOP.
programmed. The ECM has been powered for three
seconds.
i01955125
System Response:
MID 047 - CID 0001 - FMI 06
The CID-FMI is logged in memory. The engine will Injector Cylinder 1 short
start. The ECM will use a default setting of 0000 for
an unprogrammed injector trim code. SMCS Code: 1290-038
Program the Missing Injector Trim Conditions Which Generate This Code:
Code(s).
A. Connect the Caterpillar Electronic Technician (ET) circuit or short to ground in the No. 1 cylinder injector
to the service tool connector. solenoid.
B. Go to the calibration screen for the injector trim System Response:

code(s).
C. Enter the injector trim code that is stamped on the continue to operate all injectors.
bottom of the injector for the appropriate cylinder.
Results: Solenoids
OK The injector trim code has been entered. Results:
Repair: After entering the injector trim code, turn OK STOP.

the engine control to the OFF position. Leave
the engine control in the OFF position for three REPAIRED, OK STOP.
seconds. Turn the engine control to the ON
position. The diagnostic code should not be active.
i01955127
STOP. MID 047 - CID 0002 - FMI 05

i01955123
MID 047 - CID 0001 - FMI 05 SMCS Code: 1290-038
Injector Cylinder 1 open circuit Conditions Which Generate This Code:
SMCS Code: 1290-038 The Electronic Control Module (ECM) detects an

Conditions Which Generate This Code: cylinder injector solenoid.
The Electronic Control Module (ECM) detects an System Response:

cylinder injector solenoid. The CID-FMI is logged in memory. The ECM will

Solenoids
RENR5009-07 89
Results: i01955131
OK STOP. MID 047 - CID 0003 - FMI 06

Injector Cylinder 3 short
REPAIRED, OK STOP.
SMCS Code: 1290-038
i01955129
MID 047 - CID 0002 - FMI 06
Injector Cylinder 2 short circuit or short to ground in the No. 3 cylinder injector
solenoid.
SMCS Code: 1290-038
System Response:
The Electronic Control Module (ECM) detects a short continue to operate all injectors.
circuit or short to ground in the No. 2 cylinder injector
solenoid. Perform the following diagnostic procedure: Injector
Solenoids
System Response:
Results:
REPAIRED, OK STOP.
Solenoids
OK STOP.
Results: i01955132
OK STOP. MID 047 - CID 0004 - FMI 05

REPAIRED, OK STOP.
SMCS Code: 1290-038
i01955130
MID 047 - CID 0003 - FMI 05
Injector Cylinder 3 open circuit open circuit or short to battery voltage in the No. 4
SMCS Code: 1290-038
System Response:
The Electronic Control Module (ECM) detects an continue to operate all injectors.
cylinder injector solenoid. Perform the following diagnostic procedure: Injector
Solenoids
System Response:
Results:
OK STOP.
Solenoids
REPAIRED, OK STOP.
Results:
OK STOP.
REPAIRED, OK STOP.
90 RENR5009-07
i01955133 i01955136
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955135 i01955139
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
RENR5009-07 91
i01955140 i01955143
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955142 i01955144
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
92 RENR5009-07
i01955145 i01955148
solenoid. solenoid.
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955146 i01955150
Injector Cylinder 9 open circuit Injector Cylinder 10 open
SMCS Code: 1290-038
circuit
SMCS Code: 1290-038
The Electronic Control Module (ECM) detects an Conditions Which Generate This Code:
System Response:
The CID-FMI is logged in memory. The ECM will System Response:

Perform the following diagnostic procedure: Injector continue to operate all injectors.
Solenoids
Results: Solenoids
Results:
OK STOP.
REPAIRED, OK STOP.
RENR5009-07 93
i01955152 i01955155
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955154 i01955156
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
94 RENR5009-07
i01955157 i01955159
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955158 i01955160
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
RENR5009-07 95
i01955161 i01955163
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
i01955162 i01955164
circuit circuit
Solenoids Solenoids
Results: Results:
OK STOP. OK STOP.
96 RENR5009-07
i01955166 i01955209
Injector Cylinder 16 short Engine Speed signal abnormal
The Electronic Control Module (ECM) detects a The diagnostic code will become active if the following
short circuit or short to ground in the No. 16 cylinder conditions exist. The engine speed is greater than 0
injector solenoid. rpm. The engine speed/timing signal is incorrect.
The CID-FMI is logged in memory. The ECM will The code will become logged if the following
continue to operate all injectors. conditions exist. The engine speed is greater than
0 rpm. The engine speed/timing signal is incorrect
Perform the following diagnostic procedure: Injector for ve seconds. The engine speed/timing signal
Solenoids returns for ve seconds. When the primary engine
speed/timing signal is abnormal, the secondary
Results: engine speed/timing signal will be used.
OK STOP. Perform the following diagnostic procedure: Engine

Speed/Timing Sensor
REPAIRED, OK STOP.
Results:
i01955201
OK STOP.
MID 047 - CID 0190 - FMI 02
REPAIRED, OK STOP.
Loss of Engine Speed signal
SMCS Code: 1912-038 i01955213

MID 047 - CID 0342 - FMI 02
Loss of Secondary Engine
The primary engine speed signal cannot be detected.
The timing gear pattern returns within one second
Speed signal
before being lost and the battery voltage is greater
than 9 VDC for the last two seconds. The fault is SMCS Code: 1912-038
logged only if the engine has been running for three
seconds. The fault will be active and logged if the
Electronic Control Module (ECM) detects an incorrect
The secondary engine speed/timing signal cannot be
signal for one second. The battery voltage is greater
detected. The timing gear pattern returns within one
than 9 VDC for the last two seconds.
second of being lost and battery voltage is greater
than 9 VDC for the last two seconds. The fault will
System Response:
be active if the Electronic Control Module (ECM)
The CID-FMI is logged in memory. If the primary detects an incorrect signal for one second. The
battery voltage is greater than 9 VDC for the last two
engine speed/timing signal is lost, the secondary
seconds.
engine speed/timing signal will be used.
System Response:
Speed/Timing Sensor
The fault is logged only if the engine has been
running for three seconds.
Results:
OK STOP. Speed/Timing Sensor
REPAIRED, OK STOP.
RENR5009-07 97
Results:
OK STOP.
REPAIRED, OK STOP.
i01955218
MID 047 - CID 0342 - FMI 08

Secondary Engine Speed
signal abnormal
SMCS Code: 1912-038
The diagnostic code will become active if the following

rpm. The engine speed/timing signal is incorrect.
System Response:
The code will become logged if the following

rpm. The engine speed/timing signal is incorrect for
ve seconds. The engine speed/timing signal returns
for ve seconds.

Speed/Timing Sensor
Results:
OK STOP.
REPAIRED, OK STOP.
98 RENR5009-07
Troubleshooting with an
Event Code
i01909353
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. When the event code is
generated, the event is active. Any generated code
becomes logged in the permanent memory of the
Electronic Control Module (ECM).
Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
Events do not indicate problems with the electronic
system. Event codes also indicate the nature of the
problem. Event codes may be viewed on a personal
computer that has the software for the Caterpillar
g00740986
Illustration 20
Typical example
Illustration 20 indicates output voltage from the

Coolant Temperature Sensor. The Cat ET can be
used to turn these features ON and OFF. When the
features are turned ON, the display will appear on an
electronic monitoring module and an event will also
be logged in the ECM. When the features are turned
OFF, the display will not appear on a monitoring
module, but an Event will still be logged.
Programmable Engine Parameters

You can program the engine to perform the following
actions for some applications:
Engine Alarm
Engine Derate
RENR5009-07 99
Engine Shutdown i01909366
Table 25 E007 High Aftercooler

3500B System Event Codes Temperature Derate
Event Code Description
SMCS Code: 1901-038
E007 High Aftercooler
Temperature Derate Conditions Which Generate This Code:
E008 High Aftercooler
Temperature Shutdown The Electronic Control Module (ECM) detects the
E012 High Crankcase Pressure
Derate Engine coolant temperature that is greater than
E013 High Crankcase Pressure the default temperature of 107 C (225 F) for ve
Shutdown seconds
E015 High Engine Coolant System Response:
Temperature Derate
E016 High Engine Coolant The event is logged. The ECM derates the engine
Temperature Shutdown from 0% to a maximum derate of 25% over a period
of 480 seconds when the coolant temperature is
E017 High Engine Coolant
Temperature Warning above 107 C (225 F). The fuel limiting function
will continue until the coolant temperature returns
E021 High Exhaust Temperature below 104 C (219 F) or until the maximum derate
Derate has been reached. After the temperature returns
E031 Air Filter Restriction Derate below 104 C (219 F) the derate due to high coolant
temperature will be turned off.
E038 Low Engine Coolant
Temperature Warning Possible Performance Effect:
E040 Low Engine Oil Pressure
Shutdown Low power
E043 Low System Voltage Troubleshooting:
Warning
E095 Fuel Filter Restriction There may be a problem with the cooling system.
Warning
E099 Engine Oil Filter Restriction There may be a problem with the coolant
Warning temperature sensor.
E100 Low Engine Oil Pressure Test Step 1. Check for ACTIVE
Warning Diagnostic Codes.
Warning A. Start the Caterpillar Electronic Technician (ET).
E173 High Exhaust Temperature B. Turn the main power to the ON position.
Warning
E190 Engine Overspeed C. Check for any active diagnostic codes or logged
Warning diagnostic codes.
E272 Inlet Air Restriction
Warning Expected Result:
E279 High Aftercooler No diagnostic codes are present.

Temperature Warning
Results:
OK No diagnostic codes are present. Proceed

to Test Step 2.
Not OK Diagnostic codes are present.

100 RENR5009-07
Repair: Repair the diagnostic codes that are Troubleshooting:

present. Refer to the appropriate topic in the
Troubleshooting With a Diagnostic Code section There may be a problem with the cooling system.
of this manual. Ensure that the repair eliminates
the problem. There may be a problem with the coolant
temperature sensor.
STOP.
Test Step 1. Check for ACTIVE
Test Step 2. Perform a Check of the Diagnostic Codes.
Cooling System.
A. Start the Caterpillar Electronic Technician (ET).
A. Perform a check of the cooling system. Refer
to the diagnostic procedure Troubleshooting, B. Turn the main power to the ON position.
Coolant Temperature is Too High for possible
causes. C. Check for any active diagnostic codes or logged
diagnostic codes.
Expected Result:
Expected Result:
There are no problems with the cooling system.
No diagnostic codes are present.
Results:
Results:
OK There may be an intermittent problem.
Repair: Monitor the operation of the engine. Repair to Test Step 2.
the problem. Ensure that the repair eliminates the
problem. Not OK Diagnostic codes are present.
STOP. Repair: Repair the diagnostic codes that are
Not OK There is a problem with the cooling Troubleshooting With a Diagnostic Code section
system. of this manual. Ensure that the repair eliminates
the problem.
Repair: Repair the problem. Ensure that the repair
eliminates the problem. STOP.
STOP. Test Step 2. Perform a Check of the

Cooling System.
i01909394
E008 High Aftercooler to the diagnostic procedure Troubleshooting,
Temperature Shutdown causes.
SMCS Code: 1901-038 Expected Result:
Conditions Which Generate This Code: There are no problems with the cooling system.
The Electronic Control Module (ECM) detects the Results:

Engine coolant temperature that is greater than
the default temperature of 107 C (225 F) for ve Repair: Monitor the operation of the engine. Repair
seconds the problem. Ensure that the repair eliminates the
problem.
System Response:
STOP.
The engine will shut down after all of the conditions
for shutdown are met. The event is logged. Not OK There is a problem with the cooling
system.
Engine shutdown
RENR5009-07 101
Repair: Repair the problem. Ensure that the repair Repair: Repair the diagnostic codes that are
eliminates the problem. present. Refer to the appropriate topic in the
Troubleshooting With a Diagnostic Code section
STOP. of this manual. Ensure that the repair eliminates
the problem.
i02399535
STOP.
E009 High Altitude Derate
i04037608
SMCS Code: 1901-038
Derate
The Electronic Control Module (ECM) detects
SMCS Code: 1901-038
atmospheric pressure that is less than 70 kPa
System Response:
The event is logged. The ECM limits the fuel above The engine crankcase pressure has exceeded the
setpoint and the delay time has expired.
the default altitude of 762 m (2500 ft). The ECM
will derate the engine in 3 percent increments for
every 305 m (1000 ft) increase in elevation up to a System Response:
maximum derate of 35 percent.
Then engine power is derated. The code is logged.
Troubleshooting:
Low power There may be a problem with one of the following
engine components:
Troubleshooting:
The engine is being operated at an altitude over Plugged crankcase breather

762 m (2500 ft) above sea level.
Crankcase pressure sensor
There may be a problem with the atmospheric
pressure sensor. Worn engine components
Check for ACTIVE Diagnostic Codes. Test Step 1. Check the Crankcase
Breather
A. Check for a plugged crankcase breather.
B. Turn the main power to the ON position.
A plugged crankcase breather will cause
C. Check for any active diagnostic codes or logged excessive crankcase pressure. Leakage of the
diagnostic codes. crankshaft seal can occur. Sealing of the piston
rings can be lost. The crankcase blowby will
Expected Result: increase the crankcase pressure.
Results:
Results: The crankcase breather is plugged.

Repair: Clean the crankcase breather.
OK No diagnostic codes are present. The engine
is still derated.
STOP.
Repair: The engine is being operated at an altitude
in excess of 762 m (2500 ft) above sea level. The crankcase breather is not plugged. Continue
to Test Step 2.
STOP.

102 RENR5009-07
Test Step 2. Check the Crankcase i04037613

Pressure Sensor
A. Inspect the crankcase pressure sensor for Shutdown
cleanliness. If the sensor is fouled, clean the
sensor. If the condition is corrected, put the engine SMCS Code: 1901-038
back in service. If the condition is not corrected,
proceed to the next step. Conditions Which Generate This Code:
B. Replace the crankcase pressure sensor with a The engine crankcase pressure has exceeded the
sensor that is known to be good. setpoint and the delay time has expired.
Results: System Response:
The condition is corrected. STOP. Then engine is shut down. The code is logged.
The condition is not corrected. Continue to test Troubleshooting:

Step 3.
There may be a problem with one of the following
Test Step 3. Check for Worn Engine engine components:
Components
Plugged crankcase breather
A. Damaged pistons or rings can cause too much
pressure in the crankcase. This condition will Crankcase pressure sensor
cause the engine to run rough. There will be
more than the normal fumes (blowby) rising from Worn engine components
the crankcase breather. The breather can then
become restricted quickly, causing oil leakage at Test Step 1. Check the Crankcase
gaskets and seals that would not normally have Breather
leakage. Blowby can also be caused by worn
valve guides or by a failed turbocharger seal. A. Check for a plugged crankcase breather.
B. The 8T-2700 Blowby/Air Flow Indicator is used A plugged crankcase breather will cause
to check the amount of blowby. Refer to Special excessive crankcase pressure. Leakage of the
Instruction, SEHS8712, Using the 8T-2700 crankshaft seal can occur. Sealing of the piston
Blowby/Air Flow Indicator for the test procedure rings can be lost. The crankcase blowby will
for checking the blowby. increase the crankcase pressure.
Expected Result: Results:
A thorough inspection revealed a problem. The crankcase breather is plugged.
Results: Repair: Clean the crankcase breather.
OK There is a problem with an engine STOP.

component.
The crankcase breather is not plugged. Continue
Repair: Repair the problem. Ensure that the repair to Test Step 2.
eliminates the problem.
Test Step 2. Check the Crankcase
STOP. Pressure Sensor
A. Inspect the crankcase pressure sensor for
cleanliness. If the sensor is fouled, clean the
sensor. If the condition is corrected, put the engine
back in service. If the condition is not corrected,
proceed to the next step.
B. Replace the crankcase pressure sensor with a

sensor that is known to be good.
RENR5009-07 103
The condition is corrected. STOP. The event is logged. The ECM derates the engine
from 0% to a maximum derate of 25% over a period
The condition is not corrected. Continue to test of 480 seconds when the coolant temperature is
Step 3. above 107 C (225 F). The fuel limiting function
will continue until the coolant temperature returns
Test Step 3. Check for Worn Engine below 102 C (215 F) or until the maximum derate
Components has been reached. After the temperature returns
below 102 C (215 F) the derate due to high coolant
A. Damaged pistons or rings can cause too much temperature will be turned off.
pressure in the crankcase. This condition will
cause the engine to run rough. There will be Possible Performance Effect:
more than the normal fumes (blowby) rising from
the crankcase breather. The breather can then Low power
become restricted quickly, causing oil leakage at
gaskets and seals that would not normally have Troubleshooting:
valve guides or by a failed turbocharger seal. There may be a problem with the cooling system.
B. The 8T-2700 Blowby/Air Flow Indicator is used There may be a problem with the coolant
to check the amount of blowby. Refer to Special temperature sensor.
Instruction, SEHS8712, Using the 8T-2700
Blowby/Air Flow Indicator for the test procedure Test Step 1. Check for ACTIVE
for checking the blowby. Diagnostic Codes.
Expected Result: A. Start the Caterpillar Electronic Technician (ET).
A thorough inspection revealed a problem. B. Turn the main power to the ON position.
Results: C. Check for any active diagnostic codes or logged

diagnostic codes.
OK There is a problem with an engine
component. Expected Result:
Repair: Repair the problem. Ensure that the repair No diagnostic codes are present.
Results:
STOP.
to Test Step 2.
i01909398
E015 High Engine Coolant Not OK Diagnostic codes are present.

Temperature Derate Repair: Repair the diagnostic codes that are
SMCS Code: 1901-038 Troubleshooting With a Diagnostic Code section
Conditions Which Generate This Code: the problem.
The Electronic Control Module (ECM) detects the STOP.

Test Step 2. Perform a Check of the
Engine coolant temperature that is greater than Cooling System.
the default temperature of 107 C (225 F) for 30
seconds A. Perform a check of the cooling system. Refer
to the diagnostic procedure Troubleshooting,
causes.
Expected Result:

104 RENR5009-07
Results: Results:
OK There may be an intermittent problem. OK No diagnostic codes are present. Proceed

to Test Step 2.
Repair: Monitor the operation of the engine. Repair
the problem. Ensure that the repair eliminates the Not OK Diagnostic codes are present.
problem.
Repair: Repair the diagnostic codes that are
STOP. present. Refer to the appropriate topic in the
Not OK There is a problem with the cooling of this manual. Ensure that the repair eliminates
system. the problem.
Repair: Repair the problem. Ensure that the repair STOP.

STOP. Cooling System
i02399551
E016 High Engine Coolant Coolant Temperature Is Too High for possible
causes.
Temperature Shutdown
Expected Result:
SMCS Code: 1901-038
The cooling system is operating properly.
Results:
The Electronic Control Module (ECM) engine
coolant temperature that is greater than the default OK The cooling system is operating properly.
temperature of 107 C (225 F) for ve seconds. There may be an intermittent problem.
System Response: Repair: Monitor the operation of the engine. Repair

The ECM will shut down the engine after all of the problem.
conditions for shutdown are met. The event is logged.
STOP.
Not OK There is a problem with the cooling
Engine shutdown system.
Troubleshooting: Repair: Repair the problem. Ensure that the repair

There may be a problem with the cooling system.
STOP.
There may be a problem with the coolant
temperature sensor.
i02399617
Test Step 1. Check for ACTIVE E017 High Engine Coolant

Diagnostic Codes
Temperature Warning
SMCS Code: 1901-038
B. Restore electrical power to the ECM.
C. Check for any active diagnostic codes or logged
diagnostic codes. The Electronic Control Module (ECM) detects engine
coolant temperature that is greater than the default
Expected Result: temperature of 102 C (216 F) for ve seconds.

RENR5009-07 105

The event is logged. After the temperature returns problem.
below 97 C (207 F) the warning due to high coolant
temperature will be turned off. STOP.
Possible Performance Effect: Not OK There is a problem with the cooling

system.
None
Troubleshooting: eliminates the problem.
There may be a problem with the cooling system. STOP.
There may be a problem with the coolant i01909403

temperature sensor.

E021 High Exhaust
Diagnostic Codes. Temperature Derate
A. Start the Caterpillar Electronic Technician (ET). SMCS Code: 1901-038
B. Turn the keyswitch to the ON position. Conditions Which Generate This Code:
C. Check for any active diagnostic codes or for The Electronic Control Module (ECM) detects the
logged diagnostic codes. following condition:
Expected Result: Exhaust inlet temperature is greater than the

default temperature of 750 C (1382 F) for ve
No diagnostic codes are present. seconds.
Results: The engine has been running for three seconds.

OK No diagnostic codes are present. Proceed The diagnostic codes CID-FMI 827-08 and
to Test Step 2. CID-FMI 828-08 are not active.
Not OK Diagnostic codes are present. System Response:
Repair: Repair the diagnostic codes that are The event is logged. The ECM derates the engine
present. Refer to the appropriate topic in the at 15 second intervals in 2% increments when
Troubleshooting With a Diagnostic Code section the exhaust inlet temperature is above 750 C
of this manual. Ensure that the repair eliminates (1382 F) for 5 seconds. The fuel limiting function will
the problem. continue until the exhaust temperature returns below
740 C (1364 F) or until the maximum derate has
STOP. been reached. After the temperature returns below
740 C (1364 F) the derate due to a high exhaust
Test Step 2. Perform a Check of the temperature will be deactivated.
Cooling System.
to the diagnostic procedure Troubleshooting, Low power
causes. Troubleshooting:
Expected Result: There may be an exhaust restriction.

There are no problems with the cooling system. There may be an air leak.
Results: Test Step 1. Check for ACTIVE
Diagnostic Codes.
106 RENR5009-07
B. Turn the main power to the ON position. i01909427
C. Check for any active diagnostic codes or logged E031 Air Inlet Restriction
diagnostic codes. Derate
Expected Result: SMCS Code: 1901-038
No diagnostic codes are present. Conditions Which Generate This Code:
Results: The Electronic Control Module (ECM) detects the
to Test Step 2. The air inlet pressure for the left turbocharger
is above the default pressure of 7 kPa
Not OK Diagnostic codes are present. (28 inches of H2O) for ve seconds.
Repair: Repair the diagnostic codes that are The air inlet pressure for the right turbocharger
present. Refer to the appropriate topic in the is above the default pressure of 7 kPa
Troubleshooting With a Diagnostic Code section (28 inches of H2O) for ve seconds.
the problem. System Response:
STOP. The event is logged. When the air inlet restriction
exceeds 7 kPa (28 inches of H2O) the ECM will
Test Step 2. Perform a Check of the derate the engine. The ECM will derate the engine in
Cooling System. increments of 2% per 1 kPa (4 inches of H2O) up to a
maximum derate level of 25%. Air lter restriction is
A. Perform a check of the exhaust system. Refer determined by measuring the atmospheric pressure
to the diagnostic procedure Troubleshooting, and the turbocharger inlet pressures and calculating
Exhaust Temperature is Too High for possible the difference.
causes.
Expected Result:
Low power
There are no problems with the exhaust system.
Troubleshooting:
Results:
There may be a problem with the air inlet system.
OK There are no problems with the exhaust
system. There may be an intermittent problem. There may be a problem with the atmospheric
pressure sensor or the left or right turbocharger
Repair: Monitor the operation of the engine. Repair inlet pressure sensors.
problem. Test Step 1. Check for ACTIVE
Diagnostic Codes.
STOP.
Not OK There is a problem with the exhaust
system. B. Turn the main power to the ON position.
Repair: Repair the problem. Ensure that the repair C. Check for any active diagnostic codes or logged
eliminates the problem. diagnostic codes.
STOP. Expected Result:
Results:

to Test Step 2.

RENR5009-07 107
Repair: Repair the diagnostic codes that are System Response:

Troubleshooting With a Diagnostic Code section The event is logged. After the temperature returns
of this manual. Ensure that the repair eliminates above 75 C (167 F) the warning due to low coolant
the problem. temperature will be turned off.
STOP. Possible Performance Effect:
Test Step 2. Perform a Check of the Air None

Inlet System.
Troubleshooting:
A. Check for restrictions in the air inlet system.
Refer to the Testing and Adjusting manual for There may be a problem with the coolant
information on inspecting the air inlet system. temperature sensor.
Expected Result: Faulty water temperature regulator

There are no problems with the air inlet system. Long idle periods
Results: Very light loads
OK There are no problems with the air inlet Test Step 1. Check for Active Diagnostic
system. There may be an intermittent problem. Codes
Repair: Monitor the operation of the engine. Repair A. Start the Caterpillar Electronic Technician (ET).
problem. B. Turn the keyswitch to the ON position.
STOP. C. Check for any active diagnostic codes or logged

diagnostic codes.
Not OK There is a problem with the air inlet
system. Expected Result:
Repair: Repair the problem. Ensure that the repair No diagnostic codes are present.
Results:
STOP.
to Test Step 2.
i02658702
E038 Low Engine Coolant Not OK Diagnostic codes are present.

Temperature Warning Repair: Repair the diagnostic codes that are
present.
SMCS Code: 1901-038
STOP.
The Electronic Control Module (ECM) detects the Cooling System
following conditions:
A. Perform a check of the cooling system. Test
The engine has been running for at least two the water temperature regulator for proper
minutes. operation. A regulator that is stuck open can
cause overcooling. Coolant leaks that are around
Engine coolant temperature that has increased the water temperature regulator can cause
above 75 C (167 F) overcooling. An example would be a leak in the
vent line.
Engine coolant temperature that has decreased
below 70 C (158 F) for two minutes Note: Refer to the Systems Operation/Testing and
Adjusting manual for information on testing the water
temperature regulator.
108 RENR5009-07
Expected Result:
The water temperature regulator is operating

correctly.
Results:
OK The water temperature regulator is operating

correctly.
Repair: Cold ambient temperatures, light loads, or

a slow engine speed can cause overcooling. This
overcooling is caused by the low heat input of the
engine.
STOP.
Not OK There is a problem with the water

temperature regulator.
Repair: Replace the water temperature regulator.
STOP.
i01909471

Shutdown Illustration 21
g00994984
Oil pressure map

SMCS Code: 1901-038
System Response:
The event is logged.
The Electronic Control Module (ECM) detects all of
the following conditions: Possible Performance Effect:
The engine has been running for at least ten Engine shutdown
seconds.
Troubleshooting:
Engine oil pressure is below the default trip line in
Illustration 21 for an additional nine seconds. There may be a problem with the engine lubrication
system.
100-03 Engine Oil Pressure open/short to +batt is
not active. There may be a problem with the engine oil
pressure sensor.
100-04 Engine Oil Pressure short to ground is
not active. Test Step 1. Check for ACTIVE
Diagnostic Codes.

diagnostic codes.
Expected Result:

RENR5009-07 109
OK No diagnostic codes are present. Proceed The event is logged. If the system voltage rises
to Test Step 2. above 22 VDC, the warning will become inactive.
Not OK Diagnostic codes are present. Possible Performance Effect:
Repair: Repair the diagnostic codes that are None

Troubleshooting With a Diagnostic Code section Troubleshooting:
the problem. There may be a problem with the batteries.
STOP. There may be a problem with the electrical
connections.
Engine Lubrication System. Test Step 1. Check for ACTIVE
Diagnostic Codes.
A. Perform a check of the engine lubrication system.
Refer to the diagnostic procedure Troubleshooting, A. Start the Caterpillar Electronic Technician (ET).
Low Engine Oil Pressure.
Expected Result:
There are no problems with engine oil pressure. diagnostic codes.
Results: Expected Result:
OK There are no problems with engine oil No diagnostic codes are present.
pressure. There may be an intermittent problem.
Results:
the problem. Ensure that the repair eliminates the OK No diagnostic codes are present. Proceed
problem. to Test Step 2.
STOP. Not OK Diagnostic codes are present.

Not OK There are problems with engine oil Repair: Repair the diagnostic codes that are
pressure. present. Refer to the appropriate topic in the
Repair: Repair the problem. Ensure that the repair of this manual. Ensure that the repair eliminates
eliminates the problem. the problem.
STOP. STOP.

i01909494
Batteries.
E043 Low System Voltage A. Measure no-load voltage at the battery posts.
Warning Refer to the Testing and Adjusting manual for the
proper procedures to check the batteries.
SMCS Code: 1901-038
B. Load test the batteries. Use the 4C-4911
Conditions Which Generate This Code: Battery Load Tester. Refer to the Operating
Manual, SEHS9249. Refer to Special Instruction,
The Electronic Control Module (ECM) detects the SEHS7633.
Expected Result:
The ECM has been powered up for ten seconds.
The no-load voltage at the batteries should be at
The supply voltage is below 20 VDC. least 23.5 VDC, and the batteries should pass the
load test.
110 RENR5009-07
Results: Repair: Troubleshoot the diagnostic codes. Refer

to Troubleshooting, Injector Solenoids.
OK The no-load voltage at the batteries is at
least 23.5 VDC, and the batteries pass the load STOP.
test. There may be an intermittent problem.
Test Step 2. Check the electrical power
Repair: Monitor the operation of the engine. Repair for the primary ECM
problem. Check the primary ECM for problems with the
electrical power supply. Check the circuit breakers
STOP. and check for a grounding problem.
Not OK The no-load voltage at the batteries is Results:

less than 23.5 VDC, and/or the batteries fail the
load test. There are no problems with the electrical power for
the primary ECM. Proceed to Test Step 3.
Repair: The batteries or the alternator are causing
the problem. Recharge the batteries or replace There is a problem with the electrical power for the
the batteries. Verify that the original condition primary ECM.
is resolved. Refer to the Testing and Adjusting
manual for information on the charging system. Repair: Refer to Troubleshooting, Electrical
Power Supply. The power to the primary ECM
STOP. must be cycled before the primary ECM can
resume control of the engine.
i04036315
STOP.
E048 Backup ECM Took Test Step 3. Check the circuit for the
Control heartbeat signal
SMCS Code: 1901-038-UB Troubleshoot the C179-BK wire for the circuit
between the primary ECM J2-28 and secondary ECM
Conditions Which Generate This Code: J1-21 terminals. Check for the following conditions:
Either of these two conditions can cause the code: Loose connector
The heartbeat signal from the primary Electronic Loose terminal
Control Module (ECM) to the secondary ECM is
lost. Open circuit
Two or more diagnostic codes for the injector Short circuit
solenoids are active.
Results:
System Response:
A problem was found in the circuit for the heartbeat
The secondary ECM sends a signal to the primary signal.
ECM which indicates that the secondary ECM is in
control of the engine. The primary ECM shuts down. Repair: Repair the problem. The power to the
primary ECM must be cycled before the primary
Test Step 1. Check for active codes for ECM can resume control of the engine.
the injector solenoids
STOP.
Use Caterpillar Electronic Technician (ET) to check
for active diagnostic codes for the injector solenoids. No problems were found with the circuit for the
heartbeat signal.
Results:
Repair: There could be an intermittent problem,
There are no active codes for the injector most likely a loose connection. Make a thorough
solenoids Proceed to Test Step 2. inspection of the circuit and repair the circuit, if
needed.
There are at least two active diagnostic codes for
the injector solenoids. STOP.
RENR5009-07 111
i01909540 Repair: Repair the diagnostic codes that are

E095 Fuel Filter Restriction Troubleshooting With a Diagnostic Code section
Warning of this manual. Ensure that the repair eliminates
the problem.
SMCS Code: 1901-038
STOP.
Test Step 2. Perform a Check of the Fuel
The Electronic Control Module (ECM) detects the System.
A. Check the fuel tank for foreign objects which may
The fuel lter differential pressure is above the block the fuel supply. Check for air in the low
default pressure of 105 kPa (15 psi) for the default pressure fuel supply system after you perform the
time of ve seconds. following procedures:
System Response: Replacing the fuel lters

The event is logged. The warning for the fuel lter Working on the low pressure fuel supply circuit
differential pressure becomes active when the fuel
lter differential pressure exceeds the default trip Replacing fuel injectors
point of 105 kPa (15 psi). The warning becomes
inactive when the fuel lter differential pressure B. Purge air from the low pressure fuel supply circuit
decreases below 95 kPa (14 psi). with the hand priming pump and by cranking the
engine in 30 second cycles. After you crank the
Possible Performance Effect: engine, stop for two minutes. This will allow the
starting motor to cool. Loosen the vent plug on
None the fuel return. The plug is located on the rear
upper left side of the engine block. Hand prime
Troubleshooting: the engine again if air in fuel continues. A sight
glass in the low pressure supply line is helpful in
There may be a problem with the fuel system. diagnosing air in the fuel.
There may be a problem with the ltered fuel C. Check fuel quality. In temperatures below 0 C
sensor or the unltered fuel sensor. (32 F), check for solidied fuel (wax). Refer to
Special Publication, SEBD0717, Diesel Fuels
Test Step 1. Check for ACTIVE And Your Engine. Check the fuel pressure while
Diagnostic Codes. the engine is cranking. Check the fuel pressure at
the lter. If the pressure is low, check for plugged
A. Start the Caterpillar Electronic Technician (ET). fuel lters. If the fuel pressure is still low, check the
following items: fuel transfer pump, fuel transfer
B. Turn the main power to the ON position. The pump coupling, and fuel pressure regulating valve.
engine should be OFF. Check for a combustion problem.
C. Check for any active diagnostic codes or logged Expected Result:

diagnostic codes.
There are no problems with the fuel system.
Expected Result:
Results:
OK There are no problems with the fuel system.
Results: There may be an intermittent problem.
OK No diagnostic codes are present. Proceed Repair: Monitor the operation of the engine. Repair
to Test Step 2. the problem. Ensure that the repair eliminates the
problem.
STOP.
Not OK There are problems with the fuel system.

112 RENR5009-07
Repair: Repair the problem. Ensure that the repair Repair: Repair the diagnostic codes that are
eliminates the problem. present. Refer to the appropriate topic in the
STOP. of this manual. Ensure that the repair eliminates
the problem.
i01909632
STOP.
E099 Engine Oil Filter Test Step 2. Perform a Check of the
Restriction Warning Lubrication System.
SMCS Code: 1901-038 A. Check for dirty oil lters.
Conditions Which Generate This Code: Expected Result:
The Electronic Control Module (ECM) detects the There are problems with the oil lters.
Results:
The oil lter differential pressure is above the
default value of 105 kPa (15 psi) for the default OK The oil lters are dirty.
time of ve seconds.
Repair: Replace the oil lters with new oil lters.
System Response: Ensure that the repair eliminates the problem.
The event is logged. The warning for the oil lter STOP.
differential pressure becomes active when the oil lter
differential pressure exceeds the default trip point Not OK There are problems with the lubrication
of 105 kPa (15 psi). The warning becomes inactive system.
when the fuel lter differential pressure decreases
below 95 kPa (14 psi). Repair: Refer to the appropriate topic in the
Troubleshooting Without a Diagnostic Code
Possible Performance Effect: section of this manual. Ensure that the repair
None
STOP.
Troubleshooting:
i01909487
There may be a problem with the oil lters.
There may be a problem with the ltered oil sensor
or the unltered oil sensor. Warning
Test Step 1. Check for ACTIVE SMCS Code: 1901-038
Diagnostic Codes.
The Electronic Control Module (ECM) detects all of
B. Turn the main power to the ON position. The the following conditions:
engine should be OFF.
The engine has been running for at least ten
C. Check for any active diagnostic codes or logged seconds.
diagnostic codes.
Engine oil pressure is below the default trip line in
Expected Result: Illustration 22 for an additional four seconds.
No diagnostic codes are present. 100-03 Engine Oil Pressure open/short to +batt is
not active.
Results:
100-04 Engine Oil Pressure short to ground is
OK No diagnostic codes are present. Proceed not active.
to Test Step 2.

RENR5009-07 113
Results:

to Test Step 2.

the problem.
STOP.

Engine Lubrication System.
A. Perform a check of the engine lubrication system.
Refer to the diagnostic procedure Troubleshooting,
Low Engine Oil Pressure.
Expected Result:
There are no problems with engine oil pressure.
Results:
g00994984
Illustration 22 OK There are no problems with engine oil
Oil pressure map pressure. There may be an intermittent problem.

The event is logged. problem.
Possible Performance Effect: STOP.
None Not OK There are problems with engine oil

pressure.
Troubleshooting:
There may be a problem with the engine lubrication eliminates the problem.
system.
STOP.
There may be a problem with the engine oil
pressure sensor.
i04001515
Test Step 1. Check for ACTIVE E101 High Crankcase Pressure

Diagnostic Codes.
Warning
SMCS Code: 1901-038
diagnostic codes. The engine crankcase pressure has exceeded the
setpoint and the delay time has expired.
Expected Result:
System Response:
The event code will be logged.
114 RENR5009-07
Possible Performance Effect: Test Step 3. Check for Worn Engine

Components
None
A. Damaged pistons or rings can cause too much
Troubleshooting: pressure in the crankcase. This condition will
cause the engine to run rough. There will be
There may be a problem with one of the following more than the normal fumes (blowby) rising from
engine components: the crankcase breather. The breather can then
become restricted quickly, causing oil leakage at
Plugged crankcase breather gaskets and seals that would not normally have
Crankcase pressure sensor valve guides or by a failed turbocharger seal.
Worn engine components B. The 8T-2700 Blowby/Air Flow Indicator is used

to check the amount of blowby. Refer to Special
Test Step 1. Check the Crankcase Instruction, SEHS8712, Using the 8T-2700
Breather Blowby/Air Flow Indicator for the test procedure
for checking the blowby.
A. Check for a plugged crankcase breather.
Expected Result:
A plugged crankcase breather will cause
excessive crankcase pressure. Leakage of the A thorough inspection revealed a problem.
crankshaft seal can occur. Sealing of the piston
rings can be lost. The crankcase blowby will Results:
increase the crankcase pressure.
OK There is a problem with an engine
Results: component.
The crankcase breather is plugged. Repair: Repair the problem. Ensure that the repair
Repair: Clean the crankcase breather.
STOP.
STOP.
i01909644
The crankcase breather is not plugged. Continue
to Test Step 2. E173 High Exhaust
Test Step 2. Check the Crankcase Temperature Warning
Pressure Sensor
SMCS Code: 1901-038
A. Inspect the crankcase pressure sensor for
cleanliness. If the sensor is fouled, clean the Conditions Which Generate This Code:
sensor. If the condition is corrected, put the engine
back in service. If the condition is not corrected, The Electronic Control Module (ECM) detects the
proceed to the next step. following condition:
B. Replace the crankcase pressure sensor with a Exhaust inlet temperature is greater than the
sensor that is known to be good. default temperature of 600 C (1112 F) for ve
seconds.
Results:
The engine has been running for three seconds.
The condition is corrected. STOP.
The diagnostic codes CID-FMI 827-08 and
The condition is not corrected. Continue to test CID-FMI 828-08 are not active.
Step 3.
System Response:
The event is logged. The warning is active when the

exhaust inlet temperature is above 600 C (1112 F)
for 5 seconds. After the temperature returns below
590 C (1094 F) the warning will become inactive. If
the exhaust inlet temperature exceeds the trip point
for one second, a new warning will take effect.
RENR5009-07 115
Possible Performance Effect: Repair: Monitor the operation of the engine. Repair
None problem.
Troubleshooting: STOP.
There may be an exhaust restriction above Not OK There is a problem with the cooling
recommended levels. system.
There may be a problem with the cooling system. Repair: Repair the problem. Ensure that the repair
There may be a problem with the coolant
temperature sensor. STOP.

i01962210
Diagnostic Codes.
E190 Engine Overspeed
Warning
SMCS Code: 1901-038
diagnostic codes. Conditions Which Generate This Code:
Expected Result: Engine speed is above the setpoint for engine

overspeed. The default value for engine overspeed
No diagnostic codes are present. is dependent on the application. Use the Caterpillar
Electronic Technician (ET) in order to monitor the
Results: system parameter for engine overspeed.
OK No diagnostic codes are present. Proceed System Response:

to Test Step 2.
The event is logged in memory. If the engine speed
Not OK Diagnostic codes are present. decreases 100 rpm below the default setpoint, the
warning will become inactive.
present. Refer to the appropriate topic in the Possible Performance Effect:
of this manual. Ensure that the repair eliminates None
the problem.
Troubleshooting:
STOP.
This event indicates excessive engine speed. This
Test Step 2. Perform a Check of the does not represent a problem with the Electronic
Cooling System. Control Module (ECM). This event does not represent
a problem with the engine speed/timing sensor.
to the diagnostic procedure Troubleshooting, Engine Overspeed Warning
causes. This event records the engine overspeed warning.
No troubleshooting is required.
Expected Result:
Expected Result:
Results:
Results:
OK STOP.
116 RENR5009-07
i02174584 Ensure that the repair eliminates the problem.

E272 Inlet Air Restriction STOP.
Warning
Test Step 2. Perform a Check of the Air
SMCS Code: 1901-038 Inlet System
Conditions Which Generate This Code: A. Perform a check of the air inlet system. Refer to
the Testing and Adjusting manual for information
The Electronic Control Module (ECM) detects one of on inspecting the air inlet and exhaust system.
the following conditions:
Expected Result:
The air inlet pressure for the left turbocharger is
above the default value of 7 kPa (28 inches of H2O) There are no problems with the air inlet system.
for ve seconds.
Results:
The air inlet pressure for the right turbocharger is
above the default value of 7 kPa (28 inches of H2O) OK There may be an intermittent problem.
for ve seconds.
System Response: the problem. Ensure that the repair eliminates the
problem.
The ECM will log the event.
STOP.
Not OK There is a problem with the air inlet
None system.

There may be a problem with the air inlet system.
STOP.
There may be a problem with one of the air inlet
pressure sensors. i01909668
Test Step 1. Check for ACTIVE E279 High Aftercooler

Diagnostic Codes
Temperature Warning
SMCS Code: 1901-038
B. Turn the keyswitch to the ON position. The engine
should be OFF. Conditions Which Generate This Code:
C. Check for any active diagnostic codes or logged The Electronic Control Module (ECM) detects the
diagnostic codes. following condition:
Expected Result: The aftercooler temperature is greater than the

default temperature of 102 C (216 F) for ve
There are no diagnostic codes that are present. seconds.
Results: The diagnostic codes 279-03 and 279-04 are not

active.
OK There are no diagnostic codes that are System Response:
present. Proceed to Test Step 2.
The ECM will log the event. The warning is
Not OK There are diagnostic codes that are deactivated if the temperature decreases below
present.
99 C (210 F).
present. Refer to the appropriate topic in the Possible Performance Effect:
of this manual. None
RENR5009-07 117

There may be a problem with the aftercooler.
STOP.
There may be a problem with the aftercooler
temperature sensor.

Diagnostic Codes.
B. Turn the main power to the ON position. The

engine should be OFF.
C. Check for any Active Diagnostic Codes or Logged

Diagnostic Codes.
Expected Result:
There should be no diagnostic codes that are present.
Results:
OK There are no diagnostic codes that are

Not OK There are diagnostic codes that are

present.

the problem.
STOP.

Cooling System.
causes.
Expected Result:
Results:

problem.
STOP.
Not OK There is a problem with the cooling

system.
118 RENR5009-07
Diagnostic Functional The contact of relay R3A also supplies power to

terminal 1 of the connector for a timer and to the
Tests overspeed indicator on the instrument panel. When
power is applied to terminal 1 of the connector for
the timer, the timer will activate. The timer outputs 24
i01988346 VDC from terminal 4 of the connector for the timer for
Air Shutoff System 2.5 seconds. The 24 VDC from the timer is applied to
the coil of the ASOS switch and to terminal 2 of the
diode assembly. The ASOS switch energizes the
SMCS Code: 1078-038
two air shutoff solenoids. The solenoids trip the air
System Operation Description: shutoff valves. The 2.5 second time limit for activation
of the ASOS switch prevents damage to the air
The secondary Electronic Control Module (ECM) has shutoff solenoids. A normally open switch at the air
the ability to stop the engine by shutting off the inlet shutoff valves will close when the air shutoff solenoid
activates the air shutoff valve. The switch input to
air supply in an emergency situation. The secondary
ECM activates the output driver for the emergency the primary ECM noties the primary ECM that the
shutdown system. The ASOS switch energizes the air shutoff valves are closed. The ECM will not send
injection signals to the injector solenoids until the
two air shutoff solenoids. The solenoids trip the air
shutoff valves. switch inputs from the air shutoff valves indicate that
the valves are open.
There are two conditions which cause the engine
control to activate the output driver for the air shutoff The ASOS switch can also be activated without
relay. The rst condition occurs when the operator the aid of the secondary ECM. When the local
emergency stop switch on the instrument panel is
activates the customer's emergency stop. When the
customer's emergency stop button is activated, the depressed or the customer's remote emergency stop
emergency stop inputs U and T to the primary ECM switch is activated, the coils of relay R4 and relay
R4A are energized. The contacts of relay R4A
and the secondary ECM from the customer connector
go high. The secondary ECM will recognize this supplies power to terminal 1 of the connector for the
change. The secondary ECM will energize the output timer and to the coils of relay R2 and relay R2A.
When relays R2 and R2A are energized, power is
drive for the emergency shutdown system for one
second through the diode assembly. removed from the primary ECM and the secondary
ECM. The circuit with the timer will operate in the
same manner that was described above except that
The second condition occurs for an engine
overspeed. If an engine overspeed occurs, the ECM the emergency stop lamp on the instrument panel
will activate the output driver for the emergency will illuminate and the relays R3A and R3 will
de-energize after 2.5 seconds. When relays R3A
shutdown system through the diode assembly. An
overspeed can be simulated by using the Caterpillar and R3 de-energize, the overspeed indicator turns
Electronic Technician (ET). In order to verify that the off.
overspeed function is operable, the operator must
access the screen for overriding parameters on Cat Regardless of the reason for activation, the Engine
ET. When the override for the engine overspeed is Control Switch (ECS) must be turned to the
OFF/RESET position for three seconds. This resets
set to the ON position, the setpoint for the engine
overspeed is at 75% of the original setpoint. When the ECM and the relays in the circuit. In addition
the engine reaches the modied setpoint, the normal to turning the ECS to the OFF/RESET position,
the operator must determine the cause for the
strategy for an engine overspeed is initiated.
emergency shutdown before resetting the circuit. The
Relay R3A and relay R3 are energized through operator must manually open the air shutoff valves
before restarting the engine.
terminal 3 of the diode assembly. Terminal 3 of the
diode assembly will energize relay R3A and relay
R3 for 1 second. The contacts of relay R3 keeps
relay R3A and relay R3 energized until power is
cycled. The contact of relay R3A keeps the coils of
relay R2 and relay R2A energized. When relays
R2 and R2A are energized, power is removed
from the primary ECM and the secondary ECM. The
primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop.
RENR5009-07 119
g01029797
Illustration 23
Typical example
120 RENR5009-07
Test Step 1. Check for Connector Results:

Damage.
OK The air shutoff solenoids activated correctly.
A. Verify that the circuit breakers are not tripped.
Repair: The problem may be intermittent. If the
B. Turn the circuit breaker for the battery to the OFF problem is intermittent, refer to the diagnostic
position. functional test Troubleshooting, Inspecting
C. Turn the ECS to the OFF/RESET position.
STOP.
D. Thoroughly inspect the ECM connectors J1/P1 and
J2/P2. Inspect all of the other connectors. Refer Not OK The air shutoff solenoids failed to
to the diagnostic functional test Troubleshooting, activate. Proceed to Test Step 3.
Inspecting Electrical Connectors for details.
Test Step 3. Check for the Signal from the
E. Perform a 45 N (10 lb) pull test on each of the ASOS Switch at the Connector P-C1 for
wires in the ECM connectors that are associated the Power Distribution Panel.
with the circuit.
A. Turn the ECS to the STOP position. The engine
F. Check the ECM connectors (allen head screw) for should be off.
the proper torque of 6 1 Nm (53 9 lb in).
B. Activate the customer's emergency stop switch.
G. Check the harness and the wiring for abrasion
and for pinch points. C. Monitor the voltage on wire G708 on pin I at
connector P-C1 of the rigid harness.
Expected Result:
D. Deactivate the customer's emergency stop switch.
All connectors, pins, and sockets are completely
coupled and/or inserted, and the harness and wiring Expected Result:
are free of corrosion, of abrasion or of pinch points.
The voltage measures 24 3 VDC for approximately
Results: 2.5 seconds.
OK The connectors and wiring are okay. Proceed Results:

to Test Step 2.
OK The voltage measures 24 3 VDC for
Not OK The connectors and/or wiring are not approximately 2.5 seconds. The circuit is operating
okay. correctly to this point. Proceed to Test Step 7.
Repair: Repair the connectors or wiring and/or Not OK The voltage did not measure 24 3
replace the connectors or wiring. VDC for approximately 2.5 seconds. Proceed to
Test Step 4.
STOP.
Test Step 4. Test for Voltage to the Coil
Test Step 2. Test the Air Shutoff System. of the ASOS Switch at the Connector
P-C1 for the Power Distribution Panel.
A. Turn the circuit breaker for the battery to the ON
position. A. Turn the ECS to the STOP position. The engine
should be off.
B. Turn the ECS to the STOP position. The engine
should be off. B. Activate the customer's emergency stop switch.
C. Activate the customer's emergency stop switch. C. Monitor the voltage on wire F708 on pin G at
D. Monitor the air shutoff solenoids.
D. Deactivate the customer's emergency stop switch.
E. Deactivate the customer's emergency stop switch.
Expected Result:
Expected Result:
The air shutoff solenoids activated. 1 second.
RENR5009-07 121
Results: E. Activate the customer's emergency stop switch.
OK The voltage measures 24 3 VDC for F. Monitor the voltage on the voltmeter.
approximately 1 second. The circuit is operating
correctly to this point. Proceed to Test Step 5. G. Deactivate the customer's emergency stop switch.
Not OK No voltage was measured. Proceed to H. Reconnect wire G708 to the ASOS switch.
Test Step 14.
Expected Result:
Test Step 5. Test for Voltage to the Coil of
the ASOS Switch. The voltage measures 24 3 VDC for approximately
2.5 seconds.
A. Turn the ECS to the OFF/RESET position.
Results:
B. The input to the coil of the ASOS switch is
wire T708 from the diode assembly. Connect OK The voltage measures 24 3 VDC for
a voltmeter between wire T708 on the ASOS approximately 2.5 seconds. The circuit is operating
switch and the engine ground. correctly to this point.
Note: The ASOS switch is turned on for one second Repair: Repair the wire G708 between the ASOS
by the ECM. The timer keeps the ASOS switch switch and terminal I at connector P-C1 of the rigid
energized for approximately 2.5 seconds. harness.
C. Turn the ECS to the STOP position. The engine STOP.

should be off.
Not OK The voltage did not measure 24 3 VDC
D. Activate the customer's emergency stop switch. for approximately 2.5 seconds.
E. Monitor the voltage on the voltmeter. Repair: Verify that 24 3 VDC is present on wire
K708 at the normally open contacts of the ASOS
F. Deactivate the customer's emergency stop switch. switch. If voltage is not present on wire K708,
check the wiring and the circuit breaker for the air
Expected Result: shutoff for problems.
The voltage measures 24 3 VDC for approximately Check wire 220 on the coil of the ASOS switch
2.5 seconds. for continuity to the Battery. If necessary, repair
the wire or replace the wire.
Results:
If wire 220 is okay and voltage is present on wire
OK The voltage measures 24 3 VDC for K708, replace the ASOS switch.
approximately 2.5 seconds. The circuit is operating
correctly to this point. Proceed to Test Step 6. STOP.
Not OK No voltage was measured. Proceed to Test Step 7. Check the Voltage at the
Test Step 10. Connector for the Air Shutoff Solenoids.
Not OK The voltage did not measure 24 3 VDC A. Turn the ECS to the OFF/RESET position.
for 2.5 seconds. Proceed to Test Step 8.
B. Disconnect the connector for the air shutoff
Test Step 6. Check for Voltage from solenoids. Disconnect the connector for the right
the ASOS Switch to the Air Shutoff and left sides of the engine.
Solenoids.
C. Connect a voltmeter between wire G708 on the
A. Turn the ECS to the OFF/RESET position. connector for the air shutoff solenoid and the
engine ground.
B. Disconnect wire G708 from the ASOS switch.
D. Turn the ECS to the STOP position. The engine
C. Connect a voltmeter to the empty terminal on the should be off.
ASOS switch. Connect the other lead of the
voltmeter to engine ground. E. Activate the customer's emergency stop switch.
D. Turn the ECS to the STOP position. The engine F. Monitor the voltage on the voltmeter.
should be off.
122 RENR5009-07
G. Deactivate the customer's emergency stop switch. Results:
H. Reconnect the connectors for the air shutoff OK The voltage measures 24 3 VDC. Proceed
solenoids. to Test Step 9.
Expected Result: Not OK The voltage did not measure 24 3

VDC. Proceed to Test Step 11.
2.5 seconds. Test Step 9. Check the Voltage at Terminal
4 of the Connector for the Timer.
Results:
OK The voltage measures 24 3 VDC for
approximately 2.5 seconds. The circuit is operating B. Connect a voltmeter between terminal 4 of the
correctly to this point. connector for the timer and engine ground.
Repair: Check the wire H708 from terminal A C. Turn the ECS to the STOP position. The engine
of the connectorfor the air shutoff solenoid for should be off.
continuity to the Battery terminal. If the wire H708
to the Battery terminal is okay, replace the air D. Activate the customer's emergency stop switch.
shutoff solenoid.
E. Monitor the voltage on the voltmeter.
STOP.
F. Deactivate the customer's emergency stop switch.
for approximately 2.5 seconds. System voltage Expected Result:
was not available at the solenoid connector.
Repair: Repair the wire G708 between the 2.5 seconds.
connector for the air shutoff solenoids and terminal
I at connector P-C1 of the rigid harness. Results:
STOP. OK The voltage measures 24 3 VDC for

approximately 2.5 seconds. Proceed to Test Step
Test Step 8. Check the Voltage at the 12.
Contact of Relay R3A.
A. Turn the ECS to the OFF/RESET position. for approximately 2.5 seconds.
B. Disconnect wire T120 from terminal 87 of relay Repair: Check for 24 3 VDC on terminal 1 of the
R3A. connector for the timer. If voltage is not present on
terminal 1, repair the wire T120 between terminal
C. Connect a voltmeter between terminal 87 of relay 87 of relay R3A and terminal 1 of the connector
R3A and the engine ground. for the timer.
D. Turn the ECS to the STOP position. The engine If voltage is present on terminal 1 of the connector
should be off. for the timer, verify that wire 220 on terminal 2 of
the connector for the timer has continuity to the
E. Activate the customer's emergency stop switch. Battery. If wire 220 does not have continuity to the
Battery, repair the wire.
F. Monitor the voltage on the voltmeter.
Verify that 24 3 VDC is present on terminal 3
G. Deactivate the customer's emergency stop switch. of the connector for the timer. If 24 3 VDC is
not present on terminal 3 of the connector for the
H. Reconnect wire T120. timer, verify that the engine control switch is not in
the OFF/RESET position. Verify that the MPD
Expected Result: breaker is not tripped. Check the normally closed
contact of relay R1 for proper operation. Check
The voltage measures 24 3 VDC. the wire 120 between terminal 3 of the connector
for the timer and relay R1 for damage. Check
the wire A120 between relay R1 and the MPD
breaker for damage. If necessary, repair the wires.
RENR5009-07 123
If the voltage is present on terminal 1 and 3 of the If the voltage does not measure 24 3 VDC for
timer and wire 220 is okay, replace the timer. approximately 1 second, repair the wire F708
between the connector for the diodes and wire
STOP. F708 on pin G at connector P-C1 of the right rail.
Test Step 10. Check the Voltage at STOP.

Terminal 4 of the Connector for the
Diodes. Test Step 11. Check the Voltage at the
Coil of Relay R3A.
B. Connect a voltmeter between terminal 4 of the
connector for the diodes and the engine ground. B. Connect a voltmeter between wire 918 on terminal
86 of relay R3A and the engine ground.
C. Turn the ECS to the STOP position. The engine
should be off. C. Turn the ECS to the STOP position. The engine
should be off.
D. Activate the customer's emergency stop switch.
Expected Result:
Expected Result:
2.5 seconds. The voltage measures 24 3 VDC.
Results: Results:
OK The voltage measures 24 3 VDC for OK The voltage measures 24 3 VDC.

approximately 2.5 seconds.
Repair: Check wire 220 on the coil of the R3A
Repair: Repair the wire T708 between the relay for continuity to the Battery. If necessary,
connector for the diodes and the ASOS switch. repair the wire or replace the wire.
STOP. Check for 24 3 VDC on wire 120 on terminal 30

of relay R3A. If 24 3 VDC is not present on wire
Not OK The voltage did not measure 24 3 VDC 120, verify that the engine control switch is not in
for approximately 2.5 seconds. the OFF/RESET position. Verify that the MPD
breaker is not tripped. Check the normally closed
Repair: contact of relay R1 for proper operation. Check
the wire 120 between terminal 30 of the relay
1. Turn the ECS to the OFF/RESET position. R3A and relay R1 for damage. Check the wire
A120 between relay R1 and the MPD breaker
2. Connect a voltmeter between terminal 1 of the for damage. If necessary, repair the wires.
connector for the diodes and the engine ground.
If wire 220 is okay and voltage is present on wire
3. Turn the ECS to the STOP position. The engine 120 on terminal 30, replace relay R3A.
should be off.
STOP.
4. Activate the customer's emergency stop switch.
Not OK The voltage did not measure 24 3
5. Monitor the voltage on the voltmeter. VDC. Proceed to Test Step 13.
6. Deactivate the customer's emergency stop Test Step 12. Check the Voltage to
switch. Terminal 2 of the Connector for the
Diodes from the Timer.
If the voltage measures 24 3 VDC for
approximately 1 second, replace the diodes. A. Turn the ECS to the OFF/RESET position.
B. Connect a voltmeter between the terminal 2 of the

connector for the diodes and the engine ground.
124 RENR5009-07
C. Turn the ECS to the STOP position. The engine Repair: Replace the diodes.
should be off.
STOP.
Test Step 14. Check the Output Driver for
E. Monitor the voltage on the voltmeter. the Air Shutoff System at the ECM.
F. Deactivate the customer's emergency stop switch. A. Turn the ECS to the OFF/RESET position.
Expected Result: B. Disconnect the secondary ECM connector J2.
The voltage measures 24 3 VDC. C. Remove wire F708 from ECM connector P2-13.
Install a wire jumper into P2-13.
Results:
D. Reconnect ECM connector P2.
OK The voltage measures 24 3 VDC. Proceed
to Test Step 13. E. Connect a voltmeter between the wire jumper in
P2-13 and engine ground.
VDC. F. Turn the ECS to the STOP position. The engine
should be off.
Repair: Repair the wire T708 between the diodes
and the timer. G. Activate the customer's emergency stop switch.
STOP. H. Monitor the voltage on the voltmeter.
Test Step 13. Check the Voltage from I. Deactivate the customer's emergency stop switch.
Terminal 3 of the Connector for the Diode
Assembly. Expected Result:
A. Turn the ECS to the OFF/RESET position. The voltage measures 24 3 VDC for one second.
B. Connect a voltmeter between terminal 3 of the Results:

connector for the diode assembly and the engine
ground. OK The voltage measures 24 3 VDC for one
second.
should be off. Repair: Repair the wire F708 between the ECM
connector and terminal G at connector P-C1 of the
D. Activate the customer's emergency stop switch. rigid harness.
E. Monitor the voltage on the voltmeter. STOP.
F. Deactivate the customer's emergency stop switch. Not OK The voltage did not measure 24 3
VDC.
Expected Result:
Repair: Replace the ECM.
The voltage measures 24 3 VDC.
STOP.
Results:
OK The voltage measures 24 3 VDC.

Repair: Repair the wire 918 between the diodes
and relay R3A.
STOP.

VDC.
RENR5009-07 125
i01900689
Analog Sensor Supply

SMCS Code: 1901-038
System Operation Description:
The analog sensor supply provides power to all

analog sensors. The primary Electronic Control
Module (ECM) supplies 5.0 0.2 VDC from the
ECM connector J1/P1 to each analog sensor
connector. The sensor return line connects to the
ECM connector J1/P1. The analog sensor supply is
output short circuit protected. A short circuit to the
battery will not damage the circuit inside the ECM.
Note: The analog sensors are not protected from

overvoltage. A short from the analog supply line
to the +Battery supply may damage the sensors.
If CID-FMI 262-03 is logged, it is possible that all
of the analog sensors have been damaged. Repair
the analog sensor supply and check for any active
sensor diagnostic codes in order to determine if a
sensor has failed.
The ECM calibrates the sensor within the rst ve

seconds after power is applied to the ECM. The
ECM checks the sensor value against an acceptable
pressure range. If the pressure value is not in this
range, the previous calibration will be used. Refer to
the calibration procedure Troubleshooting, Anolog
Sensor - Calibrate.
The following analog sensors are found on the

engine: aftercooler temperature sensor, coolant
temperature sensor, ltered fuel pressure sensor,
unltered fuel pressure sensor, ltered engine oil
pressure sensor, unltered engine oil pressure
sensor, left turbocharger compressor inlet pressure
sensor, right turbocharger compressor inlet pressure
sensor, turbocharger compressor outlet pressure
sensor, atmospheric pressure sensor, and crankcase
pressure sensor.
126 RENR5009-07
g01001876
Illustration 24
Typical example
Test Step 1. Check for Connector B. Turn the Engine Control Switch (ECS) to the
Damage. OFF/RESET position.
A. Turn the circuit breaker for the battery to the OFF

position.
RENR5009-07 127
C. Thoroughly inspect the ECM connectors J1/P1 Results:

and J2/P2. Inspect all of the other connectors.
Refer to Troubleshooting, Inspecting Electrical OK The resistance is more than 20,000 Ohms
Connectors for details. for each measurement. Proceed to Test Step 3.
D. Perform a 45 N (10 lb) pull test on each of the Not OK The resistance is less than 20,000 Ohms
wires in the ECM connector that are associated for each measurement.
with the circuit.
Repair: Repair the connectors or wiring and/or
E. Check the ECM connectors (allen head screw) for replace the connectors or wiring.
STOP.
F. Check the harness and the wiring for abrasion
and for pinch points. Test Step 3. Check the Analog Sensor
Supply Voltage at the Primary ECM.
Expected Result:
A. Disconnect the primary ECM connector J1/P1.
coupled and/or inserted, and the harness and wiring B. Remove the wire 997 from the primary ECM
are free of corrosion, of abrasion or of pinch points. connector P1-02. Remove the wire 993 from
the primary ECM connector P1-03. Install wire
Results: jumpers into P1-02 and into P1-03.
OK The connectors and wiring are okay. Proceed C. Remove the wire A997 from the primary ECM
to Test Step 2. connector P1-18. Remove the wire A993 from
the primary ECM connector P1-35. Install wire
Not OK The connectors and/or wiring need jumpers into P1-18 and into P1-35.
repair.
Note: If you remove the sensor common from
Repair: Repair the connectors or wiring and/or the ECM, an open circuit diagnostic code will
replace the connectors or wiring. be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the
STOP. logged diagnostic codes when you are nished.
Test Step 2. Check the Harness for D. Reconnect ECM connector J1/P1.
Shorts.
E. Turn the circuit breaker for the battery to the ON
A. Disconnect the primary ECM connector J1/P1. position.
Disconnect all of the analog sensors.
F. Turn the ECS to the STOP position. The engine
B. Measure the resistance between the analog should be off.
supply P1-02 and the analog return P1-03.
G. Measure the voltage between the wire jumper in
C. Measure the resistance between P1-18 and the analog supply P1-02 and the wire jumper in
P1-35. the analog return P1-03.
D. Measure the resistance between P1-02 and H. Measure the voltage between the wire jumper in
engine ground. the analog supply P1-18 and the wire jumper in
the analog return P1-35.
E. Measure the resistance between P1-03 and
engine ground. I. Turn the ECS to the OFF/RESET position.
F. Measure the resistance between P1-18 and J. Remove the wire jumpers. Replace the wires that
engine ground. were removed above. Reconnect ECM connector
J1/P1.
G. Measure the resistance between P1-35 and
engine ground. Expected Result:
Expected Result: The supply voltage is 5.0 0.2 VDC.
The resistance is more than 20,000 Ohms for each

measurement.
128 RENR5009-07
Results: E. Turn the ECS to the OFF/RESET position.
OK The supply voltage is 5.0 0.2 VDC. F. Reconnect all sensors.

Proceed to Test Step 4.
Expected Result:
Not OK The supply voltage is not 5.0 0.2 VDC.
The supply voltage is 5.0 0.2 VDC after each
Repair: Perform the diagnostic functional test analog sensor is connected.
Troubleshooting, Electrical Power Suply.
Results:
STOP.
OK The supply voltage is 5.0 0.2 VDC after
Test Step 4. Check the Analog Sensor each analog sensor is connected.
Supply Voltage at the Sensor Connector.
A. Turn the ECS to the STOP position. The engine problem is intermittent, perform the diagnostic
should be off. functional test Troubleshooting, Inspecting
B. Measure the voltage between socket-A and
socket-B on the harness side of all analog sensor STOP.
connectors.
Not OK The voltage is okay before the sensor
C. Turn the ECS to the OFF/RESET position. is connected. The voltage is not okay after the
sensor is connected. The sensor may be internally
Expected Result: shorted.
The supply voltage is 5.0 0.2 VDC. Repair: Temporarily replace the sensor. Verify
that the new sensor solves the problem before
Results: permanently installing the new sensor.
OK The supply voltage is 5.0 0.2 VDC. STOP.

i01900697
Repair: There is an open circuit in the harness or
CAN Data Link
connectors. Repair the connectors or wiring and/or SMCS Code: 1901-038
replace the connectors or wiring.
STOP.
The CAN Data Link is used for communication
Test Step 5. Check the Analog Sensors between the following modules: engine's Electronic
for Short Circuits. Control Module (ECM), customer devices, and
various display modules. Two 120 Ohm terminating
A. Turn the ECS to the STOP position. The engine resistors must be installed in the wiring harness in
should be off. order for the CAN Data Link to function properly.
B. Measure the voltage between socket-A and
socket-B on the harness side of an analog sensor
connector. Leave this sensor disconnected.
C. Connect one sensor at a time.
Note: If the sensor is disconnected from the harness,

an open circuit diagnostic code will be generated
for that sensor. Troubleshoot the original diagnostic
code. Delete the logged diagnostic codes when you
are nished.
D. Repeat this step with all of the analog sensors.

For the last sensor, move the voltmeter to another
sensor connector. Check the last sensor, as
described above.
RENR5009-07 129
g01027471
Illustration 25
Typical example
Test Step 1. Check for Connector Expected Result:

Damage.
A. Turn the Engine Control Switch (ECS) to the OFF coupled and/or inserted. The harness and wiring are
position. free of corrosion, of abrasion or of pinch points.
B. Turn the battery disconnect switch to the OFF Results:

position.
OK The connectors and wiring are okay. Proceed
C. Thoroughly inspect the primary ECM connectors to Test Step 2.
J1/P1 and J2/P2. Inspect all of the other
connectors. Refer to the diagnostic functional Not OK The connectors and/or wiring are not
test Troubleshooting, Inspecting Electrical okay.
Connectors for details.
D. Perform a 45 N (10 lb) pull test on each of the replace the connectors or wiring.
wires in the primary ECM connector that are
associated with the circuit. STOP.
E. Check the ECM connectors (allen head screw) for Test Step 2. Verify Proper Installation of
the proper torque of 6 1 Nm (53 9 lb in). the Terminating Resistors.
F. Check the harness and the wiring for abrasion A. Verify that the terminating resistors are installed
and for pinch points. on the ends of the data link.
130 RENR5009-07
B. Disconnect J1/P1 ECM connector and measure Expected Result:

the resistance between P1-50 (CAN Data Link +)
and P1-34 (CAN Data Link -). The resistance measures more than 20,000 Ohms.
Expected Result: Results:
The resistance is between 60 3 Ohms. OK The resistance is more than 20,000 Ohms.
Results:
Not OK The resistance is less than 20,000
OK The resistance is within the range. Proceed Ohms.
to Test Step 3.
Repair: There is a short in the harness wiring.
Not OK The range of the resistance is 120 Repair the connectors or wiring and/or replace the
6 Ohms. A terminating resistor is missing or connectors or wiring.
damaged.
Verify that the repair eliminates the problem.
Repair: If a termination resistor is missing, install
the missing resistor. If both resistors are present, STOP.
measure the resistance between pin A and pin B
of the termination resistor. The resistance should Test Step 4. Check for an Open Circuit
measure 120 3 Ohms. Replace the termination in the Harness.
resistor if the resistance is not 120 3 Ohms.
A. All connections should remain disconnected.
Refer to the Schematic in order to determine the
missing resistor. B. Fabricate a jumper wire. Short pin 7 and pin 8 on
the connector for the marine power display.
C. Measure the resistance between P1-50 (CAN
STOP. Data Link +) and P1-34 (CAN Data Link -) at the
primary ECM connector P1.
Test Step 3. Check for a Short Circuit in
the Harness. Expected Result:
A. Disconnect the J1/P1 ECM connector. The resistance is less than 5 Ohms.
B. Remove the terminating resistors from the CAN Results:

Data Link harness.
OK The resistance is less than 5 Ohms.
C. If a Marine Power Display (MPD) is installed,
disconnect the MPD. Repair: The harness for the CAN Data Link is
okay. There may be a problem in the modules that
D. Measure the resistance between the following are connected to the CAN Data Link. Reconnect
pins. all connectors and modules to the CAN Data Link.
Connect a spare module in place of one of the
P1-50 (CAN Data Link +) and +Battery modules on the CAN Data Link. If the diagnostic
code disappears, replace the module. If the
P1-34 (CAN Data Link -) and +Battery diagnostic code does not disappear, install the
original module. Repeat this step until the problem
P1-50 (CAN Data Link +) to P1-34 (CAN Data is found.
Link -)
STOP.
P1-50 (CAN Data Link +) to P1-42 (CAN Data
Link Shield) Not OK The resistance is greater than 5 Ohms.
P1-34 (CAN Data Link -) to P1-42 (CAN Data Repair: There is an open in the harness wiring.
Link Shield) Repair the connectors or wiring and/or replace the
connectors or wiring.
P1-50 (CAN Data Link +) and the Battery
terminal Verify that the repair eliminates the problem.
STOP.
RENR5009-07 131
i02302453
Cat Data Link

SMCS Code: 1901-038
The Cat Data Link is used for communication

between electronic modules. The Cat Data Link is
used to communicate information from the Electronic
Control Module (ECM) to the Electronic Monitoring
System (EMS). The Cat Data Link is used for
programming and troubleshooting the ECM.
The ECM communicates with the EMS in order to

share engine information and diagnostics that may
affect engine operation.
The ECM communicates with the Caterpillar

Electronic Technician (ET) in order to share status
and diagnostic information. The Cat ET can also
be used to congure the ECM parameters on the
engine. This information will not be available if
communications fail between the ECM and the Cat
ET.
g01027471
Illustration 26
Typical example
132 RENR5009-07
Test Step 1. Check for Connector Damage Cat Data Link to +Battery terminal
A. Turn the Engine Control Switch (ECS) to the Cat Data Link + to engine ground
OFF/RESET position. The engine should be off.
Cat Data Link to engine ground
B. Turn the circuit breaker for the battery to the OFF
position. Expected Result:
C. Thoroughly inspect the ECM connectors J1/P1 and The resistance is greater than 20,000 Ohms for each
J2/P2. Inspect all of the other connectors. Refer measurement.
Inspecting Electrical Connectors for details. Results:
D. Perform a 45 N (10 lb) pull test on each of the OK The resistance is greater than 20,000 Ohms.
wires in the ECM connector that are associated Proceed to Test Step 3.
with the circuit.
E. Check the ECM connectors (allen head screw) Ohms. There is a short in the harness or in the
for the proper torque. Refer to Troubleshooting, connectors.
Inspecting Electrical Connectors.
Repair: Repair the connector and/or wiring or
F. Check the harness and the wiring for abrasion replace the connector and/or wiring.
and for pinch points.
STOP.
Expected Result:
Test Step 3. Check the Resistance
All connectors, pins, and sockets are completely through the Harness for an Open Circuit
coupled and/or inserted, and the harness and wiring
are free of corrosion, of abrasion and of pinch points. A. Turn the ECS to the OFF/RESET position. The
engine should be off.
Results:
B. Turn the circuit breaker for the battery to the OFF
OK The connectors and wiring are okay. Proceed position.
to Test Step 2.
C. Disconnect the ECM connectors for the primary
Not OK The connectors and/or wiring need ECM and for the secondary ECM.
repair.
D. Disconnect any module that is connected to the
Repair: Repair the connectors and/or wiring or Cat Data Link.
replace the connectors and/or wiring.
E. Short the wires of the Cat Data Link together.
STOP. Create the short at P1-9 and P1-8 of the primary
ECM connector.
Test Step 2. Check for Electrical Shorts
in the Harness F. Set an ohmmeter on the 200 ohm scale. Measure
the resistance between the terminals of the Cat
A. Disconnect the ECM connectors for the primary Data Link + and the Cat Data Link . Measure
ECM and for the secondary ECM. the resistance at the connectors for the primary
ECM and the secondary ECM. Measure the
B. Disconnect any module that is connected to the resistance between the terminals of any module
Cat Data Link. that was connected to the Cat Data Link. Wiggle
the harness during the measurements in order to
C. Measure the resistance at the following points. reveal an intermittent open condition.
Wiggle the harness during the measurement in
order to reveal an intermittent short. G. Reconnect all connectors and modules.
Cat Data Link + to Cat Data Link Expected Result:
Cat Data Link + to Battery terminal The resistance is less than ve Ohms for each
measurement.
Cat Data Link to Battery terminal
Cat Data Link + to +Battery terminal
RENR5009-07 133
Results: Left exhaust temperature sensor The primary

ECM uses the signal from the sensor to monitor left
OK The resistance is less than ve Ohms for exhaust temperature. The sensor is mounted in the
each measurement. left exhaust manifold before the turbocharger. The
sensor's output frequency is 500 Hz with a pulse
Repair: The harness is okay. There could be a width that varies with the exhaust temperature. The
problem with a module or with the ECM. Connect output signal is referred to as a duty cycle or as
the suspect module on another engine. If the a pulse width modulated signal. The output signal
problem returns on the other engine, replace the is expressed as a percentage between 0 and 100
suspect module. Turn the ECS to the OFF/RESET percent. The Caterpillar Electronic Technician (ET)
position. Turn the ECS to the ON position. If the will display the exhaust temperature as a value
diagnostic code is still present, replace the ECM. between 49 C to 850 C (120 F to 1562 F). If
Refer to the diagnostic procedure Troubleshooting, the actual temperature is between 40 C to 49 C
Replacing the ECM. (40 F to 120 F), the display will read 30 C (86 F).
If the temperature is above 851 C (1564 F), the
STOP. display will read 851 C (1564 F).
Not OK The resistance is greater than ve Ohms Right exhaust temperature sensor The primary
for each measurement. ECM uses the signal from the sensor to monitor
right exhaust temperature. The sensor is mounted in
Repair: There is an open circuit or there is the right exhaust manifold before the turbocharger.
excessive resistance in the harness. Repair the The sensor's output frequency is 500 Hz with a
connectors and/or wiring or replace the connectors pulse width that varies with the exhaust temperature.
and/or wiring. The output signal is referred to as a duty cycle
or as a pulse width modulated signal. The output
STOP. signal is expressed as a percentage between 0 and
100 percent. The Cat ET will display the exhaust
temperature as a value between 49 C to 850 C
i01900698
(120 F to 1562 F). If the actual temperature is
Digital Sensor Supply between 40 C to 49 C (40 F to 120 F), the
display will read 30 C (86 F). If the temperature is
SMCS Code: 1901-038 above 851 C (1564 F), the display will read 851 C
(1564 F).
The digital sensor supply provides power to all of the

digital sensors on the engine. The primary Electronic
Control Module (ECM) supplies 8.0 0.4 VDC from
the primary ECM connectors J1/P1 and J2/P2 to
each digital sensor connector pin A. The digital
sensor reference is used as the return line for the
digital sensors, speed/timing sensors, and the switch
inputs to the primary ECM. The digital reference line
is from the primary ECM connector J1/P1 and J2/P2
to each digital sensor connector pin B. The digital
sensor supply is output short circuit protected. A
short circuit to the battery will not damage the circuit
inside the primary ECM. The digital sensors are not
protected from overvoltage.
The following list contains a description of the digital

sensors that are found on the engine.
134 RENR5009-07
g00989851
Illustration 27
Typical example
Test Step 1. Check for Connector Repair: Repair the connectors or wiring and/or
Damage. replace the connectors or wiring.
A. Turn the Engine Control Switch (ECS) to the STOP.

OFF/RESET position.
Test Step 2. Check for a Short Circuit in
B. Turn the battery disconnect switch to the OFF the Wiring Harness.
position.
A. Disconnect the primary ECM connector J1/P1 and
C. Thoroughly inspect the primary ECM connectors the secondary ECM connector J2/P2. Disconnect
J1/P1 and J2/P2. Inspect all of the other all of the digital sensors.
connectors. Refer to the diagnostic functional
test Troubleshooting, Inspecting Electrical B. Measure the resistance between the digital supply
Connectors for details. wire 700 in P1-4 and the digital return wire D998
in P1-5 of connector P1.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the primary ECM connector that are C. Measure the resistance between the digital supply
associated with the circuit. wire 700 in P1-4 and engine ground.
E. Check the primary ECM connector (allen head D. Measure the resistance between the digital return
screw) for the proper torque of 6 1 Nm wire D998 in P1-5 and engine ground.
(53 9 lb in).
E. Measure the resistance between the digital supply
F. Check the harness and the wiring for abrasion wire 700 in P1-4 and the +Battery terminal.
F. Measure the resistance between the digital return
Expected Result: wire D998 in P1-5 and the +Battery terminal.
All connectors, pins, and sockets are completely G. Measure the resistance between the digital supply
coupled and/or inserted. The harness and wiring are P2-56 (A700-BK) and the digital return P2-66
free of corrosion, of abrasion or of pinch points. (F998-BK) on connector P2.
Results: H. Measure the resistance between the digital supply

wire A700 in P2-56 and engine ground.
to Test Step 2. I. Measure the resistance between the digital return
wire F998 in P2-66 and engine ground.
Not OK The connectors and/or wiring are not
okay.
RENR5009-07 135
J. Measure the resistance between the digital supply J. Turn the battery disconnect switch to the OFF
wire A700 in P2-56 and the +Battery terminal. position.
K. Measure the resistance between the digital return K. Remove the wire jumpers and reconnect the
wire F998 in P2-66 and the +Battery terminal. primary ECM connector J1/P1.
Expected Result: L. Remove the wire jumpers and reconnect the

primary ECM connector J2/P2.
The resistance is greater than 20,000 Ohms for each
measurement. Expected Result:
Results: The supply voltage is 8.0 0.4 VDC.
OK The resistance is greater than 20,000 Ohms. Results:

OK The supply voltage is 8.0 0.4 VDC. The
Not OK The resistance is less than 20,000 digital sensor supplies are producing the correct
Ohms. voltage. Proceed to Test Step 4.
Repair: There is a short in the wiring harness. Not OK The supply voltage is not 8.0 0.4 VDC.
Repair the connectors or wiring and/or replace the The digital sensor supplies are not producing the
connectors or wiring. correct voltage.
STOP. Repair: Perform the diagnostic functional test

Test Step 3. Check the Digital Supply
Voltage at the Primary ECM. STOP.
A. Remove the wire 700 from the ECM connector Test Step 4. Check the Digital Sensor
P1-4. Install a jumper wire into the socket for P1-4. Supply Voltage at the Sensor Connector.
B. Remove the wire D998 from the ECM connector A. Turn the battery disconnect switch to the ON
P1-5. Install a jumper wire into the socket for P1-5. position.
C. Remove the wire A700 from the ECM connector B. Turn the ECS to the STOP position. The engine
P1-4. Install a jumper wire into the socket for should be off.
P2-56.
C. Measure the digital sensor supply voltage between
D. Remove the wire F998 from the ECM connector the digital supply wire 700 in terminal-A and the
P2-66. Install a jumper wire into the socket for digital return wire D998 in terminal-B at all of the
P2-66. digital sensors.
Note: If you remove the sensor common from D. Measure the digital sensor supply voltage between
the ECM, an open circuit diagnostic code will the digital supply wire A700 in terminal-A and the
be generated for all sensors that use the sensor digital return wire F998 in terminal-B at all of the
common. Troubleshoot the original code. Delete the digital sensors.
logged diagnostic codes when you are nished.
Note: If the sensor is disconnected from the harness,
E. Turn the battery disconnect switch to the ON an open circuit diagnostic code will be generated for
position. that sensor. Troubleshoot the original code. Delete
the logged diagnostic codes when you are nished.
F. Turn the ECS to the STOP position. The engine
should be off. E. Turn the ECS to the OFF/RESET position.
G. Measure the voltage between the digital sensor F. Turn the battery disconnect switch to the OFF
supply P1-4 and the digital sensor return P1-5 at position.
the wire jumpers.
Expected Result:
H. Measure the voltage between the digital sensor
supply P2-56 and the digital sensor return P2-66 The supply voltage is 8.0 0.4 VDC.
at the wire jumpers.
I. Turn the ECS to the OFF/RESET position.

136 RENR5009-07
Results: Repair: Temporarily install a new sensor. Ensure

that the problem is no longer present. Reinstall
OK The supply voltage is 8.0 0.4 VDC at all the old sensor. If the problem returns, replace the
of the digital sensor connectors. Proceed to Test sensor.
Step 5.
STOP.
Not OK The supply voltage is not 8.0 0.4
VDC. There is an open circuit in the harness or Intermittent The problem is intermittent.
connectors.
Repair: If the problem is intermittent, perform
Repair: Repair the connectors or wiring and/or the diagnostic functional test Troubleshooting,
replace the connectors or wiring. Inspecting Electrical Connectors.
STOP. STOP.
Test Step 5. Check the Digital Sensors

i01988349
for Short Circuits.
A. Turn the battery disconnect switch to the ON
position. SMCS Code: 1401-038
B. Turn the ECS to the STOP position. The engine System Operation Description:
should be off.
The engine has a Primary Electronic Control Module
Note: If the sensor is disconnected from the harness, (ECM) and a Secondary Electronic Control Module
an open circuit diagnostic code will be generated for (ECM). The electrical power to the primary ECM
that sensor. Troubleshoot the original code. Delete comes through the breaker for the primary ECM and
the logged diagnostic codes when you are nished. the contact of relay R2A. The electrical power to the
secondary ECM comes through the breaker for the
C. Connect one digital sensor at a time. secondary ECM and the contact of relay R2. Power
goes to pin P1-53 and pin P1-52 of the ECM(s).
D. Measure the voltage between the digital sensor The Battery comes through the breakers for the
supply P1-4 and the digital sensor return P1-5 at primary ECM and the secondary ECM. The Battery
the ECM connector J1/P1. Repeat these steps connects to pin P1-63 and pin P1-65 of the ECM(s).
with all of the digital sensors.
The Engine Control Switch (ECS) sends a signal to
E. Measure the voltage between the digital sensor pin P1-70 on the primary ECM and to pin P2-70 on
supply P2-56 and the digital sensor return P2-66 the secondary ECM when the ECS is in the following
at the ECM connector J2/P2. Repeat these steps positions: REMOTE, STOP, and START. When the
with all of the digital sensors. primary ECM senses battery voltage on pin P1-70 of
the primary ECM, the primary ECM will power up.
F. Turn the ECS to the OFF/RESET position. When the secondary ECM senses battery voltage on
pin P2-70 of the secondary ECM, the secondary ECM
G. Turn the battery disconnect switch to the OFF will power up. When the ECS is in the OFF/RESET
position. position, voltage is not present on these inputs and
the ECM(s) will power down.
Expected Result:
If an emergency shutdown occurs, circuitry will
The supply voltage is 8.0 0.4 VDC. energize relay R2 and relay R2A. When these two
relays are energized the contacts of the relays will
Results: open. When the contacts of the relays open, battery
power is removed from the ECM(s).
OK The supply voltage is 8.0 0.4 VDC. The
digital sensor supply is correct. The harness and In order to restart the engine, the operator must
sensors are okay. correct the cause of the emergency shutdown. The
Engine Control Switch (ECS) must be turned to
Repair: Check the system for any diagnostic the OFF/RESET position. This resets the electrical
codes. circuits in the circuit. In addition to turning the ECS to
the OFF/RESET position, the operator must manually
STOP. open the air shutoff valves before starting the engine.
The sensor may be internally shorted.
RENR5009-07 137
The presence of two +Battery connections and two

Battery connections to the ECM reduce harness
resistance. All of these connections must be complete
in order to ensure proper engine operation.
138 RENR5009-07
g01029806
Illustration 28
Typical example
RENR5009-07 139
Note: If a remotestart switch is installed, the remote D. Measure the voltage at the primary ECM and
start switch must be in the LOCAL position for this at the secondary ECM. Measure the voltage
test. between P1-53 and P1-65. Measure the voltage
between P1-52 and P1-63.
Test Step 1. Check for Connector
Damage. E. Measure the voltage between P1-70 and P1-65 at
the primary ECM.
F. Measure the voltage between P1-70 and P1-65
B. Turn the circuit breaker for the battery to the OFF at the secondary ECM.
position.
Expected Result:
C. Verify that the circuit breakers are not tripped.
The voltage measures 24 3 VDC. The difference
D. Thoroughly inspect the ECM connectors J1/P1 and between the three voltage measurements is less
J2/P2. Inspect all of the other connectors. Refer than 0.5 VDC.
Inspecting Electrical Connectors for details. Results:
E. Perform a 45 N (10 lb) pull test on each of the OK The ECM is receiving the correct battery
wires in the ECM connector that are associated voltage. Proceed to Test Step 5.
with the circuit.
Not OK - P1-70 The voltage is not 24 3 VDC
F. Check the ECM connector (allen head screw) for on the input for the keyswitch to the ECM. Proceed
the proper torque of 6 1 Nm (53 9 lb in). to Test Step 6.
G. Check the harness and the wiring for abrasion Not OK The voltage is incorrect at the battery
and for pinch points. connections to the ECM(s). The wiring or
components between the battery and the ECM are
Expected Result: preventing the voltage from reaching the ECM.
coupled and/or inserted, and the harness and wiring Test Step 3. Check the Battery Voltage.
Results: position.
OK The connectors and wiring are okay. Proceed B. Turn the ECS to the OFF/RESET position.
to Test Step 2.
C. Measure no-load battery voltage at the battery
Not OK The connectors and/or wiring need terminals. Refer to Testing and Adjusting, Test
repair. Tools for the Electrical System for the proper
procedures to check the batteries.
replace the connectors or wiring. D. Load test the batteries. Use the 4C-4911
Battery Load Tester. Refer to the Operating
STOP. Manual, SEHS9249. Refer to Special Instruction,
SEHS7633.
Test Step 2. Check the Voltage to the
ECM. Expected Result:
A. Disconnect the primary ECM connector and the The no-load voltage at the batteries is at least 23.5
secondary ECM connector J1/P1. VDC and the batteries pass the load test.
B. Turn the circuit breaker for the battery to the ON Results:

position.
OK The battery voltage is okay and the battery
C. Turn the ECS to the STOP position. passes the load test. Proceed to Test Step 4.
Note: Verify that wires D229(229) and wires Not OK The battery voltage is incorrect and/or
A287(287) have continuity from the ECM(s) to the the battery fails the load test.
Battery terminal.
140 RENR5009-07
Repair: The batteries or the alternator are causing Verify that voltage is not present on wire T120
the problem. Recharge the batteries or replace at the coil of relay R2. If voltage is present on
the batteries. Verify that the original condition is wire T120, check all emergency stop switches for
resolved. Refer to Testing and Adjusting, Electrical proper operation. Check for a diagnostic code for
System. an engine overspeed. If voltage is not present on
wire T120, replace relay R2.
STOP.
STOP.
Test Step 4. Check the Voltage at Relay
R2 and/or Relay R2A. Test Step 5. Check the Voltage at the
Sensor Power Supplies.
position. A. Turn the ECS to the OFF/RESET position.
B. Measure the voltage from wire A103(103) on B. Disconnect the primary ECM connector P1/J1.
terminal 87A of relay R2 to the Battery terminal.
Measure the voltage from wire B103 on terminal Note: If you remove the sensor common from
30 of relay R2 to the Battery terminal. the ECM, an open circuit diagnostic code will
be generated for all sensors that use the sensor
C. Measure the voltage from wire C150(150) on common. Troubleshoot the original code. Delete the
terminal 87A of relay R2A to the Battery logged diagnostic codes when you are nished.
terminal. Measure the voltage from wire A150 on
terminal 30 of relay R2A to the Battery terminal. C. Check the analog supply voltage. Remove the
wire 997 from P1-2. Remove the wire 993 from
Expected Result: P1-3. Install wire jumpers into the sockets for the
above wires.
The voltage measures 24 3 VDC on all terminals.
D. Check the analog supply voltage. Remove the
Results: wire A997 from P1-18. Remove the wire A993
from P1-35. Install wire jumpers into the sockets
OK The voltage is 24 3 VDC. for the above wires.
Repair: Repair the wiring between relay R2 E. Check the digital supply voltage. Remove the wire
and/or relay R2A and the ECM(s). 700 from P1-4. Remove the wire D998 from P1-5.
Install wire jumpers into the sockets for the above
STOP. wires.
Not OK The voltage is not 24 3 VDC on F. Reconnect the primary ECM connector P1/J1.
terminal 30 of the ECM(s).
G. Disconnect the primary ECM connector P2/J2.
Repair: Verify that voltage is present on wire A150
at the breaker for the primary ECM. If voltage is H. Check the digital supply voltage. Remove the wire
present at the breaker, repair the wiring between A700 from P2-56. Remove the wire F998 from
the breaker for the primary ECM and relay R2A. P2-66. Install wire jumpers into the sockets for the
above wires.
Verify that voltage is present on wire B103 at
the breaker for the secondary ECM. If voltage is I. Reconnect the primary ECM connector P2/J2.
present at the breaker, repair the wiring between
the breaker for the secondary ECM and relay R2. J. Turn the ECS to the STOP position.
STOP. K. Measure the analog voltage between the wire

jumpers in the following pins:
Not OK The voltage is not 24 3 VDC on
terminal 87A of the ECM(s). P1-2 and P1-3
Repair: Verify that voltage is not present on wire P1-18 and P1-35
T120 at the coil of relay R2A. If voltage is present
on wire T120, check all emergency stop switches L. Measure the digital voltage between the wire
for proper operation. Check for diagnostic codes jumpers in the following pins:
for an engine overspeed. If voltage is not present
on wire T120, replace relay R2A. P1-4 and P1-5
P2-56 and P2-66
RENR5009-07 141
M. Turn the ECS to the OFF/RESET position. Repair: If 24 3 VDC is present on terminal 20 of
the ECS, replace the ECS.
N. Remove the wire jumpers. Replace all of the wires
that were removed in the above steps. Reconnect STOP.
the ECM connectors.
Not OK - Terminal 20 The correct voltage is not
Expected Result: present on terminal 20 of the ECS. Proceed to Test
Step 7.
The voltage measures 5.0 0.2 VDC on the analog
supplies. The voltage measures 8.0 0.4 VDC on Test Step 7. Check the Voltages at Relay
the digital supplies. R1.
Results: A. Turn the ECS to the STOP position.
OK The sensor power supplies are functioning B. Measure the voltage between wire 120 on terminal
properly. The ECM is powered up. 87A of relay R1 and engine ground.
Repair: The problem may be intermittent. If the C. Measure the voltage between wire A120 on
problem is intermittent, perform the diagnostic terminal 30 of relay R1 and engine ground.
Electrical Connectors. D. Turn the ECS to the OFF/RESET position.
Not OK If the ECM is getting the correct voltage The voltage measures 24 3 VDC on both terminals.
at the +Battery terminal, but the ECM does not
supply the correct voltages to the sensor supplies, Results:
replace the ECM.
OK The voltage is 24 3 VDC on both terminals.
Repair: Refer to the diagnostic procedure
Troubleshooting, Replacing the ECM. Repair: The wiring between relay R1 and the
ECS needs repair. Repair the connectors or wiring
STOP. and/or replace the connectors or wiring.
Test Step 6. Check the Voltage at the ECS. STOP.
A. Turn the ECS to the STOP position. Not OK The voltage is not 24 3 VDC on
terminal 30 of relay R1.
B. Measure the voltage at the ECS when the switch
is in the STOP position. Measure the voltage Repair: Verify that voltage is present on wire A120
between terminal 16 and engine ground. Measure at the MPD breaker. If voltage is present at the
the voltage between terminal 20 and engine breaker, repair the wiring between the MPD
ground. breaker and relay R1.
Expected Result: STOP.
The voltage measures 24 3 VDC on both terminals. Not OK The voltage is not 24 3 VDC on
terminal 87A of relay R1.
Results:
Repair: Verify that voltage is not present on wire
OK The voltage is 24 3 VDC on both terminals. R907 at the coil of relay R1. If voltage is present
on wire R907, verify that the ECS is in the STOP
Repair: The wiring between the ECS and the position. If voltage is present on wire R907, check
primary ECM and/or the secondary ECM needs for a short to the +Battery on wire R907 or check
repair. Repair the connectors or wiring and/or the ECS for an internal short. If voltage is not
replace the connectors or wiring. present on wire R907, replace relay R1.
STOP. STOP.
Not OK - Terminal 16 The correct voltage is not

present on terminal 16 of the ECS.
142 RENR5009-07
i01988352
Emergency Stop Switch

SMCS Code: 1901-038
When the local emergency stop switch on the

instrument panel is depressed, the coils of relay
R4 and relay R4A are energized. The contacts
of relay R4 keeps the coils of relay R4 and relay
R4A energized until the Engine Control Switch
(ECS) is cycled to the OFF/RESET position. The
contacts of relay R4A energizes the coils of relays
R2 and R2A. When relays R2 and R2A are
energized, power is removed from the engine's
primary Electronic Control Module (ECM) and the
engine's secondary ECM. The primary ECM and
the secondary ECM will power down. The injection
signals to the injector solenoids will stop. The
emergency stop lamp on the instrument panel will
illuminate.
The contact of relay R4A also supplies power

to terminal 1 of the connector for the timer. When
power is applied to terminal 1 of the connector for
the timer, the timer will activate. The timer outputs
24 VDC to terminal 4 of the connector for the timer
for 2.5 seconds. The 24 VDC from terminal 4 of
the connector for the timer is applied to the coil of
the air shutoff switch (ASOS). The contact of the
ASOS switch energizes the air shutoff solenoids.
The timer will output voltage to the coil of the ASOS
switch for approximately 2.5 seconds. The ASOS
switch will then deactivate removing power to the air
shutoff solenoids. This prevents damage to the air
shutoff solenoids. A normally open switch at the air
shutoff valves will close when the air shutoff solenoid
activates the air shutoff valve. The switch input to the
ECM noties the ECM that the air shutoff valves are
closed. The ECM will not send injection signals to the
injector solenoids until the switch inputs from the air
shutoff valves indicate that the valves are open.
Relay R3A and relay R3 are energized at the

same time as the ASOS switch through terminal 3 of
the diode assembly. Terminal 3 of the diode assembly
will energize relay R3A and relay R3 for 2.5
seconds. The relays R3A and R3 will de-energize
after 2.5 seconds. The overspeed indicator on the
instrument panel will illuminate for 2.5 seconds.
In order to start the engine after an emergency

stop condition, the ECS must be turned to the
OFF/RESET position. This resets the ECM and the
air shutoff timer. In addition to turning the ECS to the
OFF/RESET position, the operator must manually
open the air shutoff valves before starting the engine.
RENR5009-07 143
g01029797
Illustration 29
Typical example
144 RENR5009-07

Damage.
STOP.
with the circuit.
A. Turn the ECS to the STOP position.
F. Check the ECM connectors (allen head screw) for
the proper torque of 6 1 Nm (53 9 lb in). B. Activate the local emergency stop switch.
G. Check the harness and the wiring for abrasion C. Monitor the voltage on wire G708 on pin I at
and for pinch points. connector P-C1 of the rigid harness.
Expected Result: D. Deactivate the local emergency stop switch.
All connectors, pins, and sockets are completely Expected Result:

are free of corrosion, of abrasion or of pinch points. The voltage measures 24 3 VDC for approximately
2.5 seconds.
Results:
Results:
to Test Step 2. OK The voltage measures 24 3 VDC for
Not OK The connectors and/or wiring are not correctly to this point. Proceed to Test Step 7.
okay.
Repair: Repair the connectors or wiring and/or VDC for approximately 2.5 seconds. Proceed to
replace the connectors or wiring. Test Step 4.
STOP. Test Step 4. Test for Voltage to the Coil of

Relay R4A at the Connector P-C2 for
Test Step 2. Test the Circuit for the Local the Power Distribution Panel.
Emergency Stop.
position. B. Activate the local emergency stop switch.
B. Turn the ECS to the STOP position. C. Monitor the voltage on wire 354 on pin B at
C. Activate the local emergency stop switch on the
instrument panel. D. Deactivate the local emergency stop switch.
D. Monitor the air shutoff solenoids. Expected Result:
E. Deactivate the local emergency stop switch. The voltage measures 24 3 VDC.
Expected Result:
The air shutoff solenoids activated.

RENR5009-07 145
OK The voltage measures 24 3 VDC. The The voltage measures 24 3 VDC for approximately
circuit is operating correctly to this point. Proceed 2.5 seconds.
to Test Step 5.
Results:
Not OK No voltage was measured. Proceed to
Test Step 11. OK The voltage measures 24 3 VDC for
Test Step 5. Test for Voltage at the Coil of correctly to this point.
the ASOS Switch.
Repair: Repair the wire G708 between the ASOS
A. Turn the ECS to the OFF/RESET position. switch and wire G708 on pin I at connector P-C1 of
the rigid harness.
wire T708 from terminal 4 of the timer. Connect STOP.
a voltmeter between wire T708 on the ASOS
switch and the engine ground. Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds.
C. Turn the ECS to the STOP position.
Repair: Verify that 24 3 VDC is present on wire
D. Activate the local emergency stop switch. K708 at the normally open contacts of the ASOS
switch. If voltage is not present on wire K708,
E. Monitor the voltage on the voltmeter. check the wire K708 and the circuit breaker for the
air shutoff for problems.
F. Deactivate the local emergency stop switch.
If voltage is present on the wire K708, check wire
Expected Result: 220 on the coil of the ASOS switch for continuity
to the Battery. If necessary, repair the wire or
The voltage measures 24 3 VDC for approximately replace the wire. If wire 220 is okay and voltage is
2.5 seconds. present on wire K708, replace the ASOS switch.
Results: STOP.
OK The voltage measures 24 3 VDC for Test Step 7. Check the Voltage at the
approximately 2.5 seconds. The circuit is operating Connector for the Air Shutoff Solenoids.
correctly to this point. Proceed to Test Step 6.
VDC. Proceed to Test Step 8. B. Disconnect the connector for the air shutoff
solenoids. Disconnect the connector for the right
Test Step 6. Check for Voltage from and left sides of the engine.
the ASOS Switch to the Air Shutoff
Solenoids. C. Connect a voltmeter between wire G708 on the
connector for the air shutoff solenoid and the
A. Turn the ECS to the OFF/RESET position. engine ground.
B. Disconnect wire G708 from the ASOS switch. D. Turn the ECS to the STOP position.
C. Connect a voltmeter to the empty terminal on the E. Activate the local emergency stop switch.
ASOS switch. Connect the other lead from the
voltmeter to engine ground. F. Monitor the voltage on the voltmeter.
D. Turn the ECS to the STOP position. G. Deactivate the local emergency stop switch.
E. Activate the local emergency stop switch. H. Reconnect the connectors for the air shutoff
solenoids.
Expected Result:
G. Deactivate the local emergency stop switch.
H. Reconnect wire G708 to the ASOS switch. 2.5 seconds.
146 RENR5009-07
Results: Results:
OK The voltage measures 24 3 VDC for OK The voltage measures 24 3 VDC. Proceed
approximately 2.5 seconds. The circuit is operating to Test Step 9.
correctly to this point.
Repair: Check the wire H708 from terminal A of the VDC. Proceed to Test Step 10.
connector for continuity to the Battery. If the wire
H708 does not have continuity to the Battery from Test Step 9. Check the Voltage at Terminal
terminal A of the connector, check for continuity 4 of the Connector for the Timer.
on wire H708 on pin H at connector P-C1 of the
rigid harness to Battery. If the wire H708 does A. Connect a voltmeter between terminal 4 of the
not have continuity to the Battery from pin H at connector for the timer and engine ground.
connector P-C1 of the rigid harness, verify that
the breaker for the prelube and air shutoff is not B. Turn the ECS to the STOP position.
tripped. If the wire H708 to the Battery terminal is
okay, replace the air shutoff solenoid. Verify that C. Activate the local emergency stop switch.
the circuit operates correctly.
D. Monitor the voltage on the voltmeter.
STOP.
E. Deactivate the local emergency stop switch.
Repair: There is a problem in the wiring between 2.5 seconds.
the connector for the air shutoff solenoids and
wire G708 on pin I at connector P-C1 of the rigid Results:
harness. Repair the connectors or wiring and/or
replace the connectors or wiring. OK The voltage measures 24 3 VDC for
STOP.
Repair: Repair wire T708 between the ASOS
Test Step 8. Check the Voltage at the switch and terminal 4 of the timer.
STOP.
B. Disconnect wire T120 from terminal 87 of relay for approximately 2.5 seconds.
R4A.
Repair: Check for 24 3 VDC on terminal 1 of the
C. Connect a voltmeter between terminal 87 of relay connector for the timer.
R4A and the engine ground.
If voltage is not present on terminal 1, repair the
D. Turn the ECS to the STOP position. wire T120 between terminal 87 of relay R4A and
terminal 1 of the connector for the timer.
E. Activate the local emergency stop switch.
If voltage is present on terminal 1 of the connector
F. Monitor the voltage on the voltmeter. for the timer, verify that wire 220 on terminal 2 of
G. Deactivate the local emergency stop switch. Battery. If wire 220 does not have continuity to the
H. Turn the ECS to the OFF/RESET position.
I. Reconnect wire T120.
Expected Result:

RENR5009-07 147
Verify that 24 3 VDC is present on terminal 3 of Test Step 11. Check the Voltage from the
the connector for the timer. If 24 3 VDC is not Local emergency Stop Switch to Relay
present on terminal 3 of the connector for the timer, R4A.
verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not A. Turn the ECS to the OFF/RESET position.
tripped. Check the normally closed contact of relay
R1 for proper operation. Check the wire 120 B. Disconnect wire 354 from the local emergency
between terminal 3 of the connector for the timer stop switch.
and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for C. Connect a voltmeter to the empty terminal on the
damage. If necessary, repair the wires. local emergency stop switch. Connect the other
lead from the voltmeter to engine ground.
If the voltage is present on terminal 1 and 3 of the
timer and wire 220 is okay, replace the timer. D. Turn the ECS to the STOP position.
STOP. E. Activate the local emergency stop switch.
Test Step 10. Check the Voltage at the F. Monitor the voltage on the voltmeter.
Coil of Relay R4A.
G. Deactivate the local emergency stop switch.
A. Connect a voltmeter between wire 354 on terminal
86 of relay R4A and the engine ground. H. Reconnect wire 354.
B. Turn the ECS to the STOP position. Expected Result:
C. Activate the local emergency stop switch. The voltage measures 24 3 VDC.
D. Monitor the voltage on the voltmeter. Results:
E. Deactivate the local emergency stop switch. OK The voltage measures 24 3 VDC.
Expected Result: Repair: Repair the wire 354 between the local
emergency stop switch and the wire 354 on pin B
The voltage measures 24 3 VDC. at connector P-C2 of the rigid harness.
Results: STOP.
OK The voltage measures 24 3 VDC. Not OK The voltage did not measure 24 3
relay for continuity to the Battery. If necessary, Test Step 12. Check the Voltage to the
repair the wire or replace the wire. Local emergency Stop Switch from Wire
120 on pin E at connector P-C2 of the
Check for 24 3 VDC on wire 120 on terminal 30 rigid harness.
of relay R4A. If 24 3 VDC is not present on wire
120, verify that the ECS is not in the OFF/RESET A. Turn the ECS to the OFF/RESET position.
position. Verify that the MPD breaker is not
tripped. Check the normally closed contact of relay B. Connect a voltmeter between wire 120 on the
R1 for proper operation. Check the wire 120 local emergency stop switch and engine ground.
between terminal 30 of the relay R4A and relay
R1 for damage. Check the wire A120 between C. Turn the ECS to the STOP position.
relay R1 and the MPD breaker for damage. If
necessary, repair the wires. D. Monitor the voltage on the voltmeter.
If wire 220 is okay and voltage is present on wire Expected Result:

120 on terminal 30, replace relay R4A.
STOP.
Results:
VDC. Proceed to Test Step 11. OK The voltage measures 24 3 VDC.
148 RENR5009-07
Repair: Replace the local emergency stop switch. The contact of relay R4A also supplies power
to terminal 1 of the connector for the timer. When
STOP. power is applied to terminal 1 of the connector for
the timer, the timer will activate. The timer outputs
Not OK The voltage did not measure 24 3 24 VDC to terminal 4 of the connector for the timer
VDC. for 2.5 seconds. The 24 VDC from terminal 4 of
the connector for the timer is applied to the coil of
Repair: Check the wire 120 on pin E at connector the air shutoff switch (ASOS). The contact of the
P-C2 of the rigid harness between the connector ASOS switch energizes the air shutoff solenoids.
and the local emergency stop switch for damage. The timer will output voltage to the coil of the ASOS
Verify that the ECS is not in the OFF/RESET switch for approximately 2.5 seconds. The ASOS
position. Verify that the MPD breaker is not switch will then deactivate removing power to the air
tripped. Check the normally closed contact of relay shutoff solenoids. This prevents damage to the air
R1 for proper operation. Check the wire A120 shutoff solenoids. A normally open switch at the air
between relay R1 and the MPD breaker for shutoff valves will close when the air shutoff solenoid
damage. If necessary, repair the wires. activates the air shutoff valve. The switch input to the
ECM noties the ECM that the air shutoff valves are
STOP. closed. The ECM will not send injection signals to the
injector solenoids until the switch inputs from the air
shutoff valves indicate that the valves are open.
i01988355
Emergency Stop Switch Relay R3A and relay R3 are energized at the
same time as the ASOS switch through terminal 3 of
(Remote) the diode assembly. Terminal 3 of the diode assembly
will energize relay R3A and relay R3 for 2.5
SMCS Code: 1901-038 seconds. The relays R3A and R3 will de-energize
after 2.5 seconds. The overspeed indicator on the
System Operation Description: instrument panel will illuminate for 2.5 seconds.
The terminal AS on the customer connector is In order to start the engine after an emergency
for the customer's remote emergency stop input stop condition, the ECS must be turned to the
to the engine's power distribution panel. When OFF/RESET position. This resets the ECM and the
the customer's remote emergency stop switch is air shutoff timer. In addition to turning the ECS to the
depressed, the coils of relay R4 and relay R4A OFF/RESET position, the operator must manually
are energized. The contacts of relay R4 keeps open the air shutoff valves before starting the engine.
the coils of relay R4 and relay R4A energized
until the Engine Control Switch (ECS) is cycled to
the OFF/RESET position. The contacts of relay
R4A energizes the coils of relays R2 and R2A.
When relays R2 and R2A are energized, power is
removed from the engine's primary Electronic Control
Module (ECM) and the engine's secondary ECM.
The primary ECM and the secondary ECM will power
down. The injection signals to the injector solenoids
will stop. The emergency stop lamp on the instrument
panel will illuminate.
RENR5009-07 149
g01029797
Illustration 30
Typical example
150 RENR5009-07

Damage.
STOP.
with the circuit.
F. Check the ECM connectors (allen head screw) for
the proper torque of 6 1 Nm (53 9 lb in). B. Activate the remote emergency stop switch.
G. Check the harness and the wiring for abrasion C. Monitor the voltage on wire G708 on pin I at
and for pinch points. connector P-C1 of the rigid harness.
Expected Result: D. Deactivate the remote emergency stop switch.
All connectors, pins, and sockets are completely Expected Result:

are free of corrosion, of abrasion or of pinch points. The voltage measures 24 3 VDC for approximately
2.5 seconds.
Results:
Results:
to Test Step 2. OK The voltage measures 24 3 VDC for
Not OK The connectors and/or wiring are not correctly to this point. Proceed to Test Step 7.
okay.
Repair: Repair the connectors or wiring and/or VDC for approximately 2.5 seconds. Proceed to
replace the connectors or wiring. Test Step 4.
STOP. Test Step 4. Test for Voltage to the Coil of

Relay R4A at the Connector P-C2 for
Test Step 2. Test the Circuit for the the Power Distribution Panel.
Customer's Remote Emergency Stop.
position. B. Activate the remote emergency stop switch.
B. Turn the ECS to the STOP position. C. Monitor the voltage on wire 354 on pin B at
C. Activate the customer's remote emergency stop
switch. D. Deactivate the remote emergency stop switch.
D. Monitor the air shutoff solenoids. Expected Result:
E. Deactivate the remote emergency stop switch. The voltage measures 24 3 VDC.
Expected Result:
The air shutoff solenoids activated.

RENR5009-07 151
OK The voltage measures 24 3 VDC. The The voltage measures 24 3 VDC for approximately
circuit is operating correctly to this point. Proceed 2.5 seconds.
to Test Step 5.
Results:
Not OK No voltage was measured. Proceed to
Test Step 11. OK The voltage measures 24 3 VDC for
Test Step 5. Test for Voltage at the Coil of correctly to this point.
the ASOS Switch.
Repair: Repair the wire G708 between the ASOS
A. Turn the ECS to the OFF/RESET position. switch and wire G708 on pin I at connector P-C1 of
the rigid harness.
wire T708 from terminal 4 of the timer. Connect STOP.
a voltmeter between wire T708 on the ASOS
switch and the engine ground. Not OK The voltage did not measure 24 3 VDC
for approximately 2.5 seconds.
Repair: Verify that 24 3 VDC is present on wire
D. Activate the remote emergency stop switch. K708 at the normally open contacts of the ASOS
switch. If voltage is not present on wire K708,
E. Monitor the voltage on the voltmeter. check the wire K708 and the circuit breaker for the
air shutoff for problems.
F. Deactivate the remote emergency stop switch.
If voltage is present on the wire K708, check wire
Expected Result: 220 on the coil of the ASOS switch for continuity
to the Battery. If necessary, repair the wire or
The voltage measures 24 3 VDC for approximately replace the wire. If wire 220 is okay and voltage is
2.5 seconds. present on wire K708, replace the ASOS switch.
Results: STOP.
OK The voltage measures 24 3 VDC for Test Step 7. Check the Voltage at the
approximately 2.5 seconds. The circuit is operating Connector for the Air Shutoff Solenoids.
correctly to this point. Proceed to Test Step 6.
VDC. Proceed to Test Step 8. B. Disconnect the connector for the air shutoff
solenoids. Disconnect the connector for the right
Test Step 6. Check for Voltage from and left sides of the engine.
the ASOS Switch to the Air Shutoff
Solenoids. C. Connect a voltmeter between wire G708 on the
connector for the air shutoff solenoid and the
A. Turn the ECS to the OFF/RESET position. engine ground.
B. Disconnect wire G708 from the ASOS switch. D. Turn the ECS to the STOP position.
C. Connect a voltmeter to the empty terminal on the E. Activate the remote emergency stop switch.
ASOS switch. Connect the other lead from the
voltmeter to engine ground. F. Monitor the voltage on the voltmeter.
D. Turn the ECS to the STOP position. G. Deactivate the remote emergency stop switch.
E. Activate the remote emergency stop switch. H. Reconnect the connectors for the air shutoff
solenoids.
Expected Result:
G. Deactivate the remote emergency stop switch.
H. Reconnect wire G708 to the ASOS switch. 2.5 seconds.
152 RENR5009-07
Results: Results:
OK The voltage measures 24 3 VDC for OK The voltage measures 24 3 VDC. Proceed
approximately 2.5 seconds. The circuit is operating to Test Step 9.
correctly to this point.
Repair: Check the wire H708 from terminal A of the VDC. Proceed to Test Step 10.
connector for continuity to the Battery. If the wire
H708 does not have continuity to the Battery from Test Step 9. Check the Voltage at Terminal
terminal A of the connector, check for continuity 4 of the Connector for the Timer.
on wire H708 on pin H at connector P-C1 of the
rigid harness to Battery. If the wire H708 does A. Connect a voltmeter between terminal 4 of the
not have continuity to the Battery from pin H at connector for the timer and engine ground.
connector P-C1 of the rigid harness, verify that
the breaker for the prelube and air shutoff is not B. Turn the ECS to the STOP position.
tripped. If the wire H708 to the Battery terminal is
okay, replace the air shutoff solenoid. Verify that C. Activate the remote emergency stop switch.
the circuit operates correctly.
D. Monitor the voltage on the voltmeter.
STOP.
E. Deactivate the remote emergency stop switch.
Repair: There is a problem in the wiring between 2.5 seconds.
the connector for the air shutoff solenoids and
wire G708 on pin I at connector P-C1 of the rigid Results:
harness. Repair the connectors or wiring and/or
replace the connectors or wiring. OK The voltage measures 24 3 VDC for
STOP.
Repair: Repair wire T708 between the ASOS
Test Step 8. Check the Voltage at the switch and terminal 4 of the timer.
STOP.
B. Disconnect wire T120 from terminal 87 of relay for approximately 2.5 seconds.
R4A.
Repair: Check for 24 3 VDC on terminal 1 of the
C. Connect a voltmeter between terminal 87 of relay connector for the timer.
R4A and the engine ground.
If voltage is not present on terminal 1, repair the
D. Turn the ECS to the STOP position. wire T120 between terminal 87 of relay R4A and
terminal 1 of the connector for the timer.
E. Activate the remote emergency stop switch.
If voltage is present on terminal 1 of the connector
F. Monitor the voltage on the voltmeter. for the timer, verify that wire 220 on terminal 2 of
G. Deactivate the remote emergency stop switch. Battery. If wire 220 does not have continuity to the
I. Reconnect wire T120.
Expected Result:

RENR5009-07 153
Verify that 24 3 VDC is present on terminal 3 of Test Step 11. Check the Voltage from
the connector for the timer. If 24 3 VDC is not the Customer Connector for the Remote
present on terminal 3 of the connector for the timer, Emergency Stop to Relay R4A.
verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not A. Turn the ECS to the OFF/RESET position.
R1 for proper operation. Check the wire 120 B. Disconnect wire 354 from the terminal AS of the
between terminal 3 of the connector for the timer customer connector.
and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for C. Connect a voltmeter to terminal AS on the
damage. If necessary, repair the wires. customer connector. Connect the other lead from
the voltmeter to engine ground.
If the voltage is present on terminal 1 and 3 of the
timer and wire 220 is okay, replace the timer. D. Turn the ECS to the STOP position.
STOP. E. Activate the remote emergency stop switch.
Test Step 10. Check the Voltage at the F. Monitor the voltage on the voltmeter.
Coil of Relay R4A.
G. Deactivate the remote emergency stop switch.
A. Connect a voltmeter between wire 354 on terminal
86 of relay R4A and the engine ground. H. Reconnect wire 354.
B. Turn the ECS to the STOP position. Expected Result:
C. Activate the remote emergency stop switch. The voltage measures 24 3 VDC.
D. Monitor the voltage on the voltmeter. Results:
E. Deactivate the remote emergency stop switch. OK The voltage measures 24 3 VDC.
Expected Result: Repair: Repair the wire 354 between terminal AS
on the customer connector and the wire 354 on pin
The voltage measures 24 3 VDC. B at connector P-C2 of the rigid harness.
Results: STOP.
OK The voltage measures 24 3 VDC. Not OK The voltage did not measure 24 3
VDC.
relay for continuity to the Battery. If necessary, Repair: Troubleshoot the customer's connection to
repair the wire or replace the wire. the remote emergency stop input on terminal AS of
the customer connector.
Check for 24 3 VDC on wire 120 on terminal 30
of relay R4A. If 24 3 VDC is not present on wire STOP.
120, verify that the ECS is not in the OFF/RESET
position. Verify that the MPD breaker is not
i01900704
R1 for proper operation. Check the wire 120
between terminal 30 of the relay R4A and relay
Engine Control Switch (ECS)
R1 for damage. Check the wire A120 between SMCS Code: 1901-038
relay R1 and the MPD breaker for damage. If
necessary, repair the wires. System Operation Description:
If wire 220 is okay and voltage is present on wire The Engine Control Switch (ECS) can operate in four
120 on terminal 30, replace relay R4A. modes: OFF/RESET, START, STOP, and REMOTE.
STOP.

154 RENR5009-07
The Primary Electronic Control Module (ECM)

receives three signals that allow the ECM to
determine the mode of operation. The input signals
on P1-21 and P1-22 tell the ECM the position of the
ECS. The input signals on P1-21 and P1-22 must
be at the same potential or a diagnostic code will be
generated. The third input signal on P1-68 tells the
ECM if the ECS is in the REMOTE position. If the
input signal on P1-68 is low, the ECM knows that the
ECS is in the REMOTE position. The ECM knows that
the engine is controlled remotely by the customer. If
the input signal on P1-68 is not low, the ECM knows
that the ECS is not in the REMOTE position. The
ECM knows that the engine is controlled locally by
the ECS on the instrument panel.
When the ECS is in the REMOTE position, inputs

from the customer control the operation of the engine.
The following list contains some of the inputs from
the customer connector and the inputs function.
C remote start 2
D remote start 1
E remote stop 1
F remote stop 2
S remote input
-C keyswitch
When the ECS is in the REMOTE position, the
Remote Start relay and the Remote Stop relay are
energized. When the remote start inputs C and D go
low, the following relays energize: Run 1 relay, Run
2 relay, Reset 1 relay, and Reset 2 relay. The
start/run/stop inputs P1-21 and P1-22 will be pulled
low. The engine will begin the start cycle. When the
customer's remote stop inputs F and E are low, the
following relays energize: Stop 1 relay and Stop
2 relay. The start/run/stop inputs P1-21 and P1-22
will be high. The engine will begin the stop function.
When the ECS is in the REMOTE position, the ECS
in Remote relay energizes. The ECS in Remote
relay sends a signal to the customer connector that
allows the customer to determine the position of the
ECS.
When the ECS is in the START position, the following

relays energize: Run 1 relay, Run 2 relay, Reset
1 relay, and Reset 2 relay. The start/run/stop inputs
P1-21 and P1-22 will be pulled low. The engine will
begin the start cycle.
When the ECS is in the STOP position, the following

relays energize: Stop 1 relay and Stop 2 relay. The
start/run/stop inputs P1-21 and P1-22 will be high.
When the ECS is in the OFF/RESET position, none

of the relays are energized.
RENR5009-07 155
g00991229
Illustration 31
Typical example
156 RENR5009-07

Damage.
OK The ECS is functioning correctly. Proceed
A. Turn the circuit breaker for the battery to the OFF to Test Step 3.
position.
Not OK The status for the ECS is not STOP.
B. Turn the ECS to the OFF/RESET position. Proceed to Test Step 5.
C. Thoroughly inspect the ECM connectors J1/P1 and Test Step 3. Check the Status of the ECS
J2/P2. Inspect all of the other connectors. Refer in the START Position.
Inspecting Electrical Connectors for details. A. Turn the ECS on the instrument panel to the
START position.
wires in the ECM connector that are associated B. Observe the status for the ECS on Cat ET.
with the circuit.
Expected Result:
E. Check the ECM connector (allen head screw) for
the proper torque of 6 1 Nm (53 9 lb in). The status for the ECS is RUN.
F. Check the harness and the wiring for abrasion Results:

OK The ECS is functioning correctly. Proceed
Expected Result: to Test Step 4.
All connectors, pins, and sockets are completely Not OK The status of the ECS is not RUN.
coupled and/or inserted. The harness and wiring are Proceed to Test Step 5.
free of corrosion, of abrasion or of pinch points.
Test Step 4. Check the Status of the ECS
Results: in the REMOTE Position.
OK The connectors and wiring are okay. Proceed A. Turn the ECS on the instrument panel to the
to Test Step 2. REMOTE position.
Not OK The connectors and/or wiring need B. Observe the status for the ECS on Cat ET.
repair.
Expected Result:
replace the connectors or wiring. The status for the ECS is AUTO.
STOP. Results:
Test Step 2. Check the Status of the ECS OK The ECS is working correctly.
in the STOP Position.
A. Turn the circuit breaker for the battery to the ON problem is intermittent, perform the diagnostic
B. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. STOP.
C. Turn the ECS on the instrument panel to the ECS Not OK The status for the ECS is not
STOP position. AUTO. Proceed to Test Step 6.
D. Observe the status for the ECS on Cat ET. Test Step 5. Install a Wire Jumper at the
ECM in order to Simulate a START/STOP
Expected Result: Function.
The status for the ECS is STOP. A. Turn the ECS to the OFF/RESET position.
B. Disconnect the ECM connector P1.

RENR5009-07 157
C. Remove wire F716 from P1-21. Install a wire E. Fabricate a wire jumper.
jumper into the socket P1-21.
F. Install the wire jumper between terminal 11 of the
D. Remove wire F717 from P1-22. Install a wire ECS and the wire jumper in P1-68.
jumper into the socket P1-22.
G. Turn the ECS to the STOP position.
E. Reconnect the ECM connector P1.
H. Observe the status for the ECS on Cat ET.
F. Fabricate a wire jumper.
I. Remove the wire jumper between terminal 11 of
G. Install the wire jumper between terminal 11 of the the ECS and the wire jumper in P1-68.
ECS and the wire jumpers in P1-21 and P1-22.
J. Observe the status for the ECS on Cat ET.
H. Turn the ECS to the STOP position.
K. Turn the ECS to the OFF/RESET position.
I. Observe the status for the ECS on Cat ET. Remove the wire jumpers and replace all wires.
Reconnect the ECM connector P1.
J. Remove the wire jumper between terminal 11 of
the ECS and the wire jumpers in P1-21 and P1-22. Expected Result:
K. Observe the status for the ECS on Cat ET. The status for the ECS displays AUTO while the
wire jumper is installed. The status for the ECS
L. Turn the ECS to the OFF/RESET position. displays OFF when the wire jumper is removed.
Remove the wire jumpers and replace all wires.
Reconnect the ECM connector P1. Results:
Expected Result: OK The status for the ECS displays the

proper states. The problem is not with the ECM.
The status for the ECS displays RUN while the wire Troubleshoot the wire F716 and the wire F717. In
jumper is installed. The status for the ECS displays order to troubleshoot the wire F716, proceed to
STOP when the wire jumper is removed. Test Step 7. In order to troubleshoot the wire F717,
proceed to Test Step 13.
Results:
Not OK The status for the ECS does not display
OK The status for the ECS displays the the correct state.
proper states. The problem is not with the ECM.
Troubleshoot the wire F716 and the wire F717. In Repair: Replace the ECM. Refer to the diagnostic
order to troubleshoot the wire F716, proceed to procedure Troubleshooting, Replacing the ECM.
Test Step 7. In order to troubleshoot the wire F717,
proceed to Test Step 13. STOP.
Not OK The status for the ECS does not display Test Step 7. Check for Voltage on Wire
the correct state. F716 at the Normally Closed Contacts of
the Stop 1 Relay.
Repair: Replace the ECM. Refer to the diagnostic
procedure Troubleshooting, Replacing the ECM. A. Turn the remote start switch to the OFF position.
STOP. B. Turn the ECS on the instrument panel to the

START position.
Test Step 6. Install a Wire Jumper at
the ECM in order to Simulate an AUTO C. Measure the voltage between wire F716 at the
Condition. normally closed contacts of the Stop 1 relay and
engine ground.
A. Turn the ECS on the instrument panel to the
OFF/RESET position. D. Turn the ECS that is on the instrument panel to
the STOP position.
B. Disconnect the ECM connector P1.
Expected Result:
C. Remove wire F721 from P1-68. Install a wire
jumper into the socket P1-68. The voltage is 6.5 0.5 VDC.
D. Reconnect the ECM connector P1.

158 RENR5009-07
Results: C. Turn the ECS that is on the instrument panel to

the STOP position.
OK The voltage is 6.5 0.5 VDC. Proceed to
Test Step 8. Expected Result:
Not OK The voltage is not 6.5 0.5 VDC. The voltage is 6.5 0.5 VDC.
Repair: Repair the wire F716 between the normally Results:

closed contacts on the Stop 1 relay and the ECM.
STOP. Test Step 10.
Test Step 8. Check for Voltage on Wire Not OK The voltage is not 6.5 0.5 VDC.
DM775 at the Normally Closed Contacts
of the Stop 1 Relay. Repair: There is a problem with the wire DM775
between the Stop 1 relay and the Run 1 relay.
A. Turn the ECS on the instrument panel to the Repair the wire DM775.
START position.
STOP.
B. Measure the voltage between wire DM775 at the
normally closed contacts of the Stop 1 relay and Test Step 10. Check for Voltage on Wire
engine ground. BM775 at the Normally Open Contacts of
the Run 1 Relay.
C. Turn the ECS that is on the instrument panel to
the STOP position. A. Turn the ECS on the instrument panel to the
START position.
Expected Result:
B. Measure the voltage between wire BM775 at the
The voltage is 6.5 0.5 VDC. normally open contacts of the Run 1 relay and
engine ground.
Results:
OK The voltage is 6.5 0.5 VDC. Proceed to the STOP position.
Test Step 9.
Expected Result:
Not OK The voltage is not 6.5 0.5 VDC. The
Stop 1 relay's normally closed contacts are faulty The voltage is 6.5 0.5 VDC.
or the Stop 1 relay is energized.
Results:
Repair: Check the voltage across the coil of the
Stop 1 relay. If voltage is present across the coil OK The voltage is 6.5 0.5 VDC. Proceed to
of the Stop 1 relay, ensure that the ECS is not in Test Step 11.
the STOP position.
If no voltage is measured across the coil of Run 1 relay is not energized or there is a problem
the Stop 1 relay, the normally closed contacts with the normally open contacts between wire
between wire F716 and wire DM775 are faulty. DM775 and wire BM775.
Replace the Stop 1 relay and check for diagnostic
codes. Repair: Check the voltage across the coil of the
Run 1 relay. The voltage should measure 24 3
STOP. VDC. If the voltage is not 24 3 VDC, verify that 24
3 VDC is present between wire 120 at the coil of
Test Step 9. Check for Voltage on Wire the Run 1 relay and engine ground. If the voltage
DM775 at the Normally Open Contacts of is present, verify that wire DM775 has continuity
the Run 1 Relay. between the coil of the Run 1 relay and the ECM.
If wire DM775 is okay, replace the Run 1 relay. If
A. Turn the ECS on the instrument panel to the wire DM775 is not okay, repair the wire.
START position.
STOP.
normally open contacts of the Run 1 relay and
engine ground.
RENR5009-07 159
Test Step 11. Check for Voltage on Wire Repair: Check the voltage across the coil of the
BM775 at the Normally Closed Contacts Stop 1 relay. The voltage should not measure 24
of the Stop 1 Relay. 3 VDC. If the voltage is 24 3 VDC, the wire
SM775 is shorted to ground or the ECS is in the
A. Turn the ECS on the instrument panel to the STOP position. Repair the wire SM775 or repair
START position. the ECS. If voltage is not present across the coil of
the Stop 1 relay, replace the stop 1 relay.
normally closed contacts of the Stop 1 relay and STOP.
engine ground.
Test Step 13. Check for Voltage on Wire
C. Turn the ECS that is on the instrument panel to F717 at the Normally Closed Contacts of
the STOP position. the Stop 2 Relay.
Expected Result: A. Turn the remote start switch to the OFF position.
The voltage is 6.5 0.5 VDC. B. Turn the ECS on the instrument panel to the
START position.
Results:
C. Measure the voltage between wire F717 at the
OK The voltage is 6.5 0.5 VDC. Proceed to normally closed contacts of the Stop 2 relay and
Test Step 12. engine ground.
Not OK The voltage is not 6.5 0.5 VDC. D. Turn the ECS that is on the instrument panel to
the STOP position.
Repair: There is a problem with the wire BM775
between the Stop 1 relay and the Run 1 relay. Expected Result:
Repair the wire BM775.
The voltage is 6.5 0.5 VDC.
STOP.
Results:
Test Step 12. Check for Voltage on Wire
D998 at the Normally Closed Contacts of OK The voltage is 6.5 0.5 VDC. Proceed to
the Stop 1 Relay. Test Step 14.
A. Turn the ECS on the instrument panel to the Not OK The voltage is not 6.5 0.5 VDC.
START position.
Repair: Repair the wire F717 between the normally
B. Measure the voltage between wire D998 at the closed contacts on the Stop 2 relay and the ECM.
normally closed contacts of the Stop 1 relay and
engine ground. STOP.
C. Turn the ECS to the STOP position. Test Step 14. Check for Voltage on Wire
DM776 at the Normally Closed Contacts
Expected Result: of the Stop 2 Relay.
The voltage is 6.5 0.5 VDC. A. Turn the ECS on the instrument panel to the
START position.
Results:
OK The voltage is 6.5 0.5 VDC. The digital normally closed contacts of the Stop 2 relay and
return wire is open between the Stop 1 relay and engine ground.
the ECM.
Repair: Repair the wire D998. the STOP position.
Not OK The voltage is not 6.5 0.5 VDC. The The voltage is 6.5 0.5 VDC.
normally closed contacts between wire BM775 and
wire D998 are open.
160 RENR5009-07
Results: C. Turn the ECS that is on the instrument panel to

the STOP position.
Test Step 15. Expected Result:
Not OK The voltage is not 6.5 0.5 VDC. There The voltage is 6.5 0.5 VDC.
is a problem with the normally closed contacts of
the Stop 2 relay or the Stop 2 relay is energized. Results:
Repair: Check the voltage across the coil of the OK The voltage is 6.5 0.5 VDC. Proceed to
Stop 2 relay. If voltage is present across the coil Test Step 17.
of the Stop 2 relay, ensure that the ECS is not in
the STOP position. Not OK The voltage is not 6.5 0.5 VDC. The
Run 2 relay is not energized or there is a problem
If no voltage is measured across the coil of the with the normally open contacts between wire
Stop 2 relay, there is a problem with the normally DM776 and wire BM776.
closed contacts between wire F717 and wire
DM776. Replace the Stop 2 relay and check for Repair: Check the voltage across the coil of the
diagnostic codes. Run 2 relay. The correct voltage is 24 3 VDC.
If the voltage is not 24 3 VDC, verify that 24
STOP. 3 VDC is present between wire 120 at the coil of
the Run 2 relay and engine ground. If the voltage
Test Step 15. Check for Voltage on Wire is present, verify that wire DM776 has continuity
DM776 at the Normally Open Contacts of between the coil of the run 2 relay and the ECM.
the Run 2 Relay. If wire DM776 is okay, replace the Run 2 relay.
If wire DM776 is not okay, repair the wire or the
A. Turn the ECS on the instrument panel to the component.
START position.
STOP.
normally open contacts of the Run 2 relay and Test Step 17. Check for Voltage on Wire
engine ground. BM776 at the Normally Closed Contacts
of the Stop 2 Relay.
the STOP position. A. Turn the ECS on the instrument panel to the
START position.
Expected Result:
The voltage is 6.5 0.5 VDC. normally closed contacts of the Stop 2 relay and
engine ground.
Results:
OK The voltage is 6.5 0.5 VDC. Proceed to the STOP position.
Test Step 16.
Expected Result:
Not OK The voltage is not 6.5 0.5 VDC.
Repair: There is a problem with the wire DM776
between the Stop 2 relay and the Run 2 relay. Results:
Repair the wire DM776.
STOP. Test Step 18.
Test Step 16. Check for Voltage on Wire Not OK The voltage is not 6.5 0.5 VDC.
BM776 at the Normally Open Contacts of
the Run 2 Relay. Repair: There is a problem with the wire BM776
between the Stop 2 relay and the run 2 relay.
A. Turn the ECS on the instrument panel to the Repair the wire BM776.
START position.
STOP.
normally open contacts of the Run 2 relay and
engine ground.
RENR5009-07 161
Test Step 18. Check for Voltage on Wire The primary ECM performs an automatic calibration
D998 at the Normally Closed Contacts of of these sensors whenever power is rst applied to
the Stop 2 Relay. the engine ECM and the engine has been off for at
least ve seconds. During an automatic calibration,
A. Turn the ECS on the instrument panel to the the primary ECM calibrates pressure sensors against
START position. the atmospheric pressure sensor and an acceptable
offset pressure range.
B. Measure the voltage between wire D998 at the
normally closed contacts of the Stop 2 relay and
engine ground.

the STOP position.
Expected Result:
Results:
OK The voltage is 6.5 0.5 VDC. The digital

return wire is open between the Stop 2 relay and
the ECM.
Repair: Repair the wire D998.
STOP.

normally closed contacts between wire BM776-BK
and wire D998 are open.
Repair: Check the voltage across the coil of the

Stop 2 relay. The correct voltage is 24 3 VDC.
If the voltage is 24 3 VDC, the wire SM776 is
shorted to ground or the ECS is in the STOP
position. Repair the wire SM776 or repair the ECS.
If voltage is not present across the coil of the Stop
2 relay, replace the Stop 2 relay.
STOP.
i01905746
Engine Sensor Open/Short

Test
SMCS Code: 1901-038
Engine sensors provide various signals to the

engine's primary Electronic Control Module (ECM).
These sensors receive a regulated voltage from the
primary ECM. Analog sensors receive 5.0 0.2 VDC
and digital sensors receive 8.0 0.4 VDC.
162 RENR5009-07
g00992368
Illustration 32
Typical example
Test Step 1. Check for Connector D. Perform a 45 N (10 lb) pull test on each of the
Damage. wires in the ECM connector that are associated
with the circuit.
B. Turn the battery disconnect switch to the OFF the proper torque of 6 1 Nm (53 9 lb in).
position.
C. Thoroughly inspect the ECM connectors J1/P1 and and for pinch points.
J2/P2. Inspect all of the other connectors. Refer
RENR5009-07 163
Expected Result: 263-03 or 263-04 Active Code A diagnostic code

of 263-03 or 263-04 is present.
coupled and/or inserted. The harness and wiring are Repair: Perform the diagnostic functional test
free of corrosion, of abrasion or of pinch points. Troubleshooting, Digital Sensor Supply.
Results: STOP.
OK The connectors and wiring are okay. Proceed Test Step 3. Check the Sensor Supply
to Test Step 2. Voltage at the Sensor Connector if the
Diagnostic Code FMI-03 is Present.
okay. A. Turn the ECS to the OFF/RESET position.
Repair: Repair the connectors or wiring and/or B. Disconnect the suspect sensor.
Note: Disconnecting the sensor will generate an
STOP. open circuit diagnostic code for any sensor that is
disconnected. Troubleshoot the original diagnostic
Test Step 2. Check for Active Diagnostic code. Reset the system. Delete the logged diagnostic
Codes. codes when you are nished.
A. Connect the Caterpillar Electronic Technician (ET) C. Turn the ECS to the STOP position. The engine
to the ECM through the service tool connector. should be off.
B. Turn the battery disconnect switch to the ON D. Measure the voltage on the ECM side of the
position. sensor connector between pin A and pin B for the
suspect sensor.
should be off. Expected Result:
D. Wait for 15 seconds for the CID-FMI. The supply voltage is 5.0 0.2 VDC for all analog
sensors and 8.0 0.4 VDC for all digital sensors.
Expected Result:
Results:
Determine the failure mode identier (FMI).
Determine if the diagnostic codes 262-03 5 Volt OK The voltage is 5.0 0.2 VDC for all analog
Sensor DC Power Supply short to +batt or 262-04 5 sensors and 8.0 0.4 VDC for all digital sensors.
Volt Sensor DC Power Supply short to ground are Proceed to Test Step 5.
present. Determine if the diagnostic codes 263-03
Digital Sensor Supply short to +batt or 263-04 Digital Not OK The voltage is not 5.0 0.2 VDC for all
Sensor Supply short to ground are present. analog sensors and 8.0 0.4 VDC for all digital
sensors. Proceed to Test Step 7.
Results:
Test Step 4. Check the Sensor Supply
FMI 03 A diagnostic code with a FMI of 03 is Voltage at the Sensor Connector if the
present. Proceed to Test Step 3. Diagnostic Code FMI-04 is Present.
FMI 04 A diagnostic code with a FMI of 04 is A. Turn the ECS to the OFF/RESET position.
B. Disconnect the suspect sensor.
FMI 00 or 08 A diagnostic code with a FMI of 00
or of 08 is present. Proceed to Test Step 11. Note: Disconnecting the sensor will generate an
open circuit diagnostic code for any sensor that is
262-03 or 262-04 Active Code A diagnostic code disconnected. Troubleshoot the original diagnostic
of 262-03 or of 262-04 is present. code. Reset the system. Delete the logged diagnostic
codes when you are nished.
Repair: Perform the diagnostic functional test
Troubleshooting, Analog Sensor Supply. C. Turn the ECS to the STOP position. The engine
should be off.
STOP.
164 RENR5009-07
D. Measure the voltage on the ECM side of the Not OK The voltage on pin B should measure
sensor connector between pin A and pin B for the 0 VDC. The voltage on pin C may measure
suspect sensor. approximately 6.5 VDC. The voltage on pin C
is a pull up voltage. The ECM provides the pull
Expected Result: up voltage to the signal input when the ECM
senses an open circuit in the incoming input
The supply voltage is 5.0 0.2 VDC for all analog signal. Frequency sensors do not receive a pull up
sensors and 8.0 0.4 VDC for all digital sensors. voltage. The sensor common and signal wire are
not shorted to the +Battery. Proceed to Test Step 6.
Results:
Test Step 6. Create a Short at the Sensor
OK The voltage is 5.0 0.2 VDC for all analog Connector.
sensors and 8.0 0.4 VDC for all digital sensors.
Proceed to Test Step 8. A. Turn the ECS to the OFF/RESET position.
Not OK The voltage is not 5.0 0.2 VDC for all B. Use a wire jumper to connect pin B and pin C
analog sensors and 8.0 0.4 VDC for all digital together on the sensor connector.
sensors. Proceed to Test Step 7.
Test Step 5. Check for a Short to the should be off.
+Battery.
D. Check if the CID-FMI has changed from 03 to 04.
E. Turn the ECS to the OFF/RESET position.
B. Disconnect the suspect sensor.
F. Remove the wire jumper.
Note: Disconnecting the sensor will generate an
open circuit diagnostic code for any sensor that is Expected Result:
disconnected. Troubleshoot the original diagnostic
code. Reset the system. Delete the logged diagnostic The CID-FMI changes from 03 to 04.
codes when you are nished.
Results:
should be off. OK The CID-FMI changed from 03 to 04. The
circuit now indicates a short circuit diagnostic code.
D. Measure the voltage on the ECM side of the
sensor connector between pin B and the engine Repair: Temporarily connect a new sensor. Verify
ground. that the new sensor solves the problem before you
permanently install the new sensor. Calibrate the
E. Measure the voltage on the ECM side of the sensor.
sensor connector between pin C and the engine
ground. STOP.
F. Turn the ECS to the OFF/RESET position. Not OK The CID-FMI did not change from 03 to
04. The circuit indicates an open circuit diagnostic
Expected Result: code. Proceed to Test Step 9.
The voltage measures 24 3 VDC when a short to Test Step 7. Check the Sensor Supply
the +Battery is present. Voltage at the ECM.
Results: A. Turn the ECS to the OFF/RESET position.
OK The voltage measures 24 3 VDC. A short B. Check the analog supply voltage.
to the +Battery is present.
a. Check the left analog supply voltage by
Repair: Repair the connectors or wiring and/or removing wire 997 in P1-02 and wire 993
replace the connectors or wiring. in P1-03 from ECM connector P1. Install a
wire jumper into the sockets for P1-02 and for
STOP. P1-03.
RENR5009-07 165
b. Check the right analog supply voltage by Repair: Repair the connectors or wiring and/or
removing wire A997 in P1-18 and wire A993 replace the connectors or wiring.
in P1-35 from ECM connector P1. Install a
wire jumper into the sockets for P1-35 and for STOP.
P1-18.
Not OK - Analog or Digital The supply voltage is
Note: If you remove the sensor common from not 5.0 0.2 VDC for all analog sensors and 8.0
the ECM, an open circuit diagnostic code will 0.4 for all digital sensors. The voltage at the ECM
be generated for all sensors that use the sensor is not correct.
common. Troubleshoot the original code. Delete the
logged diagnostic codes when you are nished. Repair: Perform the diagnostic functional test
C. Check the digital supply voltage.
STOP.
a. Check the left digital supply voltage by
removing wire 700 in P1-04 and wire D998 Test Step 8. Create an Open Circuit at the
in P1-05 from ECM connector P1. Install a Sensor Connector.
P1-05. A. Turn the ECS to the OFF/RESET position.
b. Check the right digital supply voltage by B. Leave the sensor disconnected.
removing wire A700 in P2-56 and wire F998
in P2-66 from ECM connector P2. Install a C. Wait for a period of 15 seconds.
P2-66. D. Turn the ECS to the STOP position. The engine
should be off.
Note: If you remove the sensor common from
the ECM, an open circuit diagnostic code will E. The CID-FMI should change from 04 to 03.
be generated for all sensors that use the sensor
common. Troubleshoot the original code. Delete the Note: Disconnecting the atmospheric pressure
logged diagnostic codes when you are nished. sensor will cause several sensor diagnostic codes
to become active. Troubleshoot the original code.
D. Reconnect ECM connector J1/P1 and J2/P2. Delete the logged diagnostic codes when you are
nished.
E. Turn the ECS to the STOP position. The engine
should be off. F. Turn the ECS to the OFF/RESET position.
F. Measure the analog voltage between the wire G. Reconnect the suspect sensor.
jumpers.
Expected Result:
G. Measure the digital voltage between the wire
jumpers. The CID-FMI changes from 04 to 03 when the sensor
is disconnected.
Results:
I. Turn the keyswitch for the ECM to the OFF
position. OK The CID-FMI changed from 04 to 03 when
the sensor was disconnected. The open circuit was
J. Remove the wire jumpers and replace all wires. seen by the ECM. The wiring between the ECM
Reconnect ECM connector J1/P1. and the sensor is good.
Expected Result: Repair: Replace the suspect sensor. Verify that

the repair eliminates the problem.
The supply voltage is 5.0 0.2 VDC for all analog
sensors and 8.0 0.4 for all digital sensors. STOP.
Results: Not OK The CID-FMI did not change from 04 to

03 when the sensor was disconnected. The open
OK - Analog or Digital The supply voltage is 5.0 circuit was not seen at the ECM. Proceed to Test
0.2 VDC for all analog sensors and 8.0 0.4 for Step 10.
all digital sensors. The supply voltage at the ECM
is correct. There is a problem in the wiring between
the ECM and the suspect sensor.
166 RENR5009-07
Test Step 9. Create a Short at the ECM Note: Disconnecting the atmospheric pressure
Connector. sensor will cause several sensor diagnostic codes
to become active. Troubleshoot the original code.
A. Connect the suspect sensor. Delete the logged diagnostic codes when you are
nished.
B. Remove the suspect sensor's signal wire from
ECM connector P1 or P2. Install a wire jumper E. Turn the ECS to the OFF/RESET position.
into the socket for the signal wire.
F. Replace the signal wire and reconnect ECM
C. Use a jumper to create a short between the wire connector J1/P1 or J2/P2.
jumper and the sensor's common wire.
Expected Result:
D. Turn the ECS to the STOP position. The engine
should be off. The CID-FMI changes from 04 to 03 when the sensor
signal wire is disconnected.
E. The CID-FMI should change from 03 to 04 when
the jumper is in place. Results:
F. Turn the ECS to the OFF/RESET position. OK The CID-FMI changed from 04 to 03 when
the sensor signal wire was disconnected. The ECM
G. Remove the wire jumper and replace the signal recognized the open at the ECM.
wire. Reconnect ECM connector J1/P1 and/or
J2/P2. Repair: Repair the connectors or wiring and/or
Expected Result:
STOP.
The CID-FMI changes from 03 to 04 when the jumper
is in place. Not OK The CID-FMI did not change from 04 to
03 when the sensor signal wire was disconnected.
Results: The ECM did not recognize the open at the ECM.
OK The CID-FMI changed from 03 to 04 when Repair: Refer to the diagnostic procedure
the jumper was put in place. The ECM recognized Troubleshooting, Replacing the ECM.
the short at the ECM. There is a problem with the
wiring between the ECM and the suspect sensor. STOP.
Repair: Repair the connectors or wiring and/or Test Step 11. Check the Fluid Level.
A. Check the fuel level.
STOP.
B. Check the engine oil level.
Not OK The CID-FMI did not change from 03 to
04 when the jumper was put in place. The ECM did C. Check for any leaks.
not see the short at the ECM. Replace the ECM.
Expected Result:
Repair: Refer to the diagnostic procedure
Troubleshooting, Replacing the ECM. The fuel and oil level are okay. There are not any
leaks.
STOP.
Results:
Test Step 10. Create an Open at the ECM.
OK The fuel and oil levels are correct. Proceed
A. Turn the ECS to the OFF/RESET position. to Test Step 12.
B. Remove the suspect sensor signal wire from Not OK The fuel and/or oil levels are not correct.
J1/P1 or J2/P2.
Repair: If the oil level is low, add oil. If the fuel level
C. Turn the ECS to the STOP position. The engine is low, add fuel. Repair the leaks. Reset the system
should be off. and note any active diagnostic codes.
D. Check if the CID-FMI has changed from 04 to 03. STOP.

RENR5009-07 167
Test Step 12. Compare the Pressure or Repair: Reset the system and note any active
Temperature to the Actual Pressure or diagnostic codes.
Temperature.
STOP.
Not OK - Analog A constant pressure is not
B. If you are troubleshooting a temperature sensor, shown on the Cat ET. A 5 2 kPa (0.7 0.3 psi)
install a 6V-9130 Temperature Adapter near the drop in pressure is not shown on the Cat ET while
sensor. the vacuum is being applied. An analog sensor is
not producing the correct reading. Proceed to Test
C. Turn the ECS to the STOP position. The engine Step 13.
should be off.
Not OK - Digital The correct temperature is
D. Observe the temperature reading for the suspect not shown on the Cat ET. A digital sensor is not
sensor. The Cat ET screen should display the producing the correct reading. Proceed to Test
same temperature as the 6V-9130 Temperature Step 14.
Adapter.
Vacuum Leak A vacuum leak is suspected.
E. If you are troubleshooting a pressure sensor,
disconnect the sensor. Repair: Check for leaks. If no leaks are found,
there is an internal leak in the suspect pressure
F. Remove the suspect sensor from the engine. sensor. Replace the sensor and calibrate the
sensor. Reset the system and note any active
G. Reconnect the suspect sensor. diagnostic codes.
H. Connect the vacuum pump test unit to the suspect STOP.

sensor.
Test Step 13. Check the Analog Sensor's
I. Connect the vacuum pump to the differential Signal Voltage at the Sensor Connector.
pressure gauge.
J. Turn the ECS to the STOP position.
B. Remove the sensor's signal wire from pin C of the
K. Observe the pressure reading for the suspect sensor connector.
sensor. The Cat ET should display the barometric
pressure in your area. C. Turn the ECS to the STOP position. The engine
should be off.
L. Use the vacuum pump to pull 5 kPa (0.7 psi) of
vacuum on the differential pressure gauge. D. Measure the sensor signal voltage between the
sensor's signal wire and pin B at the sensor
Note: The pressure gauge reading should remain connector.
constant until the vacuum is released.
M. Compare the readings on the Cat ET and the
pressure test kit. F. Replace the sensor signal wire and reconnect the
sensor.
Expected Result:
Expected Result:
The Cat ET shows the correct temperature. The Cat
ET shows constant pressure. The Cat ET shows a The signal voltage is between 0.2 VDC and 4.8 VDC
5 2 kPa (0.7 0.3 psi) drop in pressure when the for analog sensors.
vacuum is applied.
Results:
Results:
OK The signal voltage is between 0.2 VDC and
OK The correct temperature is shown on the Cat 4.8 VDC for analog sensors. Proceed to Test Step
ET. A constant pressure is shown on the Cat ET. A 17.
5 2 kPa (0.7 0.3 psi) drop in pressure is shown
on the Cat ET when the vacuum is applied. The Not OK The signal voltage is not between 0.2
sensor is working correctly. VDC and 4.8 VDC for analog sensors. Proceed to
Test Step 15.
168 RENR5009-07
Test Step 14. Check the Digital Sensor's Results:

Signal Frequency and the Duty Cycle at
the Sensor Connector. OK The resistance is greater than 20,000 Ohms.
B. Remove the sensor's signal wire from pin C of the Ohms.
sensor connector.
C. Turn the ECS to the STOP position. The engine replace the connectors or wiring.
should be off.
STOP.
D. Measure the frequency and the duty cycle
between the sensor's signal wire and pin B of the Test Step 16. Check the Resistance
suspect digital sensor at the sensor connector. through the Harness.
E. Turn the ECS to the OFF/RESET position. A. Disconnect the suspect sensor connector.
F. Turn the keyswitch for the ECM to the OFF B. Use a suitable piece of wire to connect pin A to
position. pin C.
G. Replace the sensor's signal wire and reconnect C. Measure the resistance between the sensor signal
the sensor. wire and the sensor voltage supply at the ECM
connector P1 or P2.
Expected Result:
D. Use a suitable piece of wire to connect pin B to
The frequency reading is approximately 500 Hz. pin C.
When the temperature is below 49 C (120 F), the E. Measure the resistance between the sensor signal
duty cycle is between 16 percent to 21 percent. and the sensor common at the ECM connector
P1 or P2.
When the temperature is between 49 C (120 F)
and 851 C (1564 F), the duty cycle is between 22 F. Use a suitable piece of wire to connect pin A to
percent to 88 percent. pin B.
Results: G. Measure the resistance between the sensor

supply and the sensor common at the ECM
OK The frequency and the duty cycle are correct. connector P1 or P2.
H. Remove all wire shorts.
Not OK The frequency and the duty cycle are
not correct. Proceed to Test Step 15. I. Reconnect all connectors and all sensors.
Test Step 15. Check for Shorts in the Expected Result:

Wiring Harness.
The resistance is less than 5 Ohms.
A. Disconnect the ECM connectors J1/P1 and J2/P2.
Disconnect the suspect sensor. Results:
B. Measure the resistance between the sensor signal OK - Analog The resistance is less than 5 Ohms.
wire and engine ground. Proceed to Test Step 17.
C. Measure the resistance between the sensor OK - Digital The resistance is less than 5 Ohms.
common and engine ground. Proceed to Test Step 18.
D. Measure the resistance between the sensor Not OK The resistance is greater than 5 Ohms.
supply and engine ground at the ECM connector.
E. Reconnect all connectors and all sensors. replace the connectors or wiring.
The resistance is greater than 20,000 Ohms.

RENR5009-07 169
Test Step 17. Check the Analog Sensor's Test Step 18. Check the Digital Sensor's
Signal Voltage at the ECM. Signal Frequency and the Duty Cycle at
the ECM.
A. Turn the ECS to the STOP position. The engine
should be off. A. Turn the ECS to the STOP position.
B. Measure the sensor signal voltage between pin C B. Measure the frequency and the duty cycle
and pin B at the ECM connector P1 or P2. between pin C and pin B at the ECM connector
P1 or P2.
C. Observe the sensor reading on the status screen
on the Cat ET. C. Start the engine.
Note: The status screen on the Cat ET displays D. Observe the sensor reading on the status screen
ABNORMAL SIGNAL when the ECM reads a signal on the Cat ET.
that is out of the normal range.
Note: The status screen on the Cat ET displays
D. Turn the ECS to the OFF/RESET position. ABNORMAL SIGNAL when the ECM reads a signal
that is out of normal range.
Expected Result:
The signal voltage for the analog sensors is between
0.2 VDC and 4.8 VDC for the suspect analog sensor. Expected Result:
Results: The frequency reading is approximately 500 Hz.
OK The signal voltage for the analog sensors When the temperature is below 49 C (120 F),
is between 0.2 VDC and 4.8 VDC for the suspect the duty cycle should be between 16 percent to 21
analog sensor. The sensor voltage at the ECM is percent.
correct. The Cat ET screen displays the correct
information. When the temperature is between 49 C (120 F)
and 851 C (1564 F), the duty cycle is between 22
Repair: There may be an intermittent problem. If percent to 88 percent.
the problem is intermittent, perform the diagnostic
functional test Troubleshooting, Inspecting While the engine is cold, the Cat ET should read
Electrical Connectors. 30 C (86 F). As the engine warms up the exhaust
temperature increases.
STOP.
Results:
Not OK The signal voltage for the analog
sensors is not between 0.2 VDC and 4.8 VDC for OK The digital sensor voltage at the ECM is
the suspect analog sensor. The sensor voltage at correct.
the ECM is not correct.
Repair: There may be an intermittent problem. If
Repair: Repair the connectors and/or wiring the problem is intermittent, perform the diagnostic
between the ECM connector and the sensor. functional test Troubleshooting, Inspecting
STOP.
STOP.
ABNORMAL SIGNAL The status screen on the
Cat ET displays ABNORMAL SIGNAL. The signal Not OK The digital sensor voltage at the ECM
voltage for the analog sensors is between 0.2 VDC is not correct.
and 4.8 VDC for the suspect analog sensor. The
sensor voltage at the ECM is correct. Repair: Repair the connectors and/or wiring
between the ECM and the sensor.
procedure Troubleshooting, Replacing the ECM. STOP.
STOP. ABNORMAL SIGNAL The digital sensor voltage

at the ECM is correct. The status screen on the Cat
ET displays ABNORMAL SIGNAL. The signal is
out of normal range.
170 RENR5009-07

procedure Troubleshooting, Replacing the ECM.
STOP.
i01900706
Engine Speed/Timing Sensor

SMCS Code: 1912-038
The engine speed/timing sensors provide engine

speed information to the Electronic Control Module
(ECM). The sensor generates a pulse signal. A loss
of both signals causes the ECM to stop sending
power to the fuel injectors.
If the primary engine speed/timing sensor fails, the

ECM will use the secondary engine speed/timing
sensor until electrical power is removed from the
ECM. To prevent any unnecessary down time, the
primary sensor should be repaired or replaced at the
earliest possible convenience.
The Electronic Control Module (ECM) provides the

engine speed/timing sensor with 12 1.0 VDC. The
engine speed/timing sensor provides a pulse signal
to the ECM. The signal is created as the timing
reference gear rotates past the pickup of the engine
speed/timing sensor. The timing reference gear is
mounted on the rear of the left camshaft. A unique
tooth pattern on the timing reference gear allows the
ECM to determine the crankshaft position, rotation,
and rpm.
Note: If the ring gear is reversed, the diagnostic

codes 190-08 and 342-08 will be generated and the
ECM will not re the injector solenoids.
RENR5009-07 171
g01012369
Illustration 33
Typical example

Damage.
A. Turn the circuit breaker for the battery to the to Test Step 2.
OFF/RESET position.
Not OK The connectors and/or wiring need
B. Turn the ECS to the OFF position. repair.
C. Thoroughly inspect the ECM connectors J1/P1 and Repair: Repair the connectors or wiring and/or
J2/P2. Inspect all of the other connectors. Refer replace the connectors or wiring.
Inspecting Electrical Connectors for details. STOP.
D. Perform a 45 N (10 lb) pull test on each of the Test Step 2. Check for a CID-FMI.
wires in the ECM connector that are associated
with the circuit. A. Connect the Caterpillar Electronic Technician (ET).
E. Check the ECM connector (allen head screw) for B. Turn the circuit breaker for the battery to the ON
the proper torque of 6 1 Nm (53 9 lb in). position.
F. Check the harness and the wiring for abrasion C. Turn the ECS to the STOP position.
D. Observe logged diagnostic codes on Cat ET.
Expected Result:
Expected Result:
coupled and/or inserted, and the harness and wiring Cat ET indicates a CID-FMI 190-03 or 342-03.
Results:
OK Cat ET indicates a CID-FMI 190-03 or

342-03. Proceed to Test Step 3.
172 RENR5009-07
Not OK Cat ET indicates a CID-FMI 190-02, Results:

a CID-FMI 190-07 or a CID-FMI 190-08. Cat ET
indicates a CID-FMI 342-02, a CID-FMI 342-07 or OK The resistance is greater than 20,000 Ohms.
a CID-FMI 342-08. Proceed to Test Step 4. Proceed to Test Step 5.
Test Step 3. Check for Shorts in Wiring Not OK The resistance is less than 20,000
Harness. Ohms. There is a short circuit in the harness wiring.
A. Turn the ECS to the OFF/RESET position. Repair: Repair the connectors or wiring and/or
B. Disconnect J1/P1 from the primary ECM.
Disconnect J1/P1 from the secondary ECM. STOP.
Disconnect the primary engine speed/timing
sensor J401/P401. Disconnect the secondary Test Step 4. Check the Engine
engine speed/timing sensor J402/P402. Speed/Timing Sensor.
C. To test the primary engine speed/timing sensor, Note: An active CID-FMI 190-07 or an active
measure the resistance at the primary ECM CID-FMI 342-07 indicates that the connectors
connector P1: for the primary engine speed/timing sensor and
the secondary engine speed/timing sensor have
Measure the resistance between P1-33 and been installed incorrectly. The connector for the
P1-51. primary engine speed/timing sensor has been
installed on the secondary engine speed/timing
Measure the resistance between P1-33 and sensor and the connector for the secondary engine
P1-43. speed/timing sensor has been installed on the
primary engine speed/timing sensor. Turn the ECS to
Measure the resistance between P1-43 and the OFF/RESET position and switch the connectors.
P1-51. Turn the ECS to the STOP position and verify that
the diagnostic codes are no longer active.
Measure the resistance between P1-33 and
engine ground. NOTICE
Be sure to extend the sliphead before installing the
Measure the resistance between P1-43 and Speed/Timing Sensor and also check that the Timing
engine ground. Gear is in a position that will not allow the sliphead of
the Speed/Timing Sensor to protrude into the slot of
Measure the resistance between P1-51 and the Timing Gear before the sensor is installed (visually
engine ground. inspect with a ashlight). Turn the crankshaft to rotate
the Timing Gear, if necessary, to position the gear in a
D. To test the secondary engine speed/timing sensor, place that will not allow the sliphead to protrude into a
measure the resistance at the secondary ECM slot. If the sensor sliphead does protrude into one of
connector P1: the slots, the sliphead will be broken off as the gear
begins to rotate.
P1-51.
P1-43. B. Disconnect the sensor and remove the sensor.
Measure the resistance between P1-43 and C. Inspect the plastic sliphead for damage.
P1-51.
D. Check the tension. Gently extend the sliphead
Measure the resistance between P1-13 and 3.5 mm (0.14 inch). Return the sliphead to the
engine ground. original position.
Measure the resistance between P1-43 and E. Extend the sliphead and reinstall the sensor.
engine ground.
Note: If you are troubleshooting the primary engine
Measure the resistance between P1-51 and speed/timing sensor, disconnect the secondary
engine ground. sensor for the remainder of the test. If you are
troubleshooting the secondary engine speed/timing
Expected Result: sensor, disconnect the primary sensor for the
remainder of the test.
The resistance is greater than 20,000 Ohms.
RENR5009-07 173
Expected Result: d. Measure the resistance between P1-43

and P1-13. Wiggle the harness during the
The sliphead takes at least 22 N (5 lb) of force in measurement in order to reveal an intermittent
order to push in the sliphead from the extended condition.
position.
D. Measure the resistance between the primary
Results: ECM connector P1-33 and the secondary ECM
connector P1-33. Wiggle the harness during the
OK The engine speed/timing sensor and the measurement in order to reveal an intermittent
sliphead are undamaged. The tension on the condition.
sliphead is normal. Reinstall the sensor. Proceed
to Test Step 6. E. Measure the resistance between the primary
ECM connector P1-13 and the secondary ECM
Not OK The engine speed/timing sensor or connector P1-13. Wiggle the harness during the
the sliphead is damaged, or the sliphead has measurement in order to reveal an intermittent
insufcient tension. condition.
Repair: Replace the sensor. Calibrate the sensor. Expected Result:

Perform the following diagnostic functional test
Troubleshooting, Engine Speed/Timing Sensor - The resistance is less than 5 Ohms through the wires.
Calibrate.
Results:
STOP.
OK The resistance is less than 5 Ohms through
Test Step 5. Check for an Open in the the wires. Proceed to Test Step 11.
Harness.
Not OK The resistance is greater than 5 Ohms
A. Turn the ECS to the OFF/RESET position. through the wires. There is an open circuit in the
harness or connectors.
B. For the primary engine speed/timing sensor,
perform the following steps. Repair: Repair the connectors or wiring and/or
a. Use a suitable piece of wire to short J401-A
and J401-B together. STOP.
b. Measure the resistance between P1-43 Test Step 6. Check the Engine Speed.
measurement in order to reveal an intermittent A. Turn the ECS to the OFF/RESET position.
condition.
B. Connect Cat ET.
c. Use a suitable piece of wire to short J401-A
and J401-C. C. Crank the engine.
d. Measure the resistance between P1-43 D. Observe the engine speed on the Cat ET screen.
measurement in order to reveal an intermittent Expected Result:
condition.
Cat ET displays a steady reading between 100 and
C. For the secondary engine speed/timing sensor, 250 rpm. The engine starts.
perform the following steps.
Results:
a. Use a suitable piece of wire to short J402-A
and J402-B. OK The engine speed/timing sensor is operating
correctly at this time.
b. Measure the resistance between P1-43
and P1-51. Wiggle the harness during the Repair: The problem may be intermittent. If the
measurement in order to reveal an intermittent problem is intermittent, perform the diagnostic
condition. functional test Troubleshooting, Inspecting
c. Use a suitable piece of wire to short J402-A
and J402-C together. STOP.
174 RENR5009-07
ENGINE DOES NOT START Engine speed Results:

appears on the Cat ET screen but the engine does
not start. OK With the ECS in the STOP position, the
voltage is less than 3.0 or the voltage is greater
Repair: Refer to the diagnostic procedure than 10.0 VDC before you crank the engine. The
Troubleshooting, Engine Cranks but Will Not voltage is 2.0 to 7.0 VDC when you crank the
Start. engine. Proceed to Test Step 11.
STOP. Not OK With the ECS in the STOP position,

the voltage is not less than 3.0 or the voltage is
NO ENGINE SPEED SIGNAL The engine will not greater than 10.0 VDC before you crank the
not start and no engine speed signal appears on engine. The voltage is not 2.0 to 7.0 VDC when
the Cat ET screen. Proceed to Test Step 7. you crank the engine.
Test Step 7. Check the Supply Voltage on Repair: Replace the sensor. Calibrate the
the Sensor Side of the Sensor Connector. sensor. Perform the diagnostic functional test
Troubleshooting, Engine Speed/Timing Sensor -
A. Turn the ECS to the STOP position. Calibrate.
B. Measure the voltage between P401-A and STOP.

P401-B.
Test Step 9. Check the Supply Voltage on
C. Measure the voltage between P402-A and the ECM Side of the Sensor Connector.
P402-B.
A. Measure voltage between J401-A and J401-B.
D. Turn the ECS to the OFF/RESET position.
B. Measure voltage between J402-A and J402-B.
Expected Result:
Expected Result:
The voltage is 12 1.0 VDC.
The voltage is 12 1.0 VDC.
Results:
Results:
OK The voltage is 12 1.0 VDC. Proceed to
Test Step 8. OK The voltage is 12 1.0 VDC. The connector
for the sensor is damaged.
Not OK The voltage is not 12.5 1.0 VDC.
Proceed to Test Step 9. Repair: Repair the connector or replace the
connector.
Test Step 8. Check the Isolated Signal
from the Sensor at the Sensor Connector. STOP.
A. Remove pin-C from the sensor connector. Not OK The voltage is not 12 1.0 VDC.
B. Turn the ECS to the STOP position.
Test Step 10. Check the Supply Voltage
C. Measure the voltage between pin-C and pin-B. at the ECM.
Perform this step before you crank the engine.
Perform this step while you are cranking the A. Measure the voltage at the primary ECM
engine. connector between P1-43 and P1-51. Measure
the voltage at the secondary ECM connector
D. Turn the ECS to the OFF/RESET position. between P1-43 and P1-51.
E. Reinstall pin-C. Expected Result:
Expected Result: The voltage is 12 1.0 VDC.
With the ECS in the STOP position, the voltage is Results:

less than 3.0 or the voltage is greater than 10.0 VDC
before you crank the engine. The voltage is 2.0 to 7.0 OK There is an open circuit in the harness
VDC when you crank the engine. between the ECM and the sensor.
RENR5009-07 175
Repair: Repair the connectors or wiring and/or Expected Result:

Cat ET displays a steady engine speed between 100
STOP. and 250 rpm while the engine is cranking.
Not OK Check that the ECM is receiving the Results:

correct supply voltage.
OK Cat ET displays a steady engine speed
Repair: Perform the following diagnostic procedure between 100 and 250 rpm while the engine is
Troubleshooting, Electrical Power Supply. cranking. The sensor is operating correctly at this
time.
STOP.
Test Step 11. Check the Signal Voltage problem is intermittent, perform the diagnostic
at the ECM. functional test Troubleshooting, Inspecting
STOP.
B. Measure the voltage between P1-33 and P1-51 for
the primary engine speed/timing sensor. Measure Not OK A valid signal appears at the ECM
the voltage before you crank the engine and while connector but the ECM is not reading the signal
you crank the engine. properly.
C. Measure the voltage between P1-13 and P1-51 Repair: Replace the ECM. Refer to the diagnostic
for the secondary engine speed/timing sensor. procedure Troubleshooting, Replacing the ECM.
Measure the voltage before you crank the engine
and while you crank the engine. STOP.
Turn the ECS to the OFF/RESET position.

i01900707
Expected Result: Injector Solenoids

With the ECS in the STOP position, the voltage is SMCS Code: 1290-038-JV
less than 3.0 or the voltage is greater than 10.0 VDC
before you crank the engine. The voltage is 2.0 to 7.0 System Operation Description:
VDC when you crank the engine.
The engine has electronic fuel injectors that are
Results: mechanically actuated and electronically energized.
The Electronic Control Module (ECM) sends a 105
OK With the ECS in the STOP position, the volt pulse to each injector solenoid. The pulse is
voltage is less than 3.0 or the voltage is greater sent at the proper time and at the correct duration
than 10.0 VDC before you crank the engine. The for a given engine load and speed. The solenoid
voltage is 2.0 to 7.0 VDC when you crank the is mounted on top of the fuel injector body. The
engine. Proceed to Test Step 12. 105 volt pulse can be individually cut out to aid in
troubleshooting misre problems.
Not OK The sensor signal is not reaching the
ECM. Recheck the harness and connectors for If an open is detected in the solenoid circuit, a
shorts or excessive resistance. diagnostic code is generated. The ECM continues
to try to re the injector. If a short is detected, a
Repair: Repair the connectors or wiring and/or diagnostic code is generated. The ECM will disable
replace the connectors or wiring. the solenoid circuit. The ECM will then enable the
solenoid. If the short circuit remains this sequence of
STOP. events will be repeated until the problem is corrected.
Test Step 12. Check the Engine Speed.
B. Observe the engine speed on the Cat ET screen

while you crank the engine.
176 RENR5009-07
The injector codes must be programmed into the

ECM. The injector code is a four digit number (last
four digits of the serial number for the injector) that
is found on each of the unit injectors. The ECM
uses this number to compensate for manufacturing
variations between individual injectors. If you replace
any of the unit injectors, you must reprogram the
code for the new injectors. Also, if you replace the
ECM, you must reprogram all of the injector codes.
The ECM will generate the following diagnostic code
if the injector codes are not programmed:
1495-02 Injector Trim Codes Not Programmed
g00992542
Illustration 34
Typical example
RENR5009-07 177

Damage.
OK A CID-FMI from 1-05 to 16-05 or from 1-06
A. Turn the Engine Control Switch (ECS) to the to 16-06 is not logged. Proceed to Test Step 3.
OFF/RESET position.
Not OK A CID-FMI from 1-05 to 16-05 or from
B. Turn the circuit breaker for the battery to the OFF 1-06 to 16-06 is logged. Proceed to Test Step 5.
position.
Test Step 3. Perform the Injector
C. Thoroughly inspect the ECM connectors J1/P1 and Solenoid Test.
J2/P2. Inspect all of the other connectors. Refer
to the diagnostic functional test Troubleshooting, Note: This test will help the service technician verify
Inspecting Electrical Connectors for details. that the ECM can re the solenoids. Do not try to
manually crank the engine during this test. The ECM
D. Perform a 45 N (10 lb) pull test on each of the will terminate the Injector Solenoid Test.
with the circuit. A. Perform this test on both the primary ECM and
on the secondary ECM.
the proper torque of 6 1 Nm (53 9 lb in). B. Turn the circuit breaker for the battery to the OFF
position.
and for pinch points. C. Turn the ECS to the OFF/RESET position.
Expected Result: D. Ensure that the ECM connector J2/P2 is

connected. Ensure that the injector connectors
All connectors, pins, and sockets are completely J301/P301 through J316/P316 are connected.
are free of corrosion, of abrasion or of pinch points. E. Connect Cat ET.
Results: F. Turn the circuit breaker for the battery to the ON

position.
to Test Step 2. G. Turn the ECS to the STOP position.
Not OK The connectors and/or wiring need H. Use diagnostic tests on Cat ET in order to initiate
repair. the injector solenoid test.
Repair: Repair the connectors or wiring and/or As each solenoid is energized by the ECM an
replace the connectors or wiring. audible click can be heard at the valve cover.
Listen for a click at each valve cover. A black
STOP. square will appear over the cylinder number when
the cylinder is being red.
Test Step 2. Check for Logged Diagnostic
Codes. Note: A false reading may result from the initial test.
By the fourth consecutive test, the readings should
A. Connect the Caterpillar Electronic Technician (ET). become valid.
B. Turn the circuit breaker for the battery to the ON Expected Result:
position.
As each solenoid is energized by the ECM, an
C. Turn the ECS to the STOP position. audible click of the solenoid is heard. The solenoids
are energized one at a time in the following numerical
D. Observe the diagnostic codes on Cat ET. order: 1-16. There will be momentary delay between
each one.
Expected Result:
Results:
A CID-FMI from 1-05 to 16-05 or from 1-06 to 16-06
is not logged. OK As each solenoid is energized an audible
click is heard. Proceed to Test Step 4.
Not OK Verify that the ECM is receiving correct

battery power.
178 RENR5009-07
Repair: Perform the diagnostic functional test Not OK There was no change in the sound, feel,
Troubleshooting, Electrical Power Supply. or power of the engine as one of the cylinder's was
cut out. Proceed to Test Step 5.
STOP.
Test Step 5. Check for a Short between
Test Step 4. Perform the Cylinder Cutout Wires in the Harness.
Test.
NOTICE
Engine power is reduced when a properly functioning This engine uses high voltage to control the fuel
cylinder is cut out. Make sure that you will not damage injectors.
auxiliary or driven equipment if the engine power is
suddenly reduced. Disconnect the fuel enable circuit connector to
prevent personal injury.
position. Do not come in contact with the fuel injector ter-
minals while the engine is running.
B. Turn the ECS to the OFF/RESET position.
C. Verify that the ECM connector J2/P2 and the position.
injector connectors J301/P301 through J316/P316
are properly connected. B. Turn the ECS to the OFF/RESET position.
D. Turn the circuit breaker for the battery to the ON C. Disconnect J2/P2 and J301/P301 through
position. J316/P316.
E. Connect Cat ET. D. Measure the resistance between the solenoid wire
pairs at the ECM connector P2.
F. Start the engine.
Measure the resistance for SOLENOID 1 at
G. Apply a load to the engine. P2-1 and P2-2.
H. Use the diagnostic tests on Cat ET to initiate the Measure the resistance for SOLENOID 2 at
injector solenoid test. P2-3 and P2-4.
I. Check for a difference in the sound, feel, or power Measure the resistance for SOLENOID 3 at
of the engine as each cylinder is cut out. The P2-40 and P2-41.
amount of change should be similar for all of the
good cylinders. The amount of change should be Measure the resistance for SOLENOID 4 at
minimal for a weak cylinder or a bad cylinder. P2-42 and P2-43.
J. Disable the override. Repeat above steps for each Measure the resistance for SOLENOID 5 at
cylinder (solenoid). P2-14 and P2-15.
Expected Result: Measure the resistance for SOLENOID 6 at

P2-16 and P2-17.
The amount of change is similar for all of the
cylinders. The amount of change should be minimal Measure the resistance for SOLENOID 7 at
for a weak cylinder or for a misring cylinder. P2-48 and P2-49.
Results: Measure the resistance for SOLENOID 8 at

P2-50 and P2-51.
OK There was a similar change in the sound,
feel, or power of the engine as each cylinder was Measure the resistance for SOLENOID 9 at
cut out. The injectors are okay. P2-24 and P2-25.
Repair: The test indicates that all of the cylinders Measure the resistance for SOLENOID 10 at
are operating correctly. P2-34 and P2-35.
STOP. Measure the resistance for SOLENOID 11 at

P2-58 and P2-59.
RENR5009-07 179
Measure the resistance for SOLENOID 12 at Measure the resistance between P2-5 and
P2-52 and P2-62. engine ground.
Expected Result: Measure the resistance between P2-18 and

engine ground.
The resistance is greater than 20000 Ohms.
Results: engine ground.
OK The resistance is greater than 20000 Ohms. Measure the resistance between P2-25 and
Proceed to Test Step 6. engine ground.
Not OK The resistance is less than 20000 Ohms. Measure the resistance between P2-26 and
There is a problem in the wiring harness. engine ground.
Repair: Repair the connectors or wiring and/or Measure the resistance between P2-27 and
replace the connectors or wiring. engine ground.
STOP. Measure the resistance between P2-32 and

engine ground.
Test Step 6. Check the Harness for a
Short to Engine Ground. Measure the resistance between P2-33 and
engine ground.

engine ground.
This engine uses high voltage to control the fuel
injectors.
engine ground.
Disconnect the fuel enable circuit connector to
prevent personal injury.
engine ground.
Do not come in contact with the fuel injector ter-
minals while the engine is running.
engine ground.
A. Measure the resistance between the individual
solenoid wires and engine ground at connector Measure the resistance between P2-42 and
P2: engine ground.
Measure the resistance between P2-1 and Measure the resistance between P2-43 and
engine ground. engine ground.
180 RENR5009-07
Measure the resistance between P2-51 and Measure the resistance for SOLENOID 6 at
engine ground. P2-16 and P2-17.
Expected Result: Measure the resistance for SOLENOID 13 at

P2-32 and P2-33.
Results: P2-60 and P2-61.
OK The resistance is greater than 20000 Ohms. Measure the resistance for SOLENOID 15 at
Proceed to Test Step 7. P2-5 and P2-18.
Not OK The resistance is less than 20000 Ohms. Measure the resistance for SOLENOID 16 at
There is a short in the wiring harness. P2-26 and P2-27.
Repair: Repair the connectors or wiring and/or Note: Repeat this test step for the secondary ECM.
Expected Result:
STOP.
The resistance is less than 5 Ohms.
Test Step 7. Check for an Open in the
Harness. Results:
A. Use a suitable piece of wire to short socket-1 to OK The resistance is less than 5 Ohms. Proceed
socket-2 at each solenoid connector. to Test Step 8.
B. Measure the resistance between the following Not OK The resistance is greater than 5 Ohms.
solenoid wire pairs in connector P2: There is a problem in the wiring harness.
Measure the resistance for SOLENOID 1 at Repair: Repair the connectors or wiring and/or
P2-1 and P2-2. replace the connectors or wiring.
Measure the resistance for SOLENOID 2 at STOP.

P2-3 and P2-4.

P2-40 and P2-41.

P2-42 and P2-43.

P2-14 and P2-15.
RENR5009-07 181
Test Step 8. Measure the Resistance Test Step 9. Check the Resistance of the
of the Injector Solenoids through the Injector Solenoids and Check for Shorts.
Harness Yoke.
This engine uses high voltage to control the fuel

Personal injury can result from high voltage. injectors.
The Electronic Control Module produces high Disconnect the fuel enable circuit connector to
voltage. prevent personal injury.
Make sure the Electronic Control Module is not Do not come in contact with the fuel injector ter-
powered and the fuel injector solenoids are dis- minals while the engine is running.
connected before proceeding.
position. B. Remove the valve cover of the suspected cylinder.
B. Turn the ECS to the OFF/RESET position. C. Remove the harness yoke from the solenoid
terminals.
C. Ensure that the ECM connector J2/P2 is
disconnected. Ensure that the injector connectors D. Measure the resistance between the two solenoid
J301/P301 through J316/P316 are disconnected. terminals on top of the injector. Record the
resistance.
D. Measure the solenoid resistance between pin-1
and pin-2 at J301 through J316. E. Measure the resistance from either solenoid
terminal to the fuel injector body (metal). Record
E. Record the measured resistance for each the resistance.
solenoid.
F. Reconnect the harness yoke and install the valve
Expected Result: cover.
The resistance is between 0.5 and 1.5 Ohms. Expected Result:
Results: Resistance between the two solenoid terminals is
between 0.5 and 1.5 Ohms. Resistance from either
OK The resistance is between 0.5 and 1.5 Ohms. solenoid terminal to the fuel injector body (metal) is
greater than 20000 Ohms.
Repair: The harness and the injector solenoid
are okay. The problem may be intermittent. If the Results:
problem is intermittent, refer to the diagnostic
functional test Troubleshooting, Inspecting OK The resistance checks are okay. The injector
Electrical Connectors. is okay.
STOP. Repair: The harness yoke has a short or an open.
Repair the harness yoke or replace the harness
Not OK The resistance is not between 0.5 and yoke.
1.5 Ohms. Proceed to Test Step 9.
STOP.
Not OK The resistance checks are not okay. The

injector has failed.
Repair: Repair the injector. If the problem is still

present, replace the injector. If the new injector has
a 4-Digit code that is different from the old injector,
change the code in the ECM.
STOP.
182 RENR5009-07
i02550953 Test Step 1. Check Connectors for

Moisture and Corrosion
Inspecting Electrical
Connectors
SMCS Code: 1901-038
Most electrical problems are caused by poor

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

resolved by disconnecting and reconnecting
connectors. It is very important to check for diagnostic
codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
the connector. If the status of a diagnostic code is
changed due to disconnecting and reconnecting a
connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped g01131211
Illustration 35
terminals, moisture, corrosion, and inadequate Leaky seal at the connector (typical example)
mating of a connection.
A. Inspect all wiring harnesses. Ensure that the
Follow these guidelines: routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
Always use a 1U-5804 Crimp Tool to service angle. Otherwise, the wire will deform the seal
Deutsch HD and DT connectors. Never solder the bore. Refer to Illustration 35. This will create a
terminals onto the wires. Refer to SEHS9615, path for the entrance of moisture. Verify that the
Servicing Deutsch HD and DT Style Connectors. seals for the wires are sealing correctly.
Always use a 147-6456 Wedge Removal Tool to

remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
Always use a breakout harness for a voltmeter

probe or a test light. Never break the insulation
of a wire in order to access to a circuit for
measurements.
If a wire is cut, always install a new terminal for

the repair.
The connection of any electrical equipment and

the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
explosive atmosphere.
g01131276
Illustration 36
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR5009-07 183
B. Ensure that the sealing plugs are in place. If If moisture or corrosion is evident in the connector,
any of the plugs are missing, replace the plug. the source of the moisture entry must be found and
Ensure that the plugs are inserted correctly into the source of the moisture entry must be repaired.
the connector. Refer to Illustration 36. If the source of the moisture entry is not repaired,
the problem will recur. Simply drying the connector
will not x the problem. Check the following items
for the possible moisture entry path:
Missing seals
Improperly installed seals
Nicks in exposed insulation
Improperly mated connectors
Moisture can also travel to a connector through
the inside of a wire. If moisture is found in a
g01131019
connector, thoroughly check the connector's
Illustration 37 harness for damage. Also check other connectors
Seal for a three-pin connector (typical example) that share the harness for moisture.
Note: The ECM is a sealed unit. If moisture is found

in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.
Expected Result:
The harness wiring, connectors, and seals are in

good condition. There is no evidence of moisture in
the connectors.
Results:
OK The harness wiring, connectors, and seals

are in good condition. Proceed to Test Step 2.
Not OK A problem has been found with the

harness or the connectors.
Repair: Repair the connectors or the wiring, as

required. Ensure that all of the seals are properly
Illustration 38
g01131165 in place. Ensure that the connectors have been
reattached.
Seal for ECM connector (typical example)
If corrosion is evident on the pins, sockets or the

C. Disconnect the suspect connector and inspect the connector, use only denatured alcohol to remove
connector seal. Ensure that the seals are in good the corrosion. Use a cotton swab or a soft brush
condition. If necessary, replace the connector. to remove the corrosion.
D. Thoroughly inspect the connectors for evidence If moisture was found in the connectors, run the
of moisture entry. engine for several minutes and check again for
moisture. If moisture reappears, the moisture is
Note: It is normal to see some minor seal abrasion wicking into the connector. Even if the moisture
on connector seals. Minor seal abrasion will not allow entry path is repaired, it may be necessary to
the entry of moisture. replace the wires.
STOP.
184 RENR5009-07
Test Step 2. Check the Wires for Damage Repair: Repair the terminals and/or replace the
to the Insulation terminals, as required.
A. Carefully inspect each wire for signs of abrasion, Verify that the repair eliminates the problem.
of nicks, and of cuts.
STOP.
Inspect the wires for the following conditions:
Test Step 4. Perform a Pull Test on Each
Exposed insulation Wire Terminal Connection
Rubbing of a wire against the engine
Rubbing of a wire against a sharp point
B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a attened portion
of wire. A fastener that has been overtightened
attens the harness. This damages the wires that
are inside the harness.
Expected Result: g01131435

Illustration 39
The wires are free of abrasion, of nicks, and of cuts Receptacle lock wedge (typical example)
and the harness is properly clamped.
A. Ensure that the locking wedge for the connector
Results: is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not
OK The harness is OK. Proceed to Test Step 3. installed properly.
Not OK There is damage to the harness. B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily
Repair: Repair the wires or replace the wires, withstand 45 N (10 lb) of tension and each wire
as required. Verify that the repair eliminates the should remain in the connector body. This test
problem. checks whether the wire was properly crimped
in the terminal and whether the terminal was
STOP. properly inserted into the connector.
Test Step 3. Inspect the Connector Expected Result:

Terminals
Each terminal and each connector easily withstands
A. Visually inspect each terminal in the connector. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are not damaged. connector body.
Verify that the terminals are properly aligned in
the connector and verify that the terminals are Results:
properly located in the connector.
OK All terminals pass the pull test. Proceed to
Expected Result: Test Step 5.
The terminals are properly aligned and the terminals Not OK A wire has been pulled from a terminal
appear undamaged. or a terminal has been pulled from the connector.
Results: Repair: Use the 1U-5804 Crimp Tool to replace

the terminal. Replace damaged connectors, as
OK The terminals are OK. Proceed to Test Step required. Verify that the repair eliminates the
4. problem.
Not OK The terminals of the connector are STOP.

damaged.
RENR5009-07 185
Test Step 5. Check Individual Pin Not OK The connector's locking mechanism is
Retention into the Socket damaged or missing.
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
STOP.
Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged.
g01131604
A. Connect the ECM connectors.
Illustration 40
Diagram for testing pin retention (typical example)
A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
pin by the socket.
Expected Result:
The sockets provide good retention for the new pin.
Results:
OK The terminals are OK. Proceed to Test Step g01132827

6. Illustration 41
Allen head screw for the 120 pin ECM connector (typical example)
Not OK Terminals are damaged.
a. Torque the allen head bolt for the 120 pin ECM
Repair: Use the 1U-5804 Crimp Tool to replace connector to 7.0 0.5 Nm (60 4 lb in).
the damaged terminals. Verify that the repair
STOP.
Test Step 6. Check the Locking

Mechanism of the Connectors
A. Ensure that the connectors lock properly. After
locking the connectors, ensure that the two halves
cannot be pulled apart.
B. Verify that the latch tab of the connector is

properly latched. Also verify that the latch tab of
the connector returns to the locked position.
g01132849
Illustration 42
Expected Result: Allen head screw for the 70 pin ECM connector (typical example)
The connector will securely lock. The connector and b. Torque the allen head screw for the 70
the locking mechanism are without cracks or breaks. pin ECM connector to 6.0 + 1.5 - 0.5 Nm
(55 + 13 - 4 lb in).
Results:
OK The connectors are in good repair. Proceed

to Test Step 7.
186 RENR5009-07
Repair: Repair the connector or replace the

connector, as required. Verify that the repair
STOP.
Test Step 8. Perform the Wiggle Test

on Caterpillar Electronic Technician (ET)
A. Select the Wiggle Test from the diagnostic tests
on Cat ET.
B. Choose the appropriate group of parameters to

monitor.
g01132863
Illustration 43 C. Press the Start button. Wiggle the wiring harness
Allen head screw for the 40 pin ECM connector (typical example) in order to reproduce intermittent problems.
c. Torque the allen head screw for the 40 pin ECM If an intermittent problem exists, the status will be
connector to 2.25 0.25 Nm (20 2 lb in). highlighted and an audible beep will be heard.
Expected Result:
No intermittent problems were indicated during the

Wiggle Test.
Results:
OK No intermittent problems were found. The

harness and connectors appear to be OK. If you
were sent from another procedure, return to the
procedure and continue testing. If this test has
resolved the problem, return the engine to service.
STOP.
g01133047
Illustration 44 Not OK At least one intermittent problem was
Allen head screw for the 40 pin customer connector and the 70 pin indicated.
customer connector (typical example)
Repair: Repair the harness or the connector. Verify
B. Connect the customer connector. that the repair eliminates the problem.
Torque the allen head screw for the 40 pin STOP.
customer connector and the 70 pin customer
connector to 2.25 0.25 Nm (20 2 lb in).
Expected Result:
The ECM connector is secure and the allen head

screws are properly torqued.
Results:
OK The ECM connectors and the customer

connector is properly connected. Proceed to Test
Step 8.
Not OK The allen head screws for the ECM

connector or the customer connector is damaged.
RENR5009-07 187
i02384273
Prelubrication System
SMCS Code: 1319-038
The Electronic Control Module (ECM) has the ability

to automatically prelube the engine before cranking.
This prelubrication may increase the life of certain
engine parts. The ECM will prelube the engine, when
the Engine Control Switch (ECS) is placed in the
START position. The ECM will prelube the engine,
when the ECS is placed in the AUTO position and
the remote start/run/stop switch is closed. The length
of time for the prelube cycle can be programmed by
the customer. The prelube cycle will end when the
prelube pressure switch closes or if the customer
programmed time ends. The engine speed must
equal zero rpm before the prelube will begin.
The prelube cycle has the following status codes:

OFF, ON, COMPLETED, and DISABLED.
The OFF status is entered when the engine control

is rst powered up with the ECS in the STOP position.
The ON status is entered when the ECM is on with

the ECS in the START position.
The COMPLETED status is entered when the

engine prelube duration is reached or when the
engine prelube's pressure switch is activated.
The DISABLED status is entered when the engine

prelube duration is programmed to 0.
The prelube function will be aborted when one of the

following conditions occur:
The prelube pressure switch is activated.

The user dened engine prelube duration has been
reached.
The operator activates the prelube override switch.

When the ECM senses the ECS in the START
position, the ECM will activate the output driver for
the PPR1 relay. When the PPR1 relay energizes,
the normally open contacts of the PPR1 relay close.
This allows current to ow to the prelube motor.
The prelube motor activates the prelube pump.
The prelube pump builds pressure in the engine's
lubrication system. When the prelube pressure switch
closes as a result of the increased pressure, the ECM
input for the prelube pressure switch is taken low.
The ECM then knows that the prelube pressure is
adequate. The ECM will begin the starting sequence.
188 RENR5009-07
g01193921
Illustration 45

Damage.
OK The connectors and wiring are OK. Proceed
A. Turn the circuit breaker for the battery to the OFF to Test Step 2.
position.
B. Turn the ECS to the OFF/RESET position. OK.
C. Thoroughly inspect the ECM connectors J1/P1 and Repair: Repair the connectors or wiring and/or
J2/P2. Inspect all of the other connectors. Refer replace the connectors or wiring.
Inspecting Electrical Connectors for details. STOP.
D. Check the allen head screw on each ECM Test Step 2. Check the Resistance of the
connector for the proper torque. Refer Prelube Pressure Switch at the ECM.
to Troubleshooting, Inspecting Electrical
Connectors for the correct torque values. A. Turn the ECS to the OFF/RESET position.
E. Check the ECM connector (allen head screw) for B. Disconnect ECM connector J1/P1.
C. Ensure that the prelube override switch is not
F. Check the harness and the wiring for abrasion activated.
D. Measure the resistance between the prelube
Expected Result: pressure switch P1-66 and the digital return P1-5.
All connectors, pins, and sockets are completely E. Reconnect the ECM connector P1.
are free of corrosion, of abrasion, and of pinch points. Expected Result:

RENR5009-07 189
Note: If the engine has been running, the residual oil B. Turn the ECS to the STOP position.
pressure may be high enough to activate the prelube
pressure switch. If the residual oil pressure is high, C. Use Cat ET and view the following parameters:
the resistance would be less than 5 Ohms. Engine Prelube and Ignition Switch.
Results: D. Go to the diagnostic test in the diagnostic section

on CAT ET. Activate the override for the engine
OK The resistance is greater than 20000 Ohms. prelube.
The prelube pressure switch is not active. Proceed
to Test Step 4. E. View the parameters for the prelube pressure
switch and the ignition switch.
Not OK The resistance is less than 20000 Ohms.
The prelube pressure switch is active. Verify that F. Disable the override for the engine prelube.
the engine does not have a residual oil pressure
that is high enough to activate the switch. If there is Expected Result:
no residual oil pressure, the switch is not operating
correctly or there is a problem with the wiring. When the ECS is in the STOP position, the engine
Proceed to Test Step 3. prelube displays OFF and the ignition switch
displays STOP. When the override for the engine
Test Step 3. Measure the Resistance prelube is activated, the engine prelube displays
of the Prelube Pressure Switch at the ON and the ignition switch displays STOP.
Prelube Pressure Switch.
Results:
OK The parameters are correct. Proceed to Test
B. Disconnect the wires from the terminals of the Step 5.
prelube pressure switch.
Not OK The status of the ignition switch does
C. Measure the resistance between the terminals of not display STOP.
the prelube pressure switch.
Repair: Perform the diagnostic functional test
Expected Result: Troubleshooting, Engine Control Switch (ECS).
The resistance is greater than 20000 Ohms. STOP.
Results: Prelube Disabled The prelube function is

disabled. The engine prelube duration is set to
OK The resistance is greater than 20000 Ohms. zero.
There is a problem with the wiring between ECM
connector J1/P1 and the switch. Repair: The cycle time of the engine prelube must
be greater than zero for the prelube function to
Repair: Repair the connectors or wiring and/or work.
STOP.
STOP.
Test Step 5. Check for Output Voltage
Not OK The resistance is less than 20000 Ohms. from the PPR1 Relay at the Connector
There is a problem with the prelube pressure P-C1 to the Prelube Motor.
switch.
Repair: Temporarily replace the prelube pressure
switch with a new switch. If the problem is no B. Connect one end of the voltmeter to the Battery
longer present, reinstall the old switch. If the terminal.
problem returns, replace the switch.
C. Connect the other end of the voltmeter on wire
STOP. G705 on pin X at connector P-C1 of the rigid
harness.
Test Step 4. Check the Status of the ECS
and the Prelube Pressure Switch on the D. Turn the ECS to the STOP position.
Caterpillar Electronic Technician (ET).
E. Go to the diagnostic test in the diagnostic section
A. Connect Cat ET to the service tool connector. on CAT ET. Activate the override for the engine
prelube.
190 RENR5009-07
F. Monitor the voltage on the voltmeter. E. Go to the diagnostic test in the diagnostic section
on CAT ET. Activate the override for the engine
G. Disable the override for the engine prelube. prelube.
Expected Result: F. Monitor the voltage on the voltmeter.
The voltage is 24 3 VDC. G. Disable the override for the engine prelube.
OK The voltage is 24 3 VDC. Proceed to Test The voltage is 24 3 VDC.

Step 11.
Results:
Not OK The voltage is not 24 3 VDC. Proceed
to Test Step 6. OK The voltage is 24 3 VDC.
Test Step 6. Check for Output Voltage Repair: Repair the wire G705 between terminal 2
from the ECM at the Connector P-C1 to of the PPR1 relay and terminal X at the connector
the PPR1 Relay. P-C1 of the rigid harness.
A. Turn the ECS to the OFF/RESET position. STOP.
B. Connect one end of the voltmeter to the Battery Not OK The voltage is not 24 3 VDC. Proceed
terminal. to Test Step 8.
C. Connect the other end of the voltmeter on wire Test Step 8. Check for Output Voltage to
F705 on pin c at connector P-C1 of the rigid the PPR1 Relay from the ECM.
harness.
A. Leave one end of the voltmeter on the Battery
D. Turn the ECS to the STOP position. terminal.
E. Go to the diagnostic test in the diagnostic section B. Connect the other lead of the voltmeter to wire
on CAT ET. Activate the override for the engine F705 on terminal 3 of the PPR1 relay.
prelube.
D. Go to the diagnostic test in the diagnostic section
G. Disable the override for the engine prelube. on CAT ET. Activate the override for the engine
prelube.
Expected Result:
The voltage is 24 3 VDC.
F. Disable the override for the engine prelube.
Results:
Expected Result:
OK The voltage is 24 3 VDC. Proceed to Test
Step 7. The voltage is 24 3 VDC.
Not OK The voltage is not 24 3 VDC. Proceed Results:

to Test Step 10.
Test Step 7. Check for Output Voltage to Step 9.
the Prelube Motor from the PPR1 Relay.
Not OK The voltage is not 24 3 VDC.
Repair: Repair the wire F705 between terminal 3
B. Connect one end of the voltmeter to the Battery of the PPR1 relay and terminal c at the connector
terminal. P-C1 of the rigid harness.
C. Connect the other lead of the voltmeter to wire STOP.

G705 on terminal 2 of the PPR1 relay.
D. Turn the ECS to the STOP position.

RENR5009-07 191
Test Step 9. Check the Voltage across the F. Go to the diagnostic test in the diagnostic section
Coil of the PPR1 Relay. on CAT ET. Activate the override for the engine
prelube.
A. Connect one lead of the voltmeter to wire D229 on
terminal 4 of the PPR1 relay. G. Monitor the voltage on the voltmeter.
B. Connect the other lead of the voltmeter to wire H. Disable the override for the engine prelube.
F705 on terminal 3 of the PPR1 relay.
I. Turn the ECS to the OFF/RESET position.
J. Remove all jumpers and replace all wires.
on CAT ET. Activate the override for the engine Expected Result:
prelube.
Results:
F. Disable the override for the engine prelube.
OK The voltage is 24 3 VDC. There is a
Expected Result: problem in the wire F705 between the ECM and
terminal c at the connector P-C1 of the rigid
The voltage is 24 3 VDC. harness.
Results: Repair: Repair the connectors or wiring and/or

OK The voltage is 24 3 VDC.
STOP.
Repair: Verify that 24 3 VDC is present on
terminal 1 of the PPR1 relay. If voltage is not Not OK The voltage is not 24 3 VDC.
present on terminal 1 of the PPR1 relay, check the
wire K708 and the circuit breaker for the Prelube Repair: The problem may be the ECM. Check the
Air S/O between the PPR1 relay and the battery. electrical power to the ECM. Refer to the diagnostic
functional test Troubleshooting, Electrical Power
If 24 3 VDC is present on terminal 1 of the Supply.
PPR1 relay, replace the PPR1 relay.
STOP.
STOP.
Test Step 11. Check the Voltage at the
Not OK The voltage is not 24 3 VDC. Prelube Motor.
Repair: There is a problem with the wire D229 A. Connect one end of the voltmeter to wire G705 at
between the PPR1 relay and the circuit breaker the prelube motor.
for the primary ECM. Disconnect wire D229 from
terminal 4 of the PPR1 relay. Check wire D229 B. Connect the other end of the voltmeter to the
for continuity to the circuit breaker for the primary Battery terminal.
ECM. Repair the wire or replace the wire.
STOP.
Test Step 10. Check the Voltage from the on CAT ET. Activate the override for the engine
ECM to the PPR1 Relay. prelube.
A. Turn the ECS to the OFF/RESET position. E. Monitor the voltage on the voltmeter.
B. Disconnect ECM connector J2/P2. F. Disable the override for the engine prelube.
C. Remove wire F705 from P2-12 at ECM connector Expected Result:

P2. Install a wire jumper into P2-12.
D. Connect a voltmeter between the wire jumper in
P2-12 and the Battery terminal.
E. Turn the ECS to the STOP position.

192 RENR5009-07
Results: i01988356
OK The voltage is 24 3 VDC. There is a Secondary ECM/Personality

problem in the prelube motor. Proceed to Test Step Module
12.
SMCS Code: 1901-038
Repair: There is a problem with the wire G705
between the connector for the prelube motor The secondary Electronic Control Module (ECM)
and terminal X at the connector P-C1 of the rigid controls power to the secondary engine speed/timing
harness. Repair wire G705. sensor. The secondary ECM receives the input
signals from the secondary engine speed/timing
STOP. sensor and the primary engine speed/timing sensor.
The secondary ECM also controls the air shutoff
Test Step 12. Check the Operation of the system by activating the output driver to the ASOS
Prelube Motor. switch. The ASOS switch activates the air shutoff
solenoids. The secondary ECM can also operate the
A. Turn the ECS to the OFF/RESET position. fuel injector solenoids. This allows the secondary
ECM to control fuel to the engine when the secondary
B. Connect one side of a suitable piece of 10 AWG ECM assumes control of the governing of the engine.
wire to the +Battery terminal. All other engine functions are controlled by the
primary ECM.
C. For one second, connect the other end of the wire
to the +Battery terminal of the prelube motor. When power is applied to the system, the secondary
ECM will illuminate the Secondary ECM Ready
Expected Result: lamp and the Secondary ECM Active lamp for ve
seconds. The Secondary ECM Ready lamp should
The prelube motor starts. stay illuminated.
Results: The secondary ECM provides governing of the engine
if the primary ECM fails. If this occurs, the secondary
OK The prelube motor starts. There is a problem ECM automatically assumes engine control. When
in the wiring harness at the prelube motor. the secondary ECM assumes engine control, the
Secondary ECM Active lamp will illuminate.
Repair: Inspect the connectors at the prelube
motor. The secondary ECM will take control due to the
following reasons:
STOP.
Loss of the primary ECM heartbeat signal
Not OK The prelube motor did not start.
Two injector faults for the eight or the twelve
Repair: Verify that wire H705 has continuity cylinder engine
between the prelube motor and the circuit breaker
for the Prelube Air S/O. If wire H705 is OK, Four injector faults for the sixteen cylinder engine
replace the prelube motor with a new prelube
motor. Verify that the problem is no longer present. Note: The secondary ECM will remain in control of
the engine until the power is cycled. The secondary
STOP. ECM is not a fully functional ECM. The secondary
ECM is used to keep the engine running until the
vessel can obtain proper service.
RENR5009-07 193
g01029811
Illustration 46
Typical example
194 RENR5009-07
Test Step 1. Check for Connector Repair: The secondary ECM reads the primary
Damage. ECM heartbeat signal. Active injector codes are
not present. If the problem is intermittent, perform
A. Turn the ECS to the OFF/RESET position. the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors.
B. Disconnect the main power.
STOP.
C. Thoroughly inspect the ECM connectors J1/P1 and
J2/P2. Inspect all of the other connectors. Refer Not OK The Secondary ECM Ready lamp is
to the diagnostic functional test Troubleshooting, not illuminated. Proceed to Test Step 6.
Secondary ECM Active Lamp ON Both lamps
D. Perform a 45 N (10 lb) pull test on each of the illuminated for ve seconds. The Secondary ECM
wires in the ECM connector that are associated Active lamp remained illuminated. The secondary
with the circuit. ECM has assumed control of the engine. Proceed
to Test Step 3.
the proper torque of 6 1 Nm (53 9 lb in). Test Step 3. Check for Logged Diagnostic
Codes.
and for pinch points. A. Turn the ECS to the OFF/RESET position.
Expected Result: B. Connect the Caterpillar Electronic Technician (ET).
All connectors, pins, and sockets are completely C. Turn the ECS to the STOP position.
are free of corrosion, of abrasion or of pinch points. D. Observe the diagnostic codes on the Cat ET.
Results: Note: The secondary ECM will assume control of an

8 cylinder engine or of a 12 cylinder engine if two or
OK The connectors and wiring are okay. Proceed more diagnostic codes for the injectors are present.
to Test Step 2. The secondary ECM will assume control of a 16
cylinder engine if four or more diagnostic codes for
Not OK The connectors and/or wiring need the injectors are present.
repair.
Expected Result:
replace the connectors or wiring. Logged diagnostic codes are present.
STOP. Results:
Test Step 2. Check the Secondary ECM OK A diagnostic code of CID 0579 - FMI 05 or a
Active Lamp and the Secondary ECM diagnostic code of CID 0579 - FMI 06 is present.
Ready Lamp. Proceed to Test Step 8.
A. Observe the Secondary ECM Active lamp OK An error code for the fuel injectors is present.
and the Secondary ECM Ready lamp on the
instrument panel when the ECS is turned to the Repair: Perform the diagnostic functional test
STOP position. Troubleshooting, Injector Solenoids.
Both lamps illuminate for ve seconds. The Not OK No logged diagnostic codes are present.
Secondary ECM Ready lamp stays illuminated. The Proceed to Test Step 4.
Secondary ECM Active lamp turns off after ve
seconds. Test Step 4. Check the Primary ECM
Heartbeat Signal at the Primary ECM.
Results:
OK Both lamps illuminated for ve seconds.
The Secondary ECM Ready lamp remained B. Disconnect the primary ECM connector J2/P2.
illuminated. The Secondary ECM Active lamp is
off. The problem is no longer present.
RENR5009-07 195
C. Remove wire C401 from the primary ECM G. Observe the frequency of the primary ECM
connector P2-28. Install a wire jumper with heartbeat signal on the multimeter display. If
sockets on both ends into ECM connector P2-28. a number does not appear on the multimeter
display, verify the connections. Measure the
D. Connect a multimeter that is capable of reading frequency from another digital sensor. Verify that
frequency between the wire jumper in P2-28 and the multimeter is operating correctly.
the engine ground.
E. Reconnect the primary ECM connector J2/P2.
I. Reconnect all wires and connectors.
F. Turn the ECS to the STOP position.
Expected Result:
G. Observe the frequency of the primary ECM
heartbeat signal on the multimeter display. If The frequency is between 15.67 and 16.33 Hz.
a number does not appear on the multimeter
display, verify the connections. Measure the Results:
frequency from another digital sensor. Verify that
the multimeter is operating correctly. OK The frequency is between 15.67 and 16.33
Hz. Proceed to Test Step 6.
Not OK The frequency is not between 15.67 and
I. Remove the wire jumper. Reconnect all wires and 16.33 Hz. The signal is not within the frequency
connectors. range.
Expected Result: Repair: Repair the wire C401 between the primary
ECM connector P2-28 and the secondary ECM
The frequency is between 15.67 and 16.33 Hz. connector P1-21.
Results: STOP.
OK The frequency is between 15.67 and 16.33 Test Step 6. Test the Secondary ECM
Hz. Proceed to Test Step 5. Ready Lamp.
Not OK The frequency is not between 15.67 and A. Turn the ECS to the OFF/RESET position.
16.33 Hz. The primary ECM heartbeat signal is not
within the frequency range. B. Disconnect the secondary ECM connector J2/P2.
Repair: Verify that the proper software has been C. Remove the wire 675 from the secondary ECM
installed. Verify that the primary ECM is receiving connector J2-31.
the correct voltage. Perform the diagnostic
functional test Troubleshooting, Electrical Power D. Connect a wire jumper between wire 675 and the
Supply. engine ground.
STOP. E. Reconnect the secondary ECM connector J1/P1.
Test Step 5. Check the Primary ECM F. Turn the ECS to the STOP position.
Heartbeat Signal at the Secondary ECM.
G. Observe the Secondary ECM Ready lamp.
B. Disconnect the secondary ECM connector J1/P1.
I. Remove the wire jumper. Reconnect all wires and
C. Remove the wire C401 from the secondary ECM connectors.
connector P1-21.
Expected Result:
D. Connect a multimeter that is capable of reading
frequency between wire C401 and engine ground. The lamp illuminates while the jumper is connected.
The lamp does not illuminate when the jumper is
E. Reconnect the secondary ECM connector J1/P1. removed.
F. Turn the ECS to the STOP position.

196 RENR5009-07
Results: Repair: If the problem is intermittent, perform

OK The lamp illuminates while the jumper is Inspecting Electrical Connectors.
connected. The lamp does not illuminate when the
jumper is removed. Proceed to Test Step 7. STOP.
Not OK The lamp circuit is not functioning Not OK The lamp circuit is not functioning
properly. properly.
Repair: Verify that wire 675 is not open between Repair: Verify that wire 676 is not open between
the Secondary ECM Ready lamp and the ECM. the Secondary ECM Active lamp and the ECM.
Verify that voltage is present at wire 120 on Verify that voltage is present on wire 120 at
terminal X1 of the Secondary ECM Ready lamp. terminal X1 of the Secondary ECM Active lamp.
If voltage is present on terminal X1, replace the If voltage is present on terminal X1, replace the
Secondary ECM Ready lamp. Secondary ECM Active lamp.
If voltage is not present on terminal X1, verify that If voltage is not present on terminal X1, verify
the engine control switch is not in the OFF/RESET that the engine control switch is not in the OFF
position. Verify that the MPD breaker is not position. Verify that the MPD breaker is not
tripped. Check the normally closed contact of tripped. Check the normally closed contact of
relay R1 for proper operation. Check the wire relay R1 for proper operation. Check the wire
120 between the Secondary ECM Ready lamp 120 between the Secondary ECM Ready lamp
and relay R1 for damage. Check the wire A120 and relay R1 for damage. Check the wire A120
between relay R1 and the MPD breaker for between relay R1 and the MPD breaker for
damage. If necessary, repair the wires. damage. If necessary, repair the wires.
STOP. STOP.
Test Step 7. Test the Secondary ECM Test Step 8. Check for Shorts in the
Active lamp. Wiring Harness.
A. Turn the ECS to the OFF/RESET position. A. Turn the ECS to the OFF/RESET position.
B. Disconnect the secondary ECM connector J2/P2. B. Disconnect the primary ECM J2/P2 and the
secondary ECM connector J1/P1.
C. Remove the wire 676 from the secondary ECM
connector J2-29. C. Measure the resistance at the primary ECM
between P2-28 and engine ground.
D. Connect a wire jumper between wire 676 and the
engine ground. D. Reconnect all wires and connectors.
E. Reconnect the secondary ECM connector J1/P1. Expected Result:
F. Turn the ECS to the STOP position. The resistance is greater than 20,000 Ohms.
G. Observe the Secondary ECM Active lamp. Results:
H. Turn the ECS to the OFF/RESET position. OK The resistance is greater than 20,000 Ohms.
I. Remove the wire jumper. Reconnect all wires and
connectors. Not OK There is a problem in the wiring harness.
Expected Result: Repair: Repair the connectors or wiring and/or
The lamp illuminates while the jumper is connected.
The lamp does not illuminate when the jumper is STOP.
removed.
Test Step 9. Check for Opens in the
Results: Wiring Harness.
OK The Secondary ECM Active lamp circuit A. Measure the resistance of the wire C401 between
is okay. the secondary ECM P1-21 and the primary ECM
P2-28.
RENR5009-07 197
B. Reconnect all wires and connectors. i01900709
Expected Result: Starting Motor System

The resistance is less than 5 Ohms. SMCS Code: 1901-038
Results: System Operation Description:
OK The resistance is less than 5 Ohms. Proceed The Electronic Control Module (ECM) has the ability
to Test Step 10. to crank the engine when the Engine Control Switch
(ECS) is placed in the START position. The engine
Not OK There is a problem in the wiring harness. control will start the rst crank cycle, when the ECS
is placed in the START position. The crank cycle
Repair: Repair the connectors or wiring and/or will continue for the time that is equal to the cycle
replace the connectors or wiring. crank time that has been programmed or the crank
cycle will continue until the engine speed reaches the
STOP. crank terminate speed. If crank terminate speed is
not reached before the crank cycle time, the starting
Test Step 10. Check the Personality motor will deactivate at the end of the crank cycle
Module. time.
A. Determine if new software has recently been This process will repeat for a programmed amount of
installed. times Total Number of Crank Cycles. If the engine
does not start, Caterpillar Electronic Technician (ET)
Note: If the secondary ECM does not see a primary will display OVERCRANK. The engine control will
ECM Heartbeat Signal, the secondary ECM will be in an idle state. The process can be restarted by
assume engine control. The power must be reset. turning the ECS to the OFF/RESET position. Next,
After the power has been reset the primary ECM will turn the ECS to the STOP position. Then turn the
take control of the engine. ECS to the START position.
B. Turn the ECS to the OFF/RESET Position. After the ECS is placed in the START position, the
ECM will begin the prelube cycle. The ECM will send
C. Connect the Cat ET. a signal to terminal BH of the customer connector
after the prelube cycle is complete. The engine start
D. Wait for 70 seconds. signal will return on terminal BJ of the customer
connector to the starting motor relays SMMS1 and
E. Verify that the correct personality module SMMS2. The starting motor relays will energize
(software) is installed in the primary ECM. closing the normally open contacts of the relays.
Current will ow to the starting motors. The starting
F. Turn the ECS to the STOP position. motors will begin to crank the engine.
Expected Result: The engine can be manually started by using the

crank override switch which is located on the inside
No logged diagnostic codes should be present. of the instrument panel.
Results:
OK No logged diagnostic codes are present.

Repair: Verify that the Secondary ECM Active
lamp and the Secondary ECM Ready lamp on
the instrument panel illuminate when the ECS is
turned to the STOP position.
STOP.
Not - OK Logged diagnostic codes are present.

Repair: Repair any diagnostic codes that are
present.
STOP.
198 RENR5009-07
g01009170
Illustration 47
Typical example
Test Step 1. Check for Connector F. Check the harness and the wiring for abrasion
Damage. and for pinch points.
A. Turn the ECS to the OFF/RESET position. Expected Result:
B. Turn the circuit breaker for the battery to the OFF All connectors, pins, and sockets are completely
position. coupled and/or inserted, and the harness and wiring
C. Thoroughly inspect the ECM connectors J1/P1 and
J2/P2. Inspect all of the other connectors. Refer Results:
Inspecting Electrical Connectors for details. OK The connectors and wiring are okay. Proceed
to Test Step 2.
wires in the ECM connector that are associated Not OK The connectors and/or wiring need
with the circuit. repair.

RENR5009-07 199
Repair: Repair the connectors or wiring and/or Repair: Perform the diagnostic functional test
replace the connectors or wiring. Troubleshooting, Engine Control Switch (ECS).
STOP. STOP.
Test Step 2. Attempt to Start the Engine. Test Step 3. Check the Start Signal at the
Customer Connector.
Note: After the ECS is placed in the START position,
the ECM will begin the prelube cycle. The ECM A. Connect one end of a voltmeter to the Battery
will send a signal to terminal BH of the customer terminal. Connect the other end of the voltmeter
connector after the prelube cycle is complete. The to wire F701 on terminal BJ of the customer
engine start signal will return on terminal BJ of the connector.
customer connector to the starting motor relays
SMMS1 and SMMS2. The prelube cycle can be B. Turn the ECS to the START position.
disabled by setting the duration of the prelube cycle
to 0. C. Monitor the voltage on the voltmeter.
A. Turn the circuit breaker for the battery to the ON D. Turn the ECS to the OFF/RESET position.
position.
Expected Result:
C. Connect Cat ET to the service tool connector.
Results:
D. Observe the startup mode parameter on the Cat
ET status screen. OK The voltage is 24 3 VDC. Proceed to Test
Step 5.
E. Turn the ECS to the START position. Continue
monitoring engine parameters as the engine Not OK The voltage is not 24 3 VDC. Proceed
cranks. to Test Step 4.
The crank cycle will continue for the time that Test Step 4. Check the Start Signal at the
is equal to the cycle crank time that has been Primary ECM.
programmed or the crank cycle will continue until
the engine speed reaches the crank terminate A. Disconnect the primary ECM connector J2/P2.
speed.
B. Remove wire G701 from the primary ECM
Expected Result: connector P2-6. Install a wire jumper into P2-6.
The status screen for the startup mode parameter C. Reconnect the primary ECM connector J2/P2.
displays CRANK. The engine cranks.
D. Connect one end of a voltmeter to the Battery
Results: terminal. Connect the other end of the voltmeter
to the wire jumper in P2-6.
OK The startup mode parameter on the status
screen on Cat ET displays CRANK. The engine E. Turn the ECS to the START position.
cranks.
problem is intermittent, perform the diagnostic G. Turn the ECS to the OFF/RESET position.
Electrical Connectors. H. Remove the wire jumper and replace all wires.
Not OK - Engine Doesn't Crank The startup The voltage is 24 3 VDC.

mode parameter on the status screen on Cat
ET displays CRANK. The engine will not crank. Results:
OK The voltage is 24 3 VDC.
Not OK - Status Screen The startup mode
parameter on the status screen on Cat ET does
not display CRANK.
200 RENR5009-07
Repair: Check wire G701 for continuity between E. Connect one end of a voltmeter to the Battery
ECM connector P2-6 and terminal BH of the terminal. Connect the other end of the voltmeter
customer connector. If necessary, repair the wire. to wire 314 on terminal R of connector P-C2 of
If wire G701 is okay, repair the wiring or devices on the rigid harness.
the customer's side of the customer connector.
F. Turn the ECS to the START position.
STOP.
G. Monitor the voltage on the voltmeter.
Repair: The problem may be in the ECM.
Check the electrical power to the ECM. Refer to Expected Result:
Electrical Power Supply. The voltage is 24 3 VDC.
STOP. Results:
Test Step 5. Check the Start Signal to OK The voltage is 24 3 VDC. Proceed to Test
SMMS1 and SMMS2 at the Rigid Step 10.
Harness.
Not OK The voltage is not 24 3 VDC. Proceed
A. Connect one end of a voltmeter to the Battery to Test Step 7.
terminal. Connect the other end of the voltmeter
to wire F701 on terminal _F of connector P-C2 of Test Step 7. Check the Voltage at the Coil
the rigid harness. of SMMS1 and the Coil of SMMS2.
B. Turn the ECS to the START position. A. Turn the ECS to the OFF/RESET position.
C. Monitor the voltage on the voltmeter. B. Connect a voltmeter at the coil of SMMS1.
Connect the voltmeter between terminal 3 of
D. Turn the ECS to the OFF/RESET position. SMMS1 and engine ground.
Expected Result: C. Turn the ECS to the START position.
The voltage is 24 3 VDC. D. Monitor the voltage on the voltmeter.
Results: E. Repeat the above steps for SMMS2.
OK The voltage is 24 3 VDC. Proceed to Test F. Turn the ECS to the STOP position.
Step 6.
Expected Result:
Repair: Repair the wire F701 between terminal
BJ of the customer connector and terminal _F of Results:
STOP. Step 8.
Test Step 6. Check the Voltage from Not OK The voltage is not 24 3 VDC.
SMMS1 and SMMS2 at the Rigid
Harness. Repair: Repair the wire F701 between the diode
and terminal _F of connector P-C2 of the rigid
A. Connect one end of a voltmeter to the Battery harness or repair the wire G701 between the diode
terminal. Connect the other end of the voltmeter and terminal 3 of SMM2. Verify that the diode is
to wire 304 on terminal O of connector P-C2 of working properly.
the rigid harness.
STOP.
B. Turn the ECS to the START position.
C. Monitor the voltage on the voltmeter.
D. Turn the ECS to the OFF/RESET position.

RENR5009-07 201
Test Step 8. Check the Voltage across E. Connect one end of a voltmeter to the Battery
the Coil of SMMS1 and across the Coil terminal. Connect the other end of the voltmeter
of SMMS2. to wire 304 on terminal 2 of SMMS1.
A. Turn the ECS to the OFF/RESET position. F. Turn the ECS to the START position.
B. Connect a voltmeter across the coil of SMMS1. G. Monitor the voltage on the voltmeter.
Connect the voltmeter between terminal 4 and
terminal 3 of SMMS1. H. Turn the ECS to the STOP position.
C. Turn the ECS to the START position. Expected Result:
D. Monitor the voltage on the voltmeter. The voltage is 24 3 VDC.
E. Repeat the above steps for SMMS2. Results:
F. Turn the ECS to the STOP position. OK The voltage is 24 3 VDC.

Expected Result: Repair: Repair the wire 314 between terminal 2 of
SMM2 and terminal R of connector P-C2 of the
The voltage is 24 3 VDC. rigid harness or the wire 304 between terminal 2 of
SMM1 and terminal O of connector P-C2 of the
Results: rigid harness. Repair the wires or replace the wires.
OK The voltage is 24 3 VDC. STOP.
Repair: Verify that 24 3 VDC is present on Not OK The voltage is not 24 3 VDC.
terminal 1 of SMMS1 or on terminal 1 of
SMMS2. If voltage is not present on terminal 1 Repair: Replace either relay SMM2 or relay
of SMMS1 or on terminal 1 of SMMS2, check SMM2.
the wire A291 between terminal 1 of the starter
magnetic switches and the Starter and Alternator STOP.
breaker. Verify that the Starter and Alternator
breaker is functioning properly. Test Step 10. Check the Voltage at the
Starting Motor.
If voltage is present on terminal 1, proceed to Test
Step 9. A. Turn the ECS to the OFF/RESET position.
Not OK The voltage is not 24 3 VDC. B. Connect one end of a voltmeter to the Battery
Repair: The problem is in the wire G229 between to wire 314 on terminal S of the starting motor.
terminal 4 of SMMS1 or SMMS2 and the ECM.
Check the wire G229 for continuity between C. Turn the ECS to the START position.
terminal 4 of SMMS1 or SMMS2 and the ECM
connector P2-7. Repair the wire or replace the wire. D. Monitor the voltage on the voltmeter.
STOP. E. Turn the ECS to the STOP position.
Test Step 9. Check the Voltage to the F. Connect one end of a voltmeter to the Battery
Rigid Harness from the Starter Motor terminal. Connect the other end of the voltmeter
Magnetic Switches. to wire 304 on terminal S of the starting motor.
A. Connect one end of a voltmeter to the Battery G. Turn the ECS to the START position.
to wire 314 on terminal 2 of SMMS2. H. Monitor the voltage on the voltmeter.
B. Turn the ECS to the START position. I. Turn the ECS to the STOP position.
C. Monitor the voltage on the voltmeter. Expected Result:
D. Turn the ECS to the STOP position. The voltage is 24 3 VDC.

202 RENR5009-07
Results: The throttle signal's duty cycle should be between

5 percent to 10 percent at low idle and 90 percent
OK The voltage is 24 3 VDC. The starting to 95 percent at high idle. The percent duty cycle
motor did not activate. The problem appears to be is translated in the ECM into a throttle position of
in the starting motor. 0 percent to 100 percent. Use this procedure to
troubleshoot an active diagnostic code of 91-08
Repair: Temporarily install a new starting motor. Throttle Position signal abnormal or to troubleshoot
Verify that the problem is no longer present. an active diagnostic code of 1249-08 Secondary
Reinstall the old starting motor. If the problem Throttle Position signal abnormal. The ECM will not
returns, replace the starting motor. respond to the throttle signal if there is an active
253-02 Personality Module mismatch.
STOP.
OK The voltage is 24 3 VDC. The starting

motor activated.

problem is intermittent, refer to the diagnostic
STOP.

Repair: The problem is in the wire 314 between the
starting motor and terminal R of connector P-C2
of the rigid harness or in the wire 304 between the
starting motor and terminal O of connector P-C2
of the rigid harness. Repair the wires or replace
the wires.
STOP.
i02659958
Throttle Position Sensor

SMCS Code: 1913-038
Terminal BN on the customer connector provides

the primary throttle signal to the engine's Electronic
Control Module (ECM). Terminal BM on the customer
connector provides the secondary throttle signal
to the engine's ECM. Both of the throttle signals
should be a 500 Hz constant frequency signal with
a pulse width that varies with the throttle signal.
This output signal is referred to as a Pulse Width
Modulated signal (PWM). This signal is expressed as
a percentage between 0 percent and 100 percent.
RENR5009-07 203
g01012536
Illustration 48
Typical example
Test Step 1. Check for Connector

Damage.
A. Turn the Engine Control Switch (ECS) to the
OFF/RESET position.
B. Thoroughly inspect the ECM connectors J1/P1

and J2/P2. Inspect the wiring and the connectors
that are associated with the circuit. Refer to
Inspecting Electrical Connectors for details on
inspecting wiring and connectors.
C. Perform a 45 N (10 lb) pull test on each of the

with the circuit.
D. Check the ECM connector (allen head screw) for

E. Check the harness and the wiring for abrasion

Illustration 49
g00725481 and for pinch points.
Throttle Position Versus PWM Input
204 RENR5009-07
Expected Result: B. Remove the wire for the throttle signal from the
customer's connector. Refer to Illustration 48 for
All connectors, pins, and sockets are completely the schematic of the circuit.
are free of corrosion, of abrasion or of pinch points. C. Set the multimeter to VDC. Press the Hz button
twice so that the % symbol is displayed.
Results:
D. Place the red probe of the digital multimeter on
OK The connectors and wiring are OK. If you are the terminal for the throttle signal on the customer
troubleshooting either the primary speed control or connector. Place the black probe of the multimeter
the secondary speed control from the customer, on the Battery terminal.
proceed to Test Step 2. If you are troubleshooting
the local speed control on the instrument panel, E. Turn the ECS to the STOP position.
proceed to Test Step 5.
F. Measure the percent duty cycle of the throttle
Not OK The connectors and/or wiring need signal. Adjust the throttle from the lowest position
repair. to the highest position.
Repair: Repair the connectors or wiring and/or G. Turn the ECS to the OFF/RESET position.
H. Replace all connectors and wires.
STOP.
Expected Result:
Test Step 2. Check the Throttle Position
on the Caterpillar Electronic Technician The duty cycle is 5 to 10 percent at the lowest setting.
(ET). The duty cycle is 90 to 95 percent at the highest
setting.
A. Connect Cat ET to the service tool connector.
Results:
OK The duty cycle and throttle position readings
C. Observe the position of the throttle on Cat ET. are correct. Proceed to Test Step 4.
D. Adjust the customer's throttle to the lowest setting. Not OK The duty cycle reading is not correct.
The throttle position signal is not reaching the
E. Start at the lowest position. Slowly adjust the ECM.
customer's throttle to the highest setting. Monitor
the position of the throttle on Cat ET. Repair: Check the signal from the customer's
connector to the customer's speed control.
Expected Result:
STOP.
The throttle position on Cat ET is 0 percent at the
lowest setting and 0 to 100 percent as the throttle is Test Step 4. Check the Duty Cycle at the
adjusted to the highest setting. ECM Connector.
Results: A. Turn the ECS to the OFF/RESET position.
OK The throttle is operating correctly. B. Remove the ECM connector P1 from the ECM.
Remove the throttle signal wire from the ECM
Repair: There may be an intermittent problem. If connector P1. Refer to Illustration 48 for the
the problem is intermittent, refer to Troubleshooting, schematic of the circuit.
Inspecting Electrical Connectors for details on
inspecting wiring and connectors. C. Reconnect the ECM connector J1/P1.
STOP. D. Set the multimeter to VDC. Press the Hz button

twice so that the % symbol is displayed.
Not OK The throttle position on Cat ET does not
change correctly. Proceed to Test Step 3. E. Place the red probe of the digital multimeter on
the throttle signal wire that was removed from
Test Step 3. Check the Duty Cycle at the ECM connector P1. Place the black probe of the
Customer Connector. multimeter on the Battery terminal.
A. Turn the ECS to the OFF/RESET position. F. Turn the ECS to the STOP position.
RENR5009-07 205
G. Measure the percent duty cycle of the throttle Repair: There may be an intermittent problem. If
signal. Move the throttle from the lowest setting to the problem is intermittent, refer to Troubleshooting,
the highest setting. Inspecting Electrical Connectors for details on
inspecting wiring and connectors.
STOP.
I. Replace all connectors and wires.
Not OK The throttle position on Cat ET does not
Expected Result: change correctly. Proceed to Test Step 6.
The duty cycle is 5 to 10 percent at the lowest setting. Test Step 6. Check the Supply Voltage to
The duty cycle is 90 to 95 percent at the highest the Local Speed Control.
setting.
Results:
B. Connect the red probe of the digital multimeter to
OK The duty cycle and the throttle signal are the +B terminal of the local speed control. Connect
correct. the black probe of the digital multimeter to the B
terminal of the local speed control.
Repair: Temporarily replace the ECM and perform
the test again. If the problem is resolved, the C. Measure the voltage across the terminals of the
ECM is faulty. Permanently replace the ECM. local speed control.
Replacing the ECM. Expected Result:
STOP. The voltage is 24 3 VDC.
Not OK The duty cycle reading is not correct. Results:

The throttle signal is not reaching the ECM.
OK The voltage is 24 3 VDC. The local speed
Repair: Repair the wire between ECM connector control is receiving the correct voltage. Proceed
P1 and the customer connector. to Test Step 8.
STOP. Not OK The voltage is not 24 3 VDC. The local

speed control is not receiving the correct voltage.
Test Step 5. Check the Throttle Position Proceed to Test Step 7.
on the Caterpillar Electronic Technician
(ET). Test Step 7. Check the Voltage to the
Local Speed Control at the Rigid Harness.
B. Observe the position of the throttle on Cat ET.
B. Connect the red probe of the digital multimeter
C. Turn the local speed control potentiometer that is to wire C150 on terminal L of connector P-C2 of
on the instrument panel to the lowest setting. the rigid harness. Connect the black probe of the
digital multimeter to the Battery.
D. Start at the low idle position. Slowly turn the speed
adjust potentiometer in the other direction. Monitor C. Turn the ECS to the STOP position.
the position of the throttle on Cat ET.
D. Monitor the voltage on the digital multimeter.
Expected Result:
The throttle position on Cat ET reads 0 percent at
the lowest setting and 0 to 100 percent as the speed Expected Result:
adjust potentiometer is adjusted.
Results:
Results:
OK The local speed control is operating correctly.
OK The voltage measures 24 3 VDC.
206 RENR5009-07
Repair: Check for 24 3 VDC on wire C150 at Expected Result:

diode D9 in the instrument panel. If voltage is
not present on wire C150 at diode D9, repair the The duty cycle is between 4 and 10 percent at the
wire C150 between diode D9 and terminal L of low setting and between 90 and 95 percent at the
connector P-C2 of the rigid harness. high setting.
STOP. Results:
Not OK The voltage does not measure 24 3 OK The local speed control is supplying the
VDC. correct signal. Proceed to Test Step 9.
Repair: Verify that the breaker for the primary ECM Not OK The duty cycle is not correct on the
is not tripped. Check for 24 3 VDC on terminal multimeter.
87A at the normally closed contact of relay R2A.
Relay R2A is located in the power distribution Repair: Verify that the local speed control on the
panel. Verify that the normally closed contact of instrument panel is operating correctly. Temporarily
relay R2A is operating correctly. install another speed control. Verify that the
problem is no longer present. Reinstall the old
If voltage is present on terminal 87A at the normally speed control. If the problem returns, replace the
closed contact of relay R2A, repair the wire C150 local speed control.
between the contacts of relay R2A and terminal L
of connector P-C2 of the rigid harness. STOP.
If 24 3 VDC is present on wire C150 at diode D9, Test Step 9. Check the Duty Cycle at the
verify that voltage is present on wire M150 at diode ECM Connector.
D9. If 24 3 VDC is not present on wire M150 at
diode D9, replace the diode D9. A. Turn the ECS to the OFF/RESET position.
If 24 3 VDC is present at the diode D9 on wire B. Remove the ECM connector P2 from the primary
M150, repair the wire M150 between the diode D9 ECM. Remove the wire 389 from ECM connector
and the local speed control. P2-68.
STOP. C. Reconnect the ECM connector P2.
Test Step 8. Check the Local Speed D. Place the red probe on wire 389. Place the black
Control. probe on the Battery terminal.
A. Remove the wire 389 from the S terminal at the E. Turn the ECS to the STOP position.
local speed control.
F. Measure the percent duty cycle of the speed
B. Set the multimeter to VDC. Press the Hz button control. Turn the potentiometer from the low
twice so that the % symbol is displayed. setting to the high setting.
C. Place one probe of the multimeter on the S G. Turn the ECS to the OFF/RESET position.
terminal of the local speed control. Place the other
probe on the Battery terminal of the local speed H. Replace all connectors and wires.
control.
Expected Result:
D. Turn the ECS to the STOP position.
The duty cycle is 5 to 10 percent at the low idle stop.
E. Measure the percent duty cycle from the speed The duty cycle is 90 to 95 percent at the high idle
control on the multimeter. Turn the potentiometer stop.
from the low setting to the high setting.
Results:
Note: The throttle position on the Cat ET will not
match the percent duty cycle on the multimeter. OK The duty cycle and throttle position readings
are correct.
F. Reconnect the wire 389 to the S terminal at the
local speed control.
RENR5009-07 207
Repair: Temporarily replace the ECM and perform

the test again. If the problem is resolved, the
ECM is faulty. Permanently replace the ECM.
Replacing the ECM.
STOP.
Not OK The duty cycle reading is not correct.

The throttle position signal is not reaching the
ECM.
Repair: Verify if the throttle signal is reaching pin

P2-68 at the secondary ECM. The signal is lost
between the S terminal of the local speed control
and the ECM. Repair the wire 389 between the
local speed control and the ECM.
STOP.
208 RENR5009-07
Calibration Procedures Test Step 2. Perform a Calibration of the

Sensors
i02296725 A. Select Calibrations from the Service menu on
Cat ET. Select the Pressure Sensor Calibration
Analog Sensor - Calibrate from the Calibrations menu. The ECM will
perform a pressure sensor calibration when this
SMCS Code: 1901-524 screen is entered.
System Operation Description: Expected Result:
The Electronic Control Module (ECM) attempts to Cat ET indicates that the calibration was completed.
perform an automatic calibration of all pressure
sensors whenever the ECM is powered and the Results:
engine has been off for at least ten seconds. Cranking
the engine during the rst ten seconds causes the
ECM to abort the calibration attempt.
OK Cat ET indicates that the calibration was
completed.
During an automatic pressure sensor calibration, Repair: Reset the system and check for active
the ECM checks all pressure sensors against an diagnostic codes.
acceptable range. If any pressure sensor reading is
outside the acceptable range, the previous calibration STOP.
value is used. The ECM then calibrates all pressure
sensors against the atmospheric pressure sensor.
Not OK All pressure sensors could not be
calibrated. Proceed to Test Step 3.
A pressure sensor calibration will not be successful if
there are active sensor diagnostic codes with an FMI Test Step 3. Determine the Cause of
of 03 and/or 04. A pressure sensor calibration will not Failed Calibration
be successful if one of the following conditions exist:
A. Check if any pressure sensors have an active
The pressure reading is outside of an acceptable diagnostic code. A pressure sensor calibration will
range. not be successful if there are active diagnostic
codes with an FMI of 03 and/or 04.
The pressure reading varies signicantly during
calibration. B. Verify that the correct sensor has been installed.
Test Step 1. Check for ACTIVE C. Check the display status screen on Cat ET for the
Diagnostic Codes pressure sensor reading.
A. Disconnect the main power. Note: The valid range for atmospheric pressure must
be between 45 kPa (6.5 psi) and 111 kPa (16 psi) for
B. Start Caterpillar Electronic Technician (ET). a successful calibration.
C. Connect the main power. Expected Result:
D. Check for active diagnostics. Cat ET displays the following pressures:
Expected Result:
Crankcase pressure is atmospheric pressure
8 kPa (1.2 psi).
There are no active diagnostics.
Results:
Turbocharger compressor inlet pressure is
atmospheric pressure 8 kPa (1.2 psi).
OK There are no active diagnostics. Proceed Turbocharger compressor outlet pressure is
to Test Step 2. atmospheric pressure 15 kPa (2.2 psi).
Not OK A pressure sensor with an active Fuel pressure is atmospheric pressure 27 kPa
diagnostic code cannot be calibrated. (3.9 psi).
Repair: Perform the appropriate troubleshooting
procedure.
Engine oil pressure is atmospheric pressure
27 kPa (3.9 psi).
STOP.
RENR5009-07 209
Results:
OK Repeat calibration of the sensors.

Repair: Repeat the calibration. Verify that no active
diagnostic codes are present.
STOP.
Not OK There is a problem with the wiring

harness and/or the sensor. Inspect the components
for damage, for corrosion or for abrasion. Repair
the components and/or replace the components.
Repair: Perform the appropriate troubleshooting

procedure.
STOP.
i01900713
Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1912-524
The engine speed/timing sensors provide engine

information to the Electronic Control Module (ECM).
The sensor generates a pulse signal. A loss of the
signals from the secondary engine speed/timing
sensor and the primary engine speed/timing sensor
causes the ECM to stop sending power to the fuel
injectors.
The ECM provides the engine speed/timing sensor

with 12.5 1.0 VDC. A unique tooth on the timing
reference gear generates a unique duty cycle. The
signal provides the ECM with information on the
engine position.
If the primary engine speed/timing sensor fails, the

ECM will use the secondary engine speed/timing
sensor until electrical power is removed from the
ECM. To prevent any unnecessary down time,
replace the primary engine speed/timing sensor at
the earliest possible convenience.
210 RENR5009-07
g00992448
Illustration 50
Typical example
Test Step 1. Check for Active Engine B. Remove the timing calibration plug from the
Diagnostics. ywheel housing.
A. Start the Caterpillar Electronic Technician (ET). C. Examine the ywheel through the timing calibration
hole. Ensure that the probe is not inserted into the
B. Start the engine. timing pin hole. If necessary, turn the engine.
C. Operate the engine until normal operating D. Install the 6V-3093 Transducer Adapter into the
temperatures are obtained. hole for the timing calibration at the ywheel.
Expected Result: E. Insert the 6V-2197 Magnetic Transducer through

the 6V-3093 Transducer Adapter. Insert the
There is one active diagnostic code 261-13. transducer until contact is made with the surface
of the ywheel. Move the transducer 0.9 mm
Results: (0.04 inch) away from the ywheel.
OK The active diagnostic code is 261-13. NOTICE

Proceed to Test Step 2. Do not install the timing calibration probe over the tim-
ing pin hole at the ywheel or damage will result.
Not OK There is more than one active diagnostic
code.
F. Tighten the nut on the 6V-3093 Transducer
Repair: Repair any active diagnostic codes. Adapter.
STOP. G. Connect the 7X-1695 cable from the engine

timing calibration probe to the connector P26.
Test Step 2. Install the Timing Calibration
Probe. H. Start the engine. Allow the engine to exit cold
mode operation.
A. Turn the Engine Control Switch (ECS) to the OFF
position.
RENR5009-07 211
Expected Result: If all of the problems have been corrected but the
timing can not be calibrated, check the cable of the
Only CID-FMI 261-13 should be active. 189-5746 Speed Sensor. Check the 189-5746
Speed Sensor in order to verify that the probe is
Results: not bent. Verify that the probe is installed correctly
before restarting this procedure.
OK CID-FMI 261-13 is the only active code at
this time. Proceed to Test Step 3. STOP.
Not OK CID-FMI 261-13 is not the only active i01951619

code at this time.
Repair: Repair any active diagnostic codes.

Throttle Position Sensor -
Calibrate
STOP.
SMCS Code: 1913-524
Test Step 3. Calibrate the Fuel Injection
Timing. System Operation Description:
A. Select Calibrations from the Service menu on The throttle linkage should operate without binding
the Cat ET. Select the Timing Calibration from or without excessive drag. When the throttle position
the Calibrations menu. sensor is not connected to the throttle, the throttle
should return to low idle within one second. The
Note: Engine speed will be set to 800 rpm by the calibration of the throttle position sensor requires the
ECM during the calibration. use of Caterpillar Electronic Technician (ET).
B. Follow the instructions on the Cat ET screen.
Note: If the Cat ET screen reads COULD NOT

CALIBRATE, the timing has not been set.
Expected Result:
The timing calibration procedure is successful.
Results:
OK The timing calibration procedure was

completed successfully.
Repair: Disconnect the timing calibration probe

before you exit the Timing Calibration screen on
the Cat ET. Reset the system and check for any
diagnostic codes.
STOP.
Not OK The timing could not be calibrated.

Repair: Verify that the engine speed was stable
during the testing ( 50 rpm). If the engine speed
was unstable or the engine speed could not be
controlled within 50 rpm because of mechanical
factors or electrical factors, refer to the diagnostic
procedure Troubleshooting, Engine Misres, Runs
Rough or Is Unstable.
212 RENR5009-07
D. Turn the keyswitch to the ON position. Do not start

the engine.
E. Observe the indication for the duty cycle on the

Monitor Throttle Position Sensor Signal screen
of Cat ET.
F. Place the throttle lever in the position for low idle.

Adjust the throttle linkage. Adjust the low idle set
screw.
Expected Result:
When the throttle is in low idle, the duty cycle is 5 to

10 percent. After the adjustment is completed, the
duty cycle increases when the throttle lever is moved
from the low idle position.
Results:
OK When the throttle is in low idle, the duty

cycle is 5 to 10 percent. After the adjustment is
completed, the duty cycle increases when the
throttle lever is moved from the low idle position.
Not OK There is a problem with the throttle

position sensor.
Repair: Refer to the diagnostic functional test

Troubleshooting, Throttle Postion Sensor.
STOP.
Test Step 2. Adjust the Throttle Linkage.

A. Place the throttle lever in the position of high idle.
Adjust the throttle linkage. Adjust the high idle set
screw.
Expected Result:
g00726080
Illustration 51
When the throttle is in high idle, the duty cycle is 90
Test Step 1. Check and Adjust the to 95 percent.
Throttle Linkage.
Note: When the adjustment of the high idle is made
A. Inspect the throttle linkage for components with on some types of linkage, the adjustment may
the following conditions: change the low idle position. Repeat the adjustment
for low idle in order to verify that the low idle is
Loose correctly adjusted.
Bent Results:
Broken OK The calibration was completed and veried.

Missing Repair: Check for diagnostic codes. Repair any
diagnostic codes.
Worn
STOP.
B. Turn the keyswitch to the OFF position.
Not OK The calibration was not completed
C. Connect Cat ET to the service tool connector. and veried. There is a problem with the throttle
position sensor.
RENR5009-07 213
Repair: Refer to the diagnostic functional test

Troubleshooting, Throttle Position Sensor.
STOP.
214 RENR5009-07
Index Section
Index
A ECM Will Not Accept Factory Passwords.............. 35
Probable Causes ............................................... 35
Air Shutoff System................................................ 118 Recommended Actions...................................... 35
Air Starting Motor................................................... 31 ECM Will Not Communicate with Other Systems or
Alternator ............................................................... 32 Display Modules .................................................. 35
Analog Sensor - Calibrate ................................... 208 Probable Causes ............................................... 35
Analog Sensor Supply ......................................... 125 Recommended Actions...................................... 35
Electrical Power Supply....................................... 136
Electronic Display Module ..................................... 14
C Control Panel ..................................................... 15
Power Distribution Panel.................................... 15
Calibration Procedures ........................................ 208 Electronic Service Tool Will Not Communicate with
CAN Data Link..................................................... 128 ECM..................................................................... 35
Can Not Reach Top Engine RPM .......................... 32 Probable Causes ............................................... 35
Probable Causes ............................................... 32 Recommended Actions...................................... 36
Recommended Actions...................................... 32 Electronic Service Tools ......................................... 11
Cat Data Link....................................................... 131 Caterpillar Electronic Technician (ET)................ 12
Coolant in Engine Oil............................................. 33 Optional Service Tools ....................................... 12
Probable Causes ............................................... 33 PL1000E Communication ECM (If Equipped).... 14
Recommended Actions...................................... 33 Service Tools....................................................... 11
Coolant Temperature Is Too High .......................... 34 Electronic Troubleshooting ...................................... 6
Probable Causes ............................................... 34 Emergency Stop Switch ...................................... 142
Recommended Actions...................................... 34 Emergency Stop Switch (Remote) ...................... 148
Customer Parameters Worksheet ......................... 27 Engine Control Switch (ECS) .............................. 153
Engine Cranks but Will Not Start ........................... 36
Engine Has Early Wear ......................................... 38
D Probable Causes ............................................... 38
Recommended Actions...................................... 38
Diagnostic Codes .................................................. 63 Engine Misres, Runs Rough or Is Unstable......... 38
Diagnostic Functional Tests.................................. 118 Probable Causes ............................................... 39
Digital Sensor Supply .......................................... 133 Recommended Actions...................................... 39
Engine Monitoring System..................................... 16
Oil Pressure Map ............................................... 20
E Engine Oil in Cooling System ................................ 40
Probable Causes ............................................... 40
E007 High Aftercooler Temperature Derate .......... 99 Recommended Actions...................................... 40
E008 High Aftercooler Temperature Shutdown ... 100 Engine Sensor Open/Short Test .......................... 161
E009 High Altitude Derate ................................... 101 Engine Speed/Timing Sensor .............................. 170
E012 High Crankcase Pressure Derate .............. 101 Engine Speed/Timing Sensor - Calibrate ............ 209
E013 High Crankcase Pressure Shutdown ......... 102 Engine Stalls at Low RPM ..................................... 40
E015 High Engine Coolant Temperature Derate.. 103 Probable Causes ............................................... 40
E016 High Engine Coolant Temperature Recommended Actions...................................... 40
Shutdown........................................................... 104 Engine Will Not Crank ........................................... 41
E017 High Engine Coolant Temperature Probable Causes ............................................... 41
Warning ............................................................. 104 Recommended Actions...................................... 41
E021 High Exhaust Temperature Derate............. 105 Event Codes .......................................................... 98
E031 Air Inlet Restriction Derate ......................... 106 Programmable Engine Parameters.................... 98
E038 Low Engine Coolant Temperature Excessive Black Smoke ........................................ 43
Warning ............................................................. 107 Probable Causes ............................................... 43
E040 Low Engine Oil Pressure Shutdown........... 108 Recommended Actions...................................... 43
E043 Low System Voltage Warning .................... 109 Excessive Engine Oil Consumption....................... 42
E048 Backup ECM Took Control .......................... 110 Probable Causes ............................................... 42
E095 Fuel Filter Restriction Warning .................... 111 Recommended Actions...................................... 42
E099 Engine Oil Filter Restriction Warning .......... 112 Excessive White Smoke ........................................ 44
E100 Low Engine Oil Pressure Warning .............. 112 Probable Causes ............................................... 44
E101 High Crankcase Pressure Warning............. 113 Recommended Actions...................................... 44
E173 High Exhaust Temperature Warning ........... 114 Exhaust Temperature Is Too High ......................... 45
E190 Engine Overspeed Warning ........................ 115 Probable Causes ............................................... 45
E272 Inlet Air Restriction Warning........................ 116 Recommended Actions...................................... 45
E279 High Aftercooler Temperature Warning....... 116
RENR5009-07 215
Index Section
F MID 036 - CID 0006 - FMI 05 Injector Cylinder 6 open

circuit ................................................................... 66
Factory Passwords ................................................ 21 MID 036 - CID 0006 - FMI 06 Injector Cylinder 6
Customer Passwords......................................... 21 short..................................................................... 67
Factory Passwords ............................................ 21 MID 036 - CID 0007 - FMI 05 Injector Cylinder 7 open
Passwords ......................................................... 21 circuit ................................................................... 67
Factory Passwords Worksheet.............................. 21 MID 036 - CID 0007 - FMI 06 Injector Cylinder 7
Flash Programming ............................................... 22 short..................................................................... 67
Programming a Flash File.................................. 22 MID 036 - CID 0008 - FMI 05 Injector Cylinder 8 open
Fuel Dilution of Engine Oil ..................................... 45 circuit ................................................................... 67
Probable Causes ............................................... 45 MID 036 - CID 0008 - FMI 06 Injector Cylinder 8
Recommended Actions...................................... 45 short..................................................................... 68
Fuel in Cooling System.......................................... 46 MID 036 - CID 0009 - FMI 05 Injector Cylinder 9 open
circuit ................................................................... 68
I short..................................................................... 68
Important Safety Information ................................... 2 open circuit .......................................................... 68
Injector Solenoids ................................................ 175 MID 036 - CID 0010 - FMI 06 Injector Cylinder 10
Inspecting Electrical Connectors ......................... 182 short..................................................................... 69
Intermittent Engine Shutdown ............................... 46 MID 036 - CID 0011 - FMI 05 Injector Cylinder 11
Probable Causes ............................................... 46 open circuit .......................................................... 69
Recommended Actions...................................... 46 MID 036 - CID 0011 - FMI 06 Injector Cylinder 11
Intermittent Low Power or Power Cutout............... 47 short..................................................................... 69
Recommended Actions...................................... 47 open circuit .......................................................... 69
short..................................................................... 70
L MID 036 - CID 0013 - FMI 05 Injector Cylinder 13
open circuit .......................................................... 70
Low Engine Oil Pressure ....................................... 48 MID 036 - CID 0013 - FMI 06 Injector Cylinder 13
Probable Causes ............................................... 48 short..................................................................... 70
Low Power/Poor or No Response to Throttle ........ 49 open circuit .......................................................... 70
Recommended Actions...................................... 49 short..................................................................... 71
open circuit .......................................................... 71
M MID 036 - CID 0015 - FMI 06 Injector Cylinder 15
short..................................................................... 71
Mechanical Noise (Knock) in Engine..................... 50 MID 036 - CID 0016 - FMI 05 Injector Cylinder 16
Probable Causes ............................................... 50 open circuit .......................................................... 71
MID 036 - CID 0001 - FMI 05 Injector Cylinder 1 open short..................................................................... 72
circuit ................................................................... 64 MID 036 - CID 0091 - FMI 08 Throttle Position signal
MID 036 - CID 0001 - FMI 06 Injector Cylinder 1 abnormal.............................................................. 72
short..................................................................... 64 MID 036 - CID 0091 - FMI 13 Throttle Position
MID 036 - CID 0002 - FMI 05 Injector Cylinder 2 open calibration required .............................................. 72
circuit ................................................................... 64 MID 036 - CID 0094 - FMI 03 Fuel Pressure
MID 036 - CID 0002 - FMI 06 Injector Cylinder 2 open/short to +batt............................................... 73
short..................................................................... 65 MID 036 - CID 0094 - FMI 04 Fuel Pressure short to
MID 036 - CID 0003 - FMI 05 Injector Cylinder 3 open ground.................................................................. 73
circuit ................................................................... 65 MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
short..................................................................... 65 MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
MID 036 - CID 0004 - FMI 05 Injector Cylinder 4 open short to ground..................................................... 73
circuit ................................................................... 65 MID 036 - CID 0101 - FMI 03 Crankcase Pressure
short..................................................................... 66 MID 036 - CID 0101 - FMI 04 Crankcase Pressure
MID 036 - CID 0005 - FMI 05 Injector Cylinder 5 open short to ground..................................................... 74
circuit ................................................................... 66 MID 036 - CID 0110 - FMI 03 Engine Coolant
MID 036 - CID 0005 - FMI 06 Injector Cylinder 5 Temperature open/short to +batt ......................... 74
short..................................................................... 66
216 RENR5009-07
Index Section
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature short to ground ............................... 74 inputs ................................................................... 83
MID 036 - CID 0168 - FMI 00 System Voltage MID 036 - CID 0337 - FMI 02 Incorrect Remote
High ..................................................................... 75 E-Stop Switch inputs............................................ 83
MID 036 - CID 0168 - FMI 01 System Voltage MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Low ...................................................................... 75 circuit ................................................................... 83
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
intermittent/erratic ................................................ 75 to ground.............................................................. 84
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0342 - FMI 02 Loss of Secondary
signal ................................................................... 75 Engine Speed signal............................................ 84
MID 036 - CID 0190 - FMI 03 Engine Speed MID 036 - CID 0342 - FMI 03 Secondary Engine
open/short to +batt............................................... 76 Speed open/short to +batt ................................... 84
MID 036 - CID 0190 - FMI 07 Primary Speed Sensor MID 036 - CID 0342 - FMI 07 Secondary Speed
misinstalled .......................................................... 76 Sensor misinstalled.............................................. 84
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0342 - FMI 08 Secondary Engine
abnormal.............................................................. 76 Speed signal abnormal ........................................ 85
MID 036 - CID 0248 - FMI 09 Cat Data Link not MID 036 - CID 0444 - FMI 05 Start Relay open
communicating..................................................... 76 circuit ................................................................... 85
MID 036 - CID 0253 - FMI 02 Personality Module MID 036 - CID 0444 - FMI 06 Start Relay short to
mismatch ............................................................. 77 ground.................................................................. 85
MID 036 - CID 0254 - FMI 12 Electronic Control MID 036 - CID 0446 - FMI 05 Air Shutoff Relay
Module Error ........................................................ 77 open..................................................................... 85
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0446 - FMI 06 Air Shutoff Relay
calibration required .............................................. 77 short..................................................................... 86
Power Supply short to +batt ................................ 78 Pressure open/short to +batt ............................... 86
Power Supply short to ground ............................. 78 Pressure short to ground ..................................... 86
MID 036 - CID 0263 - FMI 03 Digital Sensor Supply MID 036 - CID 0827 - FMI 08 Left Exhaust
short to +batt........................................................ 78 Temperature signal abnormal .............................. 86
MID 036 - CID 0263 - FMI 04 Digital Sensor Supply MID 036 - CID 0828 - FMI 08 Right Exhaust
short to ground..................................................... 78 Temperature signal abnormal .............................. 87
MID 036 - CID 0268 - FMI 02 Check Programmable MID 036 - CID 1249 - FMI 08 Secondary Throttle
Parameters .......................................................... 79 Position signal abnormal...................................... 87
MID 036 - CID 0273 - FMI 00 Turbo Outlet Pressure MID 036 - CID 1249 - FMI 13 Secondary Throttle
above normal ....................................................... 79 Position calibration required ................................ 87
MID 036 - CID 0273 - FMI 03 Turbo Outlet Pressure MID 036 - CID 1495 - FMI 02 Injector Trim Codes Not
open/short to +batt............................................... 79 Programmed ........................................................ 88
MID 036 - CID 0273 - FMI 04 Turbo Outlet Pressure MID 047 - CID 0001 - FMI 05 Injector Cylinder 1 open
short to ground..................................................... 80 circuit ................................................................... 88
MID 036 - CID 0274 - FMI 03 Atmospheric Pressure MID 047 - CID 0001 - FMI 06 Injector Cylinder 1
open/short to +batt............................................... 80 short..................................................................... 88
MID 036 - CID 0274 - FMI 04 Atmospheric Pressure MID 047 - CID 0002 - FMI 05 Injector Cylinder 2 open
short to ground..................................................... 80 circuit ................................................................... 88
MID 036 - CID 0275 - FMI 03 Right Turbo Inlet MID 047 - CID 0002 - FMI 06 Injector Cylinder 2
Pressure open/short to +batt ............................... 80 short..................................................................... 89
MID 036 - CID 0275 - FMI 04 Right Turbo Inlet MID 047 - CID 0003 - FMI 05 Injector Cylinder 3 open
Pressure short to ground ..................................... 81 circuit ................................................................... 89
MID 036 - CID 0276 - FMI 03 Left Turbo Inlet MID 047 - CID 0003 - FMI 06 Injector Cylinder 3
Pressure open/short to +batt ............................... 81 short..................................................................... 89
MID 036 - CID 0276 - FMI 04 Left Turbo Inlet MID 047 - CID 0004 - FMI 05 Injector Cylinder 4 open
Pressure short to ground ..................................... 81 circuit ................................................................... 89
MID 036 - CID 0277 - FMI 08 Timing Calibration MID 047 - CID 0004 - FMI 06 Injector Cylinder 4
signal abnormal ................................................... 81 short..................................................................... 90
MID 036 - CID 0279 - FMI 03 Aftercooler Temperature MID 047 - CID 0005 - FMI 05 Injector Cylinder 5 open
open/short to +batt............................................... 82 circuit ................................................................... 90
MID 036 - CID 0279 - FMI 04 Aftercooler Temperature MID 047 - CID 0005 - FMI 06 Injector Cylinder 5
short to ground..................................................... 82 short..................................................................... 90
MID 036 - CID 0289 - FMI 03 Unltered Fuel Pressure MID 047 - CID 0006 - FMI 05 Injector Cylinder 6 open
open/short to +batt............................................... 82 circuit ................................................................... 90
MID 036 - CID 0289 - FMI 04 Unltered Fuel Pressure MID 047 - CID 0006 - FMI 06 Injector Cylinder 6
short to ground..................................................... 83 short..................................................................... 91
RENR5009-07 217
Index Section
MID 047 - CID 0007 - FMI 05 Injector Cylinder 7 open Programming Parameters ..................................... 21
circuit ................................................................... 91
short..................................................................... 91 R
circuit ................................................................... 91 Replacing the ECM................................................ 29
short..................................................................... 92
MID 047 - CID 0009 - FMI 05 Injector Cylinder 9 open S
circuit ................................................................... 92
MID 047 - CID 0009 - FMI 06 Injector Cylinder 9 Secondary ECM Assumes Control ........................ 52
short..................................................................... 92 Secondary ECM Indicator Fault............................. 53
MID 047 - CID 0010 - FMI 05 Injector Cylinder 10 Secondary ECM/Personality Module................... 192
open circuit .......................................................... 92 Self-Diagnostics..................................................... 10
MID 047 - CID 0010 - FMI 06 Injector Cylinder 10 Starting Motor System ......................................... 197
short..................................................................... 93 Symptoms.............................................................. 31
MID 047 - CID 0011 - FMI 05 Injector Cylinder 11 Synchronizing Switch Not Functioning Properly.... 53
open circuit .......................................................... 93 System Conguration Parameters......................... 23
MID 047 - CID 0011 - FMI 06 Injector Cylinder 11 Customer Parameters........................................ 24
short..................................................................... 93 Parameter Descriptions ..................................... 23
MID 047 - CID 0012 - FMI 05 Injector Cylinder 12 Parameter Table........................................... 24, 26
open circuit .......................................................... 93 System Overview..................................................... 6
MID 047 - CID 0012 - FMI 06 Injector Cylinder 12 Electronic Controls............................................... 6
short..................................................................... 94 Location of the Engine Components.............. 810
open circuit .......................................................... 94
MID 047 - CID 0013 - FMI 06 Injector Cylinder 13 T
short..................................................................... 94
MID 047 - CID 0014 - FMI 05 Injector Cylinder 14 Table of Contents..................................................... 3
open circuit .......................................................... 94 Throttle Position Sensor ...................................... 202
MID 047 - CID 0014 - FMI 06 Injector Cylinder 14 Throttle Position Sensor - Calibrate...................... 211
short..................................................................... 95 Too Much Valve Lash ............................................ 61
MID 047 - CID 0015 - FMI 05 Injector Cylinder 15 Probable Causes ............................................... 61
open circuit .......................................................... 95 Recommended Actions...................................... 61
MID 047 - CID 0015 - FMI 06 Injector Cylinder 15 Too Much Vibration................................................ 61
short..................................................................... 95 Probable Causes ............................................... 61
MID 047 - CID 0016 - FMI 05 Injector Cylinder 16 Recommended Actions...................................... 62
open circuit .......................................................... 95 Troubleshooting Section.......................................... 6
MID 047 - CID 0016 - FMI 06 Injector Cylinder 16 Troubleshooting with a Diagnostic Code ............... 63
short..................................................................... 96 Troubleshooting with an Event Code..................... 98
MID 047 - CID 0190 - FMI 02 Loss of Engine Speed Troubleshooting without a Diagnostic Code .......... 31
signal ................................................................... 96
MID 047 - CID 0190 - FMI 08 Engine Speed signal
abnormal.............................................................. 96 V
MID 047 - CID 0342 - FMI 02 Loss of Secondary
Engine Speed signal............................................ 96 Valve Rotocoil or Spring Lock Is Free ................... 62
MID 047 - CID 0342 - FMI 08 Secondary Engine Probable Causes ............................................... 62
Speed signal abnormal ........................................ 97 Recommended Actions...................................... 62
Noise Coming from Cylinder.................................. 51

Probable Causes ............................................... 51
Poor Fuel Consumption......................................... 51

Probable Causes ............................................... 51
Prelubrication System.......................................... 187
218 RENR5009-07
Index Section
RENR5009-07 219
Index Section
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RENR5009-07

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Troubleshooting Section The ECM is programmed at the factory which limits

The ECM governs engine speed. Desired engine

The ECM limits engine power during cold mode

Engine Wiring Diagram

Location of the Engine

Location of the Engine

Location of the Engine

i01977688 Event Code An event code is generated by the

Logged codes may not indicate that a repair is Table 1

Two short jumper wires are needed to check the

N/A Personal Computer (PC)

Software, JEBD3003, CATERPILLAR

Cat ET displays a message that indicates that

Dual Data Links

When the connection of the communication adapter

Refer to Troubleshooting, Electronic Service Tool

Communicating with the Wireless Communication

Note: The communication adapter will power up Table 5

5. Restore electrical power to the ECM. Verify that

6. Establish communication between Cat ET and the

7. If Cat ET and the communication adapter

Refer to Troubleshooting, Electronic Service Tool

Cat ET displays a message that refers to a

Use the following procedure in order to connect the

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctly

3. Connect cable (9) between communication radio

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

PL1000E Communication ECM (If

The PL1000E is an ECM that provides the i03158926

Power Distribution Panel

i01907886 Separate timers are used in the ECM for each

Once a parameter has exceeded the trip point the

If a warning is programmed to 102 C (216 F), the

Note: The following tables are examples. The values

Programmable Monitoring System

Shutdown Application 0 Seconds 1200 rpm 2400 rpm 0 to 5

Air Filter On/Off

Note: The engine monitoring system is enabled after

The delay for low engine oil pressure is 10 seconds.

The delay for low transmission oil pressure is 30

The delay for low engine coolant temperature is

The delay for low engine coolant level is 60

Oil Pressure Map

Programming Parameters Note: The old interlock code is required to change

Note: A mistake in recording these parameters will

Table 8 Programming a Flash File

Note: If WinFlash will not communicate with the

Flash Programming This is a method of

Caterpillar Electronic Technician (ET) is used to ash

i01908150 Engine Cooling System Conguration

Injector Codes Crank Duration

Rated Fuel Position

System Conguration Parameters

Customer Parameters Personality Module Part Number

Equipment ID Personality Module Part Number is programmed

Engine Serial Number Engine Rotation

Full Torque Setting (FTS)