SENR9969-05

October 2009

Troubleshooting
C4.4 and C6.6 Industrial Engines and
Engines for Caterpillar Built Machines
4441-Up (Engine)
6661-Up (Engine)
RSL1-Up (Machine)

SAFETY.CAT.COM
 i03684547

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
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-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

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

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

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.
SENR9969-05 3
Table of Contents

Table of Contents Low Engine Oil Pressure ......................................

Low Power/Poor or No Response to Throttle .......
73
74
Mechanical Noise (Knock) in Engine .................... 77
Noise Coming from Cylinder ................................. 77
Troubleshooting Section
Troubleshooting with a Diagnostic Code
Electronic Troubleshooting
Diagnostic Code Cross Reference ....................... 79
System Overview .................................................... 5
No Diagnostic Codes Detected ............................. 81
Glossary .................................................................. 8
CID 0001 FMI 02 .................................................. 81
Electronic Service Tools ........................................ 12
CID 0001 FMI 05 .................................................. 82
Indicator Lamps .................................................... 15
CID 0001 FMI 06 .................................................. 82
Replacing the ECM ............................................... 18
CID 0001 FMI 07 .................................................. 83
Self-Diagnostics .................................................... 19
CID 0002 FMI 02 .................................................. 83
Sensors and Electrical Connectors ....................... 19
CID 0002 FMI 05 .................................................. 83
Engine Wiring Information .................................... 26
CID 0002 FMI 06 .................................................. 84
ECM Harness Connector Terminals ..................... 30
CID 0002 FMI 07 .................................................. 84
CID 0003 FMI 02 .................................................. 85
Programming Parameters
CID 0003 FMI 05 .................................................. 85
Programming Parameters ..................................... 32
CID 0003 FMI 06 .................................................. 86
Test ECM Mode .................................................... 32
CID 0003 FMI 07 .................................................. 86
Factory Passwords ............................................... 32
CID 0004 FMI 02 .................................................. 86
Flash Programming .............................................. 33
CID 0004 FMI 05 .................................................. 87
Injector Trim File ................................................... 34
CID 0004 FMI 06 .................................................. 87
Mode Switch Setup ............................................... 34
CID 0004 FMI 07 .................................................. 88
Throttle Setup ....................................................... 35
CID 0005 FMI 02 .................................................. 88
Multiposition Switch Setup .................................... 38
CID 0005 FMI 05 .................................................. 89
CID 0005 FMI 06 .................................................. 89
Customer Specified Parameters
CID 0005 FMI 07 .................................................. 90
Customer Specified Parameters ........................... 40
CID 0006 FMI 02 .................................................. 90
Customer Specified Parameters Table ................. 43
CID 0006 FMI 05 .................................................. 90
Customer Specified Parameters Worksheet ......... 44
CID 0006 FMI 06 .................................................. 91
CID 0006 FMI 07 .................................................. 91
System Configuration Parameters
CID 0041 FMI 03 .................................................. 92
System Configuration Parameters ........................ 45
CID 0041 FMI 04 .................................................. 92
CID 0091 FMI 02 .................................................. 92
Troubleshooting without a Diagnostic Code
CID 0091 FMI 03 .................................................. 93
Alternator Noise .................................................... 46
CID 0091 FMI 04 .................................................. 94
Alternator Will Not Charge .................................... 46
CID 0091 FMI 08 .................................................. 94
Battery .................................................................. 47
CID 0100 FMI 03 .................................................. 95
Can Not Reach Top Engine RPM ......................... 47
CID 0100 FMI 04 .................................................. 95
Coolant in Engine Oil ............................................ 49
CID 0100 FMI 10 .................................................. 96
Coolant Temperature Is Too High ......................... 49
CID 0110 FMI 03 ................................................... 96
ECM Will Not Accept Factory Passwords ............. 51
CID 0110 FMI 04 ................................................... 97
ECM Will Not Communicate with Other Systems or
CID 0168 FMI 00 .................................................. 97
Display Modules .................................................. 51
CID 0168 FMI 01 .................................................. 97
Electronic Service Tool Will Not Communicate with
CID 0168 FMI 02 .................................................. 98
ECM .................................................................... 51
CID 0171 FMI 03 .................................................. 98
Engine Cranks but Will Not Start .......................... 52
CID 0171 FMI 04 .................................................. 99
Engine Has Early Wear ........................................ 56
CID 0172 FMI 03 .................................................. 99
Engine Misfires, Runs Rough or Is Unstable ........ 57
CID 0172 FMI 04 ................................................ 100
Engine Oil in Cooling System ............................... 59
CID 0190 FMI 08 ................................................ 100
Engine Speed Does Not Change .......................... 59
CID 0247 FMI 09 ................................................ 100
Engine Stalls at Low RPM .................................... 60
CID 0247 FMI 12 ................................................ 101
Engine Vibration ................................................... 61
CID 0253 FMI 02 ................................................ 101
Engine Will Not Crank ........................................... 62
CID 0261 FMI 11 ................................................. 101
Excessive Black Smoke ........................................ 63
CID 0262 FMI 03 ................................................ 102
Excessive Engine Oil Consumption ...................... 65
CID 0262 FMI 04 ................................................ 102
Excessive Fuel Consumption ............................... 66
CID 0268 FMI 02 ................................................ 102
Excessive Valve Lash ........................................... 68
CID 0342 FMI 08 ................................................ 103
Excessive White Smoke ....................................... 68
CID 0526 FMI 05 ................................................ 103
Intake Air Temperature Is Too High ...................... 70
CID 0526 FMI 06 ................................................ 104
Intermittent Engine Shutdown ............................... 71
CID 0526 FMI 07 ................................................ 104
Intermittent Low Power or Power Cutout .............. 72
CID 0774 FMI 02 ................................................ 105
4 SENR9969-05
Table of Contents

CID 0774 FMI 03 ................................................ 105

CID 0774 FMI 04 ................................................ 106
CID 0774 FMI 08 ................................................ 106
CID 1639 FMI 09 ................................................ 107
CID 1743 FMI 02 ................................................ 107
CID 1779 FMI 05 ................................................ 108
CID 1779 FMI 06 ................................................ 108
CID 1785 FMI 03 ................................................ 108
CID 1785 FMI 04 ................................................ 109
CID 1785 FMI 10 ................................................ 109
CID 1797 FMI 03 ................................................. 110
CID 1797 FMI 04 ................................................. 110
CID 1834 FMI 02 ................................................. 110
CID 2246 FMI 06 ................................................. 111

Troubleshooting with an Event Code

Event Codes ....................................................... 112
E172 High Air Filter Restriction ............................ 113
E194 High Exhaust Temperature ......................... 114
E232 High Fuel/Water Separator Water Level ..... 115
E360 Low Engine Oil Pressure ............................ 115
E361 High Engine Coolant Temperature ............. 117
E362 Engine Overspeed ...................................... 118
E396 High Fuel Rail Pressure ............................. 118
E398 Low Fuel Rail Pressure .............................. 119
E539 High Intake Manifold Air Temperature ........ 119
E2143 Low Engine Coolant Level ....................... 120

Diagnostic Functional Tests

5 Volt Sensor Supply Circuit - Test ..................... 121
Analog Throttle Position Sensor Circuit - Test .... 128
CAN Data Link Circuit - Test ............................... 133
Data Link Circuit - Test ........................................ 136
Digital Throttle Position Sensor Circuit - Test ..... 142
ECM Memory - Test ............................................ 149
Electrical Connectors - Inspect ........................... 150
Engine Pressure Sensor Open or Short Circuit -
Test ................................................................... 154
Engine Speed/Timing Sensor Circuit - Test ........ 161
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 169
Engine Temperature Sensor Open or Short Circuit -
Test ................................................................... 175
Fuel Rail Pump Solenoid - Test .......................... 180
Idle Validation Switch Circuit - Test ..................... 184
Ignition Keyswitch Circuit and Battery Supply Circuit -
Test ................................................................... 189
Indicator Lamp Circuit - Test ............................... 195
Injector Data Incorrect - Test ............................... 198
Injector Solenoid Circuit - Test ............................ 200
Mode Selection Circuit - Test .............................. 210
PTO Switch Circuit - Test .................................... 214
Starting Aid (Glow Plug) Relay Circuit - Test ...... 218
Throttle Switch Circuit - Test ............................... 222
Wastegate Solenoid - Test .................................. 225

Index Section
Index ................................................................... 231
SENR9969-05 5
Troubleshooting Section

Troubleshooting Section

Electronic Troubleshooting
i03408031

System Overview
SMCS Code: 1900

System Operation

g01765134
Illustration 1
C4.4 engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
6 SENR9969-05
Troubleshooting Section

g01765135
Illustration 2
C6.6 engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor

The engine is designed for electronic control. The The electronic system consists of the ECM, the
engine has an Electronic Control Module (ECM), engine sensors and inputs from the parent machine.
a fuel rail pump and electronic unit injectors. All of The ECM is the computer. The flash file is the
these items are electronically controlled. There are software for the computer. The flash file defines the
also a number of engine sensors. Turbocharged following characteristics of the engine:
engines can be equipped with an electronically
controlled wastegate for the turbocharger. The ECM • Engine power
controls the engine operating parameters through
the software within the ECM and the inputs from the • Torque curves
various sensors. The software contains parameters
that control the engine operation. The parameters • Engine speed (rpm)
include all of the operating maps and customer
selected parameters. • Engine Noise
SENR9969-05 7
Troubleshooting Section

• Smoke and Emissions The Fuel Ratio Control Limit is a limit that is based
on intake manifold pressure and engine rpm. The
The ECM determines the injection timing, the amount FRC Limit is used to control the air/fuel ratio in order
of fuel that is delivered to the cylinders and the intake to control the engine's exhaust emissions. When
manifold pressure if an electronically controlled the ECM senses a higher intake manifold pressure,
wastegate is installed on the turbocharger. These the ECM increases the FRC Limit. A higher intake
decisions are based on the actual conditions and the manifold pressure indicates that there is more air in
desired conditions at any given time. the cylinder. When the ECM increases the FRC Limit,
the ECM allows more fuel into the cylinder.
Engine Speed Governor
The Rated Fuel Limit is a limit that is based on the
The governor has software that compares the desired power rating of the engine and on the engine rpm.
engine speed to the actual engine speed. The actual The Rated Fuel Limit enables the engine power and
engine speed is determined through the primary torque outputs to conform to the power and torque
speed/timing sensor and the secondary speed/timing curves of a specific engine model.
sensor. If the desired engine speed is greater than
the actual engine speed, the governor injects more These limits are in the flash file and these limits
fuel in order to increase engine speed. If the actual cannot be changed by the operator.
engine speed is greater than the desired engine
speed, the governor limits the amount of fuel that is Diagnostic Codes
supplied to the electronic unit injectors in order to
reduce engine speed. When the ECM detects an electronic system problem,
the ECM generates a diagnostic code. Also, the ECM
Timing Considerations logs the diagnostic code in order to indicate the time
of the problem's occurrence. The ECM also logs the
Fuel injection timing is determined by the ECM after number of occurrences of the problem. Diagnostic
considering input from the following components: codes are provided in order to indicate that the ECM
has detected an electrical problem or an electronic
• Engine coolant temperature sensor problem with the engine control system. In some
cases, the engine performance can be affected when
• The sensor for the intake manifold air temperature the condition that is causing the code exists.

• The sensor for the intake manifold pressure If the operator indicates that a performance problem
occurs, the diagnostic code may indicate the cause
• Speed/timing sensors of the problem. Use the electronic service tool to
access the diagnostic codes. The problem should
• Throttle position sensor then be corrected.

At engine start-up, the ECM determines the top Event Codes

center position of the number 1 cylinder from the
speed/timing sensors. The ECM determines when Event Codes are used to indicate that the ECM has
fuel injection should occur relative to the top center detected an abnormal engine operating condition.
position. The ECM optimizes engine performance The ECM will log the occurrence of the event code.
by control of each of the electronic unit injectors so This does not indicate an electrical malfunction
that the required amount of fuel is injected at the or an electronic malfunction. For example, if the
precise point of the engine's cycle. The electronic unit temperature of the coolant in the engine is higher
injectors are supplied with high pressure fuel from than the permitted limit, then the ECM will detect the
the fuel rail. The ECM also provides the signal to the condition. The ECM will then log an event code for
solenoid in the fuel rail pump. The solenoid in the fuel the condition.
rail pump controls a valve in the fuel rail pump. This
valve controls the pressure in the fuel rail. Fuel that is
not required for the engine is diverted away from the Programmable Parameters
fuel rail pump back to the fuel tank.
Certain parameters that affect the engine operation
The ECM adjusts injection timing and fuel pressure may be changed with electronic service tools. The
for the best engine performance, the best fuel parameters are stored in the ECM and some of the
economy and the best control of exhaust emissions. parameters are protected from unauthorized changes
by passwords. These parameters are System
Configuration Parameters.
Fuel Injection
The flash file inside the ECM sets certain limits on
the amount of fuel that can be injected.
8 SENR9969-05
Troubleshooting Section

System Configuration Parameters are set at the Code – Refer to “Diagnostic Code” or “Event Code”.
factory. System Configuration Parameters affect
emissions or power ratings within the engine. Communication Adapter Tool – The
Factory passwords must be obtained and factory communication adapter provides a communication
passwords must be used to change some of the link between the ECM and the electronic service tool.
System Configuration Parameters. , Examples of
these parameters are FLS and FTS. Component Identifier (CID) – The CID is a number
that identifies the specific component of the electronic
control system that has experienced a diagnostic
Passwords code.
System Configuration Parameters are protected by
Coolant Temperature Sensor – The coolant
factory passwords. Factory passwords are calculated
temperature sensor detects the engine coolant
on a computer system that is available only to
Caterpillar distributors. Since factory passwords temperature for all normal operating conditions and
for engine monitoring.
contain alphabetic characters, only an electronic
service tool may change System Configuration
Parameters. System Configuration Parameters affect Data Link – The Data Link is a serial communication
port that is used for communication with other devices
the power rating or the emissions.
such as the electronic service tool.
Refer to Troubleshooting, “Programming Parameters”
Derate – Certain engine conditions will generate
and Troubleshooting, “Factory Passwords”.
event codes. Also, engine derates may be applied.
The map for the engine derate is programmed into
i03476862 the ECM software. The derate can be one or more of
3 types: reduction of rated power, reduction of rated
Glossary engine speed, and reduction of rated machine speed
for OEM products.
SMCS Code: 1900
Desired Engine Speed – The desired engine speed
Active Diagnostic Code – An active diagnostic is input to the electronic governor within the ECM.
code alerts the operator or the service technician that The electronic governor uses the signal from the
an electronic system malfunction is currently present. throttle position sensor, the engine speed/timing
Refer to the term “Diagnostic Code” in this glossary. sensor, and other sensors in order to determine the
desired engine speed.
Adaptive Trim – This is a software process that is
performed in the Electronic Control Module (ECM) Diagnostic Code – A diagnostic code is sometimes
that optimizes engine performance. referred to as a fault code. These codes indicate an
electronic system malfunction.
Alternating Current (AC) – Alternating current is an
electric current that reverses direction at a regular Diagnostic Lamp – A diagnostic lamp is sometimes
interval that is reoccurring. called the check engine light. The diagnostic lamp
is used to warn the operator of the presence of
Before Top Center (BTC) – BTC is the 180 degrees an active diagnostic code. The lamp may not be
of crankshaft rotation before the piston reaches the included in all applications.
top dead center position in the normal direction of
rotation. Digital Sensor Return – The common line (ground)
from the ECM is used as ground for the digital
Breakout Harness – A breakout harness is a sensors.
test harness that is designed to connect into the
engine harness. This connection allows a normal Digital Sensors – Digital sensors produce a pulse
circuit operation and the connection simultaneously width modulated signal. Digital sensors are supplied
provides a Breakout T in order to measure the with power from the ECM.
signals.
Digital Sensor Supply – The power supply for the
Bypass Circuit – A bypass circuit is a circuit that is digital sensors is provided by the ECM.
used as a substitute circuit for an existing circuit. A
bypass circuit is typically used as a test circuit. Direct Current (DC) – Direct current is the type of
current that flows consistently in only one direction.
CAN Data Link (see also J1939 CAN Data Link) –
The CAN Data Link is a serial communications DT, DT Connector, or Deutsch DT – This is a
port that is used for communication with other type of connector that is used on this engine. The
microprocessor based devices. connectors are manufactured by Deutsch.
SENR9969-05 9
Troubleshooting Section

Duty Cycle – Refer to “Pulse Width Modulation”. 4 – The voltage is below normal or the voltage is
shorted low.
Electronic Engine Control – The electronic
engine control is a complete electronic system. 5 – The current is below normal or the circuit is open.
The electronic engine control monitors the engine
operation under all conditions. The electronic engine 6 – The current is above normal or the circuit is
control also controls the engine operation under all grounded.
conditions.
7 – The mechanical system is not responding
Electronic Control Module (ECM) – The ECM properly.
is the control computer of the engine. The ECM
provides power to the electronics. The ECM monitors 8 – There is an abnormal frequency, an abnormal
data that is input from the sensors of the engine. The pulse width, or an abnormal time period.
ECM acts as a governor in order to control the speed
and the power of the engine. 9 – There has been an abnormal update.

Electronic Service Tool – The electronic service 10 – There is an abnormal rate of change.
tool allows a computer (PC) to communicate with the
ECM. 11 – The failure mode is not identifiable.

Engine Monitoring – Engine Monitoring is the part 12 – The device or the component is damaged.
of the electronic engine control that monitors the
sensors. This also warns the operator of detected Flash File – This file is software that is inside
problems. the ECM. The file contains all the instructions
(software) for the ECM and the file contains the
Engine Oil Pressure Sensor – The engine oil performance maps for a specific engine. The file may
pressure sensor measures engine oil pressure. The be reprogrammed through flash programming.
sensor sends a signal to the ECM that is dependent
on the engine oil pressure. Flash Programming – Flash programming is the
method of programming or updating an ECM with
Engine Speed/Timing Sensor – An engine an electronic service tool over the data link instead
speed/timing sensor is a hall effect switch that of replacing components.
provides a digital signal to the ECM. The ECM
interprets this signal as the crankshaft position and Fuel Injector E-Trim – Fuel injector E-trim is a
the engine speed. Two sensors are used to provide software process that allows precise control of fuel
the speed and timing signals to the ECM. The primary injectors by parameters that are programmed into
sensor is associated with the crankshaft and the the ECM for each fuel injector. With the use of the
secondary sensor is associated with the camshaft. electronic service tool, the service technician can
read status information for the E-Trim. Data for
Event Code – An event code may be activated E-Trim can also be programmed.
in order to indicate an abnormal engine operating
condition. These codes usually indicate a mechanical FRC – See “Fuel Ratio Control”.
problem instead of an electrical system problem.
Fuel Pump – See “Fuel Rail Pump”.
Failure Mode Identifier (FMI) – This identifier
indicates the type of failure that is associated with Fuel Rail – This item is sometimes referred to as
the component. The FMI has been adopted from the the High Pressure Fuel Rail. The fuel rail supplies
SAE practice of J1587 diagnostics. The FMI follows fuel to the electronic unit injectors. The fuel rail pump
the parameter identifier (PID) in the descriptions of and the fuel rail pressure sensor work with the ECM
the fault code. The descriptions of the FMIs are in in order to maintain the desired fuel pressure in the
the following list. fuel rail. This pressure is determined by calibration
of the engine in order to enable the engine to meet
0 – The data is valid but the data is above the normal emissions and performance requirements.
operational range.
Fuel Rail Pressure Sensor – The fuel rail pressure
1 – The data is valid but the data is below the normal sensor sends a signal to the ECM that is dependent
operational range. on the pressure of the fuel in the fuel rail.

2 – The data is erratic, intermittent, or incorrect. Fuel Rail Pump – This item is sometimes referred
to as the High Pressure Fuel Rail Pump. This is a
3 – The voltage is above normal or the voltage is device that supplies fuel under pressure to the fuel
shorted high. rail (high pressure fuel rail).
10 SENR9969-05
Troubleshooting Section

Fuel Ratio Control (FRC) – The FRC is a limit that Intake Manifold Air Temperature Sensor – The
is based on the control of the ratio of the fuel to air. intake manifold air temperature sensor detects the
The FRC is used for purposes of emission control. air temperature in the intake manifold. The ECM
When the ECM senses a higher intake manifold monitors the air temperature and other data in the
air pressure (more air into the cylinder), the FRC intake manifold in order to adjust injection timing and
increases the FRC Limit (more fuel into the cylinder). other performance functions.

Full Load Setting (FLS) – The FLS is the parameter Intake Manifold Pressure Sensor – The Intake
that represents the fuel system adjustment. This Manifold Pressure Sensor measures the pressure
adjustment is made at the factory in order to fine in the intake manifold. The pressure in the intake
tune the fuel system. This parameter must be manifold may be different to the pressure outside
programmed. the engine (atmospheric pressure). The difference
in pressure may be caused by an increase in air
Full Torque Setting (FTS) – The FTS is the pressure by a turbocharger (if equipped).
parameter that represents the adjustment for the
engine torque. This adjustment is made at the factory Integrated Electronic Controls – The engine is
in order to fine tune the fuel system. This adjustment designed with the electronic controls as a necessary
is made in conjunction with the FLS. This parameter part of the system. The engine will not operate
must be programmed. without the electronic controls.

Glow Plug – The glow plug is an optional starting aid J1939 CAN Data Link – This data link is a SAE
for cold conditions. One glow plug is installed in each standard diagnostic communications data link that
combustion chamber in order to improve the ability of is used to communicate between the ECM and the
the engine to start. The ECM uses information from electronic devices.
the engine sensors such as the engine temperature
to determine when the glow plug relay must provide Logged Diagnostic Codes – Logged diagnostic
power to each glow plug. Each of the glow plugs codes are codes which are stored in the memory.
then provides a very hot surface in the combustion These codes are meant to be an indicator of possible
chamber in order to vaporize the mixture of air and causes for intermittent problems. Refer to the
fuel. This improves ignition during the compression term “Diagnostic Code” in this glossary for more
stroke of the cylinder. information.

Glow Plug Relay – The glow plug relay is controlled OEM – OEM is an abbreviation for the Original
by the ECM in order to provide high current to the Equipment Manufacturer. This is the manufacturer of
glow plugs that are used in the starting aid system. the machine or the vehicle that uses the engine.

Harness – The harness is the bundle of wiring Open Circuit – An open circuit is a condition that is
(loom) that connects all components of the electronic caused by an open switch, or by an electrical wire
system. or a connection that is broken. When this condition
exists, the signal or the supply voltage can no longer
Hertz (Hz) – Hertz is the measure of electrical reach the intended destination.
frequency in cycles per second.
Parameter – A parameter is a value or a limit that
High Pressure Fuel Rail Pump – See “Fuel Rail is programmable. This helps determine specific
Pump”. characteristics or behaviors of the engine.

High Pressure Fuel Rail – See “Fuel Rail”. Password – A password is a group of numeric
characters or a group of alphanumeric characters
Injector Codes – The trim codes for the injectors that is designed to restrict access to parameters. The
are numeric codes or alphanumeric codes that are electronic system requires correct passwords in order
etched or stamped on individual electronic unit to change some parameters (Factory Passwords).
injectors. These codes are used to fine tune the fuel Refer to Troubleshooting, “Factory Passwords” for
delivery. more information.

Injector Trim Files – Injector trim files are Personality Module – See “Flash File”.
downloaded from a disk to the ECM. The injector
trim files compensate for variances in manufacturing
of the electronic unit injector and for the life of the
electronic unit injector. The serial number for the
electronic unit injector must be obtained in order to
retrieve the correct injector trim file.
SENR9969-05 11
Troubleshooting Section

Position Sensor – This sensor determines the Relay – A relay is an electromechanical switch. A
position of the camshaft during start-up. If the flow of electricity in one circuit is used to control the
speed/timing sensor fails during engine operation, flow of electricity in another circuit. A small current or
the position sensor is used to provide the signal. The voltage is applied to a relay in order to switch a much
sensor determines the position of the camshaft for larger current or voltage.
injection timing and for engine speed. If the position
sensor fails, the engine will continue to operate but Secondary Speed/Timing Sensor – This sensor
the engine will not start. determines the position of the camshaft during engine
operation. If the primary speed/timing sensor fails
Power Cycling – Power cycling refers to the action during engine operation, the secondary speed/timing
of cycling the keyswitch from any position to the OFF sensor is used to provide the signal.
position, and to the START/RUN position.
Sensor – A sensor is a device that is used to
Primary Speed/Timing Sensor – This sensor detect the current value of pressure or temperature,
determines the position of the crankshaft during or mechanical movement. The information that is
engine operation. If the primary speed/timing detected is converted into an electrical signal.
sensor fails during engine operation, the secondary
speed/timing sensor is used to provide the signal. Short Circuit – A short circuit is a condition that has
an electrical circuit that is inadvertently connected to
Pulse Width Modulation (PWM) – The PWM is a an undesirable point. An example of a short circuit
signal that consists of pulses that are of variable is a wire which rubs against a vehicle frame and
width. These pulses occur at fixed intervals. The ratio this rubbing eventually wears off the wire insulation.
of “TIME ON” versus “TIME OFF” can be varied. This Electrical contact with the frame is made and a short
ratio is also referred to as a duty cycle. circuit results.

Signal – The signal is a voltage or a waveform that

is used in order to transmit information typically from
a sensor to the ECM.

Supply Voltage – The supply voltage is a continuous

voltage that is supplied to a component in order to
provide the electrical power that is required for the
component to operate. The power may be generated
by the ECM or the power may be battery voltage that
is supplied by the engine wiring.

System Configuration Parameters – System

configuration parameters are parameters that affect
emissions and/or operating characteristics of the
g00284479
Illustration 3 engine.

Pump Solenoid Valve – This is a control device in Tattletale – Certain parameters that affect the
the high pressure fuel rail pump. The ECM controls operation of the engine are stored in the ECM.
the pressure in the fuel rail by using this valve to These parameters can be changed by use of the
divert excess fuel from the pump to the fuel tank. electronic service tool. The tattletale logs the number
of changes that have been made to the parameter.
Rated Fuel Limit – This is a limit that is based on The tattletale is stored in the ECM.
the power rating of the engine and on the engine rpm.
The Rated Fuel Limit enables the engine power and Throttle Position – The throttle position is the
torque outputs to conform to the power and torque interpretation by the ECM of the signal from the
curves of a specific engine model. These limits are in throttle position sensor or the throttle switch.
the flash file and these limits cannot be changed.
Throttle Position Sensor – The throttle position
Reference Voltage – Reference voltage is a sensor is a sensor that is usually connected to an
regulated voltage and a steady voltage that is accelerator pedal or a hand lever. This sensor sends
supplied by the ECM to a sensor. The reference a signal to the ECM that is used to calculate desired
voltage is used by the sensor to generate a signal engine speed.
voltage.
Throttle Switch – The throttle switch sends a signal
to the ECM that is used to calculate desired engine
speed.
12 SENR9969-05
Troubleshooting Section

Timing Calibration – The timing calibration is the Required Service Tools

adjustment of an electrical signal. This adjustment is
made in order to correct the timing error between the Table 1
camshaft and the engine speed/timing sensors or Required Service Tools
between the crankshaft and the engine speed/timing
sensors. Part Number Description
N/A 4 mm Allen Wrench
Top Center Position – The top center position refers
to the crankshaft position when the engine piston 6V-2197 Transducer
position is at the highest point of travel. The engine 7X-1171 Transducer Adapter
must be turned in the normal direction of rotation in
order to reach this point. 5P-7277 Voltage Tester
1U-5804 Crimp Tool (12−AWG TO 18−AWG)
Total Tattletale – The total tattletale is the total
number of changes to all the parameters that are 151-6320 Wire Removal Tool
stored in the ECM. 266-1683 Removal Tool

Wait To Start Lamp – This is a lamp that is included 147-6456 Removal Tool
in the cold starting aid circuit in order to indicate when 7X-1710 Multimeter Probe
the wait to start period is active. The lamp will go off
when the engine is ready to be started. The glow 6V-7070 Digital Multimeter (HEAVY-DUTY)
plugs may not have deactivated at this point in time. or

Wastegate – This is a device in a turbocharged 9U-7330 Digital Multimeter

engine that controls the maximum boost pressure or
that is provided to the inlet manifold.
146-4080 Digital Multimeter Gp (RS232)
Wastegate Regulator (if equipped) – The or
wastegate regulator controls the pressure in the 212-2160 Digital Multimeter Gp
intake manifold to a value that is determined by the
ECM. The wastegate regulator provides the interface
between the ECM and the mechanical system that Two short jumper wires are needed to check the
regulates intake manifold pressure to the desired continuity of some wiring harness circuits by shorting
value that is determined by the software. two adjacent terminals together in a connector. A
long extension wire may also be needed to check the
continuity of some wiring harness circuits.
i03303069

Electronic Service Tools Optional Service Tools

SMCS Code: 0785 Table 2 lists the optional service tools that can be
used when the engine is serviced.
Caterpillar electronic service tools are designed to
help the service technician perform the following
tasks:

• Information access
• System diagnostics
• System calibrations
• System configurations
• Data link communications
SENR9969-05 13
Troubleshooting Section

Table 2 Table 3 lists the service tools that are required in

Part Number Description order to use Cat ET.

198-4240 Table 3
Digital Pressure Indicator
or
Engine Pressure Group Service Tools for the Use of Cat ET
1U-5470
Part Description
4C-4911(1) Battery Load Tester
Number
6V-9130(2) Temperature Adapter (MULTIMETER)
Required
215-9512(3) Hose Connector (Quick Disconnect, IBM compatible PC with
Male) 266 MHz Pentium processor
64 MB of RAM
215-9513(3) Hose Connector (Quick Disconnect, 400 MB of available hard drive space
Female) N/A
CD-ROM drive
VGA monitor or display (800 x 600)
4C-4075 Crimp Tool (4−AWG TO 10−AWG)
Microsoft® Windows 2000, XP, ME,
155-5176 AC/DC Current Probe NT 4.0 (Service Pack 4), 98, or 95
RS232 port with 16550AF UART
2P-8278 Tube As
Recommended
277-4734 Bypass Harness As IBM compatible PC with
217-0113 450 MHz Pentium III processor
Harness As
128 MB of RAM
(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911 1 GB of available hard drive space
Battery Load Tester for 6, 8, and 12 Volt Lead Acid Batteries” N/A 40X speed CD-ROM drive or
and Special Instructions, SEHS7633, “Battery Test Procedure”. 8X speed DVD drive
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
Super VGA monitor or display (800 x 600)
Temperature Adapter Group”. Microsoft® Windows 2000, XP, ME,
(3) This item is used with a 2P-8278 Tube Assembly.
NT 4.0 (Service Pack 6), or 98
RS232 port with 16550AF UART
Caterpillar Electronic Technician JERD2124 Single Use Program License
(ET) Data Subscription (Truck and Commercial
JERD2128
Engine)
Cat ET can display the following information:
Data Subscription for All Engines and
JERD2129
Machines
• Status of all pressure sensors and temperature
sensors Communication Adapter (“CAT ET” TO
171-4400(1)
ECM INTERFACE)
• Programmable parameter settings 237-7547(2) Adapter Cable As
• Active diagnostic codes and logged diagnostic (1) The 7X-1700 Communication Adapter Gp may also be used.
codes (2) The 237-7547 Adapter Cable As is required to connect to the
USB port on computers that are not equipped with a RS232
serial port.
• Logged events
Note: For more information regarding the use of
• Histograms Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
Cat ET can also be used to perform the following
software.
functions:

• Diagnostic tests
• Calibrations
• Programming of flash file
• Parameter programming
• Copy configuration function for Electronic Control
Module (ECM) replacement

• Data logging
• Graphs (real time)
14 SENR9969-05
Troubleshooting Section

Connecting Cat ET and the Communicating with the Wireless

Communication Adapter Gp Communication Adapter
Table 4 lists the optional hardware that is needed
in order to connect Cat ET by using a wireless
connection.

Table 4
Optional Hardware for the Use of Cat ET
Part Number Description

N/A Personal Computer (PC)

Wireless Communication
261-3363(1)
Adapter Gp
(1) Refer to Tool Operating Manual, “Using the 261-3363
Wireless Communication Adapter Gp” for information that is
related to the installation and the configuration.

g01121866
Illustration 4
(1) Personal Computer (PC)
(2) 196-0055 Adapter Cable As
(3) 171-4401 Communication Adapter Gp
(4) 207-6845 Adapter Cable As

Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.

Use the following procedure in order to connect Cat g01335324

ET and the Communication Adapter II. Illustration 5
(1) Personal computer (PC)
1. Remove the electrical power from the ECM. (5) 261-4867 Card (PCMCIA)
(6) 239-9955 Communication Radio Gp
(7) 259-3183 Data Link Cable As
2. Connect cable (2) between the “COMPUTER”
end of communication adapter (3) and the RS232 Note: Items (5), (6), and (7) are part of the 261-3363
serial port of PC (1). Wireless Communication Adapter Gp.
Note: The 237-7547 Adapter Cable As is required Use the following procedure in order to connect the
to connect to the USB port on computers that are not wireless communication adapter for use with Cat ET.
equipped with a RS232 serial port.
1. Remove the electrical power from the ECM.
3. Connect cable (4) between the “DATA LINK” end
of communication adapter (3) and the service tool 2. Ensure that the computer has been correctly
connector. configured for the 261-4867 Card (PCMCIA).
Verify that the PC card is installed in the
4. Restore the electrical power to the ECM. If computer's PCI expansion slot.
Cat ET and the communication adapter do not
communicate with the ECM, refer to the diagnostic 3. Connect cable (7) between communication radio
procedure Troubleshooting, “Electronic Service (6) and the service tool connector.
Tool Will Not Communicate with ECM”.
SENR9969-05 15
Troubleshooting Section

4. Restore the electrical power to the ECM. If Cat ET Wait to Start Lamp
and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic Lamp check – When the keyswitch is turned to ON,
Service Tool Will Not Communicate with ECM”. the lamp will come on for 2 seconds. The lamp will
then go off unless “Wait to Start” is active.
i03476942
On – The lamp is on during a “Wait to Start” period.
Indicator Lamps
Low Oil Pressure
SMCS Code: 7431
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
Indicator Lamps then go off unless there is an active warning.
The functions of the indicator lamps are designed to On – The lamp will come on when a low oil pressure
display the maximum amount of information on the
event is detected. The “Warning” lamp and the
minimum number of lamps.
“Shutdown” lamp may also come on.
Five lamps are available as options. The “Shutdown”
lamp and the “Warning” lamp will normally be PTO Lamp
installed in the application. Dedicated optional lamps
for other items may also be installed. The remaining Lamp check – The lamp will come on for 2 seconds.
optional lamps are “Wait to start”, “Low oil pressure” The lamp will then go off unless the PTO mode is
and “PTO mode on”. active.

The “Shutdown” lamp and the “Warning” lamp can Flashing – When the keyswitch is turned to ON, the
also be used to indicate a diagnostic code by use of lamp will be flashing when the PTO mode is turned
the “Flash Code” feature. The “Flash Code” feature on but when the PTO is not engaged.
can be used to indicate all active diagnostic codes
and logged diagnostic codes. On – The lamp will come on when PTO mode is
engaged.
Functions of the Lamps
Color of Lamps
Shutdown Lamp Typically, the “Shutdown” lamp is colored red and the
“Warning” lamp is colored amber. The other lamps
Lamp check – When the keyswitch is turned to ON,
are optional.
the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.

Flashing – The lamp will be flashing when a derate

is active or when a derate is present because of
an active diagnostic code. An example of an active
diagnostic code is “System Voltage High”.

On – The lamp will be on when the shutdown level

in the engine protection strategy has been reached.
The “Warning” lamp will also be on.

Warning Lamp
Lamp check – When the keyswitch is turned to ON,
the lamp will come on for 2 seconds. The lamp will
then go off unless there is an active warning.

Flashing – The lamp will be flashing when a

“warning” or a “warning and derate” is active. This
includes low oil pressure.

On – The lamp will be on when the shutdown level

has been reached. The “Shutdown” lamp will also
be on.
16 SENR9969-05
Troubleshooting Section

Operation of the Indicator Lamps

Table 5
Warning Shutdown Lamp State Description of the Indication Engine State
Lamp Lamp
(Alert (Action
Lamp) Lamp)
Lamp Check When the keyswitch is moved to the ON position, The keyswitch is in the ON
On On the lamps come on for a period of 2 seconds and position but the engine has
the lamps will then go off. not yet been cranked.
No Faults With the engine in operation, there are no active The engine is operating with
Off Off
warnings, diagnostic codes or event codes. no detected faults.
Active If the warning lamp comes on during engine The engine is operating
Diagnostic operation, this indicates that an active diagnostic normally but there is one or
On Off code (an electrical fault) is present. more faults with the electronic
management system for the
engine.
Derate If the warning lamp comes on and the shutdown The engine is operating but
(A derate is lamp flashes during engine operation, this there is one or more active
caused by indicates that an active diagnostic code (an diagnostic codes that have
On Flashing
certain active electrical fault) is present. The diagnostic is initiated an engine derate.
codes.) sufficiently serious in order to cause an engine
derate.
Warning When the warning lamp flashes during operation The engine is operating
(Warning of the engine, the lamp indicates that one or more normally. However, there is
only) of the warning values for the engine protection one or more of the monitored
Flashing Off
strategy has been exceeded. However, the value engine parameters that are
has not been exceeded to a level that will cause outside of the range that is
a derate or a shutdown. acceptable.
Derate If both the warning lamp and shutdown lamp flash The engine is operating.
(Warning and during operation of the engine, the lamps indicate However, one or more of the
Derate) that one or more of the values for the engine monitored engine parameters
protection strategy have been exceeded beyond is outside of the acceptable
Flashing Flashing
the level that will cause an engine derate. range. The acceptable range
has been exceeded to a level
which requires a warning and
an engine derate.
Engine If both the warning lamp and the shutdown lamp The engine is either shutdown
Shutdown come on during engine operation, this indicates or an engine shutdown is
one of the following conditions. imminent. One or more
monitored engine parameters
1. One or more of the shutdown values for the have exceeded the limit for an
engine protection strategy has been exceeded. engine shutdown. This pattern
On On
of lamps can be caused by the
2. A serious active diagnostic code has been detection of a serious active
detected. diagnostic code.

After a short period of time, the engine will shut

down.

Flash Codes
The “Flash Code” feature is used to flash the code
of all active diagnostic codes and logged diagnostic
codes.
SENR9969-05 17
Troubleshooting Section

The sequence for the flash code is started by moving

the keyswitch to “Off” and then moving the keyswitch
to “On” twice within a period of three seconds. After
a delay of 2 seconds, the “Shutdown” lamp will flash
once for a period of half a second. This sequence
indicates the start of the active fault codes. After
a further delay of 2 seconds, the “Warning” lamp
will flash repeatedly in order to indicate the active
diagnostic codes. Each flash will be on for half a
second and off for 300 milliseconds. The “Warning”
lamp will remain off for 2 seconds between each digit
of a code. If there is more than one active diagnostic
code, the “Shutdown” lamp will go off for 2 seconds.
The lamp will then come on for a period of half a
second. The “Warning” lamp will go off for a period of
2 seconds before starting the next code. If there are
no active diagnostic codes, the “Warning” lamp will
flash the code “551”. Refer to Troubleshooting Guide,
“No Diagnostic Code Detected”.

As an example, an active diagnostic code of “21” is

indicated by the “Warning” lamp coming on for 500
ms, then off for 300 ms, then on for 500 ms, then off
for 2000 ms, then on for 500 ms and then off.

g01779334
Illustration 6
Timing of the flash codes

After all of the active diagnostic codes have been After all of the codes have been displayed, the
displayed, the “Shutdown” lamp will go off for 2 “Shutdown” lamp will flash 3 times in order to
seconds. The “Shutdown” lamp will flash twice in indicate that there are no further codes. Cycling the
order to indicate the start of the sequence that will keyswitch twice within a period of 3 seconds will
display the logged diagnostic codes. The process for start the process again. All codes will be displayed in
flashing logged diagnostic codes is identical to the ascending numerical order.
process for flashing active diagnostic codes.
Refer to the Troubleshooting Guide, “Diagnostic
Note: If there are no logged codes then the “551” Codes” for the diagnostic code that relates to the
code should be flashed again. flash code.

Note: Flash codes are always sent in ascending

numerical order.
18 SENR9969-05
Troubleshooting Section

i03521721 Note: When a new ECM is not available, an ECM

can be used from an engine that is not in service.
Replacing the ECM The ECM must have the same serial number
suffix. Ensure that the replacement ECM and the
SMCS Code: 1901-510 part number for the flash file match the suspect
ECM. Be sure to record the parameters from the
NOTICE replacement ECM. Use the “Copy Configuration ECM
Care must be taken to ensure that fluids are contained Replacement” function in the electronic service tool.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to NOTICE
collect the fluid with suitable containers before open- If the flash file and engine application are not matched,
ing any compartment or disassembling any compo- engine damage may result.
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar Perform the following procedure in order to replace
Dealer Service Tool Catalog” for tools and supplies the ECM.
suitable to collect and contain fluids on Caterpillar
products. 1. Connect the electronic service tool to the
diagnostic connector.
Dispose of all fluids according to local regulations and
mandates. 2. Use the “Copy Configuration ECM Replacement”
function from the electronic service tool. If the
“Copy Configuration” is successful, proceed to
NOTICE Step 4. If the “Copy Configuration” failed, proceed
Keep all parts clean from contaminants. to Step 3.
Contaminants may cause rapid wear and shortened Note: Record any Logged Faults and Events for your
component life. records.

The engine is equipped with an Electronic Control 3. Record the following parameters:
Module (ECM). The ECM contains no moving parts.
Follow the troubleshooting procedures in this manual • Record all of the parameters on the
in order to be sure that replacing the ECM will correct “Configuration” screen.
the problem. Verify that the suspect ECM is the
cause of the problem. • Record all of the parameters on the “Throttle
Configuration” screen.
Note: Ensure that the ECM is receiving power
and that the ECM is properly grounded before • Record all of the parameters on the “Mode
replacement of the ECM is attempted. Refer to the Configuration” screen.
schematic diagram.
• Record the serial numbers of the electronic unit
A test ECM can be used in order to determine if the injectors. The injector serial numbers are shown
ECM on the engine is faulty. Install a test ECM in on the “Injector Trim Calibration” screen.
place of the suspect ECM. Install the flash file with
the correct part number into the test ECM. Program Note: If the parameters cannot be read, the
the parameters for the test ECM. The parameters parameters must be obtained elsewhere. Some
must match the parameters in the suspect ECM. parameters are stamped on the engine information
Refer to the following test steps for details. If the test plate, but most parameters must be obtained from
ECM resolves the problem, reconnect the suspect the TMI data on SIS Web.
ECM. Verify that the problem returns. If the problem
returns, replace the ECM. 4. Remove power from the ECM.

Note: If an ECM is intended to be used as a test 5. Remove the ECM. Refer to Disassembly and
ECM, “Test ECM Mode” must be selected on the Assembly, “Electronic Control Module - Remove
electronic service tool before the engine serial and Install”.
number is entered.
6. Install the replacement ECM. Refer to Disassembly
Use the electronic service tool to read the parameters and Assembly, “Electronic Control Module -
in the suspect ECM. Record the parameters in Remove and Install”.
the suspect ECM. Install the flash file into the new
ECM. After the ECM is installed on the engine, the 7. If the replacement ECM is intended to be used
parameters must be programmed into the new ECM. as a test ECM, select “Test ECM Mode” on the
electronic service tool.
SENR9969-05 19
Troubleshooting Section

8. Download the flash file. Active Code – An active diagnostic code indicates
that an active problem has been detected by the
a. Connect the electronic service tool to the control system. Active codes require immediate
diagnostic connector. attention. Always service active codes prior to
servicing logged codes.
b. Select “WinFlash” from the “Utilities” menu of
the electronic service tool. Logged Code – Every generated code is stored
in the permanent memory of the ECM. The codes
c. Select the downloaded flash file. are logged for 100 operating hours unless a code is
cleared by use of the electronic service tool.
9. If necessary, use the electronic service tool to clear
the rating interlock. To clear the rating interlock, Event Code – An event code is generated by the
enter the factory password when the electronic detection of an abnormal engine operating condition.
service tool is first connected. Activating the Test For example, an event code will be generated if the
ECM mode will also clear the rating interlock. oil pressure is too low. In this case, the event code
indicates the symptom of a problem.
10. Use the electronic service tool to program the
parameters. Perform the following procedure. Logged codes may not indicate that a repair is
needed. The problem may have been temporary. The
a. If the “Copy Configuration” procedure was problem may have been resolved since the logging
successful, use the “Copy Configuration, ECM of the code. If the system is powered, it is possible
Replacement” function to load the configuration to generate an active diagnostic code whenever a
file into the ECM. component is disconnected. When the component is
reconnected, the code is no longer active. Logged
Note: During the following procedure, factory codes may be useful to help troubleshoot intermittent
passwords may be required. problems. Logged codes can also be used to review
the performance of the engine and the electronic
b. If the “Copy Configuration” procedure failed, system.
configure the parameters individually. The
parameters should match the parameters from
i03476961
step 3.

Perform the “Fuel System Verification Test”.

Sensors and Electrical
Connectors
11. Check for logged diagnostic codes. Factory
passwords are required to clear logged events. SMCS Code: 1900-NS; 7553-WW

The Electronic Control Module (ECM) and the

i02496686 sensors are located on the left side of the engine.
Self-Diagnostics Refer to Figure 7 or refer to Figure 9.

SMCS Code: 1901-038

The Electronic Control Module (ECM) has the ability

to detect problems with the electronic system and
with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
There are two types of codes:

• Diagnostic
• Event
Diagnostic Code – When a problem with the
electronic system is detected, the ECM generates a
diagnostic code. This indicates the specific problem
with the circuitry.

Diagnostic codes can have two different states:

• Active
• Logged
20 SENR9969-05
Troubleshooting Section

g01779721
Illustration 7
Sensor locations on the C4.4 engine
(1) Fuel Rail Pressure Sensor (5) Oil Pressure Sensor (9) Intake Manifold Pressure Sensor
(2) Intake Manifold Air Temperature Sensor (6) Oil Pressure Sensor (alternative location) (10) Intake Manifold Pressure Sensor
(3) Electronic Control Module (ECM) (7) Secondary Speed/Timing Sensor (alternative location)
(4) Primary Speed/Timing Sensor (8) Solenoid for the Fuel Rail Pump (11) Coolant Temperature Sensor

Note: If equipped, the wastegate regulator is installed

on the right side of the engine.
SENR9969-05 21
Troubleshooting Section

g01780734
Illustration 8
Close up views of sensor locations on the C4.4 engine
22 SENR9969-05
Troubleshooting Section

g01780873
Illustration 9
Sensor locations on the C6.6 engine
(1) Coolant Temperature Sensor (4) Fuel Rail Pressure Sensor (7) Primary Speed/Timing Sensor
(2) Intake Manifold Air Temperature Sensor (5) Electronic Control Module (ECM) (8) Secondary Speed/Timing Sensor
(3) Intake Manifold Pressure Sensor (6) Oil Pressure Sensor (9) Solenoid for the Fuel Rail Pump

Note: If equipped, the wastegate regulator is installed

on the right side of the engine.
SENR9969-05 23
Troubleshooting Section

g01780875
Illustration 10
Close up views of sensor locations on the C6.6 engine
24 SENR9969-05
Troubleshooting Section

Table 6
Connector Function
P1 Machine Harness to ECM Connector (64 Pin Connector)
P2 Engine Harness to ECM Connector (64 Pin Connector)
P532 Fuel Rail Pump Solenoid Connector (2 Pin Connector)
P402 Secondary Speed/Timing Sensor (2 Pin Connector)
P401 Primary Speed/Timing Sensor (2 Pin Connector)
P201 Engine Oil Pressure Sensor (3 Pin Connector)
P228 Fuel Rail Pressure Sensor (3 Pin Connector)
P200 Intake Manifold Pressure Sensor (3 Pin Connector)
P103 Intake Manifold Air Temperature Sensor (2 Pin Connector)
P100 Coolant Temperature Sensor (2 Pin Connector)
J23 Diagnostic Connector (if equipped)
P691/J691 Electronic Unit Injectors for No. 1 and No. 2 Cylinders (4 Pin
Connector)
P692/J692 Electronic Unit Injectors for No. 3 and No. 4 Cylinders (4 Pin
Connector)
P693/J693 (C6.6 only) Electronic Unit Injectors for No. 5 and No. 6 Cylinders (4 Pin
Connector)
P511 Wastegate regulator (if equipped) (2 Pin Connector)
SENR9969-05 25
Troubleshooting Section

g01765134
Illustration 11
Schematic diagram for the C4.4 engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor
26 SENR9969-05
Troubleshooting Section

g01765135
Illustration 12
Schematic diagram for the C6.6 engine
(1) Electronic Unit Injector (6) Primary Speed/Timing Sensor (11) Coolant Temperature Sensor
(2) Solenoid for the Fuel Rail Pump (7) Intake Manifold Pressure Sensor (12) Diagnostic Connector (if equipped)
(3) Wastegate Regulator (if equipped) (8) Fuel Rail Pressure Sensor (13) Electronic Control Module (ECM)
(4) Secondary Speed/Timing Sensor (9) Engine Oil Pressure Sensor
(5) Fuel Rail Pump (10) Intake Manifold Air Temperature Sensor

i03477280 Table 7

Engine Wiring Information Color Codes for the Harness Wire

Color Code Color Color Code Color
SMCS Code: 1408
BK Black BU Blue

Harness Wire Identification BR Brown PU Purple

RD Red GY Gray
Caterpillar identifies all wires with eleven solid colors.
The circuit number is stamped on the wire at a 25 mm OR Orange WH White
(1 inch) spacing. Table 7 lists the wire colors and the YL Yellow PK Pink
color codes.
GN Green
SENR9969-05 27
Troubleshooting Section

For example, a wire identification of F730-OR on

the schematic would signify an orange wire with the
circuit number F730. F730-OR identifies the power
supply for the oil pressure sensor.

Note: Always replace a harness wire with the same

gauge of wire and with the same color code.

Note: In the following diagrams, “Pxxx” signifies a

plug and “Jxxx” signifies a jack.
28 SENR9969-05
Troubleshooting Section

Schematic Diagrams

g01780895
Illustration 13
Schematic Diagram for the C4.4 Engine Harness
SENR9969-05 29
Troubleshooting Section

g01782875
Illustration 14
Schematic Diagram for the C6.6 Engine Harness
30 SENR9969-05
Troubleshooting Section

g01817179
Illustration 15
Schematic Diagram for a Typical Application

Note: The functionality of most of the connections to i03466241

the J1 connector depend on the engine application.
ECM Harness Connector
Terminals
SMCS Code: 7553-023-WIR

The Electronic Control Module (ECM) uses

connectors that have 64 terminals to interface to the
wiring harness.
SENR9969-05 31
Troubleshooting Section

Note: Do not use Tooling (A) to remove the Terminal

Position Assurance components.

g01746473
Illustration 16
Layout of the Connector Pins (view from the rear)
g01784822
Illustration 18
Removal and Installation of the Removal Tool

Harness Connector Terminals 3. Insert the Tooling (A) into the hole that is adjacent
to the terminal in order to release the locking
Terminal Removal device.
Table 8 Note: Make sure that the tool stays perpendicular to
Required Tools the face of the connector.
Part 4. Hold the tool in position and gently pull the wire in
Tool Part Description Qty
Number
order to remove the terminal from the rear of the
A 266-1683 Removal Tool 1 connector (3).

5. Remove the Tooling (A) from the face of the

connector (3).

Note: If a terminal must be replaced, part number

267-9572 must be used.

Terminal Insertion
1. Push the terminal into the rear of the connector (3)
until the terminal engages with the locking device.

2. Gently pull on the wire in order to make sure that

the terminal is retained by the locking device.

3. Install the two terminal position assurance

components (2) into the sides of the connector (3).

4. Connect the connector to the ECM. Refer to

Disassembly and Assembly, “Electronic Control
Module - Remove and Install”.
g01784793
Illustration 17
Removal of Terminal Position Assurance Components

1. Remove the connector from the ECM. Refer to

Disassembly and Assembly, “Electronic Control
Module - Remove and Install”.

2. Use a screwdriver that has a flat blade (1) to

remove the two terminal position assurance
components (2) from the connector (3).
32 SENR9969-05
Troubleshooting Section

Programming Parameters Note: “Test ECM Mode” can only be activated if

the engine serial number has not already been
programmed during normal operation of the ECM.
i03478860 If the engine serial number is programmed and the
ECM is not in “Test ECM Mode”, the ECM can never
Programming Parameters be used as a test ECM.
SMCS Code: 1901 6. Use the “Copy Configuration” feature on the
electronic service tool to program the test ECM.
The electronic service tool can be used to view
certain parameters that can affect the operation of the Note: If the “ECM Replacement” feature can not be
engine. The electronic service tool can also be used used, program the test ECM with the values from the
to change certain parameters. The parameters are “Customer Specified Parameters Worksheet” and the
stored in the Electronic Control Module (ECM). Some values from the System Configuration Parameters.
of the parameters are protected from unauthorized
changes by passwords. Parameters that can be 7. Program the engine serial number into the test
changed have a tattletale number. The tattletale ECM.
number shows if a parameter has been changed.
Note: The “Test ECM Mode” must be activated
i03478863
before the engine serial number is programmed into
the ECM.
Test ECM Mode
8. Verify that the test ECM eliminates the fault.
SMCS Code: 1901
When the “Test ECM Mode” is activated, an internal
“Test ECM Mode” is a feature in the software that timer sets a 24 hour clock. This clock will count down
can be used to help troubleshoot an engine that may only while the ECM is powered and the keyswitch
have a fault in the Electronic Control Module (ECM). is in the ON position. After the ECM has counted
This feature allows a standard ECM to be used as a down the 24 hour period, the ECM will exit the “Test
test ECM. This feature eliminates the need to stock ECM Mode”. The parameters and the engine serial
a test ECM. number will be set.

1. Search for the latest flash file for the engine. If the test ECM eliminates the fault, the engine can
be released while the “Test ECM Mode” is still active.
Note: If a newer software version is available for the
engine, install the newest software on the suspect Once an ECM has been activated in the “Test ECM
ECM. If the new software does not eliminate the fault, Mode”, the ECM will stay in the “Test ECM Mode”
continue with this procedure. until the timer times out. If the ECM is used as a test
ECM for more than one engine, the “Test ECM Mode”
2. Use the “Copy Configuration” feature on the must be reactivated. Anytime prior to the “Test ECM
electronic service tool to copy the parameters Mode” timing out, the ECM can be reset to 24 hours.
from the suspect ECM.
i02668317
Note: If the “ECM Replacement” feature cannot
be used, record the programmed values into the Factory Passwords
“Customer Specified Parameters Worksheet”. Also
record the system configuration parameters. SMCS Code: 0785
3. Disconnect the suspect ECM. Temporarily connect NOTICE
the test ECM to the engine. Do not mount the test Operating the engine with a flash file not designed for
ECM on the engine. that engine will damage the engine. Be sure the flash
file is correct for your engine.
4. Flash program the test ECM with the newest
software that is available.
Note: Factory passwords are provided only to
5. Start the “Test ECM Mode” on the electronic Caterpillar dealers.
service tool. Access the feature through the
“Service” menu. The electronic service tool will Factory passwords are required to perform each of
display the status of the test ECM and the hours the following functions:
that are remaining for the “Test ECM Mode”.
SENR9969-05 33
Troubleshooting Section

• Program a new Electronic Control Module (ECM). Note: If you do not have the part number for the flash
file, use the “Flash File Search” tool on the Service
When an ECM is replaced, the system configuration Technician Workbench (STW). Alternatively, use the
parameters must be programmed into the new “Flash Software Files” feature on SIS Web.
ECM. A new ECM will allow these parameters to
be programmed once without factory passwords. Note: You must have the engine serial number in
After the initial programming, some parameters are order to search for the part number of the flash file.
protected by factory passwords.
2. Connect the electronic service tool to the
• Rerate the engine. diagnostic connector.

This may require changing the interlock code, 3. Turn the keyswitch to the ON position. Do not start
which is protected by factory passwords. the engine.

• Unlock parameters. 4. Select “WinFlash” from the “Utilities” menu on the

electronic service tool.
Factory passwords are required in order to
unlock certain system configuration parameters. Note: If “WinFlash” will not communicate with the
Refer to Troubleshooting, “System Configuration ECM, refer to Troubleshooting, “Electronic Service
Parameters”. Tool Will Not Communicate with ECM”.

• Clear engine events and certain diagnostic codes. 5. Flash program the flash file into the ECM.

Most engine events require factory passwords in a. Select the engine ECM under the “Detected
order to clear the code from ECM memory. Clear ECMs”.
these codes only when you are certain that the
problem has been corrected. For example, the b. Press the “Browse” button in order to select
E362-1 Engine Overspeed requires the use of the part number of the flash file that will be
factory passwords in order to clear the code from programmed into the ECM.
ECM memory.
c. When the correct flash file is selected, press
Since factory passwords contain alphabetic the “Open” button.
characters, the electronic service tool must be
used to perform these functions. In order to obtain d. Verify that the “File Values” match the
factory passwords, proceed as if you already application. If the “File Values” do not match
have the password. If factory passwords are the application, search for the correct flash file.
needed, the electronic service tool will request
the factory passwords and the electronic service e. When the correct flash file is selected, press
tool will display the information that is required the “Begin Flash” button.
to obtain the passwords. For the worksheet that
is used for acquiring factory passwords, refer to f. The electronic service tool will indicate when
Troubleshooting, “Factory Passwords Worksheet”. flash programming has been successfully
completed.
i03478880
6. Start the engine and check for proper operation.
Flash Programming 7. Access the “Configuration” screen under the
SMCS Code: 1901-591 “Service” menu in order to determine the
parameters that require programming. Look under
Flash Programming – A method of loading a flash the “Tattletale” column. All of the parameters
file into the Electronic Control Module (ECM) should have a tattletale of 1 or more. If a parameter
has a tattletale of 0, program that parameter.
The electronic service tool can be utilized to
flash program a flash file into the ECM. The flash “WinFlash” Error Messages
programming transfers the flash file from the PC to
the ECM. If you receive any error messages during flash
programming, click on the “Cancel” button in order
to stop the process. Access the information about
Flash Programming a Flash File the “ECM Summary” under the “Information” menu.
Ensure that you are programming the correct flash
1. Obtain the part number for the new flash file. file for your engine.
34 SENR9969-05
Troubleshooting Section

i03312044 7. Select the following menu options on the electronic

service tool:
Injector Trim File
• Service
SMCS Code: 1290
• Calibrations
The electronic service tool is used to load the injector
trim files into the Electronic Control Module (ECM). • Injector Trim Calibration
The injector trim files must be loaded into the ECM if 8. Select the appropriate cylinder.
any of the following conditions occur:
9. Click on the “Change” button.
• An electronic unit injector is replaced.
10. Select the appropriate injector trim file from the
• The ECM is replaced. PC.

• Diagnostic code 0268-02 is active. 11. Click on the “Open” button.

• Electronic unit injectors are exchanged between 12. If you are prompted by the electronic service
cylinders. tool, enter the confirmation code number for the
electronic unit injector into the field.
Exchanging Electronic Unit Injectors
13. Click on the “OK” button.
Exchanging electronic unit injectors can help
determine if a combustion problem is in the electronic The injector trim file is loaded into the ECM.
unit injector or in the cylinder. If two electronic unit
injectors that are currently installed in the engine 14. Repeat the procedure for each cylinder, as
are exchanged between cylinders, the injector trim required.
files can also be exchanged. Press the “Exchange”
button at the bottom of the “Injector Trim Calibration”
screen on the electronic service tool. Select the two i03478900
electronic unit injectors that will be exchanged and
press the “OK” button. The tattletale for the electronic Mode Switch Setup
unit injectors that were exchanged will increase by
one. SMCS Code: 1901

Note: The serial number for the electronic unit The Mode Switches can be used to change the
injector and the confirmation code number for the performance characteristics of the engine. The
electronic unit injector are located on the electronic electronic service tool is used to program the
unit injector. characteristics. Select the “Service” drop-down
menu and then select “Engine Operating Mode
1. Record the serial number and the confirmation Configuration”. A maximum of two switches can be
code numberfor each electronic unit injector. used. “Switch 1” is connected to J1:39 Mode Switch
1. “Switch 2” is connected to J1:46 Mode Switch 2.
2. Obtain the injector trim file by one of the following The other contact on both switches is connected to
methods: J1:35 Switch Return.

• Select “Service Software Files” on SIS. Number of Switch Inputs

• Use the compact disc that is included with a This is the total number of switches that will be used.
replacement electronic unit injector. The switches can be individual switches or a multiple
rotary switch.
3. Enter the serial number for the electronic unit
injector in the search field. Table 9
Range Default
4. Download the injector trim file to the PC. Repeat
this procedure for each electronic unit injector, as 0 to 2 0
required.

5. Connect the electronic service tool to the

diagnostic connector. Refer to Troubleshooting,
“Electronic Service Tools”.

6. Turn the keyswitch to the ON position.

SENR9969-05 35
Troubleshooting Section

Mode Selection Number Table 12

Range Default Factory
This parameter is a non-programmable parameter Password
that represents the number of possible combinations
of switch positions. This parameter is based on the “Programmed 5.0% No
value that is programmed into the “Number of Switch Low Idle” to
Inputs” parameter. “Programmed
High Idle”

Mode Selection Switch Input 2 and

Mode Selection Switch Input 1 Throttle 1 Droop Percentage
This parameter represents the amount of droop that
The number of these non-programmable parameters
is applied to the “Throttle 1” input.
that are visible depends on the value that is
programmed into the “Number of Switch Inputs” Table 13
parameter. “Open” signifies that the switch is in the
OFF position. “Ground” signifies that the switch is Range Default Factory
in the ON position. Password
0 to 10 percent 5.0% No
Enabled
If “Yes” is selected on the drop-down menu, the Throttle 2 Droop Percentage
ECM is programmed to use the values that are
programmed into “Rating Number”, “Throttle 1 Droop This parameter represents the amount of droop that
Percentage”, “Throttle 2 Droop Percentage” and is applied to the “Throttle 2” input.
“TSC1 Droop Percentage” for the given combination Table 14
of switch positions.
Range Default Factory
Table 10 Password
Values Default Factory Password 0 to 10 percent 5.0% No
Yes No Yes
No
TSC1 Droop Percentage
Rating Number This parameter represents the amount of droop that
is applied to the “Torque Speed Control 1(TSC1)”
This parameter is the engine rating that is used by input.
the Electronic Control Module (ECM) for a given Table 15
combination of switch positions. There is a maximum
of four ratings in a flash file. Range Default Factory
Password
Table 11
0 to 10 percent 5.0% No
Range Default Factory
Password
1 to the 1 No i03478940
maximum
number of ratings Throttle Setup
in the currently
installed Flash SMCS Code: 1901
File
The engine can have a digital throttle that uses
a Pulse Width Modulated (PWM) signal, an
Rated Speed (RPM) analog throttle or a multi-position switched throttle.
The Electronic Control Module (ECM) must be
This parameter represents the engine speed that is programmed for the type of throttle input that is being
selected when the mode switch or the mode switches used.
are in a particular position.
36 SENR9969-05
Troubleshooting Section

Table 16
Throttle 1 Throttle 2
PWM (Digital Throttle) Analog Throttle
PWM (Digital Throttle) None
PWM (Digital Throttle) Multi-position Throttle
Switch
Analog Throttle Analog Throttle
Analog Throttle None
Analog Throttle Multi-position Throttle
Switch
None Analog Throttle
None None
None Multi-position Throttle
Switch
Multi-position Throttle Analog Throttle
Switch
g01785156
Multi-position Throttle None Illustration 19
Switch Typical Range of Throttle
(1) Lower Diagnostic Limit (Default=5)
(2) Lower Position Limit (Default=10)
The throttle is set up using the electronic service tool. (3) Initial Lower Position (Default=20)
From the menu, select “Services”. On the “Services” (4) Idle Validation Minimum Off Threshold (Default=21)
screen, select “Throttle Configuration”. Select the (5) Idle Validation Maximum On Threshold (Default=25)
type of throttle from the following list: (6) Lower Dead Zone % (Default=8)
(7) Upper Dead Zone % (Default=5)
(8) Initial Upper Position (Default=70)
• No throttle (9) Upper Position Limit (Default=85)
(10) Upper Diagnostic Limit (Default=95)
• Analog throttle
PWM throttles require additional programming.
• PWM throttle If a multi-position switch is selected, additional
parameters must be programmed. Refer to the
• Multi-position throttle switch Troubleshooting Guide, “Multiposition Switch Setup”.
If an analog throttle is selected, the following
parameters must be programmed into the ECM.

Idle Validation
All analog throttles on mobile applications require an
idle validation switch. If this parameter is programmed
to “Yes”, the ECM will look for this switch input on pin
J1:45 for Idle Validation Switch 1 (IVS1) and J1:44
for Idle Validation Switch 2 (IVS2).

Table 17

Values Default
No
Yes
Yes

Idle Validation Minimum Off (Open)

Threshold
This is the minimum throttle percentage that will be
detected by the ECM when the IVS is ON (Closed).
SENR9969-05 37
Troubleshooting Section

If the ECM detects a throttle percentage below this

value with the idle validation switch OFF (Open),
a fault code will be generated and the engine will
remain at idle.

Refer to Table 18 and Table 19.

Table 18
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS< IVS Min OFF OFF Minimum Position Raise missing idle Force throttle demand
to minimum
TPS< IVS Min OFF ON Throttle Position Clear missing idle Normal operation

Table 19
Range Default
0 to 100% 21%

Idle Validation Maximum On

(Closed) Threshold
This is the maximum throttle percentage that will be
detected by the ECM when the idle validation switch
(IVS) is OFF (Open) . When the idle validation switch
is OFF (Open) and the ECM detects a signal that is
higher than the programmed value for IVS Max ON,
the ECM will generate a fault code and the engine
will remain at idle.

Refer to Table 20 and Table 21.

Table 20
Throttle Position Idle Validation Switch Throttle Demand Fault Status Comment
Sensor (TPS) (IVS) Output
TPS> IVS Max ON OFF Throttle Position Clear unexpected Normal operation
idle
TPS< IVS Min Off ON Minimum Position Raise unexpected Force throttle demand
idle. to minimum

Table 21 Table 22
Range Default Range Default
0 to 100% 25% 0 to 100% 5%

Lower Diagnostic Limit Upper Diagnostic Limit

This is the minimum throttle percentage that should This is the minimum throttle percentage that is
be detected by the ECM in normal operation when detected by the ECM in normal operation when the
the pedal is in the “off” position. A value below this pedal is in the maximum position. A value above this
limit will generate a short circuit diagnostic code. limit will generate an open circuit diagnostic code.
The range of this diagnostic detection area is from The range of this diagnostic detection area is from
0 percent to the programmed value for the lower the programmed value of the upper position limit to
position limit. 100 percent.
38 SENR9969-05
Troubleshooting Section

Table 23 Lower Dead Zone

Range Default
This is a throttle range above the initial lower position
0 to 100% 95% limit before the engine will increase in rpm.

Table 28
Lower Position Limit Range Default
This is the minimum throttle percentage that will 0 to 100% 8%
be interpreted by the ECM as zero throttle. This
parameter is used with the value of initial lower
position limit to make an allowance for manufacturing Upper Dead Zone
tolerances between different pedals.
This is a throttle range that is below the initial upper
Table 24 position limit that does not allow the engine speed
Range Default
to increase.

0 to 100% 10% Table 29

Range Default
Upper Position Limit 0 to 100% %

This is the maximum throttle percentage that will be

interpreted by the ECM as full throttle. This parameter i02406888
is used with the value of the initial upper position limit
to make an allowance for manufacturing tolerances Multiposition Switch Setup
between different pedals.
SMCS Code: 1901
Table 25
The multi-position throttle switch is an optional
Range Default
throttle input. A maximum of four switches can be
0 to 100% 85% used. Four switches will allow a maximum of 16
speeds to be selected.

Initial Lower Position Limit When the multi-position switch is selected as the
“Throttle Type” on the “Throttle Configuration Screen”
This is the maximum throttle percentage that will of the electronic service tool, additional information
be interpreted by the ECM as zero throttle. This is required.
parameter is used with the value of the lower
position limit to make an allowance for manufacturing
tolerances between different pedals.
Number of Switch Inputs
Table 26 This parameter is the total number of switches that
will be used. The switches may be individual switches
Range Default or a ganged rotary switch.
0 to 100% 20%
Table 30
Range Default
Initial Upper Position Limit 1 to 4 1
This is the minimum throttle percentage that will be
interpreted by the ECM as full throttle. This parameter
is used with the value of the upper position limit to
Physical Position
make an allowance for manufacturing tolerances
This parameter is non-programmable. The parameter
between different pedals.
is used to signify the position of the rotary switch.
Table 27
Range Default
0 to 100% 70%
SENR9969-05 39
Troubleshooting Section

Input 4, Input 3, Input 2, Input 1

The number of these non-programmable parameters
that are visible depends on the value that is
programmed into the “Number of Switch Inputs”
parameter. “Open” signifies that the switch is in the
OFF position. “Ground” signifies that the switch is
in the ON position.

Physical Position Enabled

If “Yes” is selected from the drop-down menu,
the ECM sets the engine rpm to the value that
is programmed into the “Engine Speed” for the
configuration of the switches that is defined for that
Physical Position.

Table 31
Value Default
No No
Yes

Logical Position
The Logical Position is the order that is required by
the user for a unique Physical Position.

Table 32
Range Default
1 to 16 1

Engine Speed (in RPM)

The “Engine Speed” is the programmed engine rpm
for a particular position of the multi-position throttle
switch.

If the ECM detects a switch combination that

has been configured as “No”, a fault code will be
generated. In this situation, the ECM will ignore the
multi-position switch until the keyswitch is cycled
through OFF and ON.

Table 33
Range Default
Programmed Low Idle to 0
Programmed High Idle
40 SENR9969-05
Troubleshooting Section

Customer Specified Table 36

Parameters Minimum
1900 rpm
Maximum
2900 rpm
Default
2650 rpm

i03478961
ECM Identification Parameter
Customer Specified
Parameters Equipment ID
SMCS Code: 1901 “Equipment ID” is the identification of the equipment
that is assigned by the customer. The “Equipment ID”
Customer specified parameters allow the engine to is only for reference by the customer. The “Equipment
be configured to the exact needs of the application. ID” is not required by the Electronic Control Module
(ECM).
Customer parameters may be changed repeatedly as
a customer's operation changes. Table 37
Value Default
The following information is a brief description of
the customer specified parameters. The following 17 digits
parameter values are included with the descriptions: The available characters
are dependent on the Not programmed
service tool that is
• Minimum being used.

• Maximum
PTO and Throttle Lock Parameters
• Default
Throttle Lock Feature Installation Status
Engine Rating Parameter
The “Throttle Lock Feature Installation Status” is
Rating Number used to turn on the throttle lock features. When
this parameter is changed to “Installed”, the “PTO
The rating number is the selected rating within a engine Speed Setting”, the “Throttle Lock Increment
power rating family. The flash file defines the power Speed Ramp Rate” and the “Throttle Lock Engine
rating family. The flash file can contain one to four Set Speed Increment” parameters are active and the
ratings. The rating number defines the power rating parameters can be programmed.
that is used within the power rating family.
Table 38
Table 34 Value Default
Minimum Maximum Default Not Installed
Not Installed
1 4 1 Installed

Low/High Idle Parameters PTO Engine Speed Setting

The “PTO Engine Speed Setting” is the engine speed
Low Idle Speed that is attained when the PTO switch is moved to
the ON position. If the “PTO Engine Speed Setting”
The “Low Idle Speed” is the minimum engine rpm. parameter is programmed, the feature is turned off.
If the “PTO Engine Speed Setting” parameter is set
Table 35
to a value that is between “1” and the low idle speed,
Minimum Maximum Default the parameter is set to the low idle speed value. If
700 rpm 1200 rpm 750 rpm the “PTO Engine Speed Setting” parameter is set to
a value that is higher than the high idle speed, the
parameter is set to the high idle speed value.
High Idle Speed
Table 39
The “High Idle Speed” is the maximum engine rpm. Minimum Maximum Default
0 rpm 3000 rpm 0 rpm
SENR9969-05 41
Troubleshooting Section

Throttle Lock Increment Speed Ramp Limp Home Desired Engine Speed
Rate
The “Limp Home Desired Engine Speed” is the
The “Throttle Lock Increment Speed Ramp Rate” maximum speed of the engine when the engine has
is the rate of engine acceleration when the PTO been derated.
switch is held in the ACCELERATE position. If this
Table 44
parameter is set to “0”, the feature is turned off.
Minimum Maximum Default
Table 40
700 rpm 1800 rpm 1200 rpm
Minimum Maximum Default
0 rpm/sec 600 rpm/sec 400 rpm/sec
J1939 Continuous Fault Handling
Throttle Lock Engine Set Speed Remote Torque Speed Control Enable
Increment Status
The “Throttle Lock Engine Set Speed Increment” The “Remote Torque Speed Control Enable Status”
controls the increase in engine speed when the parameter determines the way that faults will be
PTO switch is briefly operated to ACCELERATE or handled by the ECM when the “J1939 Torque Speed
DECELERATE. If this parameter is set to “0”, the Control (TSC1)” message is used as a speed request
feature is turned off. input to the ECM. Programming the “Remote Torque
Speed Control Enable Status” to “Enabled” will cause
Table 41 the ECM to display a fault code if a valid TSC1
Minimum Maximum Default message is not received by the engine ECM within
30 seconds of the engine starting. If the“ Remote
0 rpm 200 rpm 10 rpm
Torque Speed Control Enable Status” is programmed
to “Disabled”, the engine will display a 247-12 Data
Link Malfunction immediately after a loss of a TSC1
Miscellaneous message. Program “Remote Torque Speed Control
Enable Status” to “Enabled” if the ECM will always be
Monitoring Mode Shutdowns receiving a TSC1 message.
“Monitoring Mode Shutdowns” controls the shutdown Table 45
feature that is associated with the engine monitoring
Value Default
feature. When this feature is enabled and an event
code with a “-3” suffix is detected, the engine will be Disabled
Disabled
shut down. Enabled

Table 42
Value Default
Configurable Inputs
Disabled Coolant Level Sensor
Disabled
Enabled
A coolant level sensor is an optional switch input.
Monitoring Mode Derates Programming the “Coolant Level Sensor” parameter
to “Enabled” notifies the ECM that a coolant
“Monitoring Mode Derates” controls the derate that is level sensor input is present. If this parameter is
associated with the engine monitoring feature. When programmed to “Enabled” and the coolant level falls
this feature is enabled and an event code with a “-2” below the measured level, a “E2143-3” event code
is detected, the engine will be derated. will be displayed.

Table 43 Table 46

Value Default Value Default

Disabled Installed
Enabled Not Installed
Enabled Not Installed
42 SENR9969-05
Troubleshooting Section

Air Filter Restriction Switch Installation

Status
An “Air Filter Restriction Switch” is an optional
switch input. Programming the “Air Filter Restriction
Switch Installation Status” parameter to “Enabled”
notifies the ECM that an input from the air filter
restriction switch is present. When this parameter is
programmed to “Enabled” and the air filter restriction
switch closes, an E172-1 or J107-15 event code will
be displayed.

Table 47
Value Default
Installed
Not Installed
Not Installed

Fuel/Water Separator Switch Installation

Status
A fuel/water separator switch is an optional switch
input. Programming the “Fuel/Water Separator Switch
Installation Status” parameter to “Enabled” notifies
the ECM that a fuel/water separator switch input
is present. When this parameter is programmed to
“Enabled” and the fuel/water separator switch closes,
an E232-1 or J97-15 event code will be displayed.

Table 48
Value Default
Installed
Not Installed
Not Installed

User Defined Switch Installation Status

A user defined shutdown switch is an optional
switch input. Programming the “User Defined Switch
Installation Status” parameter to “Enabled” notifies
the ECM that a user defined switch input is present.
If this parameter is programmed to “Enabled” and
the user defined shutdown switch closes, the engine
will shut down.

Table 49
Value Default
Installed
Not Installed
Not Installed
SENR9969-05 43
Troubleshooting Section

i02527575

Customer Specified
Parameters Table
SMCS Code: 1901

Table 50
Customer Specified Parameters
ECM Parameter Possible Values Default Value
Engine Rating Parameter
“Rating Number” 1 to 4 1
Low/High Idle Parameters
“Low Idle Speed” 700 to 1200 rpm 750 rpm
“High Idle Speed” 1900 to 2900 rpm 2650 rpm
ECM Identification Parameter
“Equipment ID” 17 Digits Not Programmed
Available characters are dependent on
the service tool that is used
PTO and Throttle Lock Parameters
“Throttle Lock Feature Installation Installed Not Installed
Status” Not Installed
“PTO Engine Speed Setting” 0 to 3000 rpm 0 rpm
“Throttle Lock Increment Speed Ramp 0 to 600 rpm/sec 400 rpm/sec
Rate”
“Throttle Lock Engine Set Speed 0 to 200 rpm 10 rpm
Increment”
Miscellaneous
“Monitoring Mode Shutdowns” Disabled Disabled
Enabled
“Monitoring Mode Derates” Disabled Enabled
Enabled
“Limp Home Desired Engine Speed” 700 to 1800 rpm 1200 rpm
J1939 Continuous Fault Handling
“Remote Torque Speed Control Enable Disabled Disabled
Status” Enabled
Configurable Inputs
“Coolant Level Sensor” Not Installed Not Installed
Installed
“Air Filter Restriction Switch Installation Not Installed Not Installed
Status” Installed
“Fuel/Water Separator Switch Not Installed Not Installed
Installation Status” Installed
“User Defined Switch Installation Status” Not Installed Not Installed
Installed
44 SENR9969-05
Troubleshooting Section

i02400062

Customer Specified
Parameters Worksheet
SMCS Code: 1901

Table 51
Customer Specified Parameters Worksheet
Engine Rating Parameter
“Rating Numbers”
Low/High Idle Parameters
“Low Idle Speed”
“High Idle Speed”
ECM Identifications Parameters
“Equipment ID”
PTO and Throttle Lock Parameters
“Throttle Lock Feature Installation Status”
“PTO Engine Speed Setting”
“Throttle Lock Increment Speed Ramp Rate”
“Throttle Lock Engine Set Speed Increment”
Miscellaneous
“Monitoring Mode Shutdowns”
“Monitoring Mode Derates”
“Limp Home Desired Engine Speed”
J1939 Continuous Fault Handling
“Remote Torque Speed Control Enable Status”
Configurable Inputs
“Coolant Level Sensor”
“Air Filter Restriction Switch Installation Status”
“Fuel/Water Separator Switch Installation Status”
“User Defined Switch Installation Status”
SENR9969-05 45
Troubleshooting Section

System Configuration • The diagnostic code 253-02 Personality Module

mismatch will be active.
Parameters
Note: The flash programming of a new rating
interlock replaces the old rating interlock.
i03466243

System Configuration This code does not need to be programmed when

the replacement ECM is for the same engine rating.
Parameters
If the ECM is for a different engine rating, then the
SMCS Code: 1901 following components may need to be changed:
pistons, fuel injectors, and other components.
System configuration parameters affect the emissions The engine information ratings plate must also be
of the engine or the power of the engine. System changed in order to reflect the new rating.
configuration parameters are programmed at the
factory. Normally, system configuration parameters Some systems such as the cooling system or the
would never need to be changed through the life of transmission may also require changes when the
the engine. System configuration parameters must be engine is rerated. Please contact the local OEM
reprogrammed if an Electronic Control Module (ECM) dealer for further information.
is replaced. System configuration parameters do not
need to be reprogrammed if the ECM software is “Engine Serial Number”
changed. Factory passwords are required to change
these parameters. The following information is a When a new ECM is delivered, the engine serial
description of the system configuration parameters. number in the ECM is not programmed. The “Engine
Serial Number” should be programmed to match the
“Full Load Setting” engine serial number that is stamped on the engine
information plate.
The “Full Load Setting” is a number that represents
the adjustment to the fuel system that was made “ECM Software Release Date”
at the factory in order to fine tune the fuel system.
If the ECM is replaced, the “full load setting” must This parameter is defined by the rating interlock
be reprogrammed in order to prevent a 268-02 and this parameter is not programmable. The “ECM
diagnostic code from becoming active. Software Release Date” is used to provide the
version of the software. The Customer parameters
“Full Torque Setting” and the software change levels can be monitored
by this date. The date is provided in the month and
“Full Torque Setting” is similar to “Full Load Setting”. the year (JAN09). Jan is the month (January). 09 is
If the ECM is replaced, the full torque setting must the year (2009).
be reprogrammed in order to prevent a 268-02
diagnostic code from becoming active.

“Rating”
The “Rating” is a code that prevents the use of
an incorrect power rating and/or emission rating
for a specific engine. Each horsepower rating
and each emission certification has a different
code to all other horsepower ratings and emission
certifications. This is a code that prevents the use of
an incorrect power rating and/or emission rating for
a specific engine. Each horsepower rating and each
emission certification has a different code to all other
horsepower ratings and emission certifications.

When an ECM is replaced, this rating interlock code

must match the code that is stored in the ECM. If the
rating interlock code does not match the code that is
stored in the ECM, both of the following situations
will exist:

• The engine will not run.

46 SENR9969-05
Troubleshooting Section

Troubleshooting without a Alternator Bearings

Diagnostic Code Check for excessive play of the shaft in the alternator.
Check for wear in the alternator bearings. The
alternator is a nonserviceable item. The alternator
i02528122 must be replaced if the bearings are worn. Refer to
Disassembly and Assembly, “Alternator - Remove”
Alternator Noise and Disassembly and Assembly , “Alternator - Install”.
SMCS Code: 1405-035
i02358818
Note: This is not an electronic system problem.
Alternator Will Not Charge
Refer to Testing and Adjusting for information on
possible electrical causes of this condition. SMCS Code: 1405-035

Note: This is not an electronic system problem.

Probable Causes
• Alternator drive belt Probable Causes
• Alternator mounting bracket • Alternator drive belt

• Automatic tensioner • Automatic tensioner

• Alternator drive pulley • Charging circuit

• Alternator bearings • Alternator

Recommended Actions Recommended Actions

Alternator Drive Belt Alternator Drive Belt

Inspect the condition of the alternator drive belt. If Inspect the condition of the alternator drive belt. If
the alternator drive belt is worn or damaged, check the alternator drive belt is worn or damaged, check
that the drive belt for the alternator and the pulley are that the drive belt for the alternator and the pulley are
correctly aligned. If the alignment is correct, replace correctly aligned. If the alignment is correct, replace
the drive belt. Refer to Disassembly and Assembly, the drive belt. Refer to Disassembly and Assembly,
“Alternator Belt - Remove and Install”. “Alternator Belt - Remove and Install”.

Alternator Mounting Bracket Automatic Tensioner

Inspect the alternator mounting bracket for cracks Check the tension on the alternator drive belt. If
and wear. Repair the mounting bracket or replace necessary, replace the automatic tensioner. Refer to
the mounting bracket in order to ensure that the Disassembly and Assembly, “Alternator - Remove”
alternator drive belt and the alternator drive pulley and Disassembly and Assembly, “Alternator - Install”.
are in alignment.
Charging Circuit
Automatic Tensioner
Inspect the battery cables, wiring, and connections in
Check the tension on the alternator drive belts. If the charging circuit. Clean all connections and tighten
necessary, replace the automatic tensioner. Refer to all connections. Replace any faulty parts.
Disassembly and Assembly, “Alternator - Remove”
and Disassembly and Assembly, “Alternator - Install”. Alternator

Alternator Drive Pulley Verify that the alternator is operating correctly. Refer
to Testing and Adjusting, “Alternator - Test”. The
Remove the nut for the alternator drive pulley and alternator is not a serviceable item. The alternator
then inspect the nut and the drive shaft. If no damage must be replaced if the alternator is not operating
is found, install the nut and tighten the nut to the correctly. Refer to Disassembly and Assembly,
correct torque. Refer to Specifications, “Alternator “Alternator - Remove” and Disassembly and
and Regulator” for the correct torque. Assembly , “Alternator - Install”.
SENR9969-05 47
Troubleshooting Section

i02358819 • Air intake and exhaust system

Battery • Fuel supply
SMCS Code: 1401-035 • Individual malfunctioning cylinders
Note: This is not an electronic system problem. • Electronic unit injectors
Probable Causes Recommended Actions
• Charging circuit Diagnostic Codes
• Battery Check for active diagnostic codes on the electronic
service tool. Troubleshoot any active codes before
• Auxiliary device continuing with this procedure.

Recommended Actions ECM Parameters

Charging Circuit 1. Ensure that the fault is not a programmed
parameter.
If a fault in the battery charging circuit is suspected,
refer to Troubleshooting, “Alternator Will Not Charge”. 2. Ensure that the correct mode was selected by
using the electronic service tool.
Faulty Battery
3. Use the electronic service tool to verify the correct
1. Check that the battery is able to maintain a charge. engine rating for the engine.
Refer to Testing and Adjusting, “Battery - Test”.
4. Use the electronic service tool to verify the
2. If the battery does not maintain a charge, maximum engine speed limit.
replace the battery. Refer to the Operation and
Maintenance Manual, “Battery - Replace”. 5. Use the electronic service tool to verify the
following parameters at maximum speed: the
boost pressure, the smoke limit, the torque limit,
Auxiliary Device
and the amount of fuel that is delivered.
1. Check that an auxiliary device has drained the
6. Use the electronic service tool to reset the
battery by being left in the ON position.
parameters to the OEM specifications.
2. Charge the battery.
7. Ensure that the repairs have eliminated the fault.
3. Verify that the battery is able to maintain a charge
8. If the repairs have not eliminated the fault proceed
when all auxiliary devices are switched off.
to “Throttle Signal for the Throttle Position Sensor”.

i03479020 Throttle Signal for the Throttle Position

Can Not Reach Top Engine Sensor
RPM 1. Use the electronic service tool and observe the
signal for the throttle position sensor. Make sure
SMCS Code: 1915-035 that the throttle reaches the 100% raw position
and the calibrated position.
Note: If this fault occurs only under load, refer to
Troubleshooting, “Low Power/Poor or No Response 2. If the signal is erratic, refer to Troubleshooting,
to Throttle”. “Analog Throttle Position Sensor Circuit - Test” or
refer to Troubleshooting, “Digital Throttle Position
Probable Causes Sensor Circuit - Test”.

• Diagnostic codes 3. If the engine has a throttle switch refer to

Troubleshooting, “Throttle Switch Circuit - Test”.
• ECM parameters
4. If the fault has not been eliminated, proceed to
• Throttle signal from the throttle position sensor “Air Intake and Exhaust System”.
48 SENR9969-05
Troubleshooting Section

Air Intake and Exhaust System

1. Check the air filter restriction indicator, if equipped.
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fu-
2. Ensure that the air filter is clean and serviceable.
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
3. Check the air intake and the exhaust system for
structions may cause personal injury or death.
the following defects:

• Blockages NOTICE
Contact with high pressure fuel may cause personal
• Restrictions injury or death. Wait 60 seconds after the engine has
stopped to allow fuel pressure to purge before any
• Damage to the air intake and exhaust lines and service or repair is performed on the engine fuel lines.
hoses

4. Make all necessary repairs to the engine. 11. If the high pressure fuel lines have a leak, the
high pressure fuel lines must be replaced. Refer to
5. Ensure that the repairs have eliminated the fault. Disassembly and Assembly, “Fuel injection lines -
Remove and Fuel injection lines - Install”.
6. If the fault has not been eliminated, proceed to
“Fuel Supply”. 12. If the repairs do not eliminate the fault proceed to
“Individual Malfunctioning Cylinders”.
Fuel Supply
Individual Malfunctioning Cylinders
1. Visually check the fuel tank for fuel. The fuel
gauge may be faulty. 1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
2. Ensure that the fuel supply valve is in the full a time. Note if there is any reduction in engine
OPEN position. speed. If a reduction in engine speed is not noted,
the isolated cylinder is not operating under normal
3. If the temperature is below 0 °C (32 °F), check conditions. If the isolation of a particular cylinder
for solidified fuel (wax). results in a reduction of engine speed that is less
than normal, this may indicate that the cylinder is
4. Visually inspect the fuel supply lines for operating below normal performance. Investigate
restrictions. the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault
5. Check that the low pressure fuel lines are tight on any cylinder that is operating below normal
and secured properly. performance.

6. Remove the fuel filters. Inspect the fuel filters for 2. If all cylinders have been checked and no
contamination. Install new fuel filters. Refer to the faults were detected proceed to “Electronic Unit
Operation and Maintenance Manual, “Fuel System Injectors”.
Filter- Replace and Fuel System Primary Filter
(Water Separator) Element - Replace”. Determine Electronic Unit Injectors
the cause of the contamination.
1. With the engine speed at a fast idle, use the
7. Check the diesel fuel for contamination. Refer to electronic service tool to isolate one cylinder at
Systems Operation, Testing and Adjusting, “Fuel a time. Note if there is any reduction in engine
Quality - Test”. speed. If a reduction in engine speed is not noted,
the isolated electronic unit injector is not operating
8. Check for air in the low pressure fuel system. Refer under normal conditions. If the isolation of a
to Systems Operation, Testing and Adjusting, “Air particular cylinder results in a reduction of engine
in Fuel - Test”. speed that is less than normal, this may indicate
that the electronic unit injector is operating below
9. Ensure that the fuel system has been primed. normal performance.
Refer to Testing and Adjusting, “Fuel System -
Prime”. 2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and
10. Check the fuel pressure. Refer to Testing and Assembly, “Electronic Unit Injector - Remove”.
Adjusting, “Fuel System Pressure - Test”.
SENR9969-05 49
Troubleshooting Section

3. Install a new electronic unit injector. Refer to Cylinder Head

Disassembly and Assembly, “Electronic Unit
Injector - Install”. 1. Check the cylinder head for flatness. Refer
to Systems Operation, Testing and Adjusting,
4. Repeat the test in 1. If the fault is still apparent, “Cylinder Head - Inspect” for the correct procedure.
remove the replacement electronic unit injector
and install the original electronic unit injector. 2. Check the mating face of the cylinder head
Refer to Disassembly and Assembly, “Electronic for faults and signs of leakage. If a fault is
Unit Injector - Remove” and Disassembly and found, replace the cylinder head. If signs of
Assembly, “Electronic Unit Injector - Install”. leakage are found, determine the cause of the
leakage. Refer to Systems Operation, Testing and
Adjusting, “Cylinder Head - Inspect” for the correct
i03479187
procedure.
Coolant in Engine Oil 3. Check the internal core plugs in the cylinder head
SMCS Code: 1300-035 for signs of leakage.

Note: This is not a fault in the electronic system. 4. If the cylinder head is flat and if the cylinder head
does not have any faults, refer to “Cylinder Block”.

Probable Causes Cylinder Block

• Engine oil cooler Inspect the top face of the cylinder block for faults
and signs of leakage. If a fault is found, replace
• Cylinder head gasket the cylinder block. If signs of leakage are found,
determine the cause of the leakage. Refer to Systems
• Cylinder head Operation, Testing and Adjusting, “Cylinder Block -
Inspect” for the correct procedure.
• Cylinder block
Assembly after Repair
Recommended Actions
1. Install the cylinder head. Refer to Disassembly
Engine Oil Cooler and Assembly, “Cylinder Head - Install”.

1. Drain the engine lubricating oil from the engine. 2. Remove the oil filter element. Install a new engine
oil filter element. Fill the engine with clean engine
2. Check for leaks in the oil cooler assembly. Refer oil to the correct level. Refer to the Operation
to Systems Operation, Testing and Adjusting, and Maintenance Manual, “Engine Oil and Filter
“Cooling System” for the correct procedure. If a - Change” for more information.
leak is found, install a new oil cooler. Refer to
Disassembly and Assembly, “Engine Oil Cooler
i03479200
- Remove” and Disassembly and Assembly,
“Engine Oil Cooler - Install” for the correct
procedure.
Coolant Temperature Is Too
High
Cylinder Head Gasket
SMCS Code: 1350-035
1. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the Note: This is not a fault in the electronic system.
correct procedure.
Probable Causes
2. Inspect the cylinder head gasket for faults and any
signs of leakage. • Radiator fins
3. To fit a new cylinder head gasket, refer to • Coolant level
Disassembly and Assembly, “Cylinder Head -
Install” for the correct procedure. • Radiator cap and/or pressure relief valve
4. If there was no obvious signs of a faulty head • Coolant temperature gauge
gasket proceed to the recommended actions for
“Cylinder Head”. • Restriction in the coolant system
50 SENR9969-05
Troubleshooting Section

• Water temperature regulator Water Temperature Regulator

• Engine cooling fan Check the water temperature regulator for correct
operation. Refer to Systems Operation, Testing and
• Coolant pump Adjusting, “Cooling System” for the proper procedure.
If necessary, replace the water temperature regulator.
• Cylinder head gasket Refer to Disassembly and Assembly, “Water
Temperature Regulator - Remove and Install” for
more information.
Recommended Actions
Radiator Fins Engine Cooling Fan
1. Make sure that the engine cooling fan is correctly
Check the radiator fins for dirt, debris, and/or damage.
Remove any dirt and/or debris and straighten any installed.
bent fins.
2. Make sure that the engine cooling fan is being
driven correctly by the drive belt. If necessary,
Coolant Level tighten the drive belt or replace the drive belt.
Refer to Disassembly and Assembly, “Alternator
1. Inspect the coolant level. If necessary, add Belt - Remove and Install”.
coolant.
3. Check the engine cooling fan for damage. If
2. Check the cooling system for leaks. Repair any necessary, replace the fan. Refer to Disassembly
leaks immediately. and Assembly, “Fan - Remove and Install”.

Radiator Cap and/or Pressure Relief Coolant Pump

Valve
1. Inspect the impeller of the coolant pump for
1. Pressure test the cooling system. Refer to damage and/or erosion.
Systems Operation, Testing and Adjusting,
“Cooling System” for the correct procedure. 2. Make sure that the drive gear is not loose on the
drive shaft of the coolant pump.
2. Check that the seating surfaces of the pressure
relief valve and the radiator cap are clean and 3. If necessary, replace the coolant pump. Refer
undamaged. to Disassembly and Assembly, “Water Pump -
Remove” and Disassembly and Assembly, “Water
3. Check operation of the pressure relief valve Pump - Install”.
and/or the radiator cap. If necessary, clean the
components and/or replace the components. Cylinder Head Gasket
Coolant Temperature Gauge Switch off the engine and allow the engine to cool
to below normal working temperature. Remove
Compare the reading for the coolant temperature the pressure cap for the coolant system. Start the
from the electronic service tool to the reading for the engine and inspect the coolant for the presence
coolant temperature from a calibrated test gauge. of bubbles. If bubbles are present in the coolant,
combustion gases may be entering the cooling
Restriction in the Coolant System system. Check the cylinder head gasket. Refer to the
recommended action for the cylinder head gasket
1. Visually inspect the cooling system for collapsed within Troubleshooting, “Coolant in Engine Oil”.
hoses and/or other restrictions. Check the cylinder head for flatness. Refer to the
recommended action for checking flatness of the
2. Clean the radiator and flush the radiator. Refer cylinder head within Systems Operation, Testing and
to Systems Operation, Testing and Adjusting, Adjusting, “Cylinder Head - Inspect”. Fit the pressure
“Cooling System”. cap if there are no bubbles in the coolant.
SENR9969-05 51
Troubleshooting Section

i03479243 • Electronic Control Module (ECM)

ECM Will Not Accept Factory • CAN data link (if applicable)
Passwords
Recommended Actions
SMCS Code: 1901-035
1. Connect the electronic service tool to the
Probable Causes diagnostic connector. If the ECM does not
communicate with the electronic service tool, refer
One of the following items may not be recorded to Troubleshooting, “Electronic Service Tool Will
correctly on the electronic service tool: Not Communicate with ECM”.

• Passwords 2. Ensure that the following items are

correctly installed and undamaged. Refer
• Serial numbers to Troubleshooting, “Electrical Connectors -
Inspect”.
• Total tattletale
• P1/J1 and P2/J2 connectors on the ECM
• Reason code
• Wiring to display modules
Recommended Actions • Wiring to other control modules
1. Verify that the correct passwords were entered. 3. Troubleshoot the data link for possible faults. Refer
Check every character in each password. Remove to Troubleshooting, “Data Link Circuit - Test”.
the electrical power from the engine for 30
seconds and then retry. 4. Verify that the CAN data link does not have an
open or short circuit. Refer to Troubleshooting,
2. Verify that the electronic service tool is displaying “CAN Data Link Circuit - Test”.
the “Enter Factory Passwords” dialog box.

3. Use the electronic service tool to verify that the i03331502

following information has been entered correctly:
Electronic Service Tool Will
• Engine serial number Not Communicate with ECM
• Serial number for the electronic control module SMCS Code: 0785-035; 1901-035

• Serial number for the electronic service tool Probable Causes

• Total tattletale
• Configuration for the communications adapter
• Reason code
• Electrical connectors
For additional information, refer to Troubleshooting,
“Factory Passwords”. • Communication adapter and/or cables
• Electrical power supply to the service tool
i03479280 connector
ECM Will Not Communicate • Electronic service tool and related hardware
with Other Systems or Display
• Electrical power supply to the Electronic Control
Modules Module (ECM)

SMCS Code: 1901-035 • Data Link

Probable Causes
• Electrical connectors
• Data Link
52 SENR9969-05
Troubleshooting Section

Recommended Actions Electrical Power Supply to the Diagnostic

Connector
Start the engine. If the engine starts, but the ECM
will not communicate with the electronic service tool, Verify that battery voltage is present between
continue with this procedure. If the engine will not terminals A and B of the diagnostic connector. If the
start, refer to Troubleshooting, “Engine Cranks but communication adapter is not receiving power, the
Will Not Start”. If the engine will not crank, refer to LED display on the communication adapter will be
Troubleshooting, “Engine Will Not Crank”. blank.

Configuration for the Communications Electronic Service Tool and Related

Adapter Hardware
1. Access “Preferences” under the “Utilities” menu In order to eliminate the electronic service tool
on the electronic service tool. and the related hardware as the fault, connect the
electronic service tool to a different engine. If the
2. Verify that the correct “Communications Interface same fault occurs on a different engine, check the
Device” is selected. electronic service tool and the related hardware in
order to determine the cause of the fault.
3. Verify that the correct port is selected for use by
the communication adapter.
Electrical Power Supply to the Electronic
Note: The most commonly used port is “COM 1”. Control Module (ECM)

4. Check for any hardware that is utilizing the Check power to the ECM. Refer to Systems
same port as the communications adapter. If any Operation, Testing and Adjusting, “Charging System
devices are configured to use the same port, exit - Test”.
or close the software programs for that device.
Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
Electrical Connectors
Check for correct installation of the P1/J1 and P2/J2 Data Link
ECM connectors and of the service tool connector.
Refer to Troubleshooting, “Electrical Connectors - Troubleshoot the Data Link for possible faults. Refer
Inspect”. to Troubleshooting, “Data Link Circuit - Test”.

Communication Adapter and/or Cables i03633419

1. Make sure that the firmware and driver files are Engine Cranks but Will Not
the most current files that are available for the
type of communication adapter that is being used.
Start
If the firmware and driver files do not match, the
SMCS Code: 1000-035
communication adapter will not communicate with
the electronic service tool.
Probable Causes
2. Disconnect the communication adapter and the
cables from the service tool connector. Reconnect • Diagnostic codes
the communication adapter to the service tool
connector. • Visible faults
3. Verify that the correct cable is being used between • Air intake and exhaust system
the communication adapter and the service tool
connector. Refer to Troubleshooting, “Electronic • Primary speed/timing sensor
Service Tools”.
• Low pressure fuel system
4. If the laptop computer is using a Windows
operating system, restart the laptop computer in • Secondary speed/timing sensor
order to eliminate the possibility of a conflict in
the software. • High pressure fuel system
• Glow plugs
• Valve lash
SENR9969-05 53
Troubleshooting Section

• Low compression (cylinder pressure) 3. Investigate any active codes before continuing
with this procedure. Refer to Troubleshooting,
“Troubleshooting with a Diagnostic Code”.
Recommended Actions
4. Attempt to start the engine. If the engine will not
NOTICE start, proceed to “Visible Faults”.
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. Visible Faults
1. Visually inspect the engine for the following faults:
Diagnostic Codes
• Missing components
Use one of the following methods to check for active
diagnostic codes: • Damaged components

• Flash Codes • Damaged electrical cables or loose electrical

cables
• The display on the control panel
• Oil leaks
• The electronic service tool
• Fuel leaks
Flash Codes
2. Check the following items:
Note: The following procedure is only applicable if
the machine is equipped with the appropriate warning • Check for smoke from the exhaust when the
lamps. engine is cranking. If smoke is seen during
cranking, there may be a mechanical fault in the
1. Check the warning lamps on the control panel engine. Refer to “Low Compression (Cylinder
for flash codes. Flash codes are explained in Pressure)”.
Troubleshooting, “Flash Codes”.
• Check for the proper level of fuel, oil and
2. If any flash codes are displayed, troubleshoot coolant.
the codes before continuing with this procedure.
Refer to Troubleshooting, “Troubleshooting with a • Ensure that the fuel supply valve (if equipped)
Diagnostic Code”. is in the full OPEN position.

3. Attempt to start the engine. If the engine will not • If the ambient temperature is below 0 °C (32 °F),
start, proceed to “Visible Faults”. make sure that the correct specification of
engine oil and oil for the machine is used.
Display on the Control Panel
• Check that the battery voltage is correct.
Note: The following procedure is only applicable
if the application is equipped with a display on the • Use the electronic service tool to check the
control panel. average cranking speed of the engine. If the
cranking speed is less than 150 rpm, investigate
1. Check the display on the control panel for active the cause of the low cranking speed.
diagnostic codes.
• Make sure that all fuel filters are correctly
2. Troubleshoot any active codes before continuing installed.
with this procedure. Refer to Troubleshooting,
“Troubleshooting with a Diagnostic Code”. • Drain any water from the primary fuel filter/water
separator.
3. Attempt to start the engine. If the engine will not
start, proceed to “Visible Faults”. 3. Rectify any faults that are found during the visual
checks.
Electronic Service Tool
4. Attempt to start the engine. If the engine will not
1. Connect the electronic service tool to the start, proceed to “Air Intake and Exhaust System”.
diagnostic connector.
Air Intake and Exhaust System
2. Check for active diagnostic codes on the electronic
service tool. 1. Check the air filter restriction indicator, if equipped.
54 SENR9969-05
Troubleshooting Section

2. Ensure that the air filter is clean and serviceable. 7. Attempt to start the engine. If the engine will not
start, continue with this procedure.
3. Check the air intake and exhaust systems for the
following defects: 8. Replace the primary fuel filter and the secondary
fuel filter. Refer to the Operation and Maintenance
• Blockages Manual, “Fuel System Primary Filter (Water
Separator) Element - Replace”.
• Restrictions
9. Attempt to start the engine. If the engine will not
• Damage to lines or hoses start, continue with this procedure.

4. Repair any defects before attempting to restart 10. Check the flow of fuel through the transfer pump.
the engine. If the flow of fuel through the transfer pump is
less than 250 mL per minute at 150 rpm, replace
5. Attempt to start the engine. If the engine will not the transfer pump. Refer to Disassembly and
start, proceed to “Primary Speed/timing Sensor”. Assembly, “Fuel Transfer Pump - Remove” and
Disassembly and Assembly, “Fuel Transfer Pump
Primary Speed/timing Sensor - Install”.

1. Disconnect connector P401 from the primary 11. Attempt to start the engine. If the engine will
speed/timing sensor. not start, proceed to “Secondary Speed/timing
Sensor”.
2. Attempt to start the engine.
Secondary Speed/timing Sensor
3. If the engine starts, check for a fault in the circuit
for the primary speed/timing sensor. Refer to 1. Connect the electronic service tool to the
Troubleshooting, “Engine Speed/Timing Sensor diagnostic connector.
Circuit - Test”.
2. Check that the desired fuel rail pressure is at least
4. If the engine does not start, inspect the timing ring 25 MPa (3625 psi) when the engine is cranking.
on the crankshaft for misalignment.
3. If the desired fuel rail pressure is less than 25 MPa
5. If necessary, repair the timing ring. Refer to (3625 psi), perform the following procedure:
Disassembly and Assembly, “Crankshaft Timing
Ring - Remove and Install”. a. Use the electronic service tool to check the
signal from the secondary speed/timing sensor
6. Attempt to start the engine. If the engine will not while the engine is cranking.
start, proceed to “Low Pressure Fuel System”.
b. If the signal from the secondary speed/timing
Low Pressure Fuel System sensor is 0 rpm, investigate the secondary
speed/timing sensor. Refer to Troubleshooting,
1. If the temperature is below 0 °C (32 °F), check “Engine Speed/Timing Sensor Circuit - Test”.
for solidified fuel (wax).
c. If a fault is identified in the circuit for the
2. Check for fuel supply lines that are restricted. secondary speed/timing sensor, repair the fault
and then attempt to start the engine. If the
3. Check that the low pressure fuel lines are correctly engine will not start, proceed to “High Pressure
installed. Fuel System”.

4. Check the diesel fuel for contamination. Refer to d. If the signal from the secondary speed/timing
Systems Operation, Testing and Adjusting, “Fuel sensor is greater than 0 rpm and the engine
Quality - Test”. will not start, proceed to “High Pressure Fuel
System”.
5. Check for air in the fuel system. Refer to Systems
Operation, Testing and Adjusting, “Air in Fuel - High Pressure Fuel System
Test”.
1. Use the electronic service tool to check the
6. Ensure that the fuel system has been primed. absolute fuel rail pressure while the engine is
Refer to Systems Operation, Testing and cranking at a minimum speed of 150 rpm.
Adjusting, “Fuel System - Prime”.
SENR9969-05 55
Troubleshooting Section

2. If the absolute fuel rail pressure is less than a. Use the electronic service tool to make sure
25 MPa (3625 psi), perform the following that the status of the electronic unit injectors
procedure: is not “Disabled”. If the injectors are disabled
but the injectors were not intentionally disabled
a. Check that the inlet pressure at the fuel rail with the electronic service tool, proceed to test
pump is greater than 50 kPa (7.25 psi). If the step 3.d.
inlet pressure is less than 50 kPa (7.25 psi),
repeat the diagnostic process from “Low b. If the electronic unit injectors are not disabled,
Pressure Fuel System”. use the electronic service tool to perform an
injector solenoid test. Refer to Troubleshooting,
b. Check for fuel leaks in the high pressure “Injector Solenoid Circuit - Test”.
fuel system. Rectify any fuel leaks and then
recheck the pressure in the fuel rail. If the fuel c. If any service has been performed as a result
rail pressure is greater than 25 MPa (3625 psi), of Step 3.b, attempt to start the engine. If the
proceed to test step 3. engine will not start, proceed to “Glow Plugs”.

c. Use the electronic service tool to perform a d. Make sure that the latest flash file for the
solenoid test on the fuel rail pump. Refer to application is installed in the ECM. Refer to
Troubleshooting, “Fuel Rail Pump Solenoid - Troubleshooting, “Flash Programming”.
Test”.
e. Contact the technical communicator at the
d. If any service has been performed as a result Caterpillar dealer.
of Step 2.c, attempt to start the engine. If the
engine will not start, repeat the diagnostic Note: This consultation can greatly reduce the repair
process from “Diagnostic Codes”. time.

e. Check the pressure relief valve in the fuel f. If the technical communicator recommends the
rail for leakage. If the pressure relief valve is use of a test ECM, install a test ECM. Refer to
leaking, replace the valve and recheck the Troubleshooting, “Replacing the ECM”.
pressure in the fuel rail.
g. Attempt to start the engine. If the engine will not
f. If the pressure relief valve in the fuel rail is not start, install the original ECM and then proceed
leaking, check for fuel in the engine oil system. to Test Step 3.l.
If fuel is suspected in the oil system, take an
engine oil sample for analysis. Refer to the h. If the engine starts normally, stop the engine
Operation and Maintenance Manual, “Engine and then attempt to start the engine again. If
Oil Sample - Obtain”. If the analysis confirms the engine will not start at the second attempt,
that there is fuel in the engine oil system, proceed to Test Step 3.k.
investigate the cause.
i. If the engine starts normally, reconnect the
g. If fuel is not found in the oil system, check the suspect ECM and then verify that the fault
electronic unit injectors for excessive fuel leak returns when the suspect ECM is installed.
off. Refer to Special Instruction KENR6938,
“High Leakoff of the Electronic Unit Injector”. j. If the engine will not start with the suspect
ECM, replace the ECM. Check that the engine
h. If the leak off is greater than 38 mL (1.3 oz) starts normally. If the engine starts normally, no
in 30 seconds for a 6 cylinder engine or the further testing is required.
leak off is greater than 25 mL (0.85 oz) in 30
seconds for a 4 cylinder engine, replace the k. Replace the ECM again and then replace the
electronic unit injectors. fuel rail pump. Verify that the fault has been
eliminated. If the engine will not start, proceed
Note: The fault is not in the fuel rail pump. Do not to “Glow Plugs”.
replace the pump.
l. Check the timing of the fuel rail pump. Refer
i. If the leak off is less than 38 mL (1.3 oz) in 30 to Systems Operation, Testing and Adjusting,
seconds for a 6 cylinder engine or the leak off “Fuel Injection Timing - Check”.
is less than 25 mL (0.85 oz) in 30 seconds for
a 4 cylinder engine, proceed to Test Step 3.d. m. If the timing of the fuel rail pump required
adjustment and the engine will not start,
3. If the absolute fuel rail pressure is greater proceed to “Glow Plugs”.
than 25 MPa (3625 psi), perform the following
procedure:
56 SENR9969-05
Troubleshooting Section

n. If the timing of the fuel rail pump was correct, i03481180

replace the fuel rail pump. If the engine will not
start, proceed to “Glow Plugs”. Engine Has Early Wear
SMCS Code: 1000-035
Glow Plugs
Note: This is not a fault in the electronic system.
Note: Faulty glow plugs will only affect engine starting
when the ambient temperature is below 10 °C (50 °F).
Probable Causes
1. Check the operation of the glow plugs. Refer to
Systems Operation, Testing and Adjusting, “Glow • Multiple starts or cold operation
Plugs - Test”.
• Incorrect maintenance intervals
2. If necessary, replace faulty glow plugs. Refer to
Disassembly and Assembly, “Glow Plug - Remove • Dirt in engine oil
and Install”.
• Incorrect oil
3. Attempt to start the engine. If the engine will not
start, proceed to “Valve Lash”. • Contaminated oil

Valve Lash • Leaks in air intake system

1. Check the valve lash. Refer to Systems Operation, • Dirt in fuel

Testing and Adjusting, “Engine Valve Lash -
Inspect/Adjust”. • Low oil pressure

2. Attempt to start the engine. If the engine will not Recommended Actions
start, proceed to “Low Compression (Cylinder
Pressure)”. Multiple Starts or Cold Operation
Low Compression (Cylinder Pressure) Frequent starting and stopping of the engine can
cause early wear. Also, operation of the engine for
1. Perform a compression test. Refer to Systems short periods of time in cold conditions can cause
Operation, Testing and Adjusting, “Compression early wear.
- Test ”.
Incorrect Maintenance Intervals
2. If low compression is noted on any cylinders,
investigate the cause and rectify the cause. If the engine is not correctly maintained, early wear
will occur.
Possible causes of low compression are shown
in the following list: Make sure that the engine is maintained at the
correct maintenance intervals. Refer to the Operation
• Loose glow plugs and Maintenance Manual, “Maintenance Interval
Schedule”.
• Faulty piston
• Faulty piston rings Dirt in Engine Oil
1. Drain the oil from the crankcase and refill the
• Worn cylinder bores crankcase with clean engine oil. Install new engine
oil filters. Refer to the Operation and Maintenance
• Worn valves Manual for more information.
• Faulty cylinder head gasket
Incorrect Oil
• Damaged cylinder head
1. Check that the engine is filled with oil of the
3. Perform all necessary repairs. correct specification. Refer to the Operation and
Maintenance Manual, “Refill Capacities and
4. Ensure that the repairs have eliminated the fault. Recommendations”.
SENR9969-05 57
Troubleshooting Section

2. If necessary, drain the engine oil system and Probable Causes

refill the engine oil system. Refer to Operation
and Maintenance Manual, “Engine Oil and Filter • Diagnostic codes
- Change”.
• Throttle position sensor
Contaminated Oil
• Air intake and exhaust system
Check an oil sample for contamination with fuel. If
contamination is found, investigate the cause. • Fuel supply

Leaks in Air Intake System • Fuel rail pump

A leak in the air intake system may allow unfiltered • Low compression (cylinder pressure)
air into the engine. Inspect the air intake system for
streaks which may indicate a leakage of unfiltered air. • Individual malfunctioning cylinder
Inspect all of the gaskets and the connections. Repair
any leaks. Refer to Systems Operation, Testing and • Electronic unit injectors
Adjusting, “Air Intake System” for more information.
Recommended Actions
Dirt in Fuel
Diagnostic Codes
1. Remove the fuel filters. Inspect the fuel filters for
contamination. Install new fuel filters. Refer to Use the electronic service tool to check for active
the Operation and Maintenance Manual, “Fuel diagnostic codes. Troubleshoot any active codes
System Filter- Replace” and Operation and before continuing with this procedure.
Maintenance Manual, “Fuel System Primary Filter
(Water Separator) Element - Replace”. Determine Throttle Position Sensor
the cause of the contamination.
1. Use the electronic service tool and observe the
2. Check the diesel fuel for contamination. Refer to signal for the throttle position sensor. Make sure
Systems Operation, Testing and Adjusting, “Fuel that the throttle reaches the 100% raw position
Quality - Test”. and the calibrated position.

Low Oil Pressure 2. If the signal is erratic, refer to Troubleshooting,

“Analog Throttle Position Sensor Circuit - Test” or
Refer to Troubleshooting, “Low Engine Oil Pressure” Troubleshooting, “Digital Throttle Position Sensor
for the testing procedure. Repair any identified faults. Circuit - Test”.

3. If the engine has a 10 position throttle switch refer

i03481200 to Troubleshooting, “Throttle Switch Circuit - Test”.
Engine Misfires, Runs Rough 4. If the repairs do not eliminate the fault proceed to
or Is Unstable “Air Intake and Exhaust System”.

SMCS Code: 1000-035 Air Intake and Exhaust System

The probable root causes are listed in order below: 1. Check the air filter restriction indicator, if equipped.
Note: If the fault is intermittent and the fault cannot 2. Ensure that the air filter is clean and serviceable.
be duplicated, refer to Troubleshooting, “Intermittent
Low Power or Power Cutout”. 3. Check the air intake and exhaust systems for the
following defects:
Note: If the fault only occurs under certain conditions,
test the engine under those conditions. Examples • Blockages
of certain conditions are high rpm, full load and
engine operating temperature. Troubleshooting • Restrictions
the symptoms under other conditions can give
misleading results. • Damage to lines or hoses
4. If the repairs do not eliminate the fault proceed to
“Fuel Supply”.
58 SENR9969-05
Troubleshooting Section

Fuel Supply Possible causes of low compression are shown

in the following list:
1. Visually check the fuel tank for fuel. The fuel
gauge may be faulty. • Loose glow plugs
2. Ensure that the fuel supply valve (if equipped) is • Faulty piston
in the full OPEN position.
• Faulty piston rings
3. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax). • Worn cylinder bores
4. Check the primary filter/water separator for water • Worn valves
in the fuel.
• Faulty cylinder head gasket
5. Check for fuel supply lines that are restricted.
• Damaged cylinder head
6. Check that the low pressure fuel lines are tight
and secured properly. 3. Perform all necessary repairs.

7. Check the fuel filters. 4. Ensure that the repairs have eliminated the faults.

8. Check the diesel fuel for contamination. Refer to 5. If the repair does not eliminate the fault refer to
Systems Operation, Testing and Adjusting, “Fuel “Individual Malfunctioning Cylinders”.
Quality - Test”.
Individual Malfunctioning Cylinders
9. Check for air in the fuel system. Refer to Systems
Operation, Testing and Adjusting, “Air in Fuel - 1. With the engine speed at a fast idle, use the
Test”. electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine
10. Ensure that the fuel system has been primed. speed. If a reduction in engine speed is not noted,
Refer to Systems Operation, Testing and the isolated cylinder is not operating under normal
Adjusting, “Fuel System - Prime”. conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less
11. Check the fuel pressure. Refer to Systems than normal, this may indicate that the cylinder is
Operation, Testing and Adjusting, “Fuel System operating below normal performance. Investigate
Pressure - Test”. the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault
12. If the repair does not eliminate the fault refer to on any cylinder that is operating below normal
“Fuel Rail Pump”. performance.

Fuel Rail Pump 2. Rectify any faults.

Note: The fuel rail pump that is installed by the 3. If all cylinders have been checked and no
factory is a nonserviceable item. If any fault occurs faults were detected proceed to “Electronic Unit
within the fuel rail pump, the fuel rail pump must be Injectors”.
replaced.
Electronic Unit Injectors
1. Use the electronic service tool to select the
correct screen display. Refer to Troubleshooting, 1. With the engine speed at a fast idle, use the
“Troubleshooting with a Diagnostic Code”. electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine
2. If the fault is not eliminated, refer to “Low speed. If a reduction in engine speed is not noted,
Compression (Cylinder Pressure)”. the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a
Low Compression (Cylinder Pressure) particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate
1. Perform a compression test. Refer to Systems that the electronic unit injector is operating below
Operation, Testing and Adjusting, “Compression normal performance.
- Test ”.
2. Remove the electronic unit injector from the
2. If low compression is noted on any cylinders, suspect cylinder. Refer to Disassembly and
investigate the cause and rectify the cause. Assembly, “Electronic Unit Injector - Remove”.
SENR9969-05 59
Troubleshooting Section

3. Install a new electronic unit injector. Refer to 3. To fit a new cylinder head gasket, refer to
Disassembly and Assembly, “Electronic Unit Disassembly and Assembly, “Cylinder Head -
Injector - Install”. Install” for the correct procedure.

4. Repeat the test in 1. If the fault is still apparent, 4. If there was no obvious signs of a faulty head
remove the replacement electronic unit injector gasket proceed to the recommended actions for
and install the original electronic unit injector. the Cylinder Head.
Refer to Disassembly and Assembly, “Electronic
Unit Injector - Remove” and Disassembly and Cylinder Head
Assembly, “Electronic Unit Injector - Install”.
1. Check the cylinder head for flatness. Refer
5. If the fault is not eliminated, repeat this test to Systems Operation, Testing and Adjusting,
procedure from Test Step 1. “Cylinder Head - Inspect” for the correct procedure.

i03481207
2. Check the mating face of the cylinder head
for faults and signs of leakage. If a fault is
Engine Oil in Cooling System found, replace the cylinder head. If signs of
leakage are found, determine the cause of the
SMCS Code: 1350-035 leakage. Refer to Systems Operation, Testing and
Adjusting, “Cylinder Head - Inspect” for the correct
Note: This is not a fault in the electronic system. procedure.

3. If the cylinder head is flat and if the cylinder head

Probable Causes does not have any faults, refer to “Cylinder Block”.
• Engine oil cooler
Cylinder Block
• Cylinder head gasket
Inspect the top face of the cylinder block for faults
• Cylinder head and signs of leakage. If a fault is found, replace
the cylinder block. If signs of leakage are found,
• Cylinder block determine the cause of the leakage. Refer to Systems
Operation, Testing and Adjusting, “Cylinder Block -
Inspect” for the correct procedure.
Recommended Actions
Assembly after Repair
Engine Oil Cooler
1. Install the cylinder head. Refer to Disassembly
1. Drain the coolant from the cooling system. Drain and Assembly, “Cylinder Head - Install”.
the lubricating oil from the engine oil cooler. Refer
to the Operation and Maintenance Manual for 2. Replenish the engine with clean engine oil to
more information. the correct level. Refer to the Operation and
Maintenance Manual, “Engine Oil and Filter -
2. Check for leaks in the oil cooler assembly. Refer Change” for more information.
to Systems Operation, Testing and Adjusting,
“Cooling System” for the correct procedure. If a 3. Fill the cooling system. Refer to the Operation and
leak is found, install a new oil cooler. Refer to Maintenance Manual, “Cooling System Coolant
Disassembly and Assembly, “Engine Oil Cooler (ELC) - Change”.
- Remove” and Disassembly and Assembly,
“Engine Oil Cooler - Install” for the correct
procedure. i02534831

Cylinder Head Gasket

Engine Speed Does Not
Change
1. Remove the cylinder head. Refer to Disassembly
and Assembly, “Cylinder Head - Remove” for the SMCS Code: 1915-035
correct procedure.
Note: Use this procedure only if the engine speed
2. Inspect the cylinder head gasket for faults and any does not change. This fault will not occur in a
signs of leakage. generator set application.
60 SENR9969-05
Troubleshooting Section

Probable Causes • Fuel supply

• Diagnostic codes • Electronic unit injectors
• Multi-position throttle switch Recommended Actions
• Throttle position sensor
Diagnostic Codes
Recommended Repairs Use the electronic service tool to check for active
diagnostic codes. Troubleshoot any active codes
Diagnostic Codes before continuing with this procedure.

Check for active diagnostic codes on the electronic Accessory Equipment

service tool. Troubleshoot any active codes before
continuing with this procedure. Check all accessory equipment for faults that may
create excessive load on the engine. Repair any
Use the electronic service tool to check the setup of damaged components or replace any damaged
the throttle. components.

Multi-position Throttle Switch If there are no faults with the accessory equipment,
refer to “Power Mode Control (If Equipped)”.
Note: When the engine is operating and the fault
occurs, the configuration of the throttle will not Power Mode Control (If Equipped)
change. The configuration of the throttle only needs
to be checked if the engine has never run. 1. Check whether the power mode control is using
the data link or the CAN data link and then use the
If a fault in the multi-position throttle switch is appropriate test. Refer to Troubleshooting, “Data
suspected, refer to Troubleshooting, “Throttle Switch Link Circuit - Test” or Troubleshooting, “CAN Data
Circuit - Test”. Link Circuit - Test”.

Throttle Position Sensor 2. Check the engine wiring harness for defects.
Refer to Troubleshooting, “Electricial Connectors
Refer to Troubleshooting, “Analog Throttle Position - Inspect”.
Sensor Circuit - Test” or Troubleshooting, “Digital
Throttle Position Sensor Circuit - Test” if any of the 3. If there are no apparent faults, refer to “Fuel
following diagnostic codes are active: Supply”.

• 0041-03 8 Volt DC Supply voltage above normal Fuel Supply

• 0041-04 8 Volt DC Supply voltage below normal 1. Visually check the fuel tank for fuel. The fuel
gauge may be faulty.
• 0091-08 Throttle Position Sensor abnormal
frequency, pulse width or period 2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position.
• 0774-08 Sec Throttle Position Sensor abnormal
frequency, pulse width or period 3. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
i03481222
4. Check the primary filter/water separator for water
Engine Stalls at Low RPM in the fuel.

SMCS Code: 1915-035 5. Check for fuel supply lines that are restricted.

6. Check that the low pressure fuel lines are tight

Probable Causes and secured properly.
• Diagnostic codes 7. Check the fuel filters.
• Accessory equipment 8. Check the diesel fuel for contamination. Refer to
Systems Operation, Testing and Adjusting, “Fuel
• Power mode control (if equipped) Quality - Test”.
SENR9969-05 61
Troubleshooting Section

9. Check for air in the fuel system. Refer to Systems Probable Causes
Operation, Testing and Adjusting, “Air in Fuel -
Test”. • Vibration damper
10. Ensure that the fuel system has been primed. • Engine supports
Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Prime”. • Low compression (cylinder pressure)
11. Check the fuel pressure. Refer to Systems • Individual malfunctioning cylinder
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”. • Electronic unit injectors
12. If necessary, repair any faults.
Recommended Actions
13. If there are no apparent faults, refer to “Electronic
Unit Injectors”. Vibration Damper
Check the vibration damper for damage. If necessary,
Electronic Unit Injectors install a new vibration damper. Inspect the mounting
bolts for damage and/or for wear. Replace any
1. With the engine speed at a fast idle, use the
damaged bolts. Refer to Disassembly and Assembly,
electronic service tool to isolate one cylinder at
“Vibration Damper and Pulley - Remove” and
a time. Note if there is any reduction in engine
Disassembly and Assembly, “Vibration Damper and
speed. If a reduction in engine speed is not noted,
Pulley - Install”.
the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a
Ensure that the repairs have eliminated the fault.
particular cylinder results in a reduction of engine
If the vibration is still present proceed to “Engine
speed that is less than normal, this may indicate
Supports”.
that the electronic unit injector is operating below
normal performance.
Engine Supports
2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and 1. Check for any of the following conditions:
Assembly, “Electronic Unit Injector - Remove”.
• Loose engine supports
3. Install a new electronic unit injector. Refer to
Disassembly and Assembly, “Electronic Unit • Loose mounting brackets or broken mounting
Injector - Install”. brackets

4. Repeat the test in 1. If the fault is still apparent, • Loose bolts

remove the replacement electronic unit injector
and install the original electronic unit injector. • Omitted bolts
Refer to Disassembly and Assembly, “Electronic
Unit Injector - Remove” and Disassembly and 2. Make all necessary repairs. Ensure that the
Assembly, “Electronic Unit Injector - Install”. repairs have eliminated the fault. If the vibration
is still present proceed to “Low Compression
5. If the fault is not eliminated, repeat this test (Cylinder Pressure)”.
procedure from Test Step 1.
Low Compression (Cylinder Pressure)
i03481242
1. Perform a compression test. Refer to Systems
Engine Vibration Operation, Testing and Adjusting, “Compression
- Test ”.
SMCS Code: 1000-035
2. If low compression is noted on any cylinders,
Note: This is not a fault in the electronic system. investigate the cause and rectify the cause.

Refer to Systems Operation, Testing and Adjusting Possible causes of low compression are shown
for information on determining the cause of this in the following list:
condition.
• Loose glow plugs
• Faulty piston
62 SENR9969-05
Troubleshooting Section

• Faulty piston rings 4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
• Worn cylinder bores and install the original electronic unit injector.
Refer to Disassembly and Assembly, “Electronic
• Worn valves Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.
• Faulty cylinder head gasket
5. If the fault is still apparent, repeat this test
• Damaged cylinder head procedure from Test Step 1.

3. Perform all necessary repairs.

i03481325

4. Ensure that the repairs have eliminated the fault. Engine Will Not Crank
5. If the repair does not eliminate the fault refer to SMCS Code: 1000-035
“Malfunctioning Individual Cylinder”.

Malfunctioning Individual Cylinder Probable Causes

1. With the engine speed at a fast idle, use the • Machine security system (if equipped)
electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine • Battery cables and/or batteries
speed. If a reduction in engine speed is not noted,
the isolated cylinder is not operating under normal • Starting motor solenoid or starting circuit
conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less • Starting motor and/or flywheel ring gear
than normal, this may indicate that the cylinder is
operating below normal performance. Investigate • Electrical power supply
the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault • Internal engine fault
on any cylinder that is operating below normal
performance. Recommended Repairs
2. If all cylinders have been checked and no Machine Security System (If Equipped)
faults were detected proceed to “Electronic Unit
Injectors”. 1. Verify that the correct ignition key is being used.
Turn the keyswitch to the ON position.
Electronic Unit Injectors
2. Use the electronic service tool in order to check if
1. With the engine speed at a fast idle, use the diagnostic code 1639-09 is active. Verify that the
electronic service tool to isolate one cylinder at lamp for the machine security system is on.
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted, 3. If diagnostic code 1639-09 is active, the machine
the isolated electronic unit injector is not operating security system is armed. Deactivate the machine
under normal conditions. If the isolation of a security system and try to start the engine.
particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate 4. If the engine will not start, use the electronic
that the electronic unit injector is operating below service tool to check for logged diagnostic codes.
normal performance.
5. Make repairs for all diagnostic codes. Ensure that
2. Remove the electronic unit injector from the the repair has eliminated the fault.
suspect cylinder. Refer to Disassembly and
Assembly, “Electronic Unit Injector - Remove”. 6. If there are no active diagnostic codes, refer to
the Troubleshooting Manual for your machine
3. Install a new electronic unit injector. Refer to application.
Disassembly and Assembly, “Electronic Unit
Injector - Install”.
SENR9969-05 63
Troubleshooting Section

Battery Cables and/or Batteries 5. Inspect the internal components for the following
conditions:
1. Inspect the main power switch, battery posts,
and battery cables for loose connections and • Seizure
corrosion. If the battery cables are corroded,
remove the battery cables and clean the battery • Failure
cables. Clean the battery posts. Replace the
cables. Tighten any loose connections. • Distortion
2. Inspect the batteries.
i03481368

a. Charge the batteries. Excessive Black Smoke

b. Load test the batteries. Refer to Systems SMCS Code: 1088-035
Operation, Testing and Adjusting, “Battery -
Test”.
Probable Causes
Starting Motor Solenoid or Starting
• Diagnostic codes
Circuit
• ECM software
1. Test the operation of the starting motor solenoid.
Refer to Systems Operation, Testing and • Air intake system or exhaust system
Adjusting, “Electric Starting System - Test”.
• Valve lash
2. Check the wiring to the starting motor solenoid.
• Turbocharger
Starting Motor and/or Flywheel Ring Gear
• Low compression (cylinder pressure)
1. Test the operation of the starting motor. Check the
wiring for the starting motor. Refer to Systems • Individual malfunctioning cylinder
Operation, Testing and Adjusting, “Electric Starting
System - Test”. • Electronic unit injectors
2. Inspect the pinion on the starting motor and the
flywheel ring gear for damage.
Recommended Actions
Diagnostic Codes
Electrical Power Supply
Use the electronic service tool to check for active
If there is no electrical power supply, investigate the
diagnostic codes. Troubleshoot any active codes
cause and rectify any defects. Refer to Systems
before continuing with this procedure.
Operation, Testing and Adjusting, “Charging System
- Test”.
ECM Software
Internal Engine Fault 1. Connect the electronic service tool to the
diagnostic connector and check for the following
1. Remove the glow plugs. Refer to Disassembly
conditions:
and Assembly, “Glow Plugs - Remove and Install”.

2. Attempt to rotate the crankshaft through 360 • Check for the correct engine serial number
degrees in both direction. If the crankshaft rotates
correctly but fluid is expelled from the hole for the • Check for the correct arrangement number
glow plug, investigate the cause of the fluid in the
cylinder. • Check for the correct software
2. Use the electronic service tool to verify any active
3. If the crankshaft rotates correctly and no fluid
diagnostic codes.
is expelled, install the glow plugs. Refer to
Disassembly and Assembly, “Glow Plugs -
3. If diagnostic codes are present, the Electronic
Remove and Install”.
Control Module (ECM) must be programmed with
the correct information.
4. If the engine does not rotate in Step 2, disassemble
the engine. Refer to Disassembly and Assembly.
64 SENR9969-05
Troubleshooting Section

4. If the repairs have not eliminated the fault proceed 7. If necessary, replace the turbocharger. Refer
to “Air Intake System or Exhaust System”. to Disassembly and Assembly, “Turbocharger
- Remove” and Disassembly and Assembly,
Air Intake System or Exhaust System “Turbocharger - Install”.

1. Check the air filter restriction indicator, if equipped. 8. Check that the repairs have eliminated the faults.

2. Ensure that the air filter is clean and serviceable. 9. If the repairs have not eliminated the fault proceed
to “Low Compression (Cylinder Pressure)”.
3. Check the air intake and the exhaust system for
the following defects: Low Compression (Cylinder Pressure)
• Blockages 1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression
• Restrictions - Test ”.

• Damage to the air intake and exhaust lines and 2. If low compression is noted on any cylinders,
hoses investigate the cause and rectify the cause.

4. Make all necessary repairs to the engine. Possible causes of low compression are shown
in the following list:
5. If the fault has not been eliminated, proceed to
“Valve Lash”. • Loose glow plugs

Valve Lash • Faulty piston

Ensure that the valve lash is correct. Reset the • Faulty piston rings
valve lash if it is not correct. Refer to Systems
Operation, Testing and Adjusting, “Engine Valve Lash • Worn cylinder bores
- Inspect/Adjust”.
• Worn valves
If the repair does not eliminate the fault proceed to
“Turbocharger”. • Faulty cylinder head gasket

Turbocharger • Damaged cylinder head

3. Perform all necessary repairs.
Note: The turbocharger that is installed on this
engine is a nonserviceable item. If any mechanical 4. Ensure that the repairs have eliminated the faults.
fault exists, then the turbocharger must be replaced.
5. If the repair does not eliminate the fault refer to
1. Ensure that the mounting bolts for the turbocharger “Individual Malfunctioning Cylinder”.
are tight.

2. Check that the oil drain for the turbocharger is not Individual Malfunctioning Cylinder
blocked or restricted.
1. With the engine speed at a fast idle, use the
3. Check that the compressor housing for the electronic service tool to isolate one cylinder at
turbocharger is free of dirt, debris and damage. a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
4. Check that the turbine housing for the turbocharger the isolated cylinder is not operating under normal
is free of dirt, debris and damage. conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less
5. Check that the turbine blades rotate freely in the than normal, this may indicate that the cylinder is
turbocharger. operating below normal performance. Investigate
the cause of the fault on any cylinder that is
6. Ensure that the wastegate on the turbocharger is not operating. Investigate the cause of the fault
adjusted correctly. Refer to Systems Operation, on any cylinder that is operating below normal
Testing and Adjusting, “Wastegate - Inspect”. performance.
If the wastegate actuator is faulty, replace the
turbocharger. Refer to Disassembly and Assembly, 2. If all cylinders have been checked and no
“Turbocharger - Remove” and Disassembly and faults were detected proceed to “Electronic Unit
Assembly, “Turbocharger - Install”. Injectors”.
SENR9969-05 65
Troubleshooting Section

Electronic Unit Injectors 2. If the oil consumption is greater than 0.2% of the
fuel consumption, use the following procedure
1. With the engine speed at a fast idle, use the in order to investigate the cause of the high oil
electronic service tool to isolate one cylinder at consumption.
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted, Oil Leaks
the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a 1. Check for evidence of oil leaks on the engine.
particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate 2. Rectify any oil leaks from the engine.
that the electronic unit injector is operating below
normal performance. 3. Check for evidence of oil in the coolant.
2. Remove the electronic unit injector from the 4. If no oil leaks are identified, refer to “Engine
suspect cylinder. Refer to Disassembly and Crankcase Breather”.
Assembly, “Electronic Unit Injector - Remove”.

3. Install a new electronic unit injector. Refer to Engine Crankcase Breather

Disassembly and Assembly, “Electronic Unit
1. Check the engine crankcase breather for blockage
Injector - Install”.
or restrictions.
4. Repeat the test in 1. If the fault is still apparent,
2. Check for excessive oil from the outlet of the
remove the replacement electronic unit injector
and install the original electronic unit injector. breather.
Refer to Disassembly and Assembly, “Electronic
3. Repair all defects. Verify that the repair has
Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”. eliminated the fault.

4. If no faults are found, refer to “Oil Level”.

5. If the fault is not eliminated, refer to the
Troubleshooting Manual for the application.
Oil Level
i03481460 1. Check the oil level in the engine.
Excessive Engine Oil 2. If the oil level is high, check for contamination
Consumption of the oil with coolant. Refer to Troubleshooting,
“Coolant in Engine Oil”.
SMCS Code: 1300-035
3. If no contamination is identified, remove any
excess oil.
Probable Causes
4. If the oil level is satisfactory, refer to “Air Intake
• Misreading oil level and Exhaust System”.
• Oil leaks
Air Intake and Exhaust System
• Engine crankcase breather
1. Check the air filter restriction indicator, if equipped.
• Oil level
2. Ensure that the air filter is clean and serviceable.
• Air intake and exhaust system
3. Check the air intake and the exhaust system for
• Turbocharger the following defects:

• Low compression (cylinder pressure) • Blockages

• Restrictions
Recommended Actions
• Damage to the air intake and exhaust lines and
Misreading Oil Level hoses

1. Accurately measure the consumption of oil and 4. Make all necessary repairs to the engine.
fuel over a period of 50 engine hours.
5. Ensure that the repairs have eliminated the fault.
66 SENR9969-05
Troubleshooting Section

6. If no faults are found, refer to “Turbocharger”. i03481624

Turbocharger
Excessive Fuel Consumption
SMCS Code: 1250-035
Note: The turbocharger that is installed on this
engine is a nonserviceable item. If any mechanical
fault exists, then the turbocharger must be replaced. Probable Causes
1. Check that the oil drain for the turbocharger is not • Diagnostic codes
blocked or restricted.
• Misreading of fuel level
2. Check the turbocharger for evidence of internal
oil leaks. • Fuel quality
3. If necessary, replace the turbocharger. Refer • Quality of oil
to Disassembly and Assembly, “Turbocharger
- Remove” and Disassembly and Assembly, • Low engine temperature
“Turbocharger - Install”.
• Prolonged operation at idle speed
4. Check that the repairs have eliminated the faults.
• Engine operating speed
5. If the repairs have not eliminated the fault proceed
to “Low Compression (cylinder pressure)”. • Air intake and exhaust system

Low Compression (cylinder pressure) • Reduced pressure of intake air

1. Perform a compression test. Refer to Systems • Excessive valve lash

Operation, Testing and Adjusting, “Compression
- Test ”. • Failure of the primary speed/timing sensor

2. If low compression is noted on any cylinders, Recommended Actions

investigate the cause and rectify the cause.
Diagnostic Codes
Possible causes of low compression are shown
in the following list: 1. Use the electronic service tool to check for any
diagnostic codes that may be related to high fuel
• Loose glow plugs consumption.
• Faulty piston Misreading of Fuel Level
• Worn piston rings 1. Monitor the fuel consumption over a period of 50
engine hours. If the fuel consumption is excessive,
• Worn cylinder bores perform the following procedure.
• Worn valves
Fuel Quality
• Faulty cylinder head gasket
1. The quality of the fuel that is used in the engine
• Damaged cylinder head will affect the rate of fuel consumption. Refer to
“General Fuel Information” in the Operation and
3. Perform all necessary repairs. Maintenance Manual, “Refill Capacities”.

4. Ensure that the repairs have eliminated the faults. 2. If the fuel is not of an acceptable quality, drain
the fuel system and replace the fuel filters. Refill
5. If the fault is not eliminated, refer to the the fuel system with fuel of an acceptable quality.
Troubleshooting Manual for your engine Refer to the applicable sections in the Operation
application. and Maintenance Manual.

3. If the fuel is of an acceptable quality, refer to

“Quality of Oil”.
SENR9969-05 67
Troubleshooting Section

Quality of Oil Operation of the engine for long periods at idle

speed will cause a deterioration of the internal
1. The nominal viscosity of the lubricating oil that components of the engine. A deterioration of the
is used in the engine will affect the rate of fuel internal components of the engine will increase fuel
consumption. The viscosity of lubricating oil is consumption.
defined by the SAE grade of the lubricating oil.
The grade of the lubricating oil must be correct Engine Operating Speed
for the ambient conditions. Lubricating oil that is
intended for use in high ambient temperatures The operating speed of the engine will affect the rate
will have a negative effect upon the rate of fuel of fuel consumption.
consumption in cold ambient temperatures. Refer
to “Engine Oil” in the Operation and Maintenance High engine speed will increase fuel consumption.
Manual, “Refill Capacities”. At high engine speeds, internal power losses in
the engine increase and more power is required to
2. The actual viscosity of the lubricating oil that is drive the alternator and the fan. These power losses
used in the engine will change throughout the increase fuel consumption.
service life of the oil. Lubricating oil that is heavily
contaminated will have a negative effect upon the Lugging down the engine to a low engine speed will
rate of fuel consumption. increase fuel consumption. At low engine speeds, the
combustion efficiency of the engine is reduced. This
3. If the oil is not of an acceptable quality or if the will require more fuel to be used.
oil has exceeded the service life, drain the oil
system and replace the oil filters. Refill the oil
system with oil of an acceptable quality. Refer Air Inlet and Exhaust System
to the applicable sections in the Operation and
Leakage of gas or an increased restriction in either
Maintenance Manual.
the air intake or the exhaust system can reduce
the flow of combustion gas through the engine. A
4. If the oil is of an acceptable quality, refer to “Low
change in the flow of combustion air into the engine
Engine Temperature”.
adversely affects combustion efficiency and the rate
of fuel consumption.
Low Engine Temperature
1. Check the air intake system for leakage or
1. The operating temperature of the engine will affect restrictions. Refer to Systems Operation, Testing
the rate of fuel consumption. Operation of the and Adjusting, “Air Inlet and Exhaust System”.
engine below the correct temperature will increase
fuel consumption. Failure of the water temperature 2. Check the exhaust system for leakage or
regulator can prevent the engine from operating at restrictions. Refer to Systems Operation, Testing
the correct temperature. and Adjusting, “Air Inlet and Exhaust System”.
2. If the engine operating temperature is low, check 3. Repair all defects. Verify that the repair has
the operation of the water temperature regulator. If eliminated the fault.
the water temperature regulator does not operate
correctly, a new water temperature regulator must
be installed. Refer to Disassembly and Assembly,
Reduced Pressure of Intake Air
“Water Temperature Regulator - Remove and
1. If the pressure of the intake air at the intake
Install”.
manifold is lower than normal, either the speed
of the engine will need to be higher or more fuel
Prolonged Operation at Idle Speed must be injected in order to produce the same
power. Either of these conditions will increase the
Prolonged operation of the engine at idle speed fuel consumption.
increases fuel consumption.
Note: If the engine is equipped with a wastegate
When the engine is operated at idle speed, the fuel regulator, low pressure in the air intake will create a
that is consumed provides no useful work. Prolonged 526-07 diagnostic code.
operation at idle speed will cause a measurable
deterioration in the overall fuel consumption of the 2. Check the pipe from the outlet of the turbocharger
engine. compressor to the intake manifold for leaks. If
necessary, repair any leaks.
68 SENR9969-05
Troubleshooting Section

3. Check for the correct operation of the wastegate Recommended Actions

in the turbocharger. Refer to Systems Operation,
Testing and Adjusting, “Turbocharger Wastegate - Lubrication
Test”.
1. Remove the valve mechanism cover. Refer to
4. If the turbocharger is suspected as being faulty, Disassembly and Assembly, “Valve Mechanism
replace the turbocharger. Refer to Disassembly Cover - Remove and Install” for the correct
and Assembly, “Turbocharger - Remove” and procedure.
Disassembly and Assembly, “Turbocharger -
Install”. 2. Crank the engine and check the lubrication in the
valve compartment. Ensure that there is adequate
Excessive Valve Lash engine oil flow in the valve compartment. The
passages for the engine oil must be clean.
Excessive valve lash will cause a change in the
timing of the opening and closing of the inlet and Note: Do not run the engine without the valve
exhaust valves. Excessive valve lash can cause mechanism cover.
a reduction of the flow of combustion air into the
engine. Reduced flow of combustion air will increase Valve Train Components
the fuel consumption rate.
1. Inspect the following components of the valve
Refer to the Troubleshooting Guide, “Excessive Valve train:
Lash”.
• Rocker arms
Failure of the Primary Speed/Timing
Sensor • Valve bridges
If the primary speed/timing sensor fails, the engine • Pushrods
will continue to operate using the signal from the
secondary speed/timing sensor on the fuel rail • Valve lifters
pump. The secondary speed/timing sensor is less
precise than the primary speed/timing sensor. Timing • Camshaft
differences between the secondary speed/timing
sensor and the primary speed/timing sensor may • Valve stems
cause an increase in fuel consumption.
• Rocker shaft
1. Use the electronic service tool to check for
active diagnostic codes that relate to the primary 2. Check the components for the following conditions:
speed/timing sensor. abnormal wear, excessive wear, straightness,
and cleanliness. If necessary, use new parts for
2. If necessary, replace the primary speed/timing replacement.
sensor. Refer to Disassembly and Assembly,
“Speed/Timing Sensor - Remove and Install”. Note: If the camshaft is replaced, new valve lifters
must also be used.

i03481662
Valve Lash
Excessive Valve Lash Adjust the valve lash of the engine. Refer to Systems
SMCS Code: 1105-035 Operation, Testing and Adjusting, “Engine Valve Lash
- Inspect/Adjust” for the correct procedure.
Note: This is not a fault in the electronic system.
i03481665
Probable Causes Excessive White Smoke
• Lubrication SMCS Code: 1088-035
• Valve train components Note: Some white smoke may be present during
cold start-up conditions when the engine is operating
• Valve lash normally. If the white smoke persists, there may be a
fault.
SENR9969-05 69
Troubleshooting Section

Probable Causes 2. If the repair does not eliminate the fault refer to
“Valve Lash”.
• Coolant temperature sensor circuit
Valve Lash
• Low coolant temperature
1. Ensure that the valve lash is correct. Refer
• Glow plugs to Systems Operation, Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust”.
• Fuel quality
2. If the repair does not eliminate the fault proceed to
• Valve lash “Low Compression (cylinder pressure)”.

• Low compression (cylinder pressure) Low Compression (cylinder pressure)

• Individual malfunctioning cylinder 1. Perform a compression test. Refer to Systems
Operation, Testing and Adjusting, “Compression
Recommended Actions - Test ”.

Coolant Temperature Sensor Circuit 2. If low compression is noted on any cylinders,

investigate the cause and rectify the cause.
1. Connect the electronic service tool to the
diagnostic connector. Possible causes of low compression are shown
in the following list:
2. Monitor the display screen on the electronic
service tool in order to verify the presence of active • Loose glow plugs
diagnostic codes for the coolant temperature.
Refer to Troubleshooting, “Engine Temperature • Faulty piston
Sensor Open or Short Circuit - Test”.
• Faulty piston rings
3. If the fault has not been eliminated, proceed to
“Low Coolant Temperature”. • Worn cylinder bores

Low Coolant Temperature • Worn valves

Check that the water temperature regulator is • Faulty cylinder head gasket
operating correctly. Refer to Systems Operation,
Testing and Adjusting, “Water Temperature Regulator • Damaged cylinder head
- Test”.
3. Perform all necessary repairs.
If the water temperature regulator is operating
4. Ensure that the repair has eliminated the fault.
correctly, refer to “Glow Plugs”.
5. If the repair does not eliminate the fault refer to
Glow Plugs “Individual Malfunctioning Cylinder”.
1. Check for correct operation of the glow plugs.
Refer to Systems Operation, Testing and
Individual Malfunctioning Cylinder
Adjusting, “Glow Plugs - Test”.
1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
2. If the repairs do not eliminate the fault refer to
a time. Note if there is any reduction in engine
“Fuel Quality”.
speed. If a reduction in engine speed is not noted,
the isolated cylinder is not operating under normal
Fuel Quality conditions. If the isolation of a particular cylinder
results in a reduction of engine speed that is less
1. Check the diesel fuel for quality. Refer to Systems than normal, this may indicate that the cylinder is
Operation, Testing and Adjusting, “Fuel Quality - operating below normal performance. Investigate
Test”. the cause of the fault on any cylinder that is
not operating. Investigate the cause of the fault
Note: Diesel fuel with a low cetane value is likely to on any cylinder that is operating below normal
cause white smoke. performance.

2. Rectify any faults.

70 SENR9969-05
Troubleshooting Section

3. If the fault has not been eliminated, repeat this Intake Air Restriction
test procedure from Test Step 1.
1. Check for blocked air filters. Check for obstructions
in the air intake.
i02358838

Intake Air Temperature Is Too 2. Replace the air filters or remove the obstruction
from the air intake.
High
High Altitude
SMCS Code: 1058-035-TA
Make sure that the settings for the engine are correct
Probable Causes for the altitude.

• High ambient air temperature Intake Air from a Heated Area

• Intake air restriction and/or high altitude 1. Ensure that the air inlet system is not receiving
air from a heated area.
• Intake air from a heated area
2. If necessary, relocate the air supply to the intake
• Intake manifold air temperature sensor and/or manifold to the outside of the engine enclosure.
circuit
3. Check for air leaks in the pipe between the air inlet
• Insufficient ambient air flow over the engine and the inlet to the turbocharger compressor.

• Reduced ambient air flow through the air charge Intake Manifold Air Temperature Sensor
cooler
and/or the Circuit
• Reduced flow of intake air through the air charge 1. Allow the intake manifold air temperature sensor
cooler
to cool and remove the sensor. Check the reading
for the intake air temperature. If the sensor is
Recommended Actions operating correctly, the reading and the ambient
temperature are approximately equal.
High Ambient Air Temperature
2. If the readings are approximately equal, reinstall
1. Determine if the ambient air temperature is within the sensor.
the design specifications for the cooling system
and the air charge cooler. 3. If the reading is not correct, replace the sensor
with a sensor that is known to be good. Verify that
2. When the ambient temperature exceeds the the fault is eliminated.
capability of the cooling system or the air charge
cooler, operate the engine at a reduced load or Insufficient Ambient Air Flow over the
operate the engine at a reduced speed. Engine
3. When possible, modify the cooling system and 1. If equipped, check the condition of the cooling fan
the air charge cooler in order to make the system and the drive belt.
suitable for local conditions.
2. If equipped, check that the cooling fan is operating
Intake Air Restriction and/or High Altitude correctly.

Low air pressure at the air intake for the turbocharger Reduced Ambient Air Flow through the
can be caused by a restriction in the air intake or a
high altitude. When the pressure of the intake air
Air Charge Cooler
is low, the turbocharger (if equipped) works harder
1. Check that the ambient air flow through the air
in order to achieve the desired intake manifold
charge cooler is not obstructed.
pressure. This increases intake air temperature.
2. Inspect the air charge cooler for contamination
Measure the intake manifold pressure while the
and/or bent fins or damaged fins.
engine is operating under load. For specific data,
refer to the Technical Marketing Information (TMI)
3. If necessary, clean the air charge cooler.
for the engine.
SENR9969-05 71
Troubleshooting Section

4. If necessary, carefully straighten any bent fins on Recommended Actions

the air charge cooler.
Diagnostic Codes
Reduced Flow of Intake Air through the
Air Charge Cooler Check for any event and active diagnostic codes on
the electronic service tool. Troubleshoot any active
1. Check for contamination in the air pipe that diagnostic codes or recently logged diagnostic codes
connects the turbocharger to the air charge cooler. before continuing with this procedure.

a. If dirt is found in the air pipe from the Air Intake

turbocharger to the air charge cooler, check
all of the air inlet pipes upstream of the 1. Check the air filter for blockage or restriction.
turbocharger for leaks.
2. Check the air intake duct for blockages or
b. Clean all contaminated air inlet pipes or replace restrictions.
all contaminated air inlet pipes.
Electrical Connectors
c. Service the air cleaner and replace the air
cleaner element. 1. Check for correct installation of connectors at the
following locations:
2. If a thick oil film is found in the air pipe, inspect the
turbocharger compressor housing. Examine both • P1 ECM connector
the inlet to the turbocharger compressor housing
and the outlet from the turbocharger compressor • P2 ECM connector
for oil.
• P532 Fuel rail pump solenoid connector
a. If oil is found in the inlet to the turbocharger
compressor housing, the oil originates from the 2. Refer to Troubleshooting, “Electrical Connectors
engine crankcase breather. - Inspect”.
b. If oil is found in the outlet from the turbocharger 3. Inspect the battery cables from the ECM to the
compressor housing but oil is not found in battery compartment. Refer to the Schematic
the inlet to the compressor housing, the oil Diagram. Inspect the cables and the power relay.
originates from the seals for the turbocharger Check the power and ground connections to the
bearings. ECM. Refer to the schematic diagram for more
information.
i03481785
4. Select the “Wiggle Test” from the diagnostic tests
Intermittent Engine Shutdown on the electronic service tool.

SMCS Code: 1000-035 5. Choose the appropriate group of parameters to

monitor.
Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted. 6. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent faults.
Probable Causes Note: If an intermittent fault exists, the status will be
highlighted and an audible beep will be heard.
• Diagnostic codes
7. Repair any faults and ensure that the symptom
• Air Intake has been cleared. If the symptom is still present,
refer to “Fuel Supply”.
• Electrical connectors
• Fuel supply Fuel Supply

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
72 SENR9969-05
Troubleshooting Section

1. Visually check the fuel tank for fuel. The fuel Recommended Actions
gauge may be faulty.
NOTICE
2. Ensure that the fuel supply valve (if equipped) is Do not crank the engine continuously for more than
in the full OPEN position. 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
3. If the temperature is below 0 °C (32 °F), check
for solidified fuel (wax).
Diagnostic Codes
4. Check the primary filter/water separator for water
in the fuel. Check for active diagnostic codes and event codes
on the electronic service tool. Troubleshoot any
5. Check for fuel supply lines that are restricted. active codes before continuing with this procedure.

6. Check that the low pressure fuel lines are tight Electrical Connectors
and secured properly.
1. Refer to Troubleshooting, “Electrical Connectors
7. Check the fuel filters. - Inspect”.
8. Check the diesel fuel for contamination. Refer to 2. Repair the electrical connectors or replace the
Systems Operation, Testing and Adjusting, “Fuel electrical connectors.
Quality - Test”.
3. Ensure that all the connector seals are in place
9. Check for air in the fuel system. Refer to Systems and that the connectors have been correctly
Operation, Testing and Adjusting, “Air in Fuel - installed.
Test”.
4. Ensure that the repairs have eliminated the fault.
10. Ensure that the fuel system has been primed. If the fault has not been eliminated proceed to
Refer to Systems Operation, Testing and “ECM Connection”.
Adjusting, “Fuel System - Prime”.

11. Check the fuel pressure. Refer to Systems ECM Connection

Operation, Testing and Adjusting, “Fuel System
Pressure - Test”. 1. Check that the P2/J2 connector is correctly
connected.
12. If the fault has not been eliminated, repeat this
test procedure from Test Step 1. 2. Check that the P1/J1 connector is correctly
connected.

i03481801 3. If a fault is suspected with the ECM power and

ground connections refer to Troubleshooting,
Intermittent Low Power or “Ignition Keyswitch Circuit and Battery Supply
Power Cutout Circuit - Test”.

SMCS Code: 1000-035 4. Verify that the ECM connections for the power and
ground connections at the fuel pump are correctly
Note: Use this procedure only if the engine does not connected.
shut down completely.
5. Repair any faults and ensure that the faults have
been eliminated.
Probable Causes
6. If the repairs do not eliminate the faults, proceed
• Diagnostic codes to “Fuel Supply”.

• Electrical connectors Fuel Supply

• ECM connection 1. Visually check the fuel tank for fuel. The fuel
gauge may be faulty.
• Fuel supply
2. Ensure that the fuel supply valve (if equipped) is
• Intake manifold pressure in the full OPEN position.
SENR9969-05 73
Troubleshooting Section

3. If the temperature is below 0 °C (32 °F), check i03481920

for solidified fuel (wax).
Low Engine Oil Pressure
4. Check the primary filter/water separator for water
in the fuel. SMCS Code: 1300-035

5. Check for fuel supply lines that are restricted. NOTICE

Do not operate the engine with low oil pressure.
6. Check that the low pressure fuel lines are tight Engine damage will result. If measured oil pressure is
and secured properly. low, discontinue engine operation until the problem is
corrected.
7. Check the fuel filters.

8. Check the diesel fuel for contamination. Refer to Probable Causes

Systems Operation, Testing and Adjusting, “Fuel
Quality - Test”. • Engine oil level
9. Check for air in the fuel system. Refer to Systems • Oil specification
Operation, Testing and Adjusting, “Air in Fuel -
Test”. • Engine oil pressure gauge
10. Ensure that the fuel system has been primed. • Engine oil filter
Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Prime”. • Engine oil cooler
11. Check the fuel pressure. Start the engine and • Piston cooling jets
then use the electronic service tool to check
that the pressure in the fuel rail is more than • Engine oil suction tube
18000 kPa (2610 psi).
• Engine oil pump
12. If the repair does not eliminate the fault refer to
“Intake Manifold Pressure”. • Bearing clearance

Intake Manifold Pressure Recommended Actions

1. Use the electronic service tool to verify the intake Engine Oil Level
manifold pressure.
1. Inspect the engine oil level. If necessary, add oil.
2. Turn the start switch to the ON position.
2. If the fault is still apparent, refer to “Oil
3. The intake manifold pressure should read Specification”.
0 ± 0.5 kPa (0 ± 0.07 psi). If the intake manifold
pressure is not within the limits, perform the
following steps. Oil Specification

4. Check the air filter restriction indicator, if equipped. 1. Make sure that engine oil of the correct
specification is used. Refer to the Operation
5. Ensure that the air filter is clean and serviceable. and Maintenance Manual, “Refill Capacities and
Recommendations”.
6. Check the air intake and the exhaust system for
the following defects: 2. If necessary, drain the oil system and refill the oil
system with engine oil of the correct specification.
Refer to Operation and Maintenance Manual,
• Blockages “Engine Oil and Filter - Change”.
• Restrictions 3. If the fault is still apparent, refer to “Engine Oil
Pressure Gauge”.
• Damage to the air intake and exhaust lines and
hoses
74 SENR9969-05
Troubleshooting Section

Engine Oil Pressure Gauge Engine Oil Pump

1. Check the actual engine oil pressure with a 1. Inspect the components of the engine oil pump for
calibrated test gauge. Compare the oil pressure excessive wear. Repair the oil pump or replace
reading from the electronic service tool to the the oil pump, if necessary. Refer to Disassembly
pressure on the test gauge. and Assembly, “Engine Oil Pump - Remove”,
Disassembly and Assembly, “Engine Oil Pump -
2. If no difference is noted between the indicated oil Install” and Disassembly and Assembly, “Engine
pressures, refer to “Engine Oil Filter”. Oil Relief Valve - Remove and Install”.

Engine Oil Filter 2. If no faults are found, refer to “Bearing Clearance”.

1. Remove the engine oil filter. Refer to the Operation Bearing Clearance
and Maintenance Manual, “Engine Oil and Filter
- Change”. Inspect the engine components for excessive bearing
clearance or damaged bearings. If necessary,
2. Inspect the engine oil filter for evidence of replace the bearings and/or the components. Inspect
blockage. the following components for excessive bearing
clearance:
3. Install a new engine oil filter. Refer to the
Operation and Maintenance Manual, “Engine Oil • Crankshaft main bearings
and Filter - Change”.
• Connecting rod bearings
4. If the fault is still apparent, refer to “Engine Oil
Cooler”. • Camshaft front bearing
Engine Oil Cooler • Idler gear bearing

1. If oil flow or coolant flow through the oil cooler i03481960

is suspected of being low, replace the oil cooler.
Refer to Disassembly and Assembly, “Engine Low Power/Poor or No
Oil Cooler - Remove” and Disassembly and
Assembly, “Engine Oil Cooler - Install”. Response to Throttle
2. If the fault is still apparent, refer to “Piston Cooling SMCS Code: 1000-035
Jets”.
Probable Causes
Piston Cooling Jets
• Diagnostic codes
1. Inspect the piston cooling jets for damage.
Replace any piston cooling jet that appears to be • ECM parameters
cracked, broken or missing. Refer to Disassembly
and Assembly, “Piston Cooling Jets - Remove • Electrical connectors
and Install”.
• Air intake and exhaust system
2. If no damage is found, refer to “Engine Oil Suction
Tube”. • Valve lash

Engine Oil Suction Tube • Turbocharger

1. Check the inlet screen on the oil suction tube • Fuel supply
and remove any material that may be restricting
oil flow. • Low compression (cylinder pressure)

2. Check the joints of the oil suction tube for cracks • Individual malfunctioning cylinder
or a damaged joint that may allow air leakage into
the supply to the oil pump. • Electronic unit injectors

3. If no faults are found, refer to “Engine Oil Pump”.

SENR9969-05 75
Troubleshooting Section

Recommended Actions 7. If the engine speed is erratic refer to

Troubleshooting, “Analog Throttle Position Sensor
NOTICE Circuit - Test” or Troubleshooting, “Digital Throttle
Do not crank the engine continuously for more than Position Sensor Circuit - Test”.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. 8. If the fault has not been eliminated, proceed to
“Air Intake and Exhaust System”.

Diagnostic Codes Air Intake and Exhaust System

Check for active diagnostic codes on the electronic 1. Check the air filter restriction indicator, if equipped.
service tool. Troubleshoot any active codes before
continuing with this procedure. 2. Ensure that the air filter is clean and serviceable.

ECM Parameters 3. Check the air intake and the exhaust system for
the following defects:
1. Use the electronic service tool to make sure that
the FLS and FTS parameters have been correctly • Blockages
entered.
• Restrictions
2. Use the electronic service tool to ensure that the
correct mode was selected. • Damage to the air intake and exhaust lines and
hoses
3. Use the electronic service tool to verify that the
correct engine rating has been provided. 4. Make all necessary repairs to the engine.

4. Use the electronic service tool to verify the 5. If the fault has not been eliminated, proceed to
maximum engine speed limit. “Valve Lash”.

5. Ensure that the repairs have restored the expected Valve Lash
performance.
1. Check the valve lash and reset the valve lash, if
6. If the repairs have not eliminated the faults necessary. Refer to Systems Operation, Testing
proceed to “Electrical Connectors”. and Adjusting, “Engine Valve lash - Inspect and
Adjust”.
Electrical Connectors
2. If the repair does not eliminate the fault proceed
1. Turn the start switch to the ON position. to “Turbocharger”.

2. Use the electronic service tool to verify that Turbocharger

the intake manifold pressure is 0 ± 0.5 kPa
(00 ± 0.070 psi). Check the 5 V sensor supply Note: The turbocharger that is installed on this
for the intake manifold pressure. Refer to engine is a nonserviceable item. If any mechanical
Troubleshooting, “5 Volt Sensor Supply Circuit - fault exists, then the turbocharger must be replaced.
Test”.
1. Ensure that the mounting bolts for the turbocharger
3. Use the electronic service tool to verify the throttle are tight.
position status.
2. Check that the oil drain for the turbocharger is not
4. Run the engine until the speed is equal to the blocked or restricted.
maximum no-load speed.
3. Check that the compressor housing for the
5. Use the electronic service tool to make sure that turbocharger is free of dirt and debris.
the throttle is set to reach the maximum no-load
speed. 4. Check that the turbine housing for the turbocharger
is free of dirt and debris.
6. If the maximum no-load speed can not be obtained
refer to Troubleshooting, “Throttle Switch Circuit 5. Check that the turbine blades rotate freely in the
- Test” and Troubleshooting, “Mode Selection turbocharger.
Circuit - Test”.
76 SENR9969-05
Troubleshooting Section

6. Ensure that the wastegate on the turbocharger is Low Compression (Cylinder Pressure)
adjusted correctly. Refer to Systems Operation,
Testing and Adjusting, “Wastegate - Inspect”. 1. Perform a compression test. Refer to Systems
If the wastegate actuator is faulty, replace the Operation, Testing and Adjusting, “Compression
turbocharger. Refer to Disassembly and Assembly, - Test ”.
“Turbocharger - Remove” and Disassembly and
Assembly, “Turbocharger - Install”. 2. If low compression is noted on any cylinders,
investigate the cause and rectify any faults.
7. If necessary, replace the turbocharger. Refer
to Disassembly and Assembly, “Turbocharger Possible causes of low compression are shown
- Remove” and Disassembly and Assembly, in the following list:
“Turbocharger - Install”.
• Loose glow plugs
8. Check that the repairs have eliminated the faults.
• Faulty piston
9. If the fault has not been eliminated, proceed to
“Fuel Supply”. • Faulty piston rings

Fuel Supply • Worn cylinder bores

1. Visually check the fuel tank for fuel. The fuel • Worn valves
gauge may be faulty.
• Faulty cylinder head gasket
2. Ensure that the fuel supply valve (if equipped) is
in the full OPEN position. • Damaged cylinder head
3. If the temperature is below 0 °C (32 °F), check 3. Perform all necessary repairs.
for solidified fuel (wax).
4. Ensure that the repairs have eliminated the faults.
4. Check the primary filter/water separator for water
in the fuel. 5. If the repair does not eliminate the fault refer to
“Individual Malfunctioning Cylinders”.
5. Check for fuel supply lines that are restricted.
Individual Malfunctioning Cylinders
6. Check that the low pressure fuel lines are tight
and secured properly. 1. Use the electronic service tool to perform the
“Cylinder Cut-out Test”. Note if there is any
7. Check the fuel filters. reduction in engine speed. If a reduction in engine
speed is not noted, the isolated cylinder is not
8. Check the diesel fuel for contamination. Refer to operating under normal conditions. If the isolation
Systems Operation, Testing and Adjusting, “Fuel of a particular cylinder results in a reduction of
Quality - Test”. engine speed that is less than normal, this may
indicate that the cylinder is operating below normal
9. Check for air in the fuel system. Refer to Systems performance. Investigate the cause of the fault on
Operation, Testing and Adjusting, “Air in Fuel - any cylinder that is not operating. Investigate the
Test”. cause of the fault on any cylinder that is operating
below normal performance.
10. Ensure that the fuel system has been primed.
Refer to Systems Operation, Testing and 2. If all cylinders have been checked and no
Adjusting, “Fuel System - Prime”. faults were detected proceed to “Electronic Unit
Injectors”.
11. Check the fuel pressure. Refer to Systems
Operation, Testing and Adjusting, “Fuel System
Pressure - Test”.

12. If the repair does not eliminate the fault refer to

“Low Compression (Cylinder Pressure)”.
SENR9969-05 77
Troubleshooting Section

Electronic Unit Injectors Valve Train Components

1. Use the electronic service tool to perform the 1. Remove the valve mechanism cover. Check
“Cylinder Cut-out Test”. Note if there is any the following items for damage: camshaft, valve
reduction in engine speed. If a reduction in engine springs, lifters, pushrods, and bridges. Thoroughly
speed is not noted, the isolated electronic unit clean the valve train components. If the camshaft
injector is not operating under normal conditions. is being replaced, also replace the valve lifters.
If the isolation of a particular cylinder results in a Ensure that all of the valves move freely. Replace
reduction of engine speed that is less than normal, any damaged parts.
this may indicate that the electronic unit injector is
operating below normal performance. 2. If the mechanical noise is still apparent, refer to
“Pistons”.
2. Remove the electronic unit injector from the
suspect cylinder. Refer to Disassembly and Pistons
Assembly, “Electronic Unit Injector - Remove”.
1. Inspect the pistons for damage and wear. Replace
3. Install a new electronic unit injector. Refer to any damaged parts.
Disassembly and Assembly, “Electronic Unit
Injector - Install”. 2. If the mechanical noise is still apparent, refer to
“Connecting Rod and Main Bearings”.
4. Repeat the test in 1. If the fault is still apparent,
remove the replacement electronic unit injector
and install the original electronic unit injector.
Connecting Rod and Main Bearings
Refer to Disassembly and Assembly, “Electronic
Inspect the connecting rod and main bearings.
Unit Injector - Remove” and Disassembly and
Also, inspect the bearing surfaces (journals) on the
Assembly, “Electronic Unit Injector - Install”.
crankshaft. Replace any damaged parts.
5. If the fault is not eliminated, repeat this test
If the fault is still apparent, refer to Troubleshooting,
procedure from Test Step 1.
“Noise Coming from Cylinder”.

i03482041
i03482012
Mechanical Noise (Knock) in Noise Coming from Cylinder
Engine
SMCS Code: 1000-035
SMCS Code: 1000-035
Probable Causes
Probable Causes
• Fuel quality
• Accessory equipment
• Pistons
• Valve train components
• Valve lash
• Pistons
• Electronic unit injectors
• Connecting rod and main bearings
Recommended Actions
Recommended Actions
Fuel Quality
Accessory Equipment
1. Check the fuel quality. Refer to Systems
1. Isolate the source of the noise. Remove the Operation, Testing and Adjusting, “Fuel Quality -
suspect engine accessory. Inspect the suspect Test”.
engine accessory. Repair the engine accessory
and/or replace the engine accessory if any defects 2. If unsatisfactory fuel is found, perform the following
are found. procedure.

2. If the mechanical noise is still apparent, refer to a. Drain the fuel system.
“Valve Train Components”.
78 SENR9969-05
Troubleshooting Section

b. Replace the fuel filters. Refer to the Operation

and Maintenance Manual, “Fuel System
Primary Filter (Water Separator) Element -
Replace” and Operation and Maintenance
Manual, “Fuel System Filter - Replace”.

c. Fill the fuel system with fuel that meets the

standard in Operation and Maintenance
Manual, “Fluid Recommendations”.

d. Prime the fuel system. Refer to Operation and

Maintenance Manual, “Fuel System - Prime”.

3. If the fault is not eliminated, refer to “Pistons”.

Pistons
1. Inspect the pistons for damage and wear. Replace
any damaged parts.

2. If the noise is still apparent, refer to “Valve Lash”.

Valve Lash
1. Refer to Troubleshooting, “Excessive Valve Lash”.

2. If the fault has not been eliminated, proceed to

“Electronic Unit Injectors”.

Electronic Unit Injectors

1. With the engine speed at a fast idle, use the
electronic service tool to isolate one cylinder at
a time. Note if there is any reduction in engine
speed. If a reduction in engine speed is not noted,
the isolated electronic unit injector is not operating
under normal conditions. If the isolation of a
particular cylinder results in a reduction of engine
speed that is less than normal, this may indicate
that the electronic unit injector is operating below
normal performance.

2. Remove the electronic unit injector from the

suspect cylinder. Refer to Disassembly and
Assembly, “Electronic Unit Injector - Remove”.

3. Install a new electronic unit injector. Refer to

Disassembly and Assembly, “Electronic Unit
Injector - Install”.

4. Repeat the test in 1. If the noise is still apparent,

remove the replacement electronic unit injector
and install the original electronic unit injector.
Refer to Disassembly and Assembly, “Electronic
Unit Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”.

5. If the fault is still apparent, refer to Troubleshooting,

“Mechanical Noise (Knock) in Engine”.
SENR9969-05 79
Troubleshooting Section

Troubleshooting with a
Diagnostic Code
i03720763

Diagnostic Code Cross

Reference
SMCS Code: 1900

Table 52
3rd Party
CAT ET
Device Flash
CDL Code Description J1939
J1939 Code
Code
Code
N/A No Diagnostic Code Detected N/A N/A 551
0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect J651-2 651-2 111
0001-05 Cylinder #1 Injector current below normal J651-5 651-5 111
0001-06 Cylinder #1 Injector current above normal J651-6 651-6 111
0001-07 Cylinder #1 Injector not responding properly J651-7 651-7 111
0002-02 Cylinder #2 Injector erratic, intermittent, or incorrect J652-2 652-2 112
0002-05 Cylinder #2 Injector current below normal J652-5 652-5 112
0002-06 Cylinder #2 Injector current above normal J652-6 652-6 112
0002-07 Cylinder #2 Injector not responding properly J652-7 652-27 112
0003-02 Cylinder #3 Injector erratic, intermittent, or incorrect J653-2 653-2 113
0003-05 Cylinder #3 Injector current below normal J653-5 653-5 113
0003-06 Cylinder #3 Injector current above normal J653-6 653-6 113
0003-07 Cylinder #3 Injector Not Responding J653-7 653-7 113
0004-02 Cylinder #4 Injector erratic, intermittent, or incorrect J654-2 654-2 114
0004-05 Cylinder #4 Injector current below normal J654-5 654-5 114
0004-06 Cylinder #4 Injector current above normal J654-6 654-6 114
0004-07 Cylinder #4 Injector not responding properly J654-7 654-7 114
0005-02 Cylinder #5 Injector erratic, intermittent, or incorrect (C6.6 engine only) J655-2 655-2 115
0005-05 Cylinder #5 Injector current below normal (C6.6 engine only) J655-5 655-5 115
0005-06 Cylinder #5 Injector current above normal (C6.6 engine only) J655-6 655-6 115
0005-07 Cylinder #5 Injector not responding properly (C6.6 engine only) J655-7 655-7 115
0006-02 Cylinder #6 Injector erratic, intermittent, or incorrect (C6.6 engine only) J656-2 656-2 116
0006-05 Cylinder #6 Injector current below normal (C6.6 engine only) J656-5 656-5 116
0006-06 Cylinder #6 Injector current above normal (C6.6 engine only) J656-6 656-6 116
0006-07 Cylinder #6 Injector not responding properly (C6.6 engine only) J656-7 656-7 116
0041-03 8 Volt DC Supply voltage above normal J678-03 678-03 517
0041-04 8 Volt DC Supply voltage below normal J678-04 678-04 517
0091-02 Throttle Position Sensor erratic, intermittent, or incorrect J91-02 91-02 154
0091-03 Throttle Position Sensor voltage above normal J91-03 91-03 154
(continued)
80 SENR9969-05
Troubleshooting Section

(Table 52, contd)

3rd Party
CAT ET
Device Flash
CDL Code Description J1939
J1939 Code
Code
Code
0091-04 Throttle Position Sensor voltage below normal J91-04 91-04 154
0091-08 Throttle Position Sensor abnormal frequency, pulse width, or period J91-08 91-08 154
0100-03 Engine Oil Pressure Sensor voltage above normal J100-03 100-03 157
0100-04 Engine Oil Pressure Sensor voltage below normal J100-04 100-04 157
0100-10 Engine Oil Pressure Sensor abnormal rate of change J100-10 100-10 157
0110-03 Engine Coolant Temperature Sensor voltage above normal J110-03 110-03 168
0110-04 Engine Coolant Temperature Sensor voltage below normal J110-04 110-04 168
0168-00 Electrical System Voltage high J168-00 168-00 511
0168-01 Electrical System Voltage low J168-01 168-01 511
0168-02 Electrical System Voltage erratic, intermittent, or incorrect J168-02 168-02 511
0171-03 Air Ambient Temperature Sensor voltage above normal J171-03 171-03 -
0171-04 Air Ambient Temperature Sensor voltage below normal J171-04 171-04 -
0172-03 Intake Manifold Air Temperature Sensor voltage above normal J105-03 105-03 133
0172-04 Intake Manifold Air Temperature Sensor voltage below normal J105-04 105-04 133
0190-08 Engine Speed Sensor abnormal frequency, pulse width, or period J190-08 190-08 141
0247-09 SAE J1939 Data Link abnormal update rate - - 514
0247-12 SAE J1939 Data Link failure - - 514
0253-02 Personality Module erratic, intermittent, or incorrect J631-02 631-02 415
0261-11 Engine Timing Offset fault J637-11 637-11 143
0262-03 5 Volt Sensor DC Power Supply voltage above normal J1079-03 1079-03 516
0262-04 5 Volt Sensor DC Power Supply voltage below normal J1079-04 1079-04 516
0268-02 Programmed Parameter Fault erratic, intermittent, or incorrect J630-02 630-02 527
Secondary Engine Speed Sensor abnormal frequency, pulse width,
0342-08 J723-08 723-08 142
or period
0526-05 Turbo Wastegate Drive current below normal J1188-05 1188-05 177
0526-06 Turbo Wastegate Drive current above normal J1188-06 1188-06 177
0526-07 Turbo Wastegate Drive not responding properly J1188-07 1188-07 177
0774-02 Secondary Throttle Position Sensor erratic, intermittent, or incorrect J29-02 29-02 155
0774-03 Secondary Throttle Position Sensor voltage above normal J29-03 29-03 155
0774-04 Secondary Throttle Position Sensor voltage below normal J29-04 29-04 155
Secondary Throttle Position Sensor abnormal frequency, pulse width,
0774-08 J29-08 29-08 155
or period
1639-09 Machine Security System Module abnormal update rate J1196-09 1196-09 426
1743-02 Engine Operation Mode Selector Switch erratic, intermittent, or incorrect J2882-02 2882-02 144
1779-05 Fuel Rail #1 Pressure Valve Solenoid current below normal J1347-05 1347-05 162
1779-06 Fuel Rail #1 Pressure Valve Solenoid current above normal J1347-06 1347-06 162
1785-03 Intake Manifold Pressure Sensor voltage above normal J102-03 102-03 197
1785-04 Intake Manifold Pressure Sensor voltage below normal J102-04 102-04 197
(continued)
SENR9969-05 81
Troubleshooting Section

(Table 52, contd)

3rd Party
CAT ET
Device Flash
CDL Code Description J1939
J1939 Code
Code
Code
1785-10 Intake Manifold Pressure Sensor abnormal rate of change J102-10 102-10 197
1797-03 Fuel Rail Pressure Sensor voltage above normal J157-03 157-03 159
1797-04 Fuel Rail Pressure Sensor voltage below normal J157-04 157-04 159
1834-02 Ignition Key Switch loss of signal J158-02 158-02 429
2246-06 Glow Plug Start Aid Relay current above normal J676-06 676-06 199
Event Codes
E172-1 High Air Filter Restriction J107-15 107-15 151
E194-1 High Exhaust Temperature J173-15 173-15 185
E232-1 High Fuel/Water Separator Water Level J97-15 97-15 -
E360-1 Low Engine Oil Pressure - Warning J100-17 100-17 157
E360-3 Low Engine Oil Pressure - Shutdown J100-01 100-01 157
E361-1 High Engine Coolant Temperature - Warning J110-15 110-15 168
E361-2 High Engine Coolant Temperature - Derate J110-16 110-16 168
E361-3 High Engine Coolant Temperature - Shutdown J110-00 110-00 168
E362-1 Engine Overspeed J190-15 190-15 141
E396-1 High Fuel Rail Pressure J157-00 157-00 159
E398-1 Low Fuel Rail Pressure J157-01 157-01 159
E539-1 High Intake Manifold Air Temperature - Warning J105-15 105-15 133
E539-2 High Intake Manifold Air Temperature - Derate J105-16 105-16 133
E2143-3 Low Engine Coolant Level J111-01 111-01 169

i03483122 Results:
No Diagnostic Codes Detected • OK – STOP.
SMCS Code: 1900
i02676132
Conditions Which Generate This Code:
CID 0001 FMI 02
A flash code 0551 indicates that there are no detected
faults in the system since the previous powering up. SMCS Code: 1290-038

System Response: Conditions Which Generate This Code:

This code will not appear on the electronic service The Electronic Control Module (ECM) detects the
tool. The indicator lamps will flash the diagnostic following condition:
code. For more information on flash codes, refer to
Troubleshooting, “Indicator Lamps”. • Data from the electronic unit injector for the No. 1
cylinder is out of limits.
Possible Performance Effect:
• Diagnostic code 0168-01 is not active.
None
• Diagnostic codes 0001-05 and 0001-06 are not
There are no faults that require troubleshooting. active.

• No 0041 diagnostic codes are active.

82 SENR9969-05
Troubleshooting Section

• No 0262 diagnostic codes are active. An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring
• Diagnostic code 0190-08 is not active. that is unique to the electronic unit injector will
prevent that individual electronic unit injector from
• No 0110 diagnostic codes are active. operating. On four cylinder engines, an open circuit
in common wiring within the ECM can prevent the
System Response: two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an
If equipped, the warning light will come on. An active open circuit in common wiring within the ECM can
diagnostic code will be generated. The ECM will log prevent the three electronic unit injectors that share
the diagnostic code. that common wiring from operating.

Possible Performance Effect: The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has
The engine will be derated while this diagnostic code been logged but an open circuit will prevent the
is active. operation of the electronic unit injector.

Troubleshooting: Perform the following diagnostic procedure: “Injector

Solenoid Circuit - Test”
Perform the following diagnostic procedure: “Injector
Data Incorrect - Test” Results:

Results: • OK – STOP.
• OK – STOP. i02676143

i03483140 CID 0001 FMI 06

CID 0001 FMI 05 SMCS Code: 1290-038

SMCS Code: 1290-038 Conditions Which Generate This Code:

Conditions Which Generate This Code: This diagnostic code is designed to indicate a short
circuit (high current) in either the solenoid or the
This diagnostic code is designed to indicate an open wiring for the electronic unit injector for No. 1 cylinder.
circuit (low current) in either the solenoid or the wiring
for the electronic unit injector for No. 1 cylinder. The Electronic Control Module (ECM) detects the
following conditions:
The Electronic Control Module (ECM) detects the
following condition: • A high current condition (short circuit) for each of
five consecutive attempts to operate
• A low current condition (open circuit) for each of
five consecutive attempts to operate • Battery voltage above 9 Volts DC for 2 seconds
• Battery voltage above 9 Volts DC for 2 seconds System Response:

System Response: If equipped, the warning light will come on. The ECM
will log the diagnostic code.
If equipped, the warning light will come on. The ECM
will log the diagnostic code. Possible Performance Effect:

Possible Performance Effect: The engine will have low power and/or rough running.

The engine will have low power and/or rough running. Troubleshooting:

Troubleshooting: When an injector cutout test is performed, a faulty

electronic unit injector will indicate a low reading in
When an injector cutout test is performed, a faulty comparison with the other electronic unit injectors.
electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors.
SENR9969-05 83
Troubleshooting Section

An electrical fault can prevent the electronic unit Results:

injector from operating. A short circuit in the wiring or
the ECM that is unique to one electronic unit injector • OK – STOP.
will prevent that individual electronic unit injector from
operating. On four cylinder engines, a short circuit
i02676150
in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a
CID 0002 FMI 02
short circuit in common wiring within the ECM can SMCS Code: 1290-038
prevent the three electronic unit injectors that share
that common wiring from operating. Conditions Which Generate This Code:
The ECM will continue to attempt to operate the The Electronic Control Module (ECM) detects the
electronic unit injector after the diagnostic code following condition:
has been logged but a short circuit will prevent the
operation of the electronic unit injector.
• Data from the electronic unit injector for the No. 2
cylinder is out of limits.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
• Diagnostic code 0168-01 is not active.
Results:
• Diagnostic codes 0002-05 and 0002-06 are not
active.
• OK – STOP.
• No 0041 diagnostic codes are active.
i03483141
• No 0262 diagnostic codes are active.
CID 0001 FMI 07
• Diagnostic code 0190-08 is not active.
SMCS Code: 1290-038
• No 0110 diagnostic codes are active.
Conditions Which Generate This Code:
System Response:
The electronic unit injector is no longer capable of
delivering the correct amount of fuel. If equipped, the warning light will come on. An active
diagnostic code will be generated. The ECM will log
System Response: the diagnostic code.

If equipped, the warning light will come on. The Possible Performance Effect:
Electronic Control Module (ECM) will log the
diagnostic code. The engine will be derated while this diagnostic code
is active.
Possible Performance Effect:
Troubleshooting:
The engine will be derated.
Perform the following diagnostic procedure: “Injector
Troubleshooting: Data Incorrect - Test”

Use the electronic service tool to perform the Fuel Results:

System Verification Test. If the diagnostic code is still
active, do the following procedure. • OK – STOP.
Replace the suspect electronic unit injector. Refer
i03483180
to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly,
“Electronic Unit Injector - Install”.
CID 0002 FMI 05
SMCS Code: 1290-038
Use the electronic service tool to perform the Fuel
System Verification Test. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “None” This diagnostic code is designed to indicate an open
circuit (low current) in either the solenoid or the wiring
for the electronic unit injector for No. 2 cylinder.
84 SENR9969-05
Troubleshooting Section

The Electronic Control Module (ECM) detects the • A high current condition (short circuit) for each of
following condition: five consecutive attempts to operate

• A low current condition (open circuit) for each of • Battery voltage above 9 Volts DC for 2 seconds
five consecutive attempts to operate
System Response:
• Battery voltage above 9 Volts DC for 2 seconds
If equipped, the warning light will come on. The ECM
System Response: will log the diagnostic code.

If equipped, the warning light will come on. The ECM Possible Performance Effect:
will log the diagnostic code.
The engine will have low power and/or rough running.
Possible Performance Effect:
Troubleshooting:
The engine will have low power and/or rough running.
When an injector cutout test is performed, a faulty
Troubleshooting: electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors.
When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in An electrical fault can prevent the electronic unit
comparison with the other electronic unit injectors. injector from operating. A short circuit in the wiring or
the ECM that is unique to one electronic unit injector
An electrical fault can prevent the electronic unit will prevent that individual electronic unit injector from
injector from operating. An open circuit in the wiring operating. On four cylinder engines, a short circuit
that is unique to the electronic unit injector will in common wiring within the ECM can prevent the
prevent that individual electronic unit injector from two electronic unit injectors that share that common
operating. On four cylinder engines, an open circuit wiring from operating. On six cylinder engines, a
in common wiring within the ECM can prevent the short circuit in common wiring within the ECM can
two electronic unit injectors that share that common prevent the three electronic unit injectors that share
wiring from operating. On six cylinder engines, an that common wiring from operating.
open circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share The ECM will continue to attempt to operate the
that common wiring from operating. electronic unit injector after the diagnostic code
has been logged but a short circuit will prevent the
The ECM will continue to attempt to operate the operation of the electronic unit injector.
electronic unit injector after the diagnostic code has
been logged but an open circuit will prevent the Perform the following diagnostic procedure: “Injector
operation of the electronic unit injector. Solenoid Circuit - Test”

Perform the following diagnostic procedure: “Injector Results:

Solenoid Circuit - Test”
• OK – STOP.
Results:
i03483183
• OK – STOP.
CID 0002 FMI 07
i02676158
SMCS Code: 1290-038
CID 0002 FMI 06
Conditions Which Generate This Code:
SMCS Code: 1290-038
The electronic unit injector is no longer capable of
Conditions Which Generate This Code: delivering the correct amount of fuel.

This diagnostic code is designed to indicate a short System Response:

circuit (high current) in either the solenoid or the
wiring for the electronic unit injector for No. 2 cylinder. If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
The Electronic Control Module (ECM) detects the diagnostic code.
following conditions:
SENR9969-05 85
Troubleshooting Section

Possible Performance Effect: Troubleshooting:

The engine will be derated. Perform the following diagnostic procedure: “Injector
Data Incorrect - Test”
Troubleshooting:
Results:
Use the electronic service tool to perform the Fuel
System Verification Test. If the diagnostic code is still • OK – STOP.
active, do the following procedure.
i03483184
Replace the suspect electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly,
CID 0003 FMI 05
“Electronic Unit Injector - Install”. SMCS Code: 1290-038
Use the electronic service tool to perform the Fuel Conditions Which Generate This Code:
System Verification Test.
This diagnostic code is designed to indicate an open
Perform the following diagnostic procedure: “None” circuit (low current) in either the solenoid or the wiring
for the electronic unit injector for No. 3 cylinder.
Results:
The Electronic Control Module (ECM) detects the
• OK – STOP. following condition:

i02697670 • A low current condition (open circuit) for each of

five consecutive attempts to operate
CID 0003 FMI 02
• Battery voltage above 9 Volts DC for 2 seconds
SMCS Code: 1290-038
System Response:
Conditions Which Generate This Code:
If equipped, the warning light will come on. The ECM
The Electronic Control Module (ECM) detects the will log the diagnostic code.
following condition:
Possible Performance Effect:
• Data from the electronic unit injector for the No. 3
cylinder is out of limits. The engine will have low power and/or rough running.

• Diagnostic code 0168-01 is not active. Troubleshooting:

• Diagnostic codes 0003-05 and 0003-06 are not When an injector cutout test is performed, a faulty
active. electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors.
• No 0041 diagnostic codes are active.
An electrical fault can prevent the electronic unit
• No 0262 diagnostic codes are active. injector from operating. An open circuit in the wiring
that is unique to the electronic unit injector will
• Diagnostic code 0190-08 is not active. prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit
• No 0110 diagnostic codes are active. in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
System Response: wiring from operating. On six cylinder engines, an
open circuit in common wiring within the ECM can
If equipped, the warning light will come on. An active prevent the three electronic unit injectors that share
diagnostic code will be generated. The ECM will log that common wiring from operating.
the diagnostic code.
The ECM will continue to attempt to operate the
Possible Performance Effect: electronic unit injector after the diagnostic code has
been logged but an open circuit will prevent the
The engine will be derated while this diagnostic code operation of the electronic unit injector.
is active.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
86 SENR9969-05
Troubleshooting Section

Results: i03483185

• OK – STOP. CID 0003 FMI 07

SMCS Code: 1290-038
i02676668
Conditions Which Generate This Code:
CID 0003 FMI 06
The electronic unit injector is no longer capable of
SMCS Code: 1290-038 delivering the correct amount of fuel.
Conditions Which Generate This Code: System Response:
This diagnostic code is designed to indicate a short If equipped, the warning light will come on. The
circuit (high current) in either the solenoid or the Electronic Control Module (ECM) will log the
wiring for the electronic unit injector for No. 3 cylinder. diagnostic code.
The Electronic Control Module (ECM) detects the Possible Performance Effect:
following conditions:
The engine will be derated.
• A high current condition (short circuit) for each of
five consecutive attempts to operate Troubleshooting:
• Battery voltage above 9 Volts DC for 2 seconds Use the electronic service tool to perform the Fuel
System Verification Test. If the diagnostic code is still
System Response: active, do the following procedure.
If equipped, the warning light will come on. The ECM Replace the suspect electronic unit injector. Refer
will log the diagnostic code. to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly,
Possible Performance Effect: “Electronic Unit Injector - Install”.
The engine will have low power and/or rough running. Use the electronic service tool to perform the Fuel
System Verification Test.
Troubleshooting:
Perform the following diagnostic procedure: “None”
When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in Results:
comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit

• OK – STOP.
injector from operating. A short circuit in the wiring or
the ECM that is unique to one electronic unit injector i02676669
will prevent that individual electronic unit injector from
operating. On four cylinder engines, a short circuit CID 0004 FMI 02
in common wiring within the ECM can prevent the
two electronic unit injectors that share that common SMCS Code: 1290-038
wiring from operating. On six cylinder engines, a
short circuit in common wiring within the ECM can Conditions Which Generate This Code:
prevent the three electronic unit injectors that share
that common wiring from operating. The Electronic Control Module (ECM) detects the
following condition:
The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code • Data from the electronic unit injector for the No. 4
has been logged but a short circuit will prevent the cylinder is out of limits.
operation of the electronic unit injector.
• Diagnostic code 0168-01 is not active.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” • Diagnostic codes 0004-05 and 0004-06 are not
active.
Results:
• No 0041 diagnostic codes are active.
• OK – STOP.
• No 0262 diagnostic codes are active.
SENR9969-05 87
Troubleshooting Section

• Diagnostic code 0190-08 is not active. An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring
• No 0110 diagnostic codes are active. that is unique to the electronic unit injector will
prevent that individual electronic unit injector from
System Response: operating. On four cylinder engines, an open circuit
in common wiring within the ECM can prevent the
If equipped, the warning light will come on. An active two electronic unit injectors that share that common
diagnostic code will be generated. The ECM will log wiring from operating. On six cylinder engines, an
the diagnostic code. open circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share
Possible Performance Effect: that common wiring from operating.

The engine will be derated while this diagnostic code The ECM will continue to attempt to operate the
is active. electronic unit injector after the diagnostic code has
been logged but an open circuit will prevent the
Troubleshooting: operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Data Incorrect - Test” Solenoid Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.

i03483200 i02676671

CID 0004 FMI 05 CID 0004 FMI 06

SMCS Code: 1290-038 SMCS Code: 1290-038

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

This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short
circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the
for the electronic unit injector for No. 4 cylinder. wiring for the electronic unit injector for No. 4 cylinder.

The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following condition: following conditions:

• A low current condition (open circuit) for each of • A high current condition (short circuit) for each of
five consecutive attempts to operate five consecutive attempts to operate

• Battery voltage above 9 Volts DC for 2 seconds • Battery voltage above 9 Volts DC for 2 seconds
System Response: System Response:

If equipped, the warning light will come on. The ECM If equipped, the warning light will come on. The ECM
will log the diagnostic code. will log the diagnostic code.

Possible Performance Effect: Possible Performance Effect:

The engine will have low power and/or rough running. The engine will have low power and/or rough running.

Troubleshooting: Troubleshooting:

When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.
88 SENR9969-05
Troubleshooting Section

An electrical fault can prevent the electronic unit Results:

injector from operating. A short circuit in the wiring or
the ECM that is unique to one electronic unit injector • OK – STOP.
will prevent that individual electronic unit injector from
operating. On four cylinder engines, a short circuit
i02676672
in common wiring within the ECM can prevent the
two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, a
CID 0005 FMI 02
short circuit in common wiring within the ECM can SMCS Code: 1290-038
prevent the three electronic unit injectors that share
that common wiring from operating. Conditions Which Generate This Code:
The ECM will continue to attempt to operate the This diagnostic code is applicable to six cylinder
electronic unit injector after the diagnostic code engines only.
has been logged but a short circuit will prevent the
operation of the electronic unit injector. The Electronic Control Module (ECM) detects the
following condition:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
• Data from the electronic unit injector for the No. 5
cylinder is out of limits.
Results:
• Diagnostic code 0168-01 is not active.
• OK – STOP.
• Diagnostic codes 0005-05 and 0005-06 are not
i03483201 active.

CID 0004 FMI 07 • No 0041 diagnostic codes are active.

SMCS Code: 1290-038 • No 0262 diagnostic codes are active.
Conditions Which Generate This Code: • Diagnostic code 0190-08 is not active.
The electronic unit injector is no longer capable of • No 0110 diagnostic codes are active.
delivering the correct amount of fuel.
System Response:
System Response:
If equipped, the warning light will come on. An active
If equipped, the warning light will come on. The diagnostic code will be generated. The ECM will log
Electronic Control Module (ECM) will log the the diagnostic code.
diagnostic code.
Possible Performance Effect:
Possible Performance Effect:
The engine will be derated while this diagnostic code
The engine will be derated. is active.

Troubleshooting: Troubleshooting:

Use the electronic service tool to perform the Fuel Perform the following diagnostic procedure: “Injector
System Verification Test. If the diagnostic code is still Data Incorrect - Test”
active, do the following procedure.
Results:
Replace the suspect electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit • OK – STOP.
Injector - Remove” and Disassembly and Assembly,
“Electronic Unit Injector - Install”.

Use the electronic service tool to perform the Fuel

System Verification Test.

Perform the following diagnostic procedure: “None”

SENR9969-05 89
Troubleshooting Section

i03483242 i02676674

CID 0005 FMI 05 CID 0005 FMI 06

SMCS Code: 1290-038 SMCS Code: 1290-038

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

This diagnostic code is applicable to six cylinder This diagnostic code is applicable to six cylinder
engines only. engines only.

This diagnostic code is designed to indicate an open This diagnostic code is designed to indicate a short
circuit (low current) in either the solenoid or the wiring circuit (high current) in either the solenoid or the
for the electronic unit injector for No. 5 cylinder. wiring for the electronic unit injector for No. 5 cylinder.

The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following condition: following conditions:

• A low current condition (open circuit) for each of • A high current condition (short circuit) for each of
five consecutive attempts to operate five consecutive attempts to operate

• Battery voltage above 9 Volts DC for 2 seconds • Battery voltage above 9 Volts DC for 2 seconds
System Response: System Response:

If equipped, the warning light will come on. The ECM If equipped, the warning light will come on. The ECM
will log the diagnostic code. will log the diagnostic code.

Possible Performance Effect: Possible Performance Effect:

The engine will have low power and/or rough running. The engine will have low power and/or rough running.

Troubleshooting: Troubleshooting:

When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.

The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” Solenoid Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.
90 SENR9969-05
Troubleshooting Section

i03483260 • Diagnostic codes 0006-05 and 0006-06 are not

active.
CID 0005 FMI 07
• No 0041 diagnostic codes are active.
SMCS Code: 1290-038
• No 0262 diagnostic codes are active.
Conditions Which Generate This Code:
• Diagnostic code 0190-08 is not active.
This diagnostic code is applicable to six cylinder
engines only. • No 0110 diagnostic codes are active.
The electronic unit injector is no longer capable of System Response:
delivering the correct amount of fuel.
If equipped, the warning light will come on. An active
System Response: diagnostic code will be generated. The ECM will log
the diagnostic code.
If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the Possible Performance Effect:
diagnostic code.
The engine will be derated while this diagnostic code
Possible Performance Effect: is active.
The engine will be derated. Troubleshooting:
Troubleshooting: Perform the following diagnostic procedure: “Injector
Data Incorrect - Test”
Use the electronic service tool to perform the Fuel
System Verification Test. If the diagnostic code is still Results:
active, do the following procedure.
• OK – STOP.
Replace the suspect electronic unit injector. Refer
to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly, i03483301
“Electronic Unit Injector - Install”.
CID 0006 FMI 05
Use the electronic service tool to perform the Fuel
System Verification Test. SMCS Code: 1290-038

Perform the following diagnostic procedure: “None” Conditions Which Generate This Code:

Results: This diagnostic code is applicable to six cylinder

engines only.
• OK – STOP. This diagnostic code is designed to indicate an open
circuit (low current) in either the solenoid or the wiring
i02676675 for the electronic unit injector for No. 6 cylinder.
CID 0006 FMI 02 The Electronic Control Module (ECM) detects the
following condition:
SMCS Code: 1290-038
• A low current condition (open circuit) for each of
Conditions Which Generate This Code: five consecutive attempts to operate
This diagnostic code is applicable to six cylinder • Battery voltage above 9 Volts DC for 2 seconds
engines only.
System Response:
The Electronic Control Module (ECM) detects the
following condition: If equipped, the warning light will come on. The ECM
will log the diagnostic code.
• Data from the electronic unit injector for the No. 6
cylinder is out of limits. Possible Performance Effect:

• Diagnostic code 0168-01 is not active. The engine will have low power and/or rough running.
SENR9969-05 91
Troubleshooting Section

Troubleshooting: Troubleshooting:

When an injector cutout test is performed, a faulty When an injector cutout test is performed, a faulty
electronic unit injector will indicate a low reading in electronic unit injector will indicate a low reading in
comparison with the other electronic unit injectors. comparison with the other electronic unit injectors.

An electrical fault can prevent the electronic unit An electrical fault can prevent the electronic unit
injector from operating. An open circuit in the wiring injector from operating. A short circuit in the wiring or
that is unique to the electronic unit injector will the ECM that is unique to one electronic unit injector
prevent that individual electronic unit injector from will prevent that individual electronic unit injector from
operating. On four cylinder engines, an open circuit operating. On four cylinder engines, a short circuit
in common wiring within the ECM can prevent the in common wiring within the ECM can prevent the
two electronic unit injectors that share that common two electronic unit injectors that share that common
wiring from operating. On six cylinder engines, an wiring from operating. On six cylinder engines, a
open circuit in common wiring within the ECM can short circuit in common wiring within the ECM can
prevent the three electronic unit injectors that share prevent the three electronic unit injectors that share
that common wiring from operating. that common wiring from operating.

The ECM will continue to attempt to operate the The ECM will continue to attempt to operate the
electronic unit injector after the diagnostic code has electronic unit injector after the diagnostic code
been logged but an open circuit will prevent the has been logged but a short circuit will prevent the
operation of the electronic unit injector. operation of the electronic unit injector.

Perform the following diagnostic procedure: “Injector Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” Solenoid Circuit - Test”

Results: Results:

• OK – STOP. • OK – STOP.

i02676677 i03483302

CID 0006 FMI 06 CID 0006 FMI 07

SMCS Code: 1290-038 SMCS Code: 1290-038

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

This diagnostic code is applicable to six cylinder This diagnostic code is applicable to six cylinder
engines only. engines only.

This diagnostic code is designed to indicate a short The electronic unit injector is no longer capable of
circuit (high current) in either the solenoid or the delivering the correct amount of fuel.
wiring for the electronic unit injector for No. 6 cylinder.
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning light will come on. The
Electronic Control Module (ECM) will log the
• A high current condition (short circuit) for each of diagnostic code.
five consecutive attempts to operate
Possible Performance Effect:
• Battery voltage above 9 Volts DC for 2 seconds
The engine will be derated.
System Response:
Troubleshooting:
If equipped, the warning light will come on. The ECM
will log the diagnostic code. Use the electronic service tool to perform the Fuel
System Verification Test. If the diagnostic code is still
Possible Performance Effect: active, do the following procedure.

The engine will have low power and/or rough running.

92 SENR9969-05
Troubleshooting Section

Replace the suspect electronic unit injector. Refer i03484642

to Disassembly and Assembly, “Electronic Unit
Injector - Remove” and Disassembly and Assembly, CID 0041 FMI 04
“Electronic Unit Injector - Install”.
SMCS Code: 1439-038
Use the electronic service tool to perform the Fuel
System Verification Test. Conditions Which Generate This Code:

Perform the following diagnostic procedure: “None” The Electronic Control Module (ECM) detects the
following conditions:
Results:
• The 8 volt supply is less than 7.2 Volts DC for more
• OK – STOP. than one second.

• The ECM has been powered for more than three

i02676678 seconds.
CID 0041 FMI 03 • Diagnostic code 0168-01 is not active at the same
time.
SMCS Code: 1439-038
System Response:
Conditions Which Generate This Code:
The ECM will log the diagnostic code and the check
The Electronic Control Module (ECM) detects the engine lamp will illuminate while this diagnostic code
following conditions: is active.
• The 8 volt supply is more than 8.8 Volts DC for Possible Performance Effect:
more than one second.
The engine may be limited to low idle.
• The ECM has been powered for more than three
seconds. An active diagnostic code may not cause any
noticeable effect on engine response unless the
System Response: voltage drops below 6.5 Volts DC.
The ECM will log the diagnostic code and the check Note: The 8 Volt supply may provide power to the
engine lamp will illuminate while this diagnostic code digital throttle position sensor.
is active.
Note: The 8 Volt supply provides power to the two
Possible Performance Effect: speed/timing sensors.
The engine may be limited to low idle. Troubleshooting:
Note: The 8 volt supply may provide power to the Perform the following diagnostic procedure: “Digital
digital throttle position sensor. Throttle Position Sensor Circuit - Test”
Note: The 8 volt supply provides power to the two Results:
speed/timing sensors.

Troubleshooting:
• OK – STOP.

Perform the following diagnostic procedure: “Digital i03484644

Throttle Position Sensor Circuit - Test”
CID 0091 FMI 02
Results:
SMCS Code: 1913-038
• OK – STOP.
Conditions Which Generate This Code:

The Electronic Control Module (ECM) has

detected an invalid combination of positions for the
multi-position switches.
SENR9969-05 93
Troubleshooting Section

If the engine is equipped with an analog throttle i03484700

position sensor then the signal from the idle validation
switch is invalid. CID 0091 FMI 03
System Response: SMCS Code: 1913-038

If equipped, the warning light will come on. The ECM Conditions Which Generate This Code:
will log the diagnostic code.
The Electronic Control Module (ECM) detects the
Possible Performance Effect: following conditions:

If a second throttle is installed, the engine will use the • ECM has been powered for at least 3 seconds.
second throttle until the fault is repaired.
• A signal voltage for the throttle position is above the
If a second throttle is not installed or if the second diagnostic upper limit that is set for the application.
throttle has a fault, the following conditions will occur:
• The power supply for the throttle sensor is within
• The engine will default to the limp home speed. the expected range.

• If the engine speed is higher than the limp home System Response:
speed, the engine will decelerate to the limp home
speed. If equipped, the warning light will come on. The ECM
logs the diagnostic code if the engine is running.
• If the engine speed is lower than the limp home
speed, the engine speed will remain at the current Possible Performance Effect:
speed.
If a second throttle is installed, the engine will use the
• The engine will remain at this speed while the second throttle until the fault is repaired.
diagnostic code remains active.
If a second throttle is not installed or if the second
• All inputs from the faulty throttle are ignored by the throttle has a fault, the following conditions will occur:
ECM until the fault is repaired.
• The engine will default to the limp home speed.
• All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been turned to • If the engine speed is higher than the limp home
the OFF position and then back to the ON position. speed, the engine will decelerate to the limp home
speed.
Troubleshooting:
• If the engine speed is lower than the limp home
Proceed to “Test Step 1” if the engine is equipped speed, the engine speed will remain at the current
with a throttle switch. speed.

Proceed to “Test Step 2” if the engine is equipped • The engine will remain at this speed while the
with an analog throttle position sensor. diagnostic code remains active.

Test Step 1. • All inputs from the faulty throttle are ignored by the
ECM until the fault is repaired.
Perform the following diagnostic procedure: “Throttle
Switch Circuit - Test” • All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been turned to
the OFF position and then back to the ON position.
Results:
Troubleshooting:
• OK – STOP.
Monitor the configuration screen on the electronic
Test Step 2. service tool in order to determine the type of throttle
position sensor that is used on the engine.
Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test” If the engine is equipped with an analog throttle
position sensor, proceed to “Test Step 1”.
Results:
If the engine is equipped with a digital throttle position
• OK – STOP. sensor, proceed to “Test Step 2”.
94 SENR9969-05
Troubleshooting Section

Test Step 1. • All inputs from the faulty throttle are ignored by the
ECM until the fault is repaired.
Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test” • All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been turned to
Results: the OFF position and then back to the ON position.

• OK – STOP. Troubleshooting:

Test Step 2. Monitor the configuration screen on the electronic

service tool in order to determine the type of throttle
Perform the following diagnostic procedure: “Digital position sensor that is used on the engine.
Throttle Position Sensor Circuit - Test”
If the engine is equipped with an analog throttle
Results: position sensor, proceed to “Test Step 1”.

• OK – STOP. If the engine is equipped with a digital throttle position

sensor, proceed to “Test Step 2”.

i03484720
Test Step 1.
CID 0091 FMI 04 Perform the following diagnostic procedure: “Analog
SMCS Code: 1913-038 Throttle Position Sensor Circuit - Test”

Conditions Which Generate This Code: Results:

The Electronic Control Module (ECM) detects all of • OK – STOP.

the following conditions:
Test Step 2.
• The ECM has been powered for at least 3 seconds.
Perform the following diagnostic procedure: “Digital
• A signal voltage for the throttle position is below the Throttle Position Sensor Circuit - Test”
diagnostic lower limit that is set for the application.
Results:
• The power supply for the throttle sensor is within
the expected range. • OK – STOP.
System Response:
i03484741

If equipped, the warning light will come on. The ECM CID 0091 FMI 08
logs the diagnostic code if the engine is running.
SMCS Code: 1913-038
Possible Performance Effect:
Conditions Which Generate This Code:
If a second throttle is installed, the engine will use the
second throttle until the fault is repaired. The Electronic Control Module (ECM) detects the
following conditions:
If a second throttle is not installed or if the second
throttle has a fault, the following conditions will occur: • The signal frequency from the accelerator pedal
position sensor is less than 150 Hz or the signal
• The engine will default to the limp home speed. frequency is greater than 1050 Hz for more than
two seconds.
• If the engine speed is higher than the limp home
speed, the engine will decelerate to the limp home • The ECM has been powered for at least three
speed. seconds.

• If the engine speed is lower than the limp home • Diagnostic code 0091-03 is not active.
speed, the engine speed will remain at the current
speed. • Diagnostic code 0091-04 is not active.
• The engine will remain at this speed while the • Diagnostic codes for the 8 Volt sensor supplies are
diagnostic code remains active. not active.
SENR9969-05 95
Troubleshooting Section

System Response: • The signal voltage from the engine oil pressure
sensor is greater than 4.95 Volts DC for more than
Limp home mode is activated. eight seconds.

The ECM sets the “Throttle Position” to “0%”. • The ECM has been powered for at least two
seconds.
If equipped, the warning light will be on. The
diagnostic code will be logged if the engine is • The engine is not running or the engine coolant
running. The diagnostic code will not be logged if the temperature is greater than 38 °C (100 °F).
engine is cranking.
System Response:
Possible Performance Effect:
The ECM will log the diagnostic code. If equipped,
If a second throttle is installed, the engine will use the the warning lamp will come on. The ECM will set data
second throttle until the fault is repaired. for engine oil pressure to the default value.

If a second throttle is not installed or if the second Note: The engine oil pressure that is displayed on
throttle has a fault, the following conditions will occur: the electronic service tool is the default value for
engine oil pressure. The default engine oil pressure
• The engine will default to the limp home speed. is 600 kPa (87 psi). The electronic service tool
will display “Voltage Above Normal” on the status
• If the engine speed is higher than the limp home screens.
speed, the engine will decelerate to the limp home
speed. Possible Performance Effect:

• If the engine speed is lower than the limp home None

speed, the engine speed will remain at the current
speed. Troubleshooting:

• The engine will remain at this speed while the This diagnostic code can be caused by an open
diagnostic code remains active. circuit or a short to another power source.

• All inputs from the faulty throttle are ignored by the Perform the following diagnostic procedure: “Engine
ECM until the fault is repaired. Pressure Sensor Open or Short Circuit - Test”

• All inputs from the repaired throttle will be ignored Results:

by the ECM until the keyswitch has been turned to
the OFF position and then back to the ON position. • OK – STOP.
Troubleshooting:
i03484761

This diagnostic code indicates that the frequency of a

digital throttle signal is out of the normal range.
CID 0100 FMI 04
SMCS Code: 1924-038
Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test” Conditions Which Generate This Code:
Results: The Electronic Control Module (ECM) detects the
following conditions:
• OK – STOP.
• The signal voltage from the engine oil pressure
i03484745 sensor is less than 0.1 Volts DC for more than
eight seconds.
CID 0100 FMI 03
• The ECM has been powered for at least two
SMCS Code: 1924-038 seconds.

Conditions Which Generate This Code: • The engine is running.

The Electronic Control Module (ECM) detects the
following conditions:
96 SENR9969-05
Troubleshooting Section

System Response: Possible Performance Effect:

The ECM will log the diagnostic code. If equipped, None

the warning lamp will come on. The ECM will set
data for engine oil pressure to the default value. The Troubleshooting:
electronic service tool will display “Voltage Below
Normal” on the status screens. This diagnostic code is designed to detect the loss
of the 5 Volt supply to the sensor.
Possible Performance Effect:
Perform the following diagnostic procedure: “Engine
None Pressure Sensor Open or Short Circuit - Test”

Troubleshooting: Results:

This diagnostic code can be caused by a short to • OK – STOP.

ground or a shorted sensor.
i03484807
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” CID 0110 FMI 03
Results: SMCS Code: 1906-038
• OK – STOP. Conditions Which Generate This Code:

i03484802 The Electronic Control Module (ECM) detects the

following conditions:
CID 0100 FMI 10
• The signal voltage from the engine coolant
SMCS Code: 1924-038 temperature sensor is greater than 4.95 Volts DC
for more than eight seconds.
Conditions Which Generate This Code:
• The ECM has been powered for at least two
The Electronic Control Module (ECM) detects the seconds.
following conditions:
System Response:
• No other codes for the oil pressure sensor are
active. If equipped, the warning light will be on. An active
diagnostic code will be generated after 8 seconds.
• No 0262 diagnostic codes are active for the 5 Volt The diagnostic code will be logged if the engine has
supply. been operating for more than 7 minutes.

• The engine speed is greater than 600 rpm. The ECM will default to 90 °C (194 °F) for engine
coolant temperature. “Voltage Above Normal” will
• The engine oil pressure signal is within the limits of be displayed next to the status for “Engine Coolant
410 kPa (59 psi) to 520 kPa (75 psi) with a pressure Temperature” on the electronic service tool.
variation of less than 1.68 kPa (0.25 psi)for more
than 30 seconds. Possible Performance Effect:

• The engine oil pressure signal remains constant • Poor stability

for 30 seconds.
• Poor cold running
System Response:
• White smoke
If equipped, the warning lamp will be on. The ECM
will log the diagnostic code. Troubleshooting:

The ECM will flag the engine oil pressure as invalid The diagnostic code will detect an excessively high
data. The data for engine oil pressure is set to a voltage from the engine coolant temperature sensor.
default value of 500 kPa (72 psi). The electronic
service tool will display “Conditions Not Met” on the Perform the following diagnostic procedure: “Engine
status screen. Temperature Sensor Open or Short Circuit - Test”
SENR9969-05 97
Troubleshooting Section

Results: i03484964

• OK – STOP. CID 0168 FMI 00

SMCS Code: 1401-038
i03484901
Conditions Which Generate This Code:
CID 0110 FMI 04
This condition indicates that the battery circuit to
SMCS Code: 1906-038 the Electronic Control Module (ECM) has excessive
voltage while the engine is running.
Conditions Which Generate This Code:
The ECM detects the following conditions:
The Electronic Control Module (ECM) detects the
following conditions:
• For 24 Volt DC systems, the battery voltage to the
ECM exceeds 32 Volts for more than 0.5 seconds.
• The signal voltage from the engine coolant
temperature sensor is less than 0.2 Volts DC for
more than eight seconds.
• For 12 Volt DC systems, the battery voltage to the
ECM exceeds 16 Volts for more than 0.5 seconds.
• The ECM has been powered for at least two • The keyswitch is in the ON mode.
seconds.
• The engine is not cranking.
• Diagnostic code 0168-01 is not active.
System Response:
• The engine is running for more than 30 seconds.
System Response:
The ECM will default to 90 °C (194 °F) for engine
coolant temperature. “Voltage Below Normal” will The ECM will log the diagnostic code. If equipped,
be displayed next to the status for “Engine Coolant the warning lamp may come on.
Temperature” on the electronic service tool.
Possible Performance Effect:
If equipped, the warning light will come on. An active
diagnostic code will be generated after 8 seconds. None
The diagnostic code will be logged if the engine has
been operating for more than 7 minutes. Troubleshooting:
Possible Performance Effect: This diagnostic code will detect excessively high
voltage in the battery circuit to the Electronic Control
• Poor stability Module (ECM) while the engine is running.
• Poor cold running Perform the following diagnostic procedure: “Ignition
Keyswitch Circuit and Battery Supply Circuit - Test”
• White smoke
Results:
Troubleshooting:

The diagnostic code will detect an excessively low

• OK – STOP.
voltage from the engine coolant temperature sensor.
i03484984
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” CID 0168 FMI 01
Results: SMCS Code: 1401-038

• OK – STOP. Conditions Which Generate This Code:

This code indicates that the battery circuit for the

Electronic Control Module (ECM) has low voltage
while the engine is running. If battery voltage
disappears without returning, the ECM will not log
this diagnostic code and the engine will shut down.

The ECM detects the following conditions:

98 SENR9969-05
Troubleshooting Section

• The keyswitch is in the ON position. • The engine is running.

• The engine is not cranking. • The engine is not cranking.
• The engine is running for more than three seconds. System Response:

• For 24 Volt DC systems, the battery voltage to the The diagnostic code will normally be logged. If the
ECM is below 18 Volts for more than 0.5 seconds. battery voltage disappears without returning, the
ECM will not log this diagnostic code and the engine
• For 12 Volt DC systems, the battery voltage to the will shut down. This will be dependent on the length
ECM is below 9 Volts for more than 0.5 seconds. of time for the occurrence of the fault.

System Response: The check engine lamp and the warning lamp may
come on.
If equipped, the warning lamp may come on. The
ECM will normally log the diagnostic code. If battery Possible Performance Effect:
voltage disappears without returning, the ECM will
not log this diagnostic code and the engine will shut The engine may experience changes in the engine
down. rpm, and intermittent engine shutdowns or complete
engine shutdowns while the conditions that cause
Possible Performance Effect: this diagnostic code are present. The ECM may stop
injecting fuel. This may be dependent on the length
The engine will derate 100 percent. of time for the occurrence of the fault.

The engine may experience changes in the engine Troubleshooting:

rpm, and intermittent engine shutdowns or complete
engine shutdowns while the conditions that cause This diagnostic code detects intermittent voltage in
this diagnostic code are present. the battery circuit for the Electronic Control Module
(ECM) while the engine is running.
Troubleshooting:
Perform the following diagnostic procedure: “Ignition
This diagnostic code will detect low voltage in the Keyswitch Circuit and Battery Supply Circuit - Test”
battery circuit for the Electronic Control Module
(ECM) while the engine is running. Results:

Perform the following diagnostic procedure: “Ignition • OK – STOP.

Keyswitch Circuit and Battery Supply Circuit - Test”
i03688611
Results:
CID 0171 FMI 03
• OK – STOP.
SMCS Code: 1928-038
i03485035
Conditions Which Generate This Code:
CID 0168 FMI 02
The Electronic Control Module (ECM) detects the
SMCS Code: 1401-038 following conditions:

Conditions Which Generate This Code: • The signal voltage from the air ambient temperature
sensor is greater than 4.98 Volts DC for more than
This condition indicates that the battery circuit for the fifteen seconds.
Electronic Control Module (ECM) is intermittent while
the engine is running. • The ECM has been powered for at least two
seconds.
The ECM detects the following conditions:
• Diagnostic code 0262-03 is not active.
• Three voltage readings that are below 6 Volts DC
in a period of 7 seconds will be detected by the System Response:
ECM. The voltage must subsequently increase to
more than 9 Volts DC. The ECM will use the default value of 25° C (77° F)
for the air ambient temperature. “Voltage High” will
• The keyswitch is in the ON position. be displayed next to the status for “Air Ambient
Temperature” on the electronic service tool.
SENR9969-05 99
Troubleshooting Section

A warning will appear on the display on the control Results:

panel. The ECM will log the diagnostic code.
• OK – STOP.
Possible Performance Effect:
i03485341
None

Troubleshooting:
CID 0172 FMI 03
SMCS Code: 1921-038
This fault can be caused by an open circuit or a short
to a power source. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Engine The Electronic Control Module (ECM) detects the
Temperature Sensor Open or Short Circuit - Test” following conditions:
Results:
• The signal voltage from the intake manifold air
temperature sensor is greater than 4.95 Volts DC
• OK – STOP. for more than eight seconds.

i03688613 • Engine coolant temperature is above −10 °C

(15.0 °F).
CID 0171 FMI 04
• The ECM has been powered for at least two
SMCS Code: 1928-038 seconds.

Conditions Which Generate This Code: • Diagnostic code 0168-01 is not active.
The Electronic Control Module (ECM) detects the System Response:
following conditions:
If equipped, the warning light will come on. The ECM
• The signal voltage from the air ambient temperature will log the diagnostic code.
sensor is less than 0.2 Volts DC for more than
fifteen seconds. The ECM will use the default value of 70 °C (158 °F)
for the intake manifold air temperature. “Voltage
• The ECM has been powered for at least two High” will be displayed next to the status for “Intake
seconds. Manifold Air Temperature” on the electronic service
tool.
• Diagnostic code 0262-04 is not active.
Possible Performance Effect:
System Response:
• Poor stability
The ECM will use the default value of 25° C (77° F)
for the air ambient temperature. “Voltage Low” will • Poor cold running
be displayed next to the status for “Air Ambient
Temperature” on the electronic service tool. • White smoke
A warning will appear on the display on the control • Black smoke
panel. The ECM will log the diagnostic code.
• Poor acceleration under load
Possible Performance Effect:
Troubleshooting:
None
This fault can be caused by an open circuit or a short
Troubleshooting: to a power source.

This fault can be caused by a sensor that is shorted Perform the following diagnostic procedure: “Engine
to ground or a sensor that is internally shorted. Temperature Sensor Open or Short Circuit - Test”

Perform the following diagnostic procedure: “Engine Results:

Temperature Sensor Open or Short Circuit - Test”
• OK – STOP.
100 SENR9969-05
Troubleshooting Section

i03485361 i03485380

CID 0172 FMI 04 CID 0190 FMI 08

SMCS Code: 1921-038 SMCS Code: 1907-038

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

The Electronic Control Module (ECM) detects the The Electronic Control Module (ECM) detects the
following conditions: following conditions:

• The signal voltage from the intake manifold air • The ECM detected an intermittent loss of signal
temperature sensor is less than 0.2 Volts DC for or a complete loss of signal from the primary
more than eight seconds. speed/timing sensor for 2 seconds.

• The ECM has been powered for at least two • The engine has been running for more than three
seconds. seconds.

• Diagnostic code 0168-01 is not active. System Response:

System Response: If equipped, the warning light will come on and the
diagnostic code will be logged.
If equipped, the warning light will come on. The ECM
will log the diagnostic code. The ECM will use the signal from the secondary
speed/timing sensor.
The ECM will use the default value of 70 °C (158°F)
for the intake manifold air temperature. “Voltage Possible Performance Effect:
Low” will be displayed next to the status for “Intake
Manifold Air Temperature” on the electronic service The engine will be derated. If the signal from the
tool. secondary speed/timing sensor is also lost, the
engine will shut down.
Possible Performance Effect:
Troubleshooting:
• Poor stability
This diagnostic code will detect a loss of signal from
• Poor cold running the primary speed/timing sensor.

• White smoke Perform the following diagnostic procedure: “Engine

Speed/Timing Sensor Circuit - Test”
• Black smoke
Results:
• Poor acceleration under load
• OK – STOP.
Troubleshooting:
i03485400
This fault can be caused by a sensor that is shorted
to ground or a sensor that is internally shorted. CID 0247 FMI 09
Perform the following diagnostic procedure: “Engine SMCS Code: 1901-038
Temperature Sensor Open or Short Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) detects the
• OK – STOP. following condition:

• Another controller has incorrectly stopped

transmitting a J1939 speed request (TSC1)or
another controller has started transmitting a J1939
speed request incorrectly.
SENR9969-05 101
Troubleshooting Section

System Response: Use the OEM information to determine the machine

ECM that provides the continuous speed signal.
If equipped, the warning lamp will come on. The Refer to the troubleshooting procedures for the
diagnostic code will be logged. machine in order to diagnose the faulty speed signal.

Some system functions may not operate correctly. Results:

Troubleshooting: • OK – STOP.
This diagnostic code detects an abnormal signal from
i02524493
the J1939 data link.

Perform the following diagnostic procedure: “CAN

CID 0253 FMI 02
Data Link Circuit - Test” SMCS Code: 1901-038
Results: Conditions Which Generate This Code:
• OK – STOP. The Electronic Control Module (ECM) detects
incorrect engine software.
i03485405
System Response:
CID 0247 FMI 12
If equipped, the warning light will come on.
SMCS Code: 1901-038
This diagnostic code is not logged.
Conditions Which Generate This Code:
Factory passwords are required to clear this
The Electronic Control Module (ECM) detects the diagnostic code.
following conditions:
Possible Performance Effect:
• There is an unexpected loss of a continuous
J1939 Torque Speed Controller (TSC1) signal on The engine will not start.
the J1939 data link.
Troubleshooting:
• The expected continuous TSC1 signal has never
been received on the J1939 data link. The flash file in the ECM is from the wrong engine
family.
System Response:
Use the electronic service tool to install the correct
If equipped, the warning lamp will come on and the flash file into the ECM. Refer to the Troubleshooting
diagnostic code will be logged. Guide, “Flash Programming”.

Engine speed functions that are controlled through Perform the following diagnostic procedure: “None”
TSC1 will be disabled until the fault is rectified and
the keyswitch is cycled through the OFF position and Results:
the ON position.
• OK – STOP.
If there is no secondary throttle, the engine speed will
be reduced to a low idle. If the engine is equipped
i03486420
with a secondary throttle, the engine speed will
change to the speed that is demanded by the
secondary throttle.
CID 0261 FMI 11
SMCS Code: 1912-038
Troubleshooting:
Conditions Which Generate This Code:
This diagnostic code will detect a loss of signal from
the J1939 data link. The Electronic Control Module (ECM) detects the
following conditions:
Check the configuration of the ECM. If the ECM for
the engine has been incorrectly configured to expect
a continuous TSC1 signal, remove “Continuous” for
• The outputs from the primary speed/timing sensor
and the secondary speed/timing sensor differ by
the TSC1 signal on the main “J1939” screen on the more than 8 crankshaft degrees.
electronic service tool.
102 SENR9969-05
Troubleshooting Section

• The engine has been running for more than five Results:
seconds.
• OK – STOP.
• Diagnostic code 0190-08 is not active.
i03486480
• No 0041 diagnostic codes are active.
System Response:
CID 0262 FMI 04
SMCS Code: 1439-038
If equipped, the warning light will come on. This code
will not be logged. Conditions Which Generate This Code:
Possible Performance Effect: The Engine Control Module (ECM) detects the
following conditions:
The pressure in the fuel rail may be unstable and the
engine may not run smoothly.
• The 5 volt supply for the pressure and temperature
sensors is less than 4.84 Volts DC for more than
Troubleshooting: one second.
Check the timing of the fuel rail pump. Refer to
Disassembly and Assembly, “Fuel Injection Pump
• The ECM has been powered for at least three
seconds.
- Install”.

Results:
• Diagnostic code 0168-01 is not active.
System Response:
• OK – STOP.
The ECM sets all of the pressure sensors and
i03486460 temperature sensors to the default values.

CID 0262 FMI 03 The ECM will derate the engine.

SMCS Code: 1439-038 Possible Performance Effect:

Conditions Which Generate This Code: The engine will be derated.

The Electronic Control Module (ECM) detects the Troubleshooting:

following conditions:
This diagnostic code will detect an excessively low
• The 5 volt supply for the pressure and temperature voltage in the 5 Volt supply circuit.
sensors is greater than 5.16 Volts DC for more
than one second. Perform the following diagnostic procedure: “5 Volt
Sensor Supply Circuit - Test”
• The ECM has been powered for at least three
seconds. Results:

• Diagnostic code 0168-01 is not active. • OK – STOP.

System Response:
i03486481

The ECM sets all of the pressure sensors and

temperature sensors to the default values.
CID 0268 FMI 02
SMCS Code: 1901-038
Possible Performance Effect:
Conditions Which Generate This Code:
The engine will be derated.
The Electronic Control Module (ECM) detects one or
Troubleshooting: more of the following conditions:
This diagnostic code will detect an excessively high
voltage in the 5 Volt supply circuit.
• One or more of the following configuration
parameters are not programmed. The effect on the
ECM depends on the parameter.
Perform the following diagnostic procedure: “5 Volt
Sensor Supply Circuit - Test”
SENR9969-05 103
Troubleshooting Section

• FLS or FTS System Response:

• Trim codes for the injectors If equipped, the warning lamp will come on and the
diagnostic code will be logged.
• Engine serial number
Possible Performance Effect:
• All of the injector trim files are not loaded into the
ECM. Engine performance and emissions are If the signal from the secondary speed/timing sensor
affected. is lost and the engine is stopped, the engine will not
restart. The performance will not be affected unless
System Response: both speed signals are lost. The loss of the signals
from both speed/timing sensors will cause the ECM
If equipped, the warning light will come on. The fault to shut down the engine.
is not logged.
Troubleshooting:
The electronic service tool will display a list of the
condition(s) on the “Active Diagnostics” screen that This diagnostic code indicates that the signal from
must be resolved. the secondary speed/timing sensor is incorrect.

Possible Performance Effect: Perform the following diagnostic procedure: “Engine

Speed/Timing Sensor Circuit - Test”
The ECM may limit the engine to low idle and/or the
ECM may derate the power. Engine performance and Results:
emissions are affected.
• OK – STOP.
Troubleshooting:
i03486577
Use the electronic service tool to correct parameters
that have not been programmed or parameters that
have been incorrectly programmed.
CID 0526 FMI 05
SMCS Code: 1057-038
Perform the following diagnostic procedure: “Flash
Programming” Conditions Which Generate This Code:
Results: This diagnostic code will only appear if an
electronically controlled wastegate is installed.
• OK – STOP.
The Electronic Control Module (ECM) detects the
i03486500 following conditions:

CID 0342 FMI 08 • A low current condition in the output from the ECM
to the solenoid for the wastegate regulator
SMCS Code: 1907-038-SE
• No active 0168 diagnostic codes
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) detects the
following conditions: If equipped, the warning lamp will come on once the
diagnostic code has been active for 30 seconds.
• The signal from the secondary speed/timing sensor The diagnostic code will be logged. After the derate
is lost and/or intermittent. has been activated, the electronic service tool will
indicate “Turbo Protection Derate Active”.
• The signal from the secondary speed/timing sensor
was lost for at least 2 seconds while the signal Possible Performance Effect:
from the primary speed/timing sensor remained
valid and the engine was running. The engine will be derated while this diagnostic code
is active.
• Diagnostic code 0168-01 is not active.
• The engine has been running for more than 3
seconds.

• No 0041 diagnostic codes are active.

104 SENR9969-05
Troubleshooting Section

Troubleshooting: i03486660

This diagnostic code will detect a fault in the circuit CID 0526 FMI 07
for the solenoid in the wastegate regulator that is
most likely to be an open circuit. SMCS Code: 1057-038

Perform the following diagnostic procedure: Conditions Which Generate This Code:
“Wastegate Solenoid - Test”
This diagnostic code will only appear if an
Results: electronically controlled wastegate is installed.

• OK – STOP. This diagnostic code indicates that the intake

manifold pressure is not being controlled correctly.

i03486646 The Electronic Control Module (ECM) will detect the

following conditions:
CID 0526 FMI 06
SMCS Code: 1057-038
• The ECM has been powered for more than 4
seconds.
Conditions Which Generate This Code:
• Diagnostic code 0168-01 is not active.
This diagnostic code will only appear if an
electronically controlled wastegate is installed.
• Diagnostic codes 0526-05 and 0526-06 are not
active.
The Electronic Control Module (ECM) detects the
following conditions:
• No 0262 diagnostic codes are active.
• No 1785 diagnostic codes are active.
• A high current condition in the output from the ECM
to the solenoid in the wastegate regulator System Response:
• No active 0168 diagnostic codes If equipped, the warning lamp will come on and the
ECM will log the diagnostic code.
System Response:
Possible Performance Effect:
If equipped, the warning lamp will come on once the
diagnostic code has been active for 30 seconds.
The diagnostic code will be logged. After the derate
• The engine may not reach top RPM.
has been activated, the electronic service tool will
indicate “Turbo Protection Derate Active”.
• The engine produces excessive black smoke.

Possible Performance Effect:

• The engine has low power.
Troubleshooting:
The engine will be derated while this diagnostic code
is active. This diagnostic code will detect a mechanical
problem in the intake air system. The electronic part
Troubleshooting: of the control system will be operating correctly.
This diagnostic code will detect a fault in the circuit Perform the following diagnostic procedure: “Systems
for the solenoid in the wastegate regulator. This Operation, Testing and Adjusting, “Turbocharger -
problem is most likely to be caused by a high side Inspect””
short to ground or a low side short to power.
Results:
Perform the following diagnostic procedure:
“Wastegate Solenoid - Test”
• OK – STOP.
Results:

• OK – STOP.
SENR9969-05 105
Troubleshooting Section

i03486700 • The ECM has been powered for 3 seconds.

CID 0774 FMI 02 • Diagnostic code 0168-01 is not active.
SMCS Code: 1913-038-SE • No 0262 diagnostic codes are active.
Conditions Which Generate This Code: • The setting for the upper diagnostic limit has been
exceeded for 1 second.
The Electronic Control Module (ECM) detects a
position for the throttle switch that has not been System Response:
defined.
If equipped, the warning lamp will come on. The
System Response: diagnostic code will be logged.
If equipped, the warning lamp will come on. The Possible Performance Effect:
diagnostic code will be logged.
The engine will use the primary throttle until the fault
Possible Performance Effect: is repaired.
The engine will use the primary throttle until the fault If the primary throttle has a fault, the following
is repaired. conditions will occur:
If the primary throttle has a fault, the following • The engine will default to the limp home speed.
conditions will occur:
• If the engine speed is higher than the limp home
• The engine will default to the limp home speed. speed, the engine will decelerate to the limp home
speed.
• If the engine speed is higher than the limp home
speed, the engine will decelerate to the limp home • If the engine speed is lower than the limp home
speed. speed, the engine speed will remain at the current
speed.
• If the engine speed is lower than the limp home
speed, the engine speed will remain at the current • The engine will remain at this speed while the
speed. diagnostic code remains active.

• The engine will remain at this speed while the • All inputs from the faulty throttle are ignored by the
diagnostic code remains active. ECM until the fault is repaired.

• All inputs from the faulty throttle are ignored by the • All inputs from the repaired throttle will be ignored
ECM until the fault is repaired. by the ECM until the keyswitch has been turned to
the OFF position and then back to the ON position.
• All inputs from the repaired throttle will be ignored
by the ECM until the keyswitch has been turned to Troubleshooting:
the OFF position and then back to the ON position.
Monitor the configuration screen on the electronic
Perform the following diagnostic procedure: “Throttle service tool in order to determine the type of throttle
Switch Circuit - Test” position sensor that is used on the engine.
Results: If the engine is equipped with an analog secondary
throttle position sensor, proceed to “Test Step 1”.
• OK – STOP.
If the engine is equipped with a digital secondary
i03486720
throttle position sensor, proceed to “Test Step 2”.

CID 0774 FMI 03 Test Step 1.

SMCS Code: 1913-038-SE Perform the following diagnostic procedure: “Analog
Throttle Position Sensor Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) detects one of
the following conditions: • OK – STOP.
106 SENR9969-05
Troubleshooting Section

Test Step 2. Troubleshooting:

Perform the following diagnostic procedure: “Digital Monitor the configuration screen on the electronic
Throttle Position Sensor Circuit - Test” service tool in order to determine the type of throttle
position sensor that is used on the engine.
Results:
If the engine is equipped with an analog secondary
• OK – STOP. throttle, proceed to “Test Step 1”.

If the engine is equipped with a digital secondary

i03486740
throttle, proceed to “Test Step 2”.
CID 0774 FMI 04
Test Step 1.
SMCS Code: 1913-038-SE
Perform the following diagnostic procedure: “Analog
Conditions Which Generate This Code: Throttle Position Sensor Circuit - Test”

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

the following conditions:
• OK – STOP.
• The ECM has been powered for 3 seconds.
Test Step 2.
• Diagnostic code 0168-01 is not active.
Perform the following diagnostic procedure: “Digital
• No 0262 diagnostic codes are active. Throttle Position Sensor Circuit - Test”

• The setting for the lower diagnostic limit has been Results:
exceeded for 1 second.
• OK – STOP.
System Response:

If equipped, the warning lamp will come on. The i03486782

diagnostic code will be logged.
CID 0774 FMI 08
Possible Performance Effect:
SMCS Code: 1913-038-SE
The engine will use the primary throttle until the fault
Conditions Which Generate This Code:
is repaired.

If the primary throttle has a fault, the following The Electronic Control Module (ECM) detects one of
the following conditions:
conditions will occur:

• The engine will default to the limp home speed. • The ECM has been powered for 3 seconds.

• If the engine speed is higher than the limp home • Diagnostic code 0168-01 is not active.
speed, the engine will decelerate to the limp home
speed. • No 0262 codes are active for the analog sensors.

• If the engine speed is lower than the limp home • No 0041 codes are active for the digital (PWM)
sensors.
speed, the engine speed will remain at the current
speed.
• Diagnostic codes 0774-03 and 0774-04 are not
active.
• The engine will remain at this speed while the
diagnostic code remains active.
• The frequency of the signal from the digital (PWM)
sensor is less than 150 Hz for more than 1 second.
• All inputs from the faulty throttle are ignored by the
ECM until the fault is repaired.
• The frequency of the signal from the digital (PWM)
sensor is greater than 1050 Hz for more than 1
• All inputs from the repaired throttle will be ignored second.
by the ECM until the keyswitch has been turned to
the OFF position and then back to the ON position.
SENR9969-05 107
Troubleshooting Section

System Response: System Response:

If equipped, the warning lamp will come on. The If equipped, the warning lamp will come on and the
diagnostic code will be logged. ECM will log the diagnostic code.

Possible Performance Effect: Possible Performance Effect:

The engine will use the primary throttle until the fault The engine will not start.
is repaired.
Troubleshooting:
If the primary throttle has a fault, the following
conditions will occur: This diagnostic code will detect a loss of
communications with the MSS.
• The engine will default to the limp home speed.
Perform the following diagnostic procedure: “Data
• If the engine speed is higher than the limp home Link Circuit - Test”
speed, the engine will decelerate to the limp home
speed. Results:

• If the engine speed is lower than the limp home • OK – STOP.

speed, the engine speed will remain at the current
speed.
i02524510

• The engine will remain at this speed while the

diagnostic code remains active.
CID 1743 FMI 02
SMCS Code: 7332-038
• All inputs from the faulty throttle are ignored by the
ECM until the fault is repaired. Conditions Which Generate This Code:
• All inputs from the repaired throttle will be ignored The Electronic Control Module (ECM) detects a
by the ECM until the keyswitch has been turned to combination of switch positions for the mode switches
the OFF position and then back to the ON position. that has not been defined.
Troubleshooting: System Response:
Monitor the configuration screen on the electronic The ECM will return the engine to the last good mode
service tool in order to determine the type of throttle selection or setting.
position sensor that is used on the engine.
Possible Performance Effect:
Perform the following diagnostic procedure: “Digital
Throttle Position Sensor Circuit - Test” The engine will start and the engine will default to the
previous mode selection. The engine may operate at
Results: reduced speed or reduced power. This will depend
on the mode that is selected.
• OK – STOP.
Perform the following diagnostic procedure: “Mode
i03486822 Selection Circuit - Test”

CID 1639 FMI 09 Results:

SMCS Code: 7631-038 • OK – STOP.

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects the

following condition:

• The ECM detects a loss of communications with

the Machine Security System (MSS).
108 SENR9969-05
Troubleshooting Section

i02676721 Results:
CID 1779 FMI 05 • OK – STOP.
SMCS Code: 1251-038
i03488840
Conditions Which Generate This Code:
CID 1785 FMI 03
This diagnostic code indicates that the Electronic
Control Module (ECM) has detected an open circuit SMCS Code: 1921-038
or low current condition in the solenoid for the fuel
rail pump. Conditions Which Generate This Code:

System Response: The Electronic Control Module (ECM) detects the

following conditions:
If equipped, the warning light will come on and the
ECM will log the diagnostic code. • The ECM has been powered for two seconds.

Possible Performance Effect: • The signal voltage from the intake manifold
pressure sensor is above 4.95 Volts DC for at least
An electrical fault may prevent the provision of two seconds.
pressure to the fuel rail. This may result in the loss
of fuel injection. If the solenoid for the fuel rail pump • This code can be caused by an open circuit or a
fails, it is likely that fuel will not be pumped into the short to another power source.
fuel rail. The engine will stop or the engine will not
start. System Response:

Perform the following diagnostic procedure: “Fuel If equipped, the warning light will be on. The
Rail Pump Solenoid - Test” diagnostic code will be logged.

Results: The data for the intake manifold pressure will be set
to a maximum valid pressure for two seconds. The
ECM will then flag the intake manifold pressure as
• OK – STOP. being invalid. A default value is then used for the
intake manifold pressure.
i02676717
Possible Performance Effect:
CID 1779 FMI 06
For engines with an electronically controlled
SMCS Code: 1251-038 wastegate, the current for the wastegate solenoid
will be set to a default value while this code is active.
Conditions Which Generate This Code: This will cause the engine to have poor acceleration
but the default setting will prevent any overpressure
This diagnostic code indicates that the Electronic in the intake manifold which could be caused by an
Control Module (ECM) has detected a short circuit overspeed of the turbocharger.
or high current condition in the solenoid for the fuel
rail pump. Troubleshooting:
System Response: This diagnostic code will detect excessively high
voltage from the intake manifold pressure sensor.
If equipped, the warning light will come on and the
ECM will log the diagnostic code. Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
Possible Performance Effect:
Results:
An electrical fault may prevent the provision of
pressure to the fuel rail. This may result in the loss • OK – STOP.
of fuel injection. If the solenoid for the fuel rail pump
fails, it is likely that fuel will not be pumped into the
fuel rail. The engine will stop or the engine will not
start.

Perform the following diagnostic procedure: “Fuel

Rail Pump Solenoid - Test”
SENR9969-05 109
Troubleshooting Section

i03488842 i03488846

CID 1785 FMI 04 CID 1785 FMI 10

SMCS Code: 1921-038 SMCS Code: 1921-038

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

The Electronic Control Module (ECM) detects the This diagnostic code is designed to detect the loss of
following conditions: the 5 Volt supply at the sensor connector.

• The signal voltage from the intake manifold The Electronic Control Module (ECM) detects the
pressure sensor is less then 0.2 Volts DC for at following conditions:
least two seconds.
• The engine speed is more than 1000 rpm.
• The ECM has been powered for two seconds.
• The intake manifold pressure is within the
• This code can be caused by a short to ground or acceptable range.
a shorted sensor.
• No 0262 codes for the 5 Volt supply are active.
• The keyswitch is in the ON position so that the
ECM is energized. • Diagnostic code 0168-01 is not active.
System Response: System Response:

If equipped, the warning light will come on. The If equipped, the warning light will come on. The
diagnostic code will be logged. diagnostic code will be logged.

The data for the intake manifold pressure will be set The ECM will flag the intake manifold pressure as
to a maximum valid pressure for two seconds. The being invalid. A default value is used for the intake
ECM will then flag the intake manifold pressure as manifold pressure.
being invalid. A default value is then used for the
intake manifold pressure. Note: Any open circuits or short circuits in the signal
wire for the oil pressure may reset this diagnostic.
Possible Performance Effect:
Possible Performance Effect:
For engines with an electronically controlled
wastegate, the current for the wastegate solenoid For engines with an electronically controlled
will be set to a default value while this code is active. wastegate, the current for the wastegate solenoid
This will cause the engine to have poor acceleration will be set to a default value while this code is active.
but the default setting will prevent any overpressure This will cause the engine to have poor acceleration
in the intake manifold which could be caused by an but the default setting will prevent any overpressure
overspeed of the turbocharger. in the intake manifold which could be caused by an
overspeed of the turbocharger.
Troubleshooting:
The engine will be derated.
This diagnostic code will detect excessively low
voltage from the intake manifold pressure sensor. Troubleshooting:

Perform the following diagnostic procedure: “Engine This diagnostic code will detect the loss of the 5 Volt
Pressure Sensor Open or Short Circuit - Test” supply to the sensor.

Results: Perform the following diagnostic procedure: “Engine

Pressure Sensor Open or Short Circuit - Test”
• OK – STOP.
Results:

• OK – STOP.
110 SENR9969-05
Troubleshooting Section

i03488860 System Response:

CID 1797 FMI 03 If equipped, the warning lamp will come on. The
diagnostic code will be logged.
SMCS Code: 1718-038
The electronic service tool will display “70000 kPa”
Conditions Which Generate This Code: next to “Desired Fuel Rail Pressure” and “Actual Fuel
Rail Pressure” on the status screens.
The Electronic Control Module (ECM) detects the
following conditions: Possible Performance Effect:

• No 0262 codes for the 5 Volt supply are active. The engine will be derated.

• Diagnostic code 0168-00 is not active. Troubleshooting:

• The signal voltage for the pressure in the fuel rail is This diagnostic code detects an excessively low
more than 4.8 Volts DC for 0.6 seconds. voltage from the fuel rail pressure sensor.
System Response: Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
If equipped, the warning lamp will come on. The
diagnostic code will be logged. Results:
The electronic service tool will display “70000 kPa” • OK – STOP.
next to “Desired Fuel Rail Pressure” and “Actual Fuel
Rail Pressure” on the status screens.
i03489085
Possible Performance Effect:
CID 1834 FMI 02
The engine will be derated.
SMCS Code: 1416-038
Troubleshooting:
Conditions Which Generate This Code:
This diagnostic code detects an excessively high
voltage from the fuel rail pressure sensor. The Electronic Control Module (ECM) detects the
following condition:
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” The signal from the keyswitch was erratic because
the keyswitch was cycled at least three times within
Results: the last second.

Note: This code can be generated by rapidly

• OK – STOP. cycling the keyswitch. Some control modules on
the application may require this action in order to
i03489061 prompt flash codes. If this occurs, clear the logged
diagnostic codes in order to prevent future confusion
CID 1797 FMI 04 or an incorrect diagnosis.
SMCS Code: 1718-038 System Response:
Conditions Which Generate This Code: If equipped, the warning lamp will come on. The
diagnostic code will be logged. The ECM will stop
The Electronic Control Module (ECM) detects the energizing the injector solenoids.
following conditions:
Possible Performance Effect:
• No 0262 codes for the 5 Volt supply are active.
The engine will shut down.
• Diagnostic code 0168-01 is not active.
Troubleshooting:
• The signal voltage for the pressure in the fuel rail is
less than 0.2 Volts DC for 0.6 seconds. Perform the following diagnostic procedure: “Ignition
Keyswitch Circuit and Battery Supply Circuit - Test”
SENR9969-05 111
Troubleshooting Section

Results:

• OK – STOP.

i03489089

CID 2246 FMI 06

SMCS Code: 4493-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) has detected a

high current condition (short circuit) after attempting
to activate the glow plug starting aid.

The ECM detects the following conditions:

• The engine is not cranking.

• The ECM has been powered for at least 1 second.
• There is a high current condition (short circuit) for
more than 2 seconds.

System Response:

If equipped, the warning light will come on. The

diagnostic code will be logged. An ECM that was
previously blank will require a total of 2 hours of
operation before the diagnostic code will be logged.

Possible Performance Effect:

The ECM is unable to activate the relay for the glow

plug starting aid. The glow plugs will not operate or
the glow plugs will operate all the time.

The engine may be difficult to start in cold

temperatures and the exhaust may emit white smoke.

Troubleshooting:

This diagnostic code detects an excessively high

current in the circuit for the starting aid relay.

Perform the following diagnostic procedure: “Starting

Aid (Glow Plug) Relay Circuit - Test”

Results:

• OK – STOP.
112 SENR9969-05
Troubleshooting Section

Troubleshooting with an
Event Code
i03489241

Event Codes
SMCS Code: 1901-038

Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure or
high coolant temperature has been detected. When
the event code is generated, the event is active.

The Electronic Control Module (ECM) can log events.

Logged events usually indicate a mechanical fault
instead of an electronic system fault or the engine is
operating outside the design specification.

Note: If a diagnostic code has already been logged

then any associated event code to that fault will not
be logged as well.

Note: If an event code is already active, a diagnostic

code that is associated with the same sensor will not
be active.

Active Event Codes

An active event code represents a fault with engine
operation. Correct the fault as soon as possible.

Active event codes are listed in ascending numerical g01365757

Illustration 20
order. The code with the lowest number is listed first.
Example of the typical operating range of a sensor
Event codes will cause a warning lamp to illuminate (1) This area represents the normal operating range of the engine
on the control panel and the event will be logged. parameter.
(2) In these areas, the engine is operating in an unsafe operating
range of the monitored parameter. An event code will be
Illustration 20 is an example of the operating range of generated for the monitored parameter. The sensor circuit does
an oil temperature sensor. Do not use the Illustration not have an electronic fault.
to troubleshoot the oil temperature sensor. (3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
electronic fault. A diagnostic code will be generated for the
sensor circuit. Refer to Troubleshooting, “Self Diagnostics” for
additional information on diagnostic codes.

The following format is used for event codes:

“EXXX-Y Description of the event”

The “E” means that the code is an event code. The

“XXX” represents a numeric identifier for the event
code. The “-Y” represents a numeric identifier for the
severity of the event. This is followed by a description
of the event. Refer to the following example:

“E362-3 Engine Overspeed Shutdown”

In this example, the number “-3” indicates the severity

of the event. The ECM has three levels of response
to events:
SENR9969-05 113
Troubleshooting Section

Level -1 – This level can be referred to as the 1. Obtain the following information about the
“Warning Level”. This condition represents a serious complaint from the operator:
problem with engine operation. However, this
condition does not require a derate or a shutdown. • The event and the time of the event
Level -2 – This level can be referred to as the • Determine the conditions for the event. The
“Derate Level”. For this condition, the ECM reduces conditions will include the engine rpm and the
the engine's power in order to help prevent possible load.
engine damage.
• Determine if there are any systems that were
Level -3 – This level can be referred to as the installed by the dealer or by the customer that
“Shutdown Level”. On this machine, a “Level 3” event could cause the event.
code will be logged in the ECM but the engine will
not shut down. • Determine whether any additional events
occurred.
Responses to certain events may be programmed
into the ECM. Refer to Troubleshooting, “System 2. Verify that the complaint is not due to normal
Configuration Parameters”. engine operation. Verify that the complaint is not
due to error of the operator.
Logged Event Codes 3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
When the ECM generates an event code, the ECM
logs the code in permanent memory. The ECM has history of the engine.
an internal diagnostic clock. The ECM will record
4. Perform a visual inspection. Inspect the following
the following information when an event code is
generated: items:

• The hour of the first occurrence of the code • Fuel supply

• The hour of the last occurrence of the code • Oil level

• The number of occurrences of the code • Oil supply

Logged events are listed in chronological order. The • Wiring

most recent event code is listed first.
• Connectors
This information can be helpful for troubleshooting
intermittent faults. Logged codes can also be used to Be sure to check the connectors. This is very
important for faults that are intermittent. Refer to
review the performance of the engine.
Troubleshooting, “Electrical Connectors - Inspect”.

Clearing Event Codes If these steps do not resolve the fault, identify the
procedures in this manual that best describe the
A code is cleared from memory when one of the event. Check each probable cause according to the
following conditions occur: tests that are recommended.

• The code does not recur for 100 hours.

i03492880

• A new code is logged and there are already ten E172 High Air Filter Restriction
codes in memory. In this case, the oldest code is
cleared.
SMCS Code: 1054-038
• The service technician manually clears the code. Conditions Which Generate This Code:
Always clear logged event codes after investigating This event code will only be generated if the switch for
and correcting the fault which generated the code.
the air filter restriction is installed and the customer
programmable feature is enabled.
Troubleshooting
The Electronic Control Module (ECM) detects a fault
For basic troubleshooting of the engine, perform the with the air flow. If the air flow has been restricted
following steps in order to diagnose a malfunction: for more than thirty seconds, the ECM will generate
this code.
114 SENR9969-05
Troubleshooting Section

Note: This code is generated only when the engine is System Response:
running. This event code will become inactive when
the restriction decreases for more than 5 seconds. If equipped, the warning lamp may come on and the
event code will be logged.
System Response:
Possible Performance Effect:
If equipped, the warning lamp will come on.
Engine power is reduced.
The event code will be logged.
Test Step 1. Determine the Operating
Possible Performance Effect: Conditions
E172-1 Determine if the engine was under heavy load or the
engine is operating at a high altitude.
A blocked filter may cause the engine to experience
symptoms such as low power. Expected Result:

Troubleshooting: The event occurred because of abnormal engine

operation.
This event code detects a restriction in the air intake
system. Results:

The event code may represent a fault with the • OK – The event occurred because of abnormal
electronic system. This event code normally indicates engine operation. Clear the logged event and
high air filter restriction. Refer to Systems Operation, return the engine to service. STOP.
Testing and Adjusting , “Air Inlet and Exhaust System
- Inspect”. • Not OK – The event indicates an engine fault. If
the engine is equipped with an air-to-air aftercooler,
Results: proceed to Test Step 2.

• OK – STOP. Test Step 2. Check the Air-to-Air

Aftercooler (ATAAC) (if equipped)
i03492900
The intake manifold air temperature can increase
E194 High Exhaust if the ATAAC is obstructed. Check the fins of the
ATAAC for obstructions.
Temperature
Expected Result:
SMCS Code: 1088-038-TA
The fins of the ATAAC are obstructed.
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) monitors the
following parameters in order to estimate the exhaust • OK – The fins of the ATAAC are obstructed.
temperature:
Repair: Clean the fins of the ATAAC. Clear the
• Intake manifold air temperature event. Refer to the OEM manual for the ATAAC.
Return the engine to service.
• Barometric pressure
STOP.
• Engine speed
• Not OK – The fins of the ATAAC are clear of
High intake manifold air temperature, high altitude obstructions.
operation, and high engine loads can cause the
exhaust temperature to increase to a level that may STOP.
damage the components of the exhaust system.
When this occurs, the ECM derates the engine
in order to reduce the exhaust temperature. This
protects the components of the exhaust system from
damage.
SENR9969-05 115
Troubleshooting Section

i03493000 • There are no active diagnostic codes for the oil

pressure sensor or for the atmospheric pressure
E232 High Fuel/Water sensor.
Separator Water Level
• Engine oil pressure is in the “LEVEL 1” area in
SMCS Code: 1261-038; 1263-038 Illustration 21 for eight seconds.

Conditions Which Generate This Code: Note: The warning will be cancelled if the oil pressure
rises 21 kPa (3 psi) above the set point for 20
This event code will only be generated if the switch seconds.
on the water separator filter is installed and correctly
wired to the Electronic Control Module (ECM). 360-2
The feature must be enabled in the customer
programmable parameters on the electronic service • The engine has been running for at least ten
tool. seconds.

The ECM detects a high water level in the fuel filter • There are no active diagnostic codes for the oil
if a water level sensor is installed in the fuel filter. pressure sensor or for the atmospheric pressure
If the water rises above a set level for more than sensor.
thirty seconds, the ECM will generate this code. The
code will become inactive when the switch has been • Engine oil pressure is in the “LEVEL 2” area in
immersed in fuel for 5 seconds. Illustration 22 for eight seconds.

Note: The code is generated only when the engine Note: The derate will be cancelled if the oil pressure
is running. rises 21 kPa (3 psi) above the set point for 20
seconds.
System Response:
360-3
If equipped, the warning lamp will come on and the
event code will be logged. • The engine has been running for at least ten
seconds.
Possible Performance Effect:
• There are no active diagnostic codes for the oil
E232-1 pressure sensor or for the atmospheric pressure
sensor.
None
• Engine oil pressure is in the “LEVEL 3” area in
Troubleshooting: Illustration 23 for four seconds.

Refer to Systems Operation, Testing and Adjusting,

“Fuel System - Inspect”.

Results:

• OK – STOP.

i03493020

E360 Low Engine Oil Pressure

SMCS Code: 1348-038-LP

Conditions Which Generate This Code:

The ECM detects low engine oil pressure under the

following conditions:

360-1
g01269377
Illustration 21
• The engine has been running for at least ten
seconds. Level 1 engine oil pressure versus engine speed
116 SENR9969-05
Troubleshooting Section

The ECM will generate a SPN 100-FMI 17 event

code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data
link.

360-2

The warning lamp will flash while the derate is active.

The ECM will generate a 46 flash code that will be

displayed via the diagnostic lamp.

The ECM will generate a E360-2 event code.

The electronic service tool will display “Engine

Derate” in the first “Engine Status” box on any status
screen on the electronic service tool.

The ECM will generate a SPN 100-FMI 18 event

code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data
Illustration 22
g01269382 link.
Level 2 engine oil pressure versus engine speed
360-3

The warning lamp will flash.

The ECM will generate a 46 flash code that will be

displayed via the diagnostic lamp.

The ECM will generate a E360-3 event code.

The ECM will generate a SPN 100-FMI 01 event

code on the J1939 data link. The event code may be
displayed on a receiving device on the J1939 data
link.

Possible Performance Effect:

360-1

Engine operation is not affected.

360-2
g01269384
Illustration 23 The ECM will derate power by 17.0 percent per
Level 3 engine oil pressure versus engine speed second up to a maximum of 100 percent while the
derate is active.
System Response:
Note: The derate of the engine will only occur if the
360-1 “Enable Derate” customer programmable parameter
has been enabled.
The warning lamp will flash while the warning is
active. 360-3

The Electronic Control Module (ECM) will generate a The engine will shut down.
46 flash code that will be displayed via the diagnostic
lamp. Note: The shutdown of the engine will only occur
if the “Enable Shutdown” customer programmable
The ECM will generate a E360-1 event code. parameter has been enabled.
SENR9969-05 117
Troubleshooting Section

Troubleshooting:

Refer to Troubleshooting, “Low Engine Oil Pressure”.

Results:

• OK – STOP.

i03493040

E361 High Engine Coolant

Temperature
SMCS Code: 1395-038-TA

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a

high engine coolant temperature under the following
conditions:

• The engine has been running for more than 185

seconds.

• The trip point for the event code for the temperature
of the engine coolant is reached.

• Diagnostic code 0110-03 Engine Coolant

Temperature voltage above normal is not active.

• Diagnostic code 0110-04 Engine Coolant

Temperature voltage below normal is not active.

• Diagnostic code 0168-01 Electrical System voltage

low is not active.

Table 53
Engine Coolant Trip Level Table
E361-1 E361-2 E361-3
Trip Point 113 °C (233 °F) 114 °C (237 °F) 118 °C (244 °F)
Delay to Activation 10 seconds 10 seconds 2 seconds
Reset Time 4 seconds 20 seconds 20 seconds

System Response: The derate of the engine will only occur if the “Enable
Derate” customer programmable parameter has
If equipped, the warning lamp will come on and the been enabled.
event code will be logged.
E361-3
Possible Performance Effect:
The ECM will shut down the engine after two seconds
E361-1 when the trip point for the engine coolant temperature
has been reached.
None
Note: The shutdown of the engine will only occur
E361-2 if the “Enable Shutdown” customer programmable
parameter has been enabled.
The ECM will derate the power at one percent per
second.
118 SENR9969-05
Troubleshooting Section

Troubleshooting: i03493180

Refer to Troubleshooting, “Coolant Temperature Is E396 High Fuel Rail Pressure

Too High”.
SMCS Code: 1702-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects
excessive fuel rail pressure. The ECM detects the
i03493061 following faults:
E362 Engine Overspeed • The ECM detects fuel rail pressure that is more
than the pressure that is required for the operating
SMCS Code: 7410-038; 7427-038 conditions.
Conditions Which Generate This Code:
• Diagnostic code 0262-03 5 Volt Sensor DC Power
Supply voltage above normal is not active.
The engine speed is above 3000 rpm for more than
0.6 seconds.
• Diagnostic code 0262-04 5 Volt Sensor DC Power
Supply voltage below normal is not active.
Note: This event code does not represent an
electronic system fault.
• Diagnostic code 1797-03 Fuel Rail Pressure
Sensor voltage above normal is not active.
System Response:

If equipped, the warning lamp will come on and the

• Diagnostic code 1797-04 Fuel Rail Pressure
Sensor voltage below normal is not active.
event code will be logged.

The ECM will reset the event when the engine speed
• No diagnostic codes are active for the fuel rail
pump.
is lower than 2800 RPM for 0.6 seconds.

Possible Performance Effect:

• No diagnostic codes are active for the fuel injectors.
System Response:
E362-1
If equipped, the warning lamp will come on and the
The fuel injection will be disabled until the event has event code will be logged.
been reset.
Possible Performance Effect:
Troubleshooting:
E396-1
This event indicates excessive engine speed. This
event does not represent a fault with the ECM. The engine will be derated until the keyswitch is
turned to OFF.
This event does not represent a fault with the
Electronic Speed/Timing Sensors. Troubleshooting:
The ECM logs the event. The event code does not indicate a fault with the
electronic system. This event indicates high fuel
No troubleshooting is required. pressure. Refer to Systems Operation, Testing and
Adjusting, “Fuel System - Inspect”.
Results:
A failed relief valve, the fuel pump or an electronic
• OK – STOP. unit injector may cause an event code to be logged.

Results:

• OK – STOP.
SENR9969-05 119
Troubleshooting Section

i03493200 Results:
E398 Low Fuel Rail Pressure • OK – STOP.
SMCS Code: 1702-038
i03493204
Conditions Which Generate This Code:
E539 High Intake Manifold Air
The Electronic Control Module (ECM) detects a fault Temperature
with low fuel rail pressure. The ECM detects the
following faults: SMCS Code: 1050-038-TA

• The ECM determines that the expected fuel Conditions Which Generate This Code:
rail pressure is lower than the pressure that is
requested by the electronic control system. The Electronic Control Module (ECM) detects a high
air temperature in the intake manifold under the
• Diagnostic code 0262-03 5 Volt Sensor DC Power following conditions:
Supply voltage above normal is not active.
• The engine has been running for more than 3
• Diagnostic code 0262-04 5 Volt Sensor DC Power minutes.
Supply voltage below normal is not active.
• The temperature of the coolant is more than 99 °C
• Diagnostic code 1797-03 Fuel Rail Pressure (210 °F) and the intake manifold pressure is more
Sensor voltage above normal is not active. than 30 kPa (4.35 psi).

• Diagnostic code 1797-04 Fuel Rail Pressure • The trip level for the intake manifold air temperature
Sensor voltage below normal is not active. is reached.

• No diagnostic codes are active for the fuel rail • Diagnostic code 0172-03 Intake Manifold Air
pump. Temperature voltage above normal is not active.

• No diagnostic codes are active for the fuel injectors. • Diagnostic code 0172-04 Intake Manifold Air
Temperature voltage below normal is not active.
System Response:

If equipped, the warning lamp will come on and the

event code will be logged.

Possible Performance Effect:

The engine will be derated until the keyswitch is

turned to OFF and then turned to ON.

Troubleshooting:

Low fuel pressure may be caused by the following

problems:

• A fault in the fuel return system

• A fault in the fuel pressure control
• A leak in the high pressure fuel system
• A failed relief valve, the fuel pump or an electronic
unit injector

The event code does not represent a fault in the

electronic system. Refer to Systems Operation,
Testing and Adjusting, “Fuel System - Inspect”.
120 SENR9969-05
Troubleshooting Section

Table 54
Intake Manifold Air Temperature Trip Level Table
E539-1 E539-2
Turbocharged Engines (T) 139 °C (282 °F) 142 °C (287 °F)
Turbocharged Aftercooled 82 °C (179 °F) 86 °C (186 °F)
Engines (TA)
Delay to activation 8 seconds 8 seconds
Reset Time 4 seconds 4 seconds

System Response: The event code will be logged.

If equipped, the warning lamp will come on and the Possible Performance Effect:
event code will be logged.
E2143-3
Possible Performance Effect:
The engine will shut down.
E539-1
Note: Engine shutdown will occur only if the “Enable
None Shutdown” programmable parameter has been
enabled.
E539-2
Troubleshooting:
The ECM will derate the power at one percent per
second. The event code may indicate a fault with the
electronic system. This event normally indicates low
The derate of the engine will only occur if the “Enable engine coolant. Refer to Systems Operation, Testing
Derate” customer programmable parameter has and Adjusting, “Cooling System - Inspect”.
been enabled.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Intake Air Temperature
Is Too High”.

Results:

• OK – STOP.

i03493240

E2143 Low Engine Coolant

Level
SMCS Code: 1395-038-LO

Conditions Which Generate This Code:

This event code will only be generated if a coolant

level sensor has been installed and the customer
programmable feature has been enabled.

The ECM detects a low coolant level in the engine for

more than thirty seconds.

System Response:

If equipped, the shutdown lamp and the warning

lamp will come on.
SENR9969-05 121
Troubleshooting Section

Diagnostic Functional
Tests
i03493427

5 Volt Sensor Supply Circuit -

Test
SMCS Code: 1439-038

System Operation Description:

Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:

• 0262-03 5 Volt Sensor DC Power Supply voltage

above normal

• 0262-04 5 Volt Sensor DC Power Supply voltage

below normal

The following background information is related

to this procedure:

The Engine Control Module (ECM) supplies regulated

+5 Volts DC to the following sensors:

• Fuel Rail Pressure Sensor through connector P228

• Intake Manifold Pressure Sensor through
connector P200

• Engine Oil Pressure Sensor through connector

P201

• Analog Throttle Demand Sensors (if equipped)

through P1 connector

The supply for the +5 Volt engine pressure sensor is

routed from the ECM through the P2 connector to
terminal 1 of each pressure sensor connector. The
supply voltage is 5.0 ± 0.16 Volts DC. The +5 Volt
supply to the Analog Throttle Demand Sensor is
routed from the ECM through the P1 connector to
the sensor pins “A”.

A diagnostic code can be caused by the following

conditions:

• A short circuit in the harness

• An open circuit in the harness
• A suspect sensor
• A suspect ECM
122 SENR9969-05
Troubleshooting Section

Table 55
P2 Pin Connections
Sensor Pin Function Fuel Rail Pressure Intake Manifold Oil Pressure Sensor
Sensor Pressure Sensor
1 Volts (5V) 48 46 47
2 Ground 40 38 39
3 Signal 51 55 56

Table 56
P1 OEM Connector
Sensor Pin Function Analog Throttle 1 Analog Throttle 2
A 5 Volt Sensor Supply 41 42
B Ground 33 34
C Signal 54 55

g01800518
Illustration 24
Typical example of the schematic for the sensors
SENR9969-05 123
Troubleshooting Section

g01173224
Illustration 25
Typical example of the fuel rail pressure sensor
(1) Voltage supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)

g01173225
Illustration 26
Typical example of the intake manifold pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)

g01173226
Illustration 27
Typical example of the oil pressure sensor
(1) Voltage Supply (Vs)
(2) Ground (GND)
(3) Signal (SIG)
124 SENR9969-05
Troubleshooting Section

g01800553
Illustration 28
Typical example of the P2 pressure sensor pin locations
(38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5V)) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
(39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5V) Fuel Rail Pressure
(40) Ground (GND) Fuel Rail Pressure Sensor
Sensor (51) Signal (SIG) Fuel Rail Pressure Sensor
(46) Voltage supply (5V) Intake Manifold (55) Signal (SIG) Intake Manifold Pressure
Pressure Sensor Sensor

g01800573
Illustration 29
Typical example of the P1 pin locations for the analog throttle demand sensor
(33) Throttle 1 ground (GND) (41) Throttle 1 voltage supply (5V) (54) Throttle 1 throttle position
(34) Throttle 2 ground (GND) (42) Throttle 2 voltage supply (5V) (55) Throttle 2 throttle position
SENR9969-05 125
Troubleshooting Section

g01800596
Illustration 30
Typical example of the schematic for the P1 connections for the analog throttle demand sensors

Test Step 1. Check for Connector Damage Expected Result:

A. Turn the keyswitch to the OFF position. The connectors and the harness should be free of
the following faults: damage, abrasion, corrosion,
B. Check the connectors and the harness for the and incorrect attachment.
following faults:
Results:
• Damage
• OK – Proceed to Test Step 2.
• Abrasion
• Not OK
• Corrosion
Repair: Repair the connectors or the harness
• Incorrect attachment and/or replace the connectors or the harness.

C. Refer to Troubleshooting, “Electrical Connectors Use the electronic service tool in order to clear all
- Inspect”. logged diagnostic codes and then verify that the
repair eliminates the fault.
D. Perform a 45 N (10 lb) pull test on each of the
wires in the harness that are associated with STOP.
the throttle demand sensor. Check the wire
connectors at the following positions: Test Step 2. Check for Active Diagnostic
Codes
• ECM
A. Connect the electronic service tool to the
• Pressure sensors diagnostic connector.

• Throttle sensor B. Turn the keyswitch to the ON position.

The wire connectors are shown in Table 55 and C. Use the electronic service tool in order to monitor
Table 56. the diagnostic codes. Check and record any active
diagnostic codes.
E. Check the screws for the ECM connectors for the
correct torque of 5.0 N·m (44 lb in). Note: Wait at least 15 seconds in order for the
diagnostic codes to become active.
126 SENR9969-05
Troubleshooting Section

Expected Result: Test Step 4. Install a New Sensor

One of the following diagnostic codes is active: A. Install the connector on a replacement sensor. Do
not install the replacement sensor on the engine.
• 0262-03 5 Volt Sensor DC Power Supply voltage
above normal B. Use the electronic service tool in order to monitor
the diagnostic codes.
• 0262-04 5 Volt Sensor DC Power Supply voltage
below normal Expected Result:

Results: Diagnostic codes 0262-03 and 0262-04 are not

active.
• OK – Diagnostic code 0262-04 is active. Proceed
to Test Step 3. Results:

• OK – Diagnostic code 0262-03 is active. Proceed • OK – The 5 Volt diagnostic code is not active.
to Test Step 6.
Repair: Use the electronic service tool in order
• Not OK – Diagnostic codes 0262-04 and 0262-03 to clear all logged diagnostic codes. Remove the
are not active. Proceed to Test Step 4. suspect sensor and then install the replacement
sensor. Install the connector on the sensor.
Test Step 3. Disconnect the Sensors
Verify that the repair eliminates the fault.
A. Turn the keyswitch to the ON position.
STOP.
B. Use the electronic service tool in order to monitor
the diagnostic codes. • Not OK – The 5 Volt diagnostic code is still active.
C. Disconnect the pressure sensors one at a time. Repair: Do not use the new sensor.
If an analog throttle demand sensor is installed,
then disconnect the throttle sensor. Wait for 30 Proceed to Test Step 5.
seconds after the sensor is disconnected.
Test Step 5. Disconnect the ECM
Note: Diagnostic code 0262-04 will become inactive Connector and Check for Active
when the sensor that caused the 5 Volt diagnostic Diagnostic Codes
code is disconnected.
A. Turn the keyswitch to the OFF position.
D. Ensure that all the pressure sensors and the
throttle demand sensors (if equipped) are B. Connect the electronic service tool to the
disconnected. diagnostic connector.

Expected Result: C. Check the ECM connectors for corrosion and

moisture.
The 5 Volt diagnostic code is not active when all of
the sensors are disconnected. D. Disconnect the P2 connector from the ECM.

Results: E. If P1:41 is installed, then temporarily disconnect

the pin. If P1:42 is installed, then temporarily
• OK – Diagnostic code 0262-04 is not active when disconnect the pin.
all of the sensors are disconnected.
F. Reconnect connector P1 to the ECM.
Repair: Reconnect all of the sensors except the
suspect sensor. G. Turn the keyswitch to the ON position.

Proceed to Test Step 4. H. Check for active diagnostic codes on the electronic
service tool.
• Not OK – Diagnostic code 0262-04 is still active.
Note: A “Voltage High” diagnostic code (open circuit)
Repair: Leave all of the sensors disconnected. should be active for all of the following sensors:

Proceed to Test Step 5. • Engine pressure sensors

• Engine temperature sensors
SENR9969-05 127
Troubleshooting Section

• Analog throttle demand sensors (if equipped) C. Measure the voltage between terminal A (analog
throttle demand sensors +5 Volts) and the engine
Expected Result: ground for each of the analog throttle demand
sensors.
Diagnostic code 0262-04 is not active. A “Voltage
High” diagnostic code (open circuit) is active for all of Expected Result:
the engine pressure sensors, temperature sensors
and throttle demand sensors (if equipped). The voltage is 5.0 ± 0.16 Volts DC.

Results: Results:

• OK – Diagnostic code 0262-04 is not active. • OK – The +5 Volt DC supply is within the expected
range. Proceed to Test Step 7.
Repair: Replace all wires to the original
configuration. • Not OK – The voltage is greater than 5.16 Volts
DC.
Proceed to Test Step 6.
Repair: Check the +5 Volt DC supply wire for a
• Not OK – The 5 Volt diagnostic codes are still short to a higher voltage source.
active.
Repair the +5 Volt DC supply wire and/or replace
Repair: Perform the following repair: the +5 Volt DC supply wire.

1. Make sure that the latest flash file for the Use the electronic service tool in order to clear all
application is installed in the ECM. Refer to logged diagnostic codes and then verify that the
Troubleshooting, “Flash Programming”. repair eliminates the fault.

2. Contact the Technical Communicator. STOP.

Note: This consultation can greatly reduce the repair • Not OK – The voltage is less than 4.84 Volts DC.
time.
Repair: Check the +5 Volt DC supply wire for a
3. If the Technical Communicator recommends the short to ground.
use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”. Repair the +5 Volt DC supply wire and/or replace
the +5 Volt DC supply wire.
4. Use the electronic service tool to recheck the
system for active diagnostic codes. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
5. If the fault is resolved with the test ECM, repair eliminates the fault.
reconnect the suspect ECM.
STOP.
6. If the fault returns with the suspect ECM,
replace the ECM. Test Step 7. Perform the “Wiggle Test”
on the Electronic Service Tool
7. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that A. Select the “Wiggle Test” from the diagnostic tests
the repair eliminates the fault. on the electronic service tool.

STOP. B. Choose the appropriate group of parameters to

monitor.
Test Step 6. Measure the +5 Volt Supply
to the Sensor C. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent faults.
A. Turn the keyswitch to the ON position.
If an intermittent fault exists, the status will be
Note: Disconnect all the pressure sensors and the highlighted and an audible beep will be heard.
analog throttle demand sensors (if equipped).
Expected Result:
B. Measure the voltage between terminal 1 (Pressure
sensor +5 Volts) and the engine ground for each No intermittent faults were indicated during the
of the pressure sensors. “Wiggle Test”.
128 SENR9969-05
Troubleshooting Section

Results: The sensor senses the speed requirement from

the throttle position. A second sensor may override
• OK – No intermittent faults were found. The this speed requirement from the first sensor. This
harness and connectors appear to be OK. If you override will be subject to an input from a secondary
were sent from another procedure, return to the throttle or from the SAE J1939 (CAN) data link or
procedure and continue testing. If this test has from a PTO control.
resolved the fault, return the engine to service.
STOP. Use the electronic service tool in order to check the
input status.
• Not OK – At least one intermittent fault was
indicated. Table 57
P1 Pin Connections
Repair: Repair the harness or the connector.
Function Throttle 1 Throttle 2
Use the electronic service tool in order to clear all +5 Volt DC Supply 41 42
logged diagnostic codes and then verify that the
repair eliminates the fault. Sensor Ground 33 34
Throttle Position Input 54 55
STOP.

i03494341

Analog Throttle Position

Sensor Circuit - Test
SMCS Code: 1913-038

System Operation Description:

Use this procedure if any of the following diagnostic

codes are active:

• 0091-03 Throttle Position Sensor voltage above

normal

• 0091-04 Throttle Position Sensor voltage below

normal

• 0774-03 Secondary Throttle Position Sensor

voltage above normal

• 0774-04 Secondary Throttle Position Sensor

voltage below normal

The diagnostic codes above relate to an analog

sensor. Use this procedure only if the analog sensor
is a variable resistance potentiometer sensor.

The sensor is most likely to be mounted on a throttle

pedal. The sensor is attached directly to the throttle
assembly. The sensor provides an output voltage to
the Electronic Control Module (ECM). The sensor
output voltage will vary with the position of the
throttle. Foot operated or hand operated throttle
assemblies are available.

The sensor receives +5 Volt DC power from the

ECM. The sensor will produce a raw signal voltage
that will alter between low idle and high idle. The
voltage is changed into a throttle position within the
range 0% to 100% by the ECM.
SENR9969-05 129
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g01800755
Illustration 31
Schematic of the analog throttle demand sensors

g01800768
Illustration 32
Typical view of the P1 connector pin locations
(33) Sensor Ground (GND) (41) Sensor supply (5V) (54) Analog throttle input 1
(34) Sensor Ground (GND) (42) Sensor supply (5V) (55) Analog throttle input 2

Test Step 1. Check for Connector Damage D. Perform a 45 N (10 lb) pull test on each of the
wires in the harness that are associated with
A. Turn the keyswitch to the OFF position. the throttle demand sensor. Check the wire
connectors at the ECM and at the throttle sensor.
B. Check the connectors and the harness for the The wire connectors are shown in table 57.
following faults: damage, abrasion, corrosion, and
incorrect attachment. E. Check the screw for the ECM connector for the
correct torque of 5.0 N·m (44 lb in).
C. Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
130 SENR9969-05
Troubleshooting Section

Expected Result: C. Observe the throttle position reading on the

electronic service tool.
The connectors and the harness should be free of
the following faults: damage, abrasion, corrosion, D. Operate the throttle over the full range of
and incorrect attachment. movement.

Results: Expected Result:

• OK – Proceed to Test Step 2. The output should increase when the throttle is
increased.
• Not OK
The output should be between “20 percent” and “27
Repair: Repair the connectors or the harness percent” at the low idle position. The output should
and/or replace the connectors or the harness. be between “80 percent” and “87 percent” at the high
idle position.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Results:
repair eliminates the fault.
• OK – The sensor is operating correctly. Proceed
STOP. to Test Step 4.

Test Step 2. Check for Active Diagnostic • Not OK – The ECM is not receiving a correct
Codes signal from the sensor. Proceed to Test Step 5.

A. Turn the keyswitch to the ON position. Test Step 4. Check the Throttle Selection
Status with the Electronic Service Tool
B. Use the electronic service tool to check for
diagnostic codes. A. Check the status of the throttle selection switch (if
equipped). Use the electronic service tool in order
Expected Result: to check the status of the throttle selection switch.

RESULT 1 The electronic service tool displays the Expected Result:

following active diagnostic codes or recently logged
diagnostic codes: If the status of the throttle selection switch is shown
in the OFF position, then the throttle 1 has control of
• 91-3 Throttle Position Sensor voltage above normal the engine speed.

• 91-4 Throttle Position Sensor voltage below normal If the throttle selection switch status is shown in the
ON position, then the throttle 2 has control of the
• 774-3 Secondary Throttle Position Sensor voltage engine speed.
above normal
The throttle may be overridden by using the SAE
• 774-4 Secondary Throttle Position Sensor voltage J1939 (CAN) data link or a PTO control.
below normal
Results:
RESULT 2 The electronic service tool displays no
active diagnostic codes: • OK – The throttle demand switch is operating
correctly.
Results:
Repair: There may be an intermittent fault. Refer to
• Result 1 – Proceed to Test Step 3. Troubleshooting, “Electrical Connectors - Inspect”.

• Result 2 – Proceed to Test Step 5. STOP.

Test Step 3. Check the Throttle Position • Not OK – The wrong throttle is selected. Change
with the Electronic Service Tool to the other throttle. There may be a fault with the
selector switch input.
A. Connect the electronic service tool to the
diagnostic connector.

B. Turn the keyswitch to the ON position. Do not start

the engine.
SENR9969-05 131
Troubleshooting Section

Repair: Check the connections between the Results:

throttle selection switch and P1:47 and P1:35.
Refer to Troubleshooting, “Electrical Connectors • OK – The throttle demand sensor is operating
- Inspect”. correctly. Proceed to Test Step 7.

STOP. • Not OK – The throttle demand sensor is faulty.

Proceed to Test Step 8.
Test Step 5. Check the Voltage at the
Sensor Test Step 7. Check the Sensor at the ECM
A. Turn the keyswitch to the OFF position. A. Turn the keyswitch to the OFF position.

B. Install a breakout “T” with 3 terminals to the B. Remove the P1 connector.

sensor.
C. Temporarily remove pin P1:54 from the connector.
C. Turn the keyswitch to the ON position.
D. Reconnect the P1 connector.
D. Measure the voltage between terminal “A” and
terminal “B” on the breakout “T”. E. Connect the red probe of a multimeter to the
removed pin and the black probe of the multimeter
Expected Result: to P1:33.

The supply voltage should be between 4.84 Volts DC F. Turn the keyswitch to the ON position.
and 5.16 Volts DC.
G. Use the multimeter to display the output voltage
Results: of the sensor while the engine speed control is
moved from the minimum position to the maximum
• OK – The supply voltage is reaching the sensor. position.
Proceed to Test Step 6.
H. Turn the keyswitch to the OFF position.
• Not OK – The supply voltage is not reaching the
sensor. I. Remove the P1 connector and reinstall P1:54.

Repair: Refer to Troubleshooting, “5 Volt Sensor J. Reconnect the P1 connector.

Supply Circuit - Test”.
Expected Result:
STOP.
The output from the throttle demand sensor is 0.5
Test Step 6. Check the Position of the Volts DC or less with the sensor slot in the released
Sensor position.

A. Turn the keyswitch to the OFF position. The output from the throttle demand sensor is 4.5
Volts DC or more with the sensor slot in the advanced
B. Install a breakout “T” with 3 terminals to the position.
sensor.
Results:
C. Turn the keyswitch to the ON position.
• OK – The ECM terminals have the correct voltage
D. Measure the voltage between terminal “C” and for the sensor.
terminal “B” on the breakout “T”.
Repair: Check for the correct supply voltage at the
E. Observe the voltage while the engine speed ECM. If the voltage is correct, then perform the
control is moved from the minimum to the following procedure.
maximum position.
1. Make sure that the latest flash file for the
Expected Result: application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.
The voltage should vary between 1.5 Volts DC and
4.4 Volts DC when the speed control is moved from 2. Contact the Technical Communicator.
the minimum to the maximum position.
Note: This consultation can greatly reduce the repair
time.
132 SENR9969-05
Troubleshooting Section

3. If the Technical Communicator recommends the

use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.

4. Use the electronic service tool to recheck the

system for active diagnostic codes.

5. If the fault is resolved with the test ECM,

reconnect the suspect ECM.

6. If the fault returns with the suspect ECM,

replace the ECM.

7. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that g01170753
the repair eliminates the fault. Illustration 34
Throttle block assembly
STOP. (1) Mounting screw holes
(2) Sensor drive slot
(3) Sensor mounting face
• Not OK – There is a fault in the harness or the
connectors between the sensor and the ECM.
Check all of the connections between the ECM and A. Turn the keyswitch to the OFF position.
the sensor. Repair the damaged cables or replace
the damaged cables. Check that the repairs have B. Record the position of the sensor and then remove
eliminated the fault. STOP. the sensor.

Test Step 8. Remove the Sensor from the C. Remove the sensor from the housing and inspect
Engine Speed Control Assembly the cables for signs of wear.

D. Connect a multimeter to terminal “C” and terminal

“B” of the breakout “T”.

E. Turn the keyswitch to the ON position.

F. Record the signal voltage of the sensor with the

sensor slot in the released position.

G. Record the signal voltage of the sensor with the

sensor slot in the advanced position.

Expected Result:

The output from the sensor is 0.5 Volts DC or less

with the sensor slot in the released position.

The output from the sensor is 4.5 Volts DC or more

with the sensor slot in the advanced position.

Results:
g01170704
Illustration 33 • OK
Throttle pedal assembly
(1) Sensor mounting face Repair: The operation of the sensor is correct.
(2) Sensor drive key The fault is caused by the foot pedal or the lever
(3) Mounting screw holes assembly. Adjust the assembly or replace the
assembly.

Use the electronic service tool in order to clear all

logged diagnostic codes and then verify that the
repairs have eliminated the fault.

STOP.
SENR9969-05 133
Troubleshooting Section

• Not OK – The sensor is faulty.

Repair: Replace the sensor.

Use the electronic service tool in order to clear all

logged diagnostic codes and then verify that the
repair has eliminated the fault.

STOP.

i03494420

CAN Data Link Circuit - Test

SMCS Code: 1901-038

System Operation Description:

Use this procedure under the following

circumstances:

Use this procedure if any of the following diagnostic

codes are active:

• 0247-09 SAE J1939 Data Link abnormal update

rate

• 0247-12 SAE J1939 Data Link failure

The following background information is related
to this procedure:

The CAN Data Link is also known as J1939 Data Link.

The data link is an industry standard for sending data
between different devices in the same application.

High speed data is transferred via the data link.

The data link cannot be accurately tested without
complicated equipment. The data link requires a
resistance of 60 Ohms between the two wires to
correctly transmit the data. This resistance is made
up of two 120 Ohm resistors. The two resistors are
known as “Terminating Resistors”. The terminating
resistors should be at opposite ends of a data link
network. If this resistance is not present, then the
data will be intermittent or completely unreadable.

Note: The wiring for the J1939 data link is a shielded

twisted pair cable. If the wiring is damaged the
replacement type must be shielded twisted pair cable.
134 SENR9969-05
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g01801898
Illustration 35
Typical example of the schematic for the CAN data link

g01801913
Illustration 36
Typical view of the pin locations on the P1connector
(20) CAN- (21) CAN+ (22) CAN Shield

Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of the
and Wiring. wires that are associated with the CAN data link.
Refer to Illustration 36.
A. Turn the keyswitch to the OFF position.
D. Check the harness for abrasion and pinch points
B. Thoroughly inspect the harness connector P1/J1 from the keyswitch to the Electronic Control
and any other connectors in the CAN data link Module (ECM).
circuit.
Expected Result:
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. All connectors, pins and sockets should be completely
coupled and/or inserted. The harness should be free
of corrosion, abrasion and/or pinch points.
SENR9969-05 135
Troubleshooting Section

Results: Measure the resistance of the two terminating

resistors.
• OK – Proceed to Test Step 2.
If one of the terminating resistors is incorrect,
• Not OK replace the faulty terminating resistor.

Repair: Perform the following repair: If the two terminating resistors are between 50 and
70 Ohms, proceed to Test Step 4.
Repair the connectors and/or the wiring, or replace
the connectors and/or the wiring. Ensure that all of • Result 4 – The resistance is greater than 150
the seals are correctly in place and ensure that the Ohms. There may be a break in the harness.
connectors are completely coupled. Proceed to Test Step 3.

Use the electronic service tool in order to clear all Test Step 3. Check the Data Link Wiring
logged diagnostic codes and then verify that the
repair eliminates the fault. A. Disconnect each of the connectors that connect
other devices on the data link.
STOP.
B. Use a multimeter in order to measure the
Test Step 2. Check the Data Link resistance between P1:20 to each of the CAN+
Terminating Resistance pins that connect other devices on the data link.

A. Disconnect the P1 connector from the ECM. C. Use a multimeter in order to measure the
resistance between P1:21 to each of the CAN-
B. Measure the resistance between P1:20 and P1:21. pins that connect other devices on the data link.

Expected Result: D. Use a multimeter in order to measure the

resistance between P1:22 to each of the CAN
The resistance is between 50 and 70 Ohms. SHIELD pins that connect other devices.

Results: Expected Result:

• Result 1 – The resistance is between 50 and 70 The resistance of each wire is less than 2.0 Ohms.
Ohms. This is the correct resistance. The fault may
be in the connection to other devices on the data Results:
link. Proceed to Test Step 3.
• OK – The resistance is less than 2.0 Ohms.
• Result 2 – The resistance is less than 50 Ohms. Proceed to Test Step 4.
There is a short circuit in the harness.
• Not OK – Some resistances are more than 2.0
Repair: Repair the connectors or the harness Ohms.
and/or replace the connectors or the harness.
Repair: Repair the connectors or the harness
Ensure that all of the seals are correctly in place and/or replace the connectors or the harness.
and ensure that the connectors are completely
coupled. Ensure that all seals are correctly in place and
ensure that the connectors are completely coupled.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Use the electronic service tool in order to clear all
repair eliminates the fault. logged diagnostic codes and then verify that the
repair has eliminated the fault.
STOP.
STOP.
• Result 3 – The resistance is between 110 and 130
Ohms. One of the terminating resistors may have Test Step 4. Check the Other Devices on
failed. the J1939 Data Link
Repair: Locate the two terminating resistors and A. Use the appropriate service tools in order to
remove the two terminating resistors from the diagnose other devices on the data link.
harness. Depending on the application, one or both
of the terminating resistors may be located in other Expected Result:
ECMs on the data link.
The other devices are working correctly.
136 SENR9969-05
Troubleshooting Section

Results: The following information refers to the pin number.

Ensure that the correct connector is used.
• OK – The other devices are operating correctly.
Communication
Repair: Repeat this test procedure from Test Step
1. The electronic service tool may indicate the following
error message:
STOP.
The version of the ECM is not recognized and the
• Not OK – The other devices are not working integrity of the changed parameters and displayed
correctly. data is not guaranteed.

Repair: Use the appropriate service tools in order This message will indicate that the version of the
to diagnose other devices on the data link. software that is in the electronic service tool is not
the same version of the software that is in the ECM.
Use the electronic service tool in order to clear all Install the latest version of the software for the
logged diagnostic codes and then verify that the electronic service tool in order to rectify the fault.
repair eliminates the fault.

STOP.

i03494560

Data Link Circuit - Test

SMCS Code: 1901-038

System Operation Description:

Use this procedure under the following

circumstances:

• 1639-09 Machine Security System Module

abnormal update rate

Use this procedure if the electronic service tool will

not communicate with the Electronic Control Module
(ECM) through the data link.

The following background information is related

to this procedure:

The data link is the standard data link that is used by

the ECM in order to communicate with the electronic
service tool.

The ECM provides multiple connections for the data

link. The technician must ensure that the correct
connector is being tested. The connection that is
used is dependent on the application.

If the diagnostic connector is on the engine, the

positive data link signal will be from P2:21 to J23:D.
The negative data link signal will be from P2:20 to
J23:E.

If the diagnostic connector is off the engine, the

positive data link signal will be from P1:23 to pin “D”
of the diagnostic connector. The negative data link
signal will be from P1:24 to pin “E” of the diagnostic
connector.
SENR9969-05 137
Troubleshooting Section

g01801933
Illustration 37
Schematic of the diagnostic connector and the data link connector

g01801995
Illustration 38
Typical view of the P1 pin locations for the diagnostic connector
(23) Data link + (24) Data link -
138 SENR9969-05
Troubleshooting Section

g01801993
Illustration 39
Typical view of the P2 pin locations for the diagnostic connector
(20) Data link - (21) Data link +

Test Step 1. Inspect Electrical Connectors Repair: Perform the following repair:
and Wiring
Repair the connectors and/or the harness, or
A. Thoroughly inspect the following electrical replace the connectors and/or the harness. Ensure
connectors: that all of the seals are correctly in place and
ensure that the connectors are completely coupled.
• P1/J1 ECM connector
Use the electronic service tool in order to clear all
• P2/J2 ECM connector logged diagnostic codes and then verify that the
repair eliminates the fault.
• J23 diagnostic connector
STOP.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. Test Step 2. Determine the Type of Fault
in the Data Link
B. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connectors that are associated A. Connect the electronic service tool to the
with the data link. diagnostic connector that is on the engine harness
or on the application.
C. Check the screw for the ECM connectors for
correct torque of 5.0 N·m (44 lb in). B. Turn the keyswitch to the ON position.

D. Check the harness for abrasion and pinch Expected Result:

points from the wires that connect the diagnostic
connector to the ECM. The power lamp should illuminate on the
communications adapter. The power lamp on the
Expected Result: communications adapter may illuminate when the
keyswitch is in any position.
All connectors, pins and sockets should be completely
coupled and/or inserted. The harness should be free Results:
of corrosion, abrasion and/or pinch points.
• OK – The communications adapter is currently
Results: receiving the correct voltage.

• OK – Proceed to Test Step 2.

• Not OK
SENR9969-05 139
Troubleshooting Section

Repair: If this step is being performed as a Test Step 4. Check the Battery Voltage at
result of an instruction in “Check the wiring of the the Diagnostic Connector
Diagnostic Connector”and if a jumper wire has
been installed between pin “A” on the diagnostic A. Turn the keyswitch to the ON position.
connector and the positive terminal on the battery
and if a jumper wire has been installed between pin B. Use a multimeter in order to measure the voltage
“B” on the diagnostic connector and the negative from pin A (battery+) and pin B (ground) of the
terminal on the battery, remove the jumper wires diagnostic connector.
and then repair the harness. If the harness cannot
be repaired, replace the harness. Expected Result:

Proceed to Test Step 5. The voltage is between 22.0 Volts DC and 27.0 Volts
DC for a 24 Volt system and between 11.0 Volts DC
• Not OK – The communications adapter is not and 13.5 Volts DC for a 12 Volt system.
receiving the correct voltage. Proceed to Test Step
3. Results:

Test Step 3. Check the Wiring of the • OK – The diagnostic connector is currently
Diagnostic Connector receiving the correct voltage. Proceed to Test Step
5.

• Not OK – The diagnostic connector is not receiving

the correct voltage.

Repair: Refer to Troubleshooting, “Engine Wiring

Information”.

Proceed to Test Step 2.

Test Step 5. Check the Data Link

Connections
A. Turn the keyswitch to the OFF position.
g01241517
Illustration 40 B. Disconnect the communications adapter from the
Typical view of the 9 pin diagnostic connector from the wire side diagnostic connector.
(A) Switched battery +
(B) Battery ground (GND) C. If the diagnostic connector is installed on the
(D) Data link + application, disconnect connector P1 from the
(E) Data link - ECM. Check the resistance between P1:23 and pin
“D” on the diagnostic connector. If the diagnostic
A. If the communications adapter is connected to connector is installed on the engine, disconnect
the diagnostic connector on the engine, ensure P2 from the ECM. Check the resistance between
that pin “A” and pin “B” are wired on the engine P2:21 and pin “D” on the diagnostic connector.
harness side of the connector.
D. If the diagnostic connector is installed on the
Expected Result: application, check the resistance between P1:24
and pin “E” on the diagnostic connector. If the
The pins are wired. diagnostic connector is installed on the engine,
check the resistance between P2:20 and pin “E”
Results: on the diagnostic connector.

• OK – The harness is fully wired. Proceed to Test Expected Result:

Step 4.
The resistance that is measured is less than 10
• Not OK – The data link connector power Ohms.
connections are not wired.
Results:
Repair: Fabricate a jumper wire in order to connect
pin “A” of the diagnostic connector to battery+ and • OK – The resistance is less than 10 Ohms.
pin “B” to the battery-. Proceed to Test Step 6.
Proceed to Test Step 2. • Not OK – The resistance is greater than 10 Ohms.
140 SENR9969-05
Troubleshooting Section

Repair: Perform the following repair: Results:

Repair the connectors and/or the harness, or • Result 1 – Proceed to Test Step 7.
replace the connectors and/or the harness. Ensure
that all of the seals are correctly in place and • Result 2
ensure that the connectors are completely coupled.
Repair: Send the faulty electronic service tool for
Use the electronic service tool in order to clear all repairs.
logged diagnostic codes and then verify that the
repair eliminates the fault. STOP.

STOP. Test Step 7. Connect an Electronic

Service Tool and the ECM to another
Test Step 6. Change the Electronic Battery
Service Tool Components
A. If another electronic engine is available, connect
the electronic service tool to the other engine.
Ensure that the same cables are used. Batteries give off flammable fumes which can ex-
plode.
B. Turn the keyswitch to the ON position. Determine
if the electronic service tool operates correctly on To avoid injury or death, do not strike a match,
the other engine. cause a spark, or smoke in the vicinity of a battery.

C. If another engine is not available, obtain a NOTICE

replacement communications adapter and a Do not connect the bypass harness to the battery until
replacement set of cables. Ensure that the set the in-line fuse has been removed from the Battery+
of cables for the electronic service tool are a line. If the fuse is not removed before connection to
complete set. the battery, a spark may result.
D. Install the replacement communications adapter
and the set of cables for the electronic service tool Note: Refer to Figure 41 for details of the bypass
and connect to the diagnostic connector. harness.

E. Turn the keyswitch to the ON position.

F. If changing the communications adapter or the

cables allows the electronic service tool to operate
correctly, perform the following procedure:

a. Replace the components from the new set of

cables with components from the oldset of
cables. Replace one component at a time.

b. Apply power to the electronic service tool after

each of the components is replaced. Use this
method to find the faulty component.

G. If changing the cables does not allow the electronic

service tool to operate correctly, connect another
electronic service tool.

H. Turn the keyswitch to the ON position.

Expected Result:

Result 1 The original electronic service tool works

on another engine.

Result 2 A different electronic service tool works on

the original engine while the engine is being tested.
SENR9969-05 141
Troubleshooting Section

g01831237
Illustration 41
Schematic of the bypass harness connector
142 SENR9969-05
Troubleshooting Section

g01802213
Illustration 42
Typical view of the pin locations on connector P1 for the diagnostic and data link connectors
(1) Battery ground (GND) (9) Battery ground (GND) (21) J1939 (CAN) +
(2) Battery ground (GND) (10) Battery ground (GND) (23) Data link +
(3) Battery ground (GND) (15) Battery + (24) Data link -
(7) Battery + (16) Battery + (40) Keyswitch
(8) Battery + (20) J1939 (CAN) -

A. Connect the battery wires from the bypass 4. If the Technical Communicator recommends the
harness of the electronic service tool to a different use of a test ECM, install a test ECM. Refer to
battery that is not on the engine. Troubleshooting, “Replacing the ECM”.

Expected Result: 5. Use the electronic service tool to recheck the

system for active diagnostic codes.
The electronic service tool is operating correctly.
6. If the fault is eliminated with the test ECM,
Results: reconnect the suspect ECM.

• Yes 7. If the fault returns with the suspect ECM,

replace the ECM.
Repair: Refer to Troubleshooting, “Engine Wiring
Information”. 8. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
STOP. the repair eliminates the fault.

• No STOP.

Repair: Perform the following repair:

i03494760

1. Make sure that the latest flash file for the

application is installed in the ECM. Refer to
Digital Throttle Position
Troubleshooting, “Flash Programming”. Sensor Circuit - Test
2. Remove all temporary jumpers and reconnect SMCS Code: 1913-038
all connectors.
System Operation Description:
3. Contact the Technical Communicator.
Use this procedure under the following situation:
Note: This consultation can greatly reduce the repair
time. Use this procedure if any of the following diagnostic
codes are indicated:
SENR9969-05 143
Troubleshooting Section

• 0041-03 8 Volt DC Supply voltage above normal

• 0041-04 8 Volt DC Supply voltage below normal
• 0091-08 Throttle Position Sensor abnormal
frequency, pulse width, or period

Also, use this procedure if the digital throttle position

sensor is suspected of incorrect operation.

Digital Throttle Position Sensor

The digital throttle position sensor is used to provide

a digital throttle position signal to the Engine Control
Module (ECM). The sensor output is a constant
frequency signal with a pulse width that varies with
the throttle position. This output signal is referred to
as either a duty cycle or a pulse width modulated
signal (PWM) and this output signal is expressed as
a percentage between 3 and 100 percent.

The digital throttle position sensor is most likely to be

attached directly to the throttle assembly. The digital
throttle position sensor requires no adjustment.

The digital throttle position sensor will produce a duty

cycle of 10 to 22 percent at low idle and 75 to 90
percent when the throttle pedal is fully depressed.
The percent of duty cycle is translated in the ECM
into a throttle position of 3 to 100 percent.

The digital throttle position sensor is powered by +8

Volts DC from the ECM. The supply voltage is from
the J1:43 to terminal “A” of the digital throttle position
sensor connector.

If the application is using the ECM dedicated PTO

functions, the digital throttle position sensor will be
ignored while the engine is in PTO mode.

The ECM is in PTO mode if the “PTO ON/OFF Switch”

is ON. This can be checked with the electronic
service tool. Refer to Troubleshooting, “PTO Switch
Circuit - Test” for testing if the PTO is being used.

g01802294
Illustration 43
Typical schematic of the digital throttle position sensor
144 SENR9969-05
Troubleshooting Section

g01802315
Illustration 44
Typical example of the pin locations on connector P1
(33) Sensor return (43) Sensor supply (+8 Volts DC) (53) Sensor input

Test Step 1. Inspect Electrical Connectors Repair: Perform the following repair:
and Wiring
Repair the connectors or the harness and/or
A. Inspect the P1/J1 connector, OEM harness and replace the connectors or the harness. Ensure that
the connectors on the harness. Thoroughly inspect all of the seals are correctly in place and ensure
the digital throttle position sensor connector. that the connectors are completely coupled.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
B. Perform a 45 N (10 lb) pull test on each of the repair eliminates the fault.
wires in the ECM connector that are associated
with the digital throttle position sensor: STOP.

• P1:33 Test Step 2. Check for Active Diagnostic

Codes
• P1:43
A. Connect the electronic service tool to the
• P1:53 diagnostic connector.

C. Check the screw for the ECM connector for the B. Turn the keyswitch to the ON position.
correct torque of 5.0 N·m (44 lb in).
C. Monitor the active diagnostic code screen on the
D. Check the harness for abrasion and pinch points electronic service tool. Check and record active
from the digital throttle position sensor to the ECM. diagnostic codes.

Expected Result:

All connectors, pins and sockets are completely

coupled and/or inserted and the harness is free of
corrosion, of abrasion or of pinch points.

Results:

• OK – Proceed to Test Step 2.

• Not OK
SENR9969-05 145
Troubleshooting Section

Note: When the ECM automatically calibrates new Test Step 4. Check the Supply Voltage at
duty cycle values for the low idle throttle position the Digital Throttle Position Sensor
and the high idle throttle position, the ECM assumes
22 percent duty cycle at low idle and 75 percent A. Turn the keyswitch to the OFF position.
duty cycle at high idle. As a result, you may notice
that the throttle position status reaches 100 percent B. Install a breakout “T” with 3 terminals at the digital
well before the throttle pedal is fully depressed. throttle position sensor connector J403/P403.
This is normal. After some cycling of the throttle
to the high idle position, the ECM will adjust the C. Turn the keyswitch to the ON position.
calibration automatically, provided that the high idle
stop position is within the 75 to 90 percent duty cycle D. Measure the voltage at terminal “A” (+8 Volts) with
range, and the low idle is in the 10 to 22 percent duty reference to terminal “B” (digital throttle position
cycle range. During normal operation, you may also sensor ground).
notice that more movement of the throttle is required
for the throttle position status to increase above Expected Result:
three percent. You may also observe that the status
reaches the 100 percent value prior to the limit of the The measured voltage is between 7.5 Volts DC and
high idle position. This is done in order to ensure 8.5 Volts DC for the digital throttle position sensor.
that the throttle reaches these two critical points for
engine operation. Results:

Expected Result: • OK – Proceed to Test Step 8.

Result 1 Diagnostic code 91-8 is active. • Not OK – The sensor is not receiving the correct
voltage. Proceed to Test Step 5.
Result 2 Diagnostic code 41-3 is active.
Test Step 5. Monitor the Electronic
Result 3 There are no active diagnostic codes that Service Tool while the Digital Throttle
are related to the sensor circuit for the position of the Position Sensor is Being Disconnected
digital throttle at this time, but a fault is suspected
with operation of the sensor circuit. A. Access the active diagnostic code screen on
the electronic service tool. Ensure that one of
Results: the following diagnostic code is active before
proceeding:
• Result 1 – Proceed to Test Step 3.
• 41-3
• Result 2 – Proceed to Test Step 5.
• 41-4
• Result 3 – Proceed to Test Step 3.
B. Monitor the active diagnostic code screen while
Test Step 3. Check the Duty Cycle of the the digital throttle position sensor is being
Digital Throttle Position Sensor disconnected and reconnected.

A. Verify that the keyswitch is in the ON position. Expected Result:

B. Monitor the duty cycle of the throttle sensor on the One of the following diagnostic codes is still active
display screen of the electronic service tool. after the digital throttle position sensor has been
disconnected:
Expected Result:
• 41-3
The duty cycle is between 10 and 22 percent with the
throttle assembly in the low idle position, and the duty • 41-4
cycle is between 75 and 90 percent with the throttle
assembly in the high idle position. Results:

Results: • OK – Ensure that the digital throttle position

sensor has been reconnected before continuing.
• OK – The digital throttle position sensor is Proceed to Test Step 7.
operating correctly. Proceed to Test Step 6.
• Not OK
• Not OK – The digital throttle position sensor circuit
is not operating correctly. Proceed to Test Step 4. Repair: Perform the following diagnostic
procedure:
146 SENR9969-05
Troubleshooting Section

Temporarily install another digital throttle position Results:

sensor. Use the electronic service tool in order to
check for an active +8 Volt DC diagnostic code. • Result 1 – The digital throttle position sensor is
Replace the digital throttle position sensor if both operating correctly. Continue troubleshooting until
of the following conditions occur: the original condition is resolved. STOP.

• The fault is corrected with the new digital throttle • Result 2 – The engine response is normal
position sensor. when the “Torque Speed Control Link” setting is
disabled. However, the engine does not respond
• The fault returns after the old digital throttle when the “Power Train Data Link” is enabled. A
position sensor has been reconnected. component within the “Power Train Data Link”
setting is causing the response fault. Refer to the
STOP. OEM documentation in order to repair the faulty
component in the “Power Train Data Link”. STOP.
Test Step 6. Check the Status of the
PTO On/Off Switch and the Status of the • Result 3 – The ECM is operating in PTO mode.
Power Train Data Link with the Electronic
Service Tool Repair: If the PTO should not be active, refer to the
following diagnostic procedure: Troubleshooting,
A. Check the status of the “PTO ON/OFF Switch” “PTO Switch Circuit - Test”
with the electronic service tool in order to verify
that the “PTO ON/OFF Switch” is switched OFF. STOP.
The PTO mode may cause the ECM to ignore the
digital throttle position sensor if demand is less Test Step 7. Disconnect the Power
than the PTO speed demand. Supply Connections for the Digital
Throttle Position Sensor at the ECM
B. Start the engine. Use the electronic service
tool in order to monitor the throttle position A. Turn the keyswitch to the OFF position.
status. While the throttle position status is being
monitored, operate the throttle over the full range B. Disconnect connector P1. Remove the P1:43 (+8
of movement. The throttle position status and Volts). Remove the P1:33 (digital throttle position
the engine should respond to the change in the sensor ground) from connector P1.
throttle position.
C. Reconnect the P1 connector to the ECM.
C. Go to the “Configuration Settings” screen on the
electronic service tool and turn off the “Torque D. Turn the keyswitch to the ON position.
Speed Control”.
E. Use the electronic service tool to check for active
Note: The “Torque Speed Control” is an option that diagnostic codes.
may be installed by the OEM.
Expected Result:
D. While the throttle position status is being
monitored, operate the throttle over the full range One of the following diagnostic codes is still active
of movement. Also, monitor the response of the after the terminals for sensor power have been
engine when the throttle is operated. disconnected:

Expected Result: • 41-3

The throttle position status and the engine should • 41-4
respond to the change in the throttle position.
Results:
Result 1 The digital throttle position sensor functions
correctly. • OK
Result 2 The throttle response is limited by a “Torque Repair: Perform the following repair:
Speed Control” message.
Check the battery voltage at pins 1, 2, 3, 9 and 10
Result 3 The PTO limits the throttle response. (Battery ground) on the P1 connector. Check the
battery voltage at pins 7, 8, 15, and 16 (Battery+)
on the J1 connector.. The measured voltage should
be in one of the following ranges:
SENR9969-05 147
Troubleshooting Section

• For 12 Volt systems, the voltage should be A. Turn the keyswitch to the OFF position.
between 11.0 Volts DC and 13.5 Volts DC.
B. Remove the signal wire for the digital throttle
• For 24 Volt systems, the voltage should be position sensor (terminal “C”) from P403. Refer to
between 22.0 Volts DC and 27.0 Volts DC. illustration 43.

If the voltage is correct, then perform the following C. Install a breakout “T” with three terminals at
procedure. the digital throttle position sensor connector
J403/P403.
1. Make sure that the latest flash file for the
application is installed in the ECM. Refer to D. Connect the multimeter probes to terminal “C”
Troubleshooting, “Flash Programming”. (digital throttle position sensor signal) and terminal
“B” (digital throttle position sensor ground) of the
2. Contact the Technical Communicator. breakout T.

Note: This consultation can greatly reduce the repair E. Turn the keyswitch to the ON position.
time.
F. While the duty cycle is being monitored on the
3. If the Technical Communicator recommends the multimeter, operate the throttle through the full
use of a test ECM, install a test ECM. Refer to range of movement.
Troubleshooting, “Replacing the ECM”.
Expected Result:
4. Use the electronic service tool to recheck the
system for active diagnostic codes. The duty cycle is between 10 and 22 percent with the
throttle assembly in the low idle position, and the duty
5. If the fault is resolved with the test ECM, cycle is between 75 and 90 percent with the throttle
reconnect the suspect ECM. assembly in the high idle position.

6. If the fault returns with the suspect ECM, Results:

replace the ECM.
• OK – Reinsert the wire (terminal “C”) into the
7. Use the electronic service tool in order to clear harness connector of the digital throttle position
all logged diagnostic codes and then verify that sensor. The digital throttle position sensor is
the repair eliminates the fault. working correctly. Proceed to Test Step 9.

STOP. • Not OK – Leave the multimeter probe connected

to the breakout “T”. Insert the wire (terminal “C”)
• Not OK into the machine harness connector. The throttle
pedal assembly is faulty. Proceed to Test Step 10.
Repair: Perform the following repair:
Test Step 9. Check the Duty Cycle of the
There is a fault in the harness between the ECM Accelerator Pedal Position Sensor at the
and the digital throttle position sensor. While active ECM
diagnostic codes are being monitored, connect
the removed wires one at a time in order to verify Note: Performing certain steps within this procedure
that the active diagnostic codes reappear. Replace requires the use of a multimeter that is capable of
pin P1:33 (digital throttle position sensor ground). measuring a PWM duty cycle.
Replace pin P1:43 (+8 Volts). This procedure is
used to find the wire that is causing the fault. Repair A. Turn the keyswitch to the OFF position.
the harness or replace the harness, as required.
B. Disconnect the P1 connector and then remove
Use the electronic service tool in order to clear all pin P1:53 (digital throttle position sensor signal).
logged diagnostic codes and then verify that the
repair eliminates the fault. C. Connect the multimeter probes between the
removed wire and pin P1:33 (digital throttle
STOP. position sensor ground).

Test Step 8. Check the Duty Cycle of the D. Reconnect the P1 connector to the ECM.
Throttle Position Sensor at the Sensor
E. Turn the keyswitch to the ON position.
Note: Performing certain steps within this procedure
requires the use of a multimeter that is capable of
measuring a PWM duty cycle.
148 SENR9969-05
Troubleshooting Section

F. Use the multimeter in order to display the Test Step 10. Remove the Digital Throttle
duty cycle output of the digital throttle position Position Sensor from the Throttle Pedal
sensor. While the duty cycle output of the digital Assembly
throttle position sensor is being monitored on the
multimeter, move the throttle assembly from the
low idle position to the high idle position. Record
the results.

G. Turn the keyswitch to the OFF position.

H. Remove the P1 connector from the ECM.

I. Install pin P1:53.

J. Connect the P1 connector to the ECM.

Expected Result:

The duty cycle is between approximately 10 and 22

percent with the throttle assembly in the low idle
position, and the duty cycle is between 75 and 90
percent with the throttle assembly in the high idle
position.

Results: g01185326
Illustration 45
Typical throttle assembly
• OK – A good signal from the digital throttle position
sensor is reaching the ECM. (1) Sensor mounting face
(2) Sensor drive key
(3) Mounting screw holes
Repair: Check for the correct supply voltage at the
ECM. If the voltage is correct, then perform the
following procedure.

1. Make sure that the latest flash file for the

application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.

2. Contact the Technical Communicator.

Note: This consultation can greatly reduce the repair

time.

3. If the Technical Communicator recommends the

use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”. Illustration 46
g01185327

Throttle block assembly

4. Use the electronic service tool to recheck the
system for active diagnostic codes. (1) Mounting screw holes
(2) Sensor housing
(3) Sensor drive slot
5. If the fault is eliminated with the test ECM,
reconnect the suspect ECM.

6. If the fault returns with the suspect ECM,

replace the ECM.

7. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP.

• Not OK – There is a fault with signal wire in the

harness. Proceed to Test Step 11.
SENR9969-05 149
Troubleshooting Section

Test Step 11. Route the Supply Bypass

Wires to the Digital Throttle Position
Sensor
A. Turn the keyswitch to the OFF position.

B. Temporarily remove the signal wire for the digital

throttle position sensor from P1:53.

C. Remove terminal “C” (digital throttle position

sensor signal) from the digital throttle position
sensor connector.

D. Route the new wiring from the ECM to the digital

g01185328 throttle position sensor.
Illustration 47
Throttle block assembly E. Turn the keyswitch to the ON position.
(1) Mounting screw holes
(2) Sensor drive slot F. Check the duty cycle of the digital throttle position
(3) Sensor mounting face sensor on the electronic service tool while the
digital throttle assembly is being moved over the
A. Verify that the keyswitch is in the OFF position. full range.
B. Note the sensor orientation in the throttle assembly Expected Result:
and the sensor connector for the harness routing
prior to sensor removal. Remove the digital The duty cycle is between 10 and 22 percent with the
throttle position sensor from the throttle assembly. throttle assembly in the low idle position, and the duty
Thoroughly inspect the connector and the harness cycle is between 75 and 90 percent with the throttle
for signs of abrasion. assembly in the high idle position.
C. Connect a multimeter that is capable of measuring Results:
a PWM duty cycle to terminal “C” of the breakout
“T”.
• OK
D. Turn the keyswitch to the ON position. Repair: Perform the following repair:
E. Display the duty cycle output of the digital throttle The wiring from the ECM to the digital throttle
position sensor while the sensor slot is released. position sensor appears faulty. Permanently install
Use a screwdriver to advance the sensor slot to new wiring.
the maximum position. Refer to Illustration 47.
Use the electronic service tool in order to clear all
Expected Result: logged diagnostic codes and then verify that the
repair eliminates the fault.
When the sensor is removed from the throttle
assembly and the sensor slot is released, the duty STOP.
cycle is 10 percent or less. When the sensor slot
is moved to the maximum position, the duty cycle
increases to 90 percent or more.
• Not OK – Double check the wiring, the P1/J1
connectors and the digital throttle position sensor
connector. If a fault still exists, repeat the test
Results: procedure from Test Step 1. STOP.
• OK – The digital throttle position sensor is working
correctly. Refer to the OEM dealer for correct i02677437
replacement of the throttle assembly. STOP.
ECM Memory - Test
• Not OK – The digital throttle position sensor is
faulty. Check the throttle assembly in order to SMCS Code: 1901-038
ensure that the throttle assembly is not causing
damage to the sensor. If the throttle assembly System Operation Description:
is causing damage to the sensor, refer to the
OEM dealer for correct replacement of the throttle This procedure covers the following diagnostic codes:
assembly. If the throttle assembly appears OK,
replace the digital throttle position sensor. STOP. • 0253-02 Personality Module erratic, intermittent,
or incorrect
150 SENR9969-05
Troubleshooting Section

Background Information • Always use a 147-6456 Removal Tool to remove

wedges from DT connectors. Never use a
0253-02 screwdriver to pry a wedge from a connector.

The flash file in the ECM is from the wrong engine • Always use a 1U-5804 Crimp Tool to service AMP
family. The engine will not start. seal connectors. Refer to Special Instruction ,
REHS2556, “AMPSEAL 16 Connector System”.
Correct the Condition
• Refer to Troubleshooting, “ECM Harness
Determine the diagnostic code that is active. Connector Terminals” in order to service the
connectors for the Electronic Control Module
Expected Result: (ECM).

A 0253-02 diagnostic code is active. • Always use a breakout harness for a voltmeter
probe or a test light. Never break the insulation of a
Results: wire in order to access a circuit for measurements.

• A 0253-02 code is active • If a wire is cut, always install a new terminal for
the repair.
Repair: Obtain the engine serial number. Use SIS
Web to determine the latest available flash file for
the engine. Verify that the latest available flash file
is loaded into the ECM.
The connection of any electrical equipment and
STOP. 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-
i03496221 ment or disconnect any electrical equipment in an
explosive atmosphere.
Electrical Connectors - Inspect
SMCS Code: 7553-040-WW Test Step 1. Check Connectors for
Moisture and Corrosion
System Operation Description:

Most electrical faults are caused by poor connections.

The following procedure will assist in detecting
faults with connectors and with wiring. If a fault is
found, correct the condition and verify that the fault
is resolved.

Intermittent electrical faults 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
terminals, moisture, corrosion, and inadequate
mating of a connection.

Follow these guidelines:

g01131211
Illustration 48
• Always use a 266-1683 Removal Tool to remove Leaky seal at the connector (typical example)
the pins from the P1/P2connectors.

• Always use a 1U-5804 Crimp Tool to service

Deutsch HD and DT connectors. Never solder
the terminals onto the wires. Refer to Special
Instruction , SEHS9615, “Servicing Deutsch HD
and DT Style Connectors”.
SENR9969-05 151
Troubleshooting Section

A. Inspect all the harnesses. Ensure that the routing

of the wiring harness allows the wires to enter the
face of each connector at a perpendicular angle.
Otherwise, the wire will deform the seal bore.
Refer to Illustration 48. This will create a path for
the entrance of moisture. Verify that the seals for
the wires are sealing correctly.

g01131165
Illustration 51
Seal for ECM connector (typical example)

C. Disconnect the suspect connector and inspect the

connector seal. Ensure that the seal is in good
condition. If necessary, replace the connector.
g01131276
Illustration 49 D. Thoroughly inspect the connectors for evidence
Diagram for the installation of a connector plug (typical example) of moisture entry.
(1) ECM connector
(2) Correctly inserted plug Note: It is normal to see some minor seal abrasion
(3) Incorrectly inserted plug on connector seals. Minor seal abrasion will not allow
the entry of moisture.
B. Ensure that the sealing plugs are in place. If
any of the plugs are missing, replace the plug. If moisture or corrosion is evident in the connector,
Ensure that the plugs are inserted correctly into the source of the moisture entry must be found and
the connector. Refer to Illustration 49. the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired,
the fault will recur. Simply drying the connector will
not rectify the fault. Check the following items for
the possible moisture entry path:

• Missing seals
• Incorrectly installed seals
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also travel to a connector through the
g01131019
inside of a wire. If moisture is found in a connector,
Illustration 50 thoroughly check the connector harness for
Seal for a three-pin connector (typical example) damage. Also check other connectors that share
the harness for moisture.

Note: The ECM is a sealed unit. If moisture is found

in an ECM connector, the ECM is not the source of
the moisture. Do not replace the ECM.
152 SENR9969-05
Troubleshooting Section

Expected Result: Expected Result:

The harness, connectors, and seals are in good The wires are free of abrasion, nicks and cuts and
condition. There is no evidence of moisture in the the harness is correctly clamped.
connectors.
Results:
Results:
• OK – The harness is OK. Proceed to Test Step 3.
• OK – The harness, connectors, and seals are in
good condition. Proceed to Test Step 2. • Not OK – There is damage to the harness.
• Not OK – A fault has been found with the harness Repair: Repair the wires or replace the wires, as
or the connectors. required.

Repair: Repair the connectors or the wiring, as Use the electronic service tool in order to clear all
required. Ensure that all of the seals are correctly logged diagnostic codes and then verify that the
installed. Ensure that the connectors have been repair eliminates the fault.
reattached.
STOP.
If corrosion is evident on the pins, sockets or the
connector, use only denatured alcohol to remove Test Step 3. Inspect the Connector
the corrosion. Use a cotton swab or a soft brush Terminals
to remove the corrosion.
A. Visually inspect each terminal in the connector.
If moisture was found in the connectors, run the Verify that the terminals are not damaged.
engine for several minutes and check again for Verify that the terminals are correctly aligned in
moisture. If moisture reappears, the moisture is the connector and verify that the terminals are
wicking into the connector. Even if the moisture correctly located in the connector.
entry path is repaired, it may be necessary to
replace the wires. Expected Result:

Use the electronic service tool in order to clear all The terminals are correctly aligned and the terminals
logged diagnostic codes and then verify that the appear undamaged.
repair eliminates the fault.
Results:
STOP.
• OK – The terminals are OK. Proceed to Test Step
Test Step 2. Check the Wires for Damage 4.
to the Insulation
• Not OK – The terminals of the connector are
A. Carefully inspect each wire for signs of abrasion, damaged.
nicks and cuts.
Repair: Repair the terminals and/or replace the
Inspect the wires for the following conditions: terminals, as required.

• Exposed insulation Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
• Rubbing of a wire against the engine repair eliminates the fault.

• Rubbing of a wire against a sharp edge STOP.

B. Check all of the fasteners for the harness and the

strain relief components on the ECM in order to
verify that the harness is correctly secured. Also
check all of the fasteners in order to verify that the
harness is not compressed. Pull back the harness
sleeves in order to check for a flattened portion
of wire. A fastener that has been overtightened
flattens the harness. This damages the wires that
are inside the harness.
SENR9969-05 153
Troubleshooting Section

Test Step 4. Perform a Pull Test on Each Test Step 5. Check Individual Pin
Wire Terminal Connection Retention into the Socket

g01802454 g01802455
Illustration 52 Illustration 53
A typical example of the lock wedge. Diagram for testing pin retention
(1) Lock wedge
A. Verify that the sockets provide good retention for
A. Ensure that the locking wedge for the connector the pins. Insert a new pin into each socket one
is installed correctly. Terminals cannot be retained at a time in order to check for a good grip on the
inside the connector if the locking wedge is not pin by the socket.
installed correctly.
Expected Result:
B. Perform the 45 N (10 lb) pull test on each wire.
Each terminal and each connector should easily The sockets provide good retention for the new pin.
withstand 45 N (10 lb) of tension and each wire
should remain in the connector body. This test Results:
checks whether the wire was correctly crimped
in the terminal and whether the terminal was • OK – The terminals are OK. Proceed to Test Step
correctly inserted into the connector. 6.

Expected Result: • Not OK – Terminals are damaged.

Each terminal and each connector easily withstands Repair: Use the 1U-5804 Crimp Tool to replace
45 N (10 lb) of pull and each wire remains in the the damaged terminals. Verify that the repair
connector body. eliminates the problem.

Results: Use the electronic service tool in order to clear all

logged diagnostic codes and then verify that the
• OK – All terminals pass the pull test. Proceed to repair eliminates the fault.
Test Step 5.
STOP.
• Not OK – A wire has been pulled from a terminal
or a terminal has been pulled from the connector. Test Step 6. Check the Locking
Mechanism of the Connectors
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as A. Ensure that the connectors lock correctly. After
required. locking the connectors, ensure that the two halves
cannot be pulled apart.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the B. Verify that the latch tab of the connector is
repair eliminates the fault. correctly latched. Also verify that the latch tab of
the connector returns to the locked position.
STOP.
Expected Result:

The connector is securely locked. The connector and

the locking mechanism are without cracks or breaks.
154 SENR9969-05
Troubleshooting Section

Results: B. Choose the appropriate group of parameters to

monitor.
• OK – The connectors are in good repair. Proceed
to Test Step 7. C. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent faults.
• Not OK – The locking mechanism for the
connectoris damaged or missing. If an intermittent fault exists, the status will be
highlighted and an audible beep will be heard.
Repair: Repair the connector or replace the
connector, as required. Expected Result:

Use the electronic service tool in order to clear all No intermittent faults were indicated during the
logged diagnostic codes and then verify that the “Wiggle Test”.
repair eliminates the fault.
Results:
STOP.
• OK – No intermittent faults were found. The
Test Step 7. Check the Screws on the harness and connectors appear to be OK. If you
ECM Connectors (64 way) were sent from another procedure, return to the
procedure and continue testing. If this test confirms
Visually inspect the screws for the ECM connectors. that the fault has been eliminated, return the
Ensure that the threads on each screw are not engine to service. STOP.
damaged.
• Not OK – At least one intermittent fault was
A. Connect the ECM connectors. indicated.

a. Use a 7 mm Torx screw in order to retain each Repair: Repair the harness or the connector.
of the ECM connectors.
Use the electronic service tool in order to clear all
b. Tighten the two Torx screws for the ECM logged diagnostic codes and then verify that the
connector to the correct torque of 5.0 ± 1.0 N·m repair eliminates the fault.
(44 ± 9 lb in).
STOP.
Expected Result:
i03571705
The ECM connectors are secure and the Torx screws
are correctly torqued. Engine Pressure Sensor Open
Results: or Short Circuit - Test
• OK – The ECM connectors are secured. Proceed SMCS Code: 1917-038; 1924-038
to Test Step 8.
System Operation Description:
• Not OK – The screws for the ECM connectors
are damaged or a threaded hole in the ECM is Use this procedure under the following
damaged. conditions:

Repair: Repair the connectors or replace the Use this procedure if any of the following diagnostic
connectors or screws, as required. If a threaded codes are active:
hole in the ECM is damaged, replace the ECM.
• 0100-03 Engine Oil Pressure Sensor voltage
Use the electronic service tool in order to clear all above normal
logged diagnostic codes and then verify that the
repair eliminates the fault. • 0100-04 Engine Oil Pressure Sensor voltage below
normal
STOP.
• 0100-10 Engine Oil Pressure Sensor abnormal
Test Step 8. Perform the “Wiggle Test” rate of change
on the Electronic Service Tool
• 1785-03 Intake Manifold Pressure Sensor voltage
A. Select the “Wiggle Test” from the diagnostic tests above normal
on the electronic service tool.
SENR9969-05 155
Troubleshooting Section

• 1785-04 Intake Manifold Pressure Sensor voltage

below normal

• 1785-10 Intake Manifold Pressure Sensor

abnormal rate of change

• 1797-03 Fuel Rail Pressure Sensor voltage above

normal

• 1797-04 Fuel Rail Pressure Sensor voltage below

normal

The following background information is related

to this procedure:

The troubleshooting procedures for the diagnostic

codes of each pressure sensor are identical. The
5 Volt sensor supply provides power to all 5 Volt
sensors. The Electronic Control Module (ECM)
supplies 5.0 ± 0.2 Volts DC to terminal “1” of each
sensor connector. The sensor common from the
ECM connector goes to terminal “2” of each sensor
connector. The sensor supply is output short circuit
protected. A short circuit to the battery will not
damage the circuit inside the ECM.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage

on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
diagnostic code (XXX-3) for the sensor.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
156 SENR9969-05
Troubleshooting Section

g01800518
Illustration 54
Typical example of the schematic for the sensors

g01458448
Illustration 55
Typical view of the pin locations on the P2 connector for the pressure sensors
(38) Ground (GND) Intake Manifold Pressure (47) Voltage supply (5 Volts DC) Oil Pressure (56) Signal (SIG) Oil Pressure Sensor
Sensor Sensor
(39) Ground (GND) Oil Pressure Sensor (48) Voltage supply (5 Volts DC) Fuel Rail
(40) Ground (GND) Fuel Rail Pressure Pressure Sensor
Sensor (51) Signal (SIG) Fuel Rail Pressure Sensor
(46) Voltage supply (5 Volts DC) Intake (55) Signal (SIG) Intake Manifold Pressure
Manifold Pressure Sensor Sensor
SENR9969-05 157
Troubleshooting Section

The troubleshooting procedures for the diagnostic

codes of each pressure sensor are identical. The
pressure sensors are active sensors. The pressure
sensor has three terminals. Active sensors require
supply voltage from the ECM. The P2/J2 ECM
connector supplies +5 Volts DC to terminal 1 of
each sensor. The common line is connected to each
sensor connector terminal 2. The signal voltage
from terminal 3 of each sensor is supplied to the
appropriate terminal at the P2/J2 ECM connector.

Test Step 1. Verify All Active Diagnostic

Codes

g01170309 A. Turn the keyswitch to the ON position. Wait at

Illustration 56 least 10 seconds for activation of the diagnostic
Fuel rail pressure sensor codes.
(1) Voltage supply (Vs)
(2) Ground (GND) B. Verify if any of the following diagnostic codes are
(3) Signal (SIG) active:

• 0100-03 Engine Oil Pressure Sensor voltage

above normal

• 0100-04 Engine Oil Pressure Sensor voltage

below normal

• 0100-10 Engine Oil Pressure Sensor abnormal

rate of change

• 1785-03 Intake Manifold Pressure Sensor

voltage above normal

• 1785-04 Intake Manifold Pressure Sensor

g01170310 voltage below normal
Illustration 57
Intake manifold pressure sensor
• 1785-10 Intake Manifold Pressure Sensor
(1) Voltage Supply (Vs) abnormal rate of change
(2) Ground (GND)
(3) Signal (SIG)
• 1797-03 Fuel Rail Pressure Sensor voltage
above normal

• 1797-04 Fuel Rail Pressure Sensor voltage

below normal

Expected Result:

One or more of the preceding diagnostic codes are

active.

Results:

• OK – Proceed to Test Step 2.

Illustration 58
g01170311 • Not OK
Typical example of the oil pressure sensor
Repair: Do not use this procedure if 1785-10 or
(1) Voltage Supply (Vs) 0100-10 diagnostic codes are active. Refer to
(2) Ground (GND)
(3) Signal (SIG)
Troubleshooting, “5 Volt Sensor Supply Circuit -
Test”. When this test is complete, return to the start
of this test.
158 SENR9969-05
Troubleshooting Section

If the preceding codes are logged, an intermittent Use the electronic service tool in order to clear all
condition may be causing the logged codes. logged diagnostic codes and then verify that the
Refer to Troubleshooting, “Electrical Connectors repair eliminates the fault.
- Inspect”.
STOP.
Perform a “Wiggle Test” by using the electronic
service tool in order to identify intermittent Test Step 3. Verify that the Diagnostic
connections. Code is Still Active
STOP. A. Turn the keyswitch to the ON position. Wait at
least 10 seconds for activation of the diagnostic
Test Step 2. Inspect Electrical Connectors codes.
And Wiring
B. Use the electronic service tool to check for active
A. Thoroughly inspect the terminal connections on diagnostic codes. Record all active diagnostic
the P2/J2 ECM connectors. codes.

B. Thoroughly inspect the following connectors for C. Determine if the fault is related to an open circuit
the engine pressure sensors: diagnostic code or a short circuit diagnostic code.

• P201 Engine Oil Pressure Sensor Expected Result:

• P228 Fuel Rail Pressure Sensor Either a short circuit diagnostic code is active or an
open circuit diagnostic code is active.
• P200 Intake Manifold Pressure Sensor
Results:
C. Refer to Troubleshooting, “Electrical Connectors
- Inspect”. • OK - Short Circuit – A voltage above normal
diagnostic code is active at this time. Proceed to
D. Perform a 45 N (10 lb) pull test on each of the Test Step 4.
wires in the ECM connector and the sensor
connectors that are associated with the active • OK - Open Circuit – A voltage below normal
diagnostic code. diagnostic code is active at this time. Proceed to
Test Step 5.
E. Check the screw for the ECM connector for the
correct torque of 5 N·m (44 lb in). • Not OK – A short circuit diagnostic code is not
active. An open circuit diagnostic code is not
F. Check the harness for abrasions and for pinch active. An intermittent fault may exist.
points from the sensors back to the ECM.
Repair: Use the electronic service tool to perform
G. Use the electronic service tool to perform a a “Wiggle Test”. If faults are indicated then go to
“Wiggle Test”. The “Wiggle Test” will identify the appropriate procedure.
intermittent connections.
STOP.
Expected Result:
Test Step 4. Disconnect The Sensor In
All connectors, pins, and sockets should be Order To Create An Open Circuit
completely coupled and inserted. The harness should
be free of corrosion, abrasions and pinch points. A. Turn the keyswitch to the OFF position.

Results: B. Disconnect the connector for the sensor with the

short circuit diagnostic code.
• OK – Proceed to Test Step 3.
C. Turn the keyswitch to the ON position. Wait for at
• Not OK least 10 seconds for activation of the diagnostic
codes.
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. D. Use the electronic service tool to check the “Active
Ensure that all of the seals are correctly in place Diagnostic Code” screen. Check for an open
and ensure that the connectors are completely circuit diagnostic code.
coupled.
SENR9969-05 159
Troubleshooting Section

Expected Result: Expected Result:

An open circuit diagnostic code for the disconnected The short circuit diagnostic code is still present.
sensor is now active.
Results:
Results:
• OK – There is a fault in the sensor.
• OK – A voltage above normal diagnostic code
was active before disconnecting the sensor. An Repair: Perform the following procedure:
open circuit diagnostic code became active after
disconnecting the sensor. Proceed to Test Step 6. 1. Temporarily connect a new sensor to the
harness but do not install the new sensor in the
• Not OK – There is a short circuit between the engine.
sensor harness connector and the ECM. Leave the
sensor disconnected. Proceed to Test Step 8. 2. Use the electronic service tool to verify that the
replacement sensor eliminates the fault.
Test Step 5. Measure the Sensor Supply
Voltage 3. If the diagnostic code is eliminated, install the
replacement sensor.
A. Turn the keyswitch to the OFF position.
4. Use the electronic service tool to clear the
B. Disconnect the sensor from the engine harness. logged diagnostic codes.

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

D. Measure the voltage at the plug for the sensor • Not OK – Repair the engine harness connector.
from the terminal 1 (pressure sensor supply) to Use the electronic service tool to clear the logged
terminal 2 (sensor common). diagnostic codes.

Expected Result: STOP.

The voltage from terminal 1 to terminal 2 measures Test Step 7. Create a Short Circuit
4.84 to 5.16 Volts DC. Between the Signal and the Common
Terminals at the Engine Harness
Results: Connector
• OK – The sensor supply voltage is correct. A. Turn the keyswitch to the ON position.
Proceed to Test Step 7.
B. Fabricate a jumper wire that is 150 mm (6 inch)
• Not OK – The sensor supply voltage is out of the long. Crimp a terminal to both ends of the wire.
nominal range. Continue testing the sensor supply
circuit. C. Monitor the “Active Diagnostic Code” screen of the
electronic service tool before installing the jumper
Repair: Go to Troubleshooting, “5 Volt Sensor wire and after installing the jumper wire.
Supply Circuit - Test”.
D. Install the jumper on the engine harness
STOP. connector. Install one end of the jumper at the
sensor signal (terminal 3). Install the other end
Test Step 6. Determine if the Short Circuit of the jumper at the common connection for
is in the Connector or in the Sensor the pressure sensor (terminal 2). Wait at least
30 seconds for activation of the short circuit
A. Thoroughly inspect the connector for moisture. diagnostic code.

B. Inspect the seals and reconnect the sensor. Expected Result:

Refer to Troubleshooting, “Electrical Connectors
- Inspect”. A short circuit diagnostic code is active when the
jumper is installed. An open circuit diagnostic code is
C. active when the jumper is removed.

D. If the short circuit diagnostic code reappears, the Results:

sensor or the sensor connector has a fault.
• OK – The engine harness and the ECM are OK.
160 SENR9969-05
Troubleshooting Section

Repair: Perform the following repair: Use the electronic service tool to verify that there
is a short circuit diagnostic code.
1. Temporarily connect a new sensor to the
harness but do not install the new sensor in the Expected Result:
engine.
Voltage below normal diagnostic codes and voltage
2. Use the electronic service tool to verify that the above normal diagnostic codes were active.
replacement sensor eliminates the fault.
Results:
3. If the diagnostic code is eliminated, install the
replacement sensor. • OK – The ECM is operating correctly. Proceed to
Test Step 9.
4. Use the electronic service tool to clear the
logged diagnostic codes. • Not OK – One of the following conditions exists:
The voltage below normal diagnostic code is not
STOP. active when the harness is disconnected. The
voltage above normal diagnostic code is not active
• Not OK – The open circuit diagnostic code when the jumper wire is installed.
remains active when the jumper is installed. The
most probable location for the open circuit is in the Repair: Perform the following repair:
common wire for the sensor, or in the sensor signal
wire of the engine harness between the ECM and 1. Make sure that the latest flash file for the
the sensor. Remove the jumper. Proceed to Test application is installed in the ECM. Refer to
Step 8. Troubleshooting, “Flash Programming”.

Test Step 8. Check the Operation of the 2. Contact the Technical Communicator at the
ECM by Creating Open and Short Circuits Caterpillar dealer.
at the ECM Connector
Note: This consultation can greatly reduce the repair
A. Turn the keyswitch to the OFF position. time.

B. Disconnect the P2 connector from the ECM. 3. If the Technical Communicator recommends the
Thoroughly inspect both halves of the connector use of a test ECM, install a test ECM. Refer to
for signs of corrosion or moisture. Refer to Troubleshooting, “Replacing the ECM”.
Troubleshooting, “Electrical Connectors - Inspect”.
4. Remove all jumpers and replace all connectors.
C. Reconnect the P2 connector.
5. Use the electronic service tool to recheck the
D. Turn the keyswitch to the ON position. Use the system for active diagnostic codes.
electronic service tool in order to monitor the
“Active Diagnostic Code” screen. Wait at least 10 6. If the fault is resolved with the test ECM,
seconds for activation of the code. reconnect the suspect ECM.

An open circuit diagnostic code should be active 7. If the fault returns with the suspect ECM,
for the suspect sensor. replace the ECM.

Note: When the P2 connector is disconnected, all of 8. Use the electronic service tool in order to clear
the open circuit diagnostic codes for the pressure all logged diagnostic codes and then verify that
sensors and temperature sensors will be active. This the repair eliminates the fault.
is normal. Disregard the diagnostic codes for the
pressure sensors and the temperature sensors that STOP.
are not suspect. Address the diagnostic codes for
the suspect sensors only. Test Step 9. Bypass the Harness Wiring
Between the ECM and the Sensor
E. Turn the keyswitch to the OFF position. Connector
F. Fabricate a jumper wire that is 150 mm (6 inch) A. Turn the keyswitch to the OFF position.
long. Crimp a terminal to both ends of the wire.
B. Disconnect the P2 connector and disconnect the
G. Install the jumper wire on the P2 connector. connector from the suspect sensor.
Insert the jumper wire between the terminal
for the suspect sensor signal and the common C. Remove the sensor signal wire from the P2
connection for the engine's pressure sensor. connector.
SENR9969-05 161
Troubleshooting Section

D. Remove the signal wire (terminal 3) from the i03496301

sensor connector on the engine harness.
Engine Speed/Timing Sensor
E. Fabricate a jumper wire that is long enough to Circuit - Test
reach from the ECM to the sensor connector or
use an engine sensor harness bypass with 3 SMCS Code: 1912-038
terminals.
System Operation Description:
Note: If an engine sensor harness bypass is being
made, crimp a socket on one end in order to connect Use this procedure to troubleshoot the system under
to the ECM. Crimp either a pin or a socket on the the following conditions:
other end, as required.
• The engine will not start and the electronic service
F. Insert the one end of the engine sensor harness tool indicates a faulty sensor by displaying “Not
bypass into P2 connector on the engine harness. Detected” against the faulty sensor on the “No
Insert the other end of the engine sensor harness Start Parameter” screen.
bypass into the sensor connector of the engine
harness. • There is an active diagnostic code or a recently
logged diagnostic code that is related to the
G. Reconnect the P2 connector and the sensor following:
connector.
• 0190-08 Engine Speed Sensor abnormal
H. Turn the keyswitch to the ON position. frequency, pulse width, or period
I. Use the electronic service tool to monitor the • 0342-08 Secondary Engine Speed Sensor
“Active Diagnostic Code” screen for either the abnormal frequency, pulse width, or period
open circuit diagnostic code for the sensor or the
short circuit diagnostic code for the sensor. The engine uses two engine speed/timing sensors.
The primary crankshaft speed/timing sensor is
Expected Result: located on the left hand side of the cylinder block
close to the flywheel housing. The secondary
The diagnostic code disappears when the jumper or camshaft/fuel rail pump sensor is part of the fuel
the bypass is installed. rail pump. The primary speed/timing sensor that is
mounted on the cylinder block generates a signal by
Results: detecting the movement of the teeth that are located
on the speed/timing wheel. The speed/timing wheel
• OK – There is a fault in the wiring harness. is connected to the crankshaft. The signal that is
generated by the speed/timing sensor is transmitted
Repair: Perform the following repair: to the Electronic Control Module (ECM). The ECM
uses the speed/timing sensor signal to calculate the
1. Repair the faulty harness or replace the faulty position of the crankshaft. The signal is also used to
harness. determine the engine speed.
2. Use the electronic service tool in order to clear The secondary speed/timing sensor is located in
all logged diagnostic codes and then verify that the fuel rail pump. The secondary speed/timing
the repair eliminates the fault. sensor generates a signal that is related to the
camshaft position. The fuel rail pump is mechanically
STOP. connected to the camshaft. The secondary
speed/timing sensor detects the movement of
• Not OK – The most likely cause is an intermittent the teeth on the speed/timing wheel in the fuel
fault. rail pump. The signal that is generated by the
speed/timing sensor is transmitted to the ECM. The
Repair: Use the electronic service tool to perform ECM calculates the speed and the rotational position
a “Wiggle Test”. If no fault is found, restart this test of the engine by using the signal. The secondary
procedure from Test Step 1. speed/timing sensor is required for starting purposes.
STOP. During normal operation, the secondary speed/timing
sensor is used to determine the cycle that the
engine is on. When the timing has been established,
the primary speed/timing sensor is then used to
determine the engine speed and the angular position.
162 SENR9969-05
Troubleshooting Section

The loss of signal to the primary sensor and/or the

secondary sensor will result in one of the following
faults:

• The loss of signal from the secondary speed/timing

sensor will prevent the engine from starting.

• The engine will continue to run when only one

sensor signal is present from either the primary
sensor or the secondary sensor.

• The loss of signal from the primary speed/timing

sensor during operation of the engine will result in
engine operation with a derate.

• Loss of signal from the primary sensor and the

secondary sensor during operation of the engine
will cause fuel injection to be terminated and the
engine will stop.

The primary sensor and the secondary sensor are

interchangeable components. If a sensor is suspect
the sensors can be exchanged in order to eliminate
a fault. If a secondary sensor is suspect and a
replacement secondary sensor is not available, then
the primary sensor and the secondary sensor can be
exchanged. This will allow testing to determine if the
secondary sensor is faulty.

Table 58
P2/J2 Pin Connections
Function Sensor Pin Crankshaft Primary Sensor Camshaft Secondary Sensor
+8 Volt Supply 1 10 10
Signal 2 52 53

g01458747
Illustration 59
The schematic for the speed/timing sensors
SENR9969-05 163
Troubleshooting Section

g01458749
Illustration 60
Typical view of the speed/timing sensor pin locations on the P2 connector
(10) Speed/ Timing sensor supply (8 Volts (52) Crankshaft speed timing sensor signal
DC) (53) Pump/Cam speed sensor signal
164 SENR9969-05
Troubleshooting Section

g01458756
Illustration 61
Typical view of the sensor locations on the C4.4 engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor
SENR9969-05 165
Troubleshooting Section

g01458829
Illustration 62
Detailed view of the sensor locations on the C4.4 engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor

g01715598
Illustration 63
Typical view of the sensor locations on the C6.6 engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor
166 SENR9969-05
Troubleshooting Section

g01715735
Illustration 64
Detailed view of the sensor locations on the C6.6 engine
(1) Primary speed/timing sensor (2) Secondary speed/timing sensor

g01212995
Illustration 65
Typical example of the speed/timing sensor
(1) Voltage Supply (8 Volts DC) (2) Signal

Test Step 1. Inspect the Electrical H. Check that the suspect sensor is installed
Connectors and the Harness correctly. Check that the suspect sensor is fully
seated into the engine. Check that the sensor is
A. Turn the keyswitch to the OFF position. securely latched.

B. Thoroughly inspect the P2 connector and Expected Result:

the suspect sensor connections. Refer to
Troubleshooting, “Electrical Connectors - Inspect”. The electrical connectors and the cables are correctly
installed.
C. Perform a 45 N (10 lb) pull test on each of
the wires in the suspect sensor connector and Results:
the sensor connections at the ECM. The wire
connectors are shown in illustration 60. • OK – The harness is OK. Proceed to Test Step 2.
D. Check that the ground connection on the ECM and • Not OK
the negative terminal on the battery are correctly
installed. Repair: Repair the faulty connectors or the
harness and/or replace the faulty connectors or the
E. Check the ground connection on the ECM for harness. Ensure that all of the seals are correctly in
abrasions and pinch points. place and ensure that the connectors are correctly
coupled.
F. Check the screws for the ECM connector for the
correct torque of 5.0 N·m (44 lb in). If a sensor must be replaced or the sensor must be
reinstalled, complete all of the following tasks:
G. Check the harness for abrasion and pinch points
from the suspect sensor to the ECM.
SENR9969-05 167
Troubleshooting Section

• Lubricate the O ring with clean engine lubricating B. Disconnect the P2 connector. Disconnect the
oil. connector for the primary speed/timing sensor.
Disconnect the connector for the secondary
• Ensure that the plug for the sensor has a seal speed/timing sensor.
inside the connector body. If a seal is damaged
or missing, replace the seal. C. Check the resistance between P2:53 to the
secondary speed/timing sensor terminal 2. The
• Ensure that the sensor is fully seated into the resistance should be less than 2.0 Ohms.
engine before tightening the bracket bolt.
D. Check the resistance between P2:10 to the
• Ensure that the connector is latched. secondary speed/timing sensor terminal 1. The
resistance should be less than 2.0 Ohms.
• Ensure that the harness is correctly secured,
and ensure that the harness is attached to the Expected Result:
harness clip.
The readings agree with the values that are listed
Use the electronic service tool in order to clear all above.
logged diagnostic codes and then verify that the
repair has eliminated the fault. Results:

STOP. • OK – The harness is not OPEN circuit. Proceed

to Test Step 5.
Test Step 2. Check for Active Diagnostic
Codes and Recently Logged Diagnostic • Not OK – The harness or the connector is an open
Codes circuit or high resistance.

A. Turn the keyswitch to the OFF position. Repair: Repair the faulty connectors or the
harness. Replace the faulty connectors or
B. Connect the electronic service tool to the the harness. Reconnect all sensor and ECM
diagnostic connector. connectors. Ensure that all of the seals are
correctly in place. Ensure that all connectors are
C. Turn the keyswitch to the ON position. If the correctly coupled.
engine will start, then run the engine.
Use the electronic service tool in order to clear all
D. Use the electronic service tool in order to monitor logged diagnostic codes and then verify that the
active diagnostic codes or recently logged repair has eliminated the fault.
diagnostic codes.
STOP.
Expected Result:
Test Step 4. Check the Harness Between
One or more of the following diagnostic codes are the Primary Speed/Timing Sensor and
active or recently logged: the ECM
• 190-08 Engine Speed Sensor abnormal frequency, A. Turn the keyswitch to the OFF position.
pulse width, or period
B. Disconnect the P2 connector. Disconnect the
• 342-08 Secondary Engine Speed Sensor abnormal connector for the primary speed/timing sensor.
frequency, pulse width, or period Disconnect the connector for the secondary
speed/timing sensor.
Results:
C. Check the resistance between P2:52 to the
• 190-08 – Proceed to Test Step 4. secondary speed/timing sensor terminal 2. The
resistance should be less than 2.0 Ohms.
• 342-08 – Proceed to Test Step 3.
D. Check the resistance between P2:10 to the
• Not OK – No active diagnostic codes or recently secondary speed/timing sensor terminal 1. The
logged diagnostic codes are displayed. STOP. resistance should be less than 2.0 Ohms.

Test Step 3. Check the Harness Between Expected Result:

the Secondary Speed/Timing Sensor and
the ECM The readings agree with the values that are listed
above.
A. Turn the keyswitch to the OFF position.
168 SENR9969-05
Troubleshooting Section

Results: Use the electronic service tool in order to clear all

logged diagnostic codes and then verify that the
• OK – The harness is not OPEN circuit. Proceed repair eliminates the fault.
to Test Step 6.
STOP.
• Not OK – The harness is OPEN circuit.
Test Step 6. Check that the Connections
Repair: Repair the faulty connectors or the harness and the Wiring to the Primary
and/or replace the faulty connectors or the harness. Speed/Timing Sensor and the ECM
Reconnect all sensor and ECM connectors. Ensure are Isolated from the Other Power
that all of the seals are correctly in place. Ensure Sources
that all connectors are correctly coupled.
A. Turn the keyswitch to the OFF position.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the B. Disconnect the P2 connector. Disconnect the
repair eliminates the fault. connector for the primary speed/timing sensor.
Disconnect the connector for the secondary
STOP. speed/timing sensor.

Test Step 5. Check that the Connections C. Check the resistance between P2:52 to each of the
and the Wiring to the Secondary other pins on P2. Check the resistance between
Speed/Timing Sensor and the ECM are P2:52 to the ground and battery+ terminals. The
Isolated from Other Power Sources resistance should be more than 20,000 Ohms.

A. Turn the keyswitch to the OFF position. D. Check the resistance between P2:10 to each of the
other pins on P2. Check the resistance between
B. Disconnect the P2 connector. Disconnect the P2:10 to the ground and battery+ terminals. The
connector for the primary speed/timing sensor. resistance should be more than 20,000 Ohms.
Disconnect the connector for the secondary
speed/timing sensor. Expected Result:

C. Measure the resistance from P2:53 secondary The readings agree with the values that are listed
speed/timing sensor signal input to all other pins above.
on the P2. Measure the resistance from P2:53
secondary speed/timing sensor signal input to the Results:
ground and battery+ terminals. The resistance
should be more than 20,000 Ohms. • OK – The sensor wiring does not have a short
circuit. Proceed to Test Step 7.
D. Measure the resistance from P2:10 speed/timing
sensor (+8 Volt DC supply) to all other pins • Not OK – The sensor wiring has a short circuit.
on the P2. Measure the resistance from P2:10
speed/timing sensor (+8 Volt DC supply) to the Repair: Repair the faulty connectors or replace
ground and the battery+ terminals. The resistance the faulty connectors. Repair the faulty harness or
should be more than 20,000 Ohms. replace the faulty harness. Reconnect all sensor
and ECM connectors. Ensure that all of the seals
Expected Result: are correctly in place. Ensure that all connectors
are correctly coupled.
The readings agree with the values that are listed
above. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
Results: repair eliminates the fault.

• OK – There is no short circuit. Proceed to Test STOP.

Step 7.
Test Step 7. Check if a Replacement
• Not OK – The harness has a short circuit. Sensor Eliminates the Fault
Repair: Repair the faulty connectors or replace A. Turn the keyswitch to the OFF position.
the faulty connectors. Repair the faulty harness or
replace the faulty harness. Reconnect all sensor B. Disconnect the suspect sensor and remove the
and ECM connectors. Ensure that all of the seals suspect sensor from the engine.
are correctly in place. Ensure that all connectors
are correctly coupled.
SENR9969-05 169
Troubleshooting Section

C. If a sensor must be replaced or a sensor must be C. If the Technical Communicator recommends the
reinstalled, complete all of the following tasks: use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.
• Lubricate the O ring with clean engine
lubricating oil. D. Use the electronic service tool to recheck the
system for active diagnostic codes.
• Ensure that the plug for the sensor has a seal
inside the connector body. If a seal is damaged Expected Result:
or missing, replace the seal.
The fault is eliminated.
• Ensure that the sensor is fully seated into
the engine or the pump before tightening the Results:
bracket bolt.
• OK – The fault is eliminated.
• Ensure that the connector is latched.
Repair: Perform the following procedure:
• Ensure that the harness is correctly secured,
and ensure that the harness is attached to the 1. Reconnect the suspect ECM.
harness clip.
2. If the fault returns with the suspect ECM,
D. Turn the keyswitch to the ON position. replace the ECM.

E. Start the engine. 3. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
F. Use the electronic service tool in order to monitor the repair eliminates the fault.
the diagnostic codes.
STOP.
G. Verify that the replacement sensor has eliminated
the fault. • Not OK – The fault was not resolved with a test
ECM.
Expected Result:
Repair: Repeat this diagnostic process. If the fault
The fault has been rectified. persists, the fault may be a damaged timing ring.
Check the timing ring and/or replace the timing
Results: ring.

• OK – If the fault is eliminated with the test sensor, Use the electronic service tool in order to clear all
reconnect the suspect sensor. If the fault returns logged diagnostic codes and then verify that the
with the suspect sensor, replace the suspect repair eliminates the fault.
sensor.
STOP.
Repair: Use the electronic service tool in order to
clear all logged diagnostic codes and then verify
i03496522
that the repair eliminates the fault.

STOP.
Engine Temperature Sensor
Open or Short Circuit - Test
• Not OK – The fault still exists. Proceed to Test
Step 8. SMCS Code: 1906-038; 1921-038; 1922-038

Test Step 8. Check if the Replacement of System Operation Description:

the ECM Eliminates the Fault
Use this procedure under the following
A. Make sure that the latest flash file for the conditions:
application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”. This procedure covers open circuit diagnostic codes
and short circuit diagnostic codes that are associated
B. Contact the Technical Communicator. with the following sensors:

Note: This consultation can greatly reduce the repair • Coolant temperature sensor
time.
• Intake manifold air temperature sensor
170 SENR9969-05
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Use this procedure to troubleshoot the system when

one of the following diagnostic codes is an active
diagnostic code or a recently logged diagnostic code
or when a diagnostic code can easily be activated.

• 0110-03 Engine Coolant Temperature Sensor

voltage above normal

• 0110-04 Engine Coolant Temperature Sensor

voltage below normal

• 0172-03 Intake Manifold Air Temperature Sensor

voltage above normal

• 0172-04 Intake Manifold Air Temperature Sensor

voltage below normal

The following background information is related

to this procedure:

The troubleshooting procedures for the diagnostic

codes of each temperature sensor are identical. The
temperature sensors have two terminals. Pin P2:37 is
the common connection for the engine temperature
sensors. The sensor common connection is shared
between the temperature sensors. The common line
is connected to each sensor connector terminal 2.
Terminal 1 is the sensor output. The signal voltage
from terminal 1 of each sensor is supplied to the
appropriate terminal in the P2/J2 connector.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage

on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
diagnostic code (3) for the sensor.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

The troubleshooting procedures for the diagnostic

codes of each temperature sensor are identical.
The temperature sensors are passive sensors. The
temperature sensor has two terminals. The common
line is connected to each sensor connector terminal
2. The signal voltage from terminal 1 of each sensor
is supplied to the appropriate terminal at the P2/J2
ECM connector.
SENR9969-05 171
Troubleshooting Section

g01803534
Illustration 66
Schematic for engine temperature sensors

g01803535
Illustration 67
Typical view of the P2 pin locations for the temperature sensors
(37) Ground (GND) Intake Manifold Air (42) Signal (SIG) Intake Manifold Air (43) Signal (SIG) Coolant Temperature
Temperature Sensor and Coolant Temperature Sensor Sensor
Temperature Sensor

Test Step 1. Verify All Active Diagnostic

Codes
A. Connect the electronic service tool to the
diagnostic connector.

B. Turn the keyswitch to the ON position.

Note: Wait at least 30 seconds for activation of the

diagnostic codes.

C. Use the electronic service tool in order to verify if

any of the following diagnostic codes are active
or recently logged:
g01170313
Illustration 68
• 0110-03 Engine Coolant Temperature Sensor
Engine coolant temperature sensor and intake manifold air voltage above normal
temperature sensor
(1) Signal (SIG)
(2) Ground (GND)
172 SENR9969-05
Troubleshooting Section

• 0110-04 Engine Coolant Temperature Sensor • Not OK – Repair the connectors or the harness
voltage below normal and/or replace the connectors or the harness.
Ensure that all of the seals are correctly in place
• 0172-03 Intake Manifold Air Temperature and ensure that the connectors are completely
Sensor voltage above normal coupled. Use the electronic service tool in order to
clear all logged diagnostic codes and then verify
• 0172-04 Intake Manifold Air Temperature that the repair has eliminated the fault. If the fault
Sensor voltage below normal has not been eliminated, proceed to Test Step 3.

Expected Result: Test Step 3. Verify That The Diagnostic

Code Is Still Active
One or more of the preceding diagnostic codes are
active or recently logged. A. Turn the keyswitch to the ON position.

Results: Note: Wait at least 10 seconds for activation of the

diagnostic codes.
• Yes – Proceed to Test Step 2.
B. Access the “Active Diagnostic Code” screen on
• No – The fault is intermittent. Proceed to Test Step the electronic service tool and check for active
8. diagnostic codes.

Test Step 2. Inspect Electrical Connectors C. Determine if the fault is related to a Voltage
And Wiring Above Normal diagnostic code or a Voltage Below
Normal diagnostic code.
A. Thoroughly inspect the P2 connector and
the suspect sensor connector. Refer to Expected Result:
Troubleshooting, “Electrical Connectors - Inspect”.
A Voltage Below Normal diagnostic code or an
B. Perform a 45 N (10 lb) pull test on each of the Voltage Above Normal diagnostic code is active.
wires in the sensor connector and the ECM
connector that are associated with the active Results:
diagnostic code.
• OK - SHORT Circuit – A Voltage Below Normal
Refer to illustration 67. diagnostic code is active at this time. Proceed to
Test Step 4.
C. Verify that the latch tab of the connector is
correctly latched. Also verify that the latch tab of • OK - OPEN Circuit – An Voltage Above Normal
the connector has returned to the fully latching diagnostic code is active at this time. Proceed to
position. Test Step 5.

D. Check the screw for the ECM connector for the • Not OK – A Voltage Below Normal diagnostic code
correct torque of 5.0 N·m (44 lb in). is not active. A Voltage Above Normal diagnostic
code is not active. An intermittent fault may exist.
E. Check the harness for abrasions and for pinch
points from the sensor to the ECM. Repair: Use the electronic service tool to perform
a “Wiggle Test”. If faults are indicated, then go to
Expected Result: the appropriate procedure.

All connectors, pins, and sockets should be STOP.

completely coupled and/or inserted. The harness
should be free of corrosion, abrasion, and pinch Test Step 4. Disconnect The Sensor In
points. Order To Create An Open Circuit
Results: A. Turn the keyswitch to the OFF position.

• OK – Proceed to Test Step 3. B. Disconnect the sensor connector of the sensor

with the Voltage Below Normal diagnostic code.

C. Turn the keyswitch to the ON position.

Note: Wait at least 10 seconds for activation of the

diagnostic codes.
SENR9969-05 173
Troubleshooting Section

D. Access the “Active Diagnostic Code” screen of the E. Install the jumper on the engine harness connector
electronic service tool. Check for an active Voltage for the suspect sensor, P100 for the coolant
Above Normal diagnostic code. temperature sensor and P103 for the intake
manifold temperature sensor. Install one end
Expected Result: of the jumper at the sensor signal (terminal 1).
Install the other end of the jumper at the common
A Voltage Above Normal diagnostic code for the connection (terminal 2).
disconnected sensor is now active.
Note: Wait at least 10 seconds for activation of the
Results: Voltage Below Normal diagnostic code.

• OK – A Voltage Below Normal diagnostic code Expected Result:

was active before disconnecting the sensor. A
Voltage Above Normal diagnostic code became A Voltage Below Normal diagnostic code is active
active after disconnecting the sensor. when the jumper is installed. A Voltage Above
Normal diagnostic code is active when the jumper
Repair: Refer to Troubleshooting, “Electrical is removed.
Connectors - Inspect”.
Results:
Inspect the seals of the connectors for damage.
• OK – The engine harness and the ECM are OK.
Connect the sensor and verify that the fault returns.
If the fault returns, the sensor is faulty. Repair: Perform the following repair:

Replace the sensor. 1. Temporarily connect the suspect sensor.

Use the electronic service tool in order to clear all 2. If the diagnostic code remains active, replace
logged diagnostic codes. the sensor.

STOP. 3. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
• Not OK – A Voltage Below Normal diagnostic code the repair eliminates the fault.
was active before disconnecting the sensor. The
Voltage Below Normal diagnostic code is still active 4. Clear all inactive diagnostic codes.
after disconnecting the sensor. There is a short
circuit between the sensor harness connector and STOP.
the ECM. Leave the sensor disconnected. Proceed
to Test Step 6. • Not OK – The Voltage Above Normal diagnostic
code remains active with the jumper in place. The
Test Step 5. Create a Short Circuit most probable location for the open circuit is in the
Between the Signal and the Common sensor common or the sensor signal wire in the
Terminals at the Sensor Harness engine harness between the ECM and the sensor.
Connector Remove the jumper. Proceed to Test Step 6.

A. Disconnect the suspect sensor connector P100 Test Step 6. Check the Operation of the
for the coolant temperature sensor or disconnect ECM by Creating an Open and a Short
P103 for the inlet manifold temperature sensor. Circuit at the ECM Connector
B. Turn the keyswitch to the ON position. A. Turn the keyswitch to the OFF position.

Note: Wait at least 10 seconds for the activation of B. Disconnect the P2 connector.
any diagnostic fault codes.
C. Thoroughly inspect the P2 connector and the J2
C. Fabricate a jumper wire 150 mm (6 inch) long. ECM connector for signs of corrosion or moisture.
Crimp a terminal to both ends of the wire. Refer to Troubleshooting, “Electrical Connectors
- Inspect”.
D. Monitor the “Active Diagnostic Code” screen on
the electronic service tool before installing the D. Turn the keyswitch to the ON position. Use the
jumper wire and after installing the jumper wire. electronic service tool in order to monitor the
“Active Diagnostic Code” screen. Wait at least 10
seconds for activation of the code.
174 SENR9969-05
Troubleshooting Section

A Voltage Above Normal diagnostic code should Note: This consultation can greatly reduce the repair
be active for the suspect sensor. time.

Note: When P2 is disconnected, all of the Voltage 3. If the Technical Communicator recommends the
Above Normal diagnostic codes for the pressure use of a test ECM, install a test ECM. Refer to
sensors and temperature sensors will be active. This Troubleshooting, “Replacing the ECM”.
is normal. Disregard the diagnostic codes for the
pressure sensors and the temperature sensors that 4. Use the electronic service tool to recheck the
are not suspect. Monitor the diagnostic codes for the system for active diagnostic codes.
suspect sensors only.
5. If the fault is eliminated with the test ECM,
E. Turn the keyswitch to the OFF position. reconnect the suspect ECM.

F. Fabricate a jumper wire 150 mm (6 inch) long. 6. If the fault returns with the suspect ECM,
Crimp a terminal to both ends of the wire. replace the ECM.

G. Monitor the “Active Diagnostic Code” screen on 7. Use the electronic service tool in order to clear
the electronic service tool before installing the all logged diagnostic codes and then verify that
jumper wire and after installing the jumper wire. the repair eliminates the fault.

H. Remove either pin P2:42 for the intake manifold STOP.

temperature sensor or pin P2:43 for the coolant
temperature sensor. Test Step 7. Bypass the Harness Wiring
between the ECM and the Sensor
I. Remove the P2:37 sensor common connector. Connector
J. Install one end of the jumper in P2:37. A. Turn the keyswitch to the OFF position.

K. Install the other end of the jumper at the suspect B. Disconnect the P2 connectorand the connector
sensor signal pin. on the suspect sensor.

L. Reassemble the P2 connector to the ECM. C. Remove the signal wire for the suspect sensor
from the P2 connector.
M. Use the electronic service tool in order to check
the diagnostic codes. Wait at least 10 seconds for D. Remove the signal wire (terminal 1) from the
activation of the Voltage Below Normal diagnostic sensor connector on the engine harness.
code.
E. Fabricate a jumper wire that is long enough to
Note: The Voltage Above Normal diagnostic code for reach from the ECM to the sensor connector with
the temperature sensor that is not suspect should sockets on both ends.
become active when the sensor common connection
is removed from the P2 connector. Ignore this code. F. Insert one end of the jumper into the ECM
connector. Insert the other end of the jumper into
Expected Result: the sensor connector of the engine harness.

A Voltage Below Normal diagnostic code is active G. Reconnect the connector for the ECM harness
when the jumper is installed. A Voltage Above and the sensor connector.
Normal diagnostic code is active when the jumper
is removed. H. Turn the keyswitch to the ON position.

Results: I. Use the electronic service tool in order to monitor

the “Active Diagnostic Code” screen for either the
• OK – Proceed to test step 7. open circuit diagnostic code for the sensor or the
short circuit diagnostic code for the sensor.
• Not OK – The ECM does not operate correctly.
J. Remove the jumper and reconnect the wires that
Repair: Perform the following procedure: were previously removed.

1. Make sure that the latest flash file for the K. Reconnect the P1 connector and the connector
application is installed in the ECM. Refer to for the suspect sensor.
Troubleshooting, “Flash Programming”.

2. Contact the Technical Communicator.

SENR9969-05 175
Troubleshooting Section

Expected Result: i03688660

The diagnostic code disappears when the jumper is Engine Temperature Sensor
installed. Open or Short Circuit - Test
Results: SMCS Code: 1906-038; 1921-038; 1922-038

• OK – There is a fault in the wiring harness. System Operation Description:

Repair: Perform the following repair: This test procedure is used for the active
temperature sensor. The active sensor has a
1. Repair the faulty harness or replace the faulty three-wire electrical connector.
harness.
Use this procedure under the following
2. Use the electronic service tool in order to clear conditions:
all logged diagnostic codes and then verify that
the repair eliminates the fault. Use this procedure if another procedure has directed
you here. Use this procedure if any of the following
STOP. diagnostic codes are active:

• Not OK – The fault is intermittent. Proceed to Test • 0171-03 Ambient Air Temperature Sensor voltage
Step 8. above normal
Test Step 8. Perform the “Wiggle Test” • 0171-04 Ambient Air Temperature Sensor voltage
on the Electronic Service Tool below normal
A. Select the “Wiggle Test” from the diagnostic tests Pull-up Voltage
on the electronic service tool.
The Electronic Control Module (ECM) continuously
B. Choose the appropriate group of parameters to outputs a pull-up voltage on the circuit for the sensor
monitor. signal wire. The ECM uses this pull-up voltage in
order to detect an open in the signal circuit. When
C. Press the “Start” button. Wiggle the wiring harness the ECM detects the presence of a voltage that is
in order to reproduce intermittent faults. above a threshold on the signal circuit, the ECM will
generate an open circuit diagnostic code -3 for the
If an intermittent fault exists, the status will be sensor.
highlighted and an audible beep will be heard.
If the sensor is disconnected at the sensor connector,
Expected Result: the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
No intermittent faults were indicated during the connector to the ECM are not open or shorted to
“Wiggle Test”. ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
Results: sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
• OK – No intermittent faults were found. The the sensor connector and the voltage at the sensor
harness and connectors appear to be OK. If this connector is different from pull-up voltage, the signal
test has not identified a fault, return the engine to wire is shorted to another wire in the harness.
service. STOP.

• Not OK – At least one intermittent fault was

indicated.

Repair: Repair the harness or the connector.

Use the electronic service tool in order to clear all

logged diagnostic codes and then verify that the
repair eliminates the fault.

STOP.
176 SENR9969-05
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g01983794
Illustration 69
Schematic for air ambient temperature sensor

g01983795
Illustration 70
Air ambient temperature sensor connector
(A) Sensor +5 Volt supply
(B) Sensor return
(C) Sensor signal

g01983796
Illustration 71
A typical view of the P1 connector (harness side) pin locations.
(33) Sensor return (41) Sensor +5 Volt supply (56) Sensor signal
SENR9969-05 177
Troubleshooting Section

Test Step 1. Inspect Electrical Connectors D. Measure the voltage between terminals A (+5
And Wiring Volts DC) and B (Return) at the sensor connector
on the engine harness.
A. Remove the electrical power from the ECM.
E. Remove the electrical power from the ECM.
B. Thoroughly inspect the ECM engine harness
connector and the connector for the air ambient F. Reconnect the sensor.
temperature sensor. Refer to Troubleshooting,
“Electrical Connectors - Inspect”. Expected Result:

C. Perform a 45 N (10 lb) pull test on each of the The voltage measurement is 5.0 ± 0.2 Volts DC.
wires that are associated with the air ambient
temperature sensor. Results:

D. Verify that the latch tab of the connector is • OK – The voltage measurement is 5.0 ± 0.2 Volts
correctly latched. DC. Proceed to Test Step 3.

E. Check the allen head screws for each ECM • Not OK – The voltage measurement is not 5.0 ±
connector for the proper torque. Refer to 0.20 Volts DC.
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values. Repair: The correct voltage is not reaching the
sensor. Refer to Troubleshooting, “Analog Sensor
F. Check the harness for abrasions, for pinch points, Supply Circuit - Test”.
and for corrosion.
STOP.
Expected Result:
Test Step 3. Check for Active and/or
All connectors, pins, and sockets are completely Logged Diagnostic Codes
coupled and/or inserted. The harness is free of
corrosion, of abrasion, and of pinch points. A. Connect the electronic service tool to the
diagnostic connector.
Results:
B. Restore the electrical power to the ECM.
• OK – The connectors and wiring appear to be OK.
Proceed to Test Step 2. C. Monitor the active diagnostic code screen on the
electronic service tool. Check and record any
• Not OK – There is a fault in the connectors and/or active diagnostic codes.
wiring.
Note: Wait at least 30 seconds in order for the
Repair: Repair the connectors or wiring and/or diagnostic codes to become active.
replace the connectors or wiring. Ensure that all of
the seals are correctly installed and ensure that the Note: A diagnostic code that is logged several
connectors are completely coupled. times is an indication of an intermittent problem.
Most intermittent problems are the result of a
If necessary, perform the “Wiggle Test” on the poor connection between a socket and a pin in a
electronic service tool. connector or of a poor connection between a wire
and a terminal.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the D. Look for a 171-3 diagnostic code or a 171-4
repair eliminates the fault. diagnostic code.

STOP. Expected Result:

Test Step 2. Check the Supply Voltage at No diagnostic codes are active.
the Sensor Connector
Results:
A. Remove the electrical power from the ECM.
• OK – No diagnostic codes are active. The problem
B. Disconnect the harness connector for the air appears to be resolved.
ambient temperature sensor.

C. Restore the electrical power to the ECM.

178 SENR9969-05
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Repair: The problem may have been intermittent. B. Disconnect the P1 ECM connector.
Carefully reinspect the connectors and wiring.
Refer to Troubleshooting, “Electrical Connectors C. Disconnect the harness connector for the ambient
- Inspect”. air temperature sensor.

STOP. D. Measure the resistance between terminal

P1-56 and the remaining terminals on the ECM
• Not OK – A 171-4 diagnostic code is active at this connector.
time. Proceed to Test Step 4.
E. Connect the P1 ECM connector. Connect the
• Not OK – A 171-3 diagnostic code is active at this connector for the air ambient temperature sensor.
time. Proceed to Test Step 5.
Expected Result:
Test Step 4. Disconnect the Sensor in
Order to Create an Open Circuit Each resistance measurement indicates an open
circuit.
A. Remove the electrical power from the ECM.
Results:
B. Disconnect the sensor from the engine harness.
• OK – Each resistance measurement indicates an
C. Restore the electrical power to the ECM. Wait at open circuit. Proceed to Test Step 6.
least 30 seconds for activation of the diagnostic
codes. • Not OK – At least one resistance measurement
does not indicate an open circuit.
D. Access the “Active Diagnostic Codes” screen on
the electronic service tool and check for an active Repair: There is a short circuit in the harness.
171-3 diagnostic code for the suspect sensor. Repair the harness or replace the harness.

E. Remove the electrical power from the ECM. If necessary, perform the “Wiggle Test” on the
electronic service tool.
Expected Result:
Use the electronic service tool in order to clear all
A 171-3 diagnostic code is now active for the sensor. logged diagnostic codes and then verify that the
repair eliminates the fault.
Results:
STOP.
• OK – A 171-4 diagnostic code was active before
disconnecting the sensor. A 171-3 diagnostic code Test Step 6. Create a Short at the Sensor
became active after the sensor was disconnected. Connector
There may be a problem with the sensor.
A. Disconnect the ambient air temperature sensor
Repair: Temporarily connect a new sensor to the at the sensor connector.
harness, but do not install the new sensor in the
engine. Use the electronic service tool in order to B. Fabricate a jumper wire that can be used to create
verify that the repair eliminates the fault. If there a short between terminal A (signal) and terminal
are no active diagnostic codes for the sensor, B (sensor return) at the connector for the ambient
permanently install the new sensor. air temperature sensor. Crimp connector pins to
each end of the jumper wire.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the C. Install the jumper onto the harness side of the
repair eliminates the fault. sensor connector.

STOP. D. Restore the electrical power to the ECM. Wait at

least 30 seconds for activation of the diagnostic
• Not OK – The 171-4 diagnostic code is still codes.
present. Leave the sensor disconnected. Proceed
to Test Step 7. E. Access the “Active Diagnostic Code” screen
on the electronic service tool. Check for an
Test Step 5. Check the Signal Wire for a active 171-4 diagnostic code for the ambient air
Short Circuit temperature sensor.

A. Remove the electrical power from the ECM. F. Remove the electrical power from the ECM.
SENR9969-05 179
Troubleshooting Section

Expected Result: a. Short the jumper wire that is installed into the
P1 ECM connector to engine ground.
A 171-4 diagnostic code is now active for the ambient
air temperature sensor. b. Monitor the “Active Diagnostic Code” screen
on the electronic service tool. Wait at least 30
Results: seconds for the activation of the code.

• OK – A 171-3 diagnostic code was active before A short circuit diagnostic code 171-4 will be
creating the short at the sensor connector. A 171-4 active for the ambient air temperature sensor.
diagnostic code became active after creating the
short at the sensor connector. c. Remove the electrical power from the ECM.

Repair: Temporarily connect a new sensor to the D. Remove the wire jumper. Reconnect all wires and
harness, but do not install the new sensor in the connectors.
engine. Use the electronic service tool in order to
verify that the repair eliminates the fault. If there Expected Result:
are no active diagnostic codes for the sensor,
permanently install the new sensor. A 171-3 diagnostic code is active when the sensor
signal wire is open at the ECM connector. A 171-4
Use the electronic service tool in order to clear all diagnostic code is active when the jumper wire is
logged diagnostic codes and then verify that the shorted to engine ground.
repair eliminates the fault.
Results:
STOP.
• OK – The ECM is working properly. The fault is
• Not OK – A 171-3 diagnostic code is still active in the wiring between the ECM and the sensor
for the ambient air temperature sensor. Proceed connector.
to Test Step 7.
Repair: The fault is most likely in the signal wire for
Test Step 7. Check the Operation of the the sensor. Repair the signal wire for the sensor.
ECM
If necessary, perform the “Wiggle Test” on the
A. Remove the electrical power from the ECM. electronic service tool.

B. Check the operation of the ECM by creating an Use the electronic service tool in order to clear all
open at the ECM. logged diagnostic codes and then verify that the
repair eliminates the fault.
a. Disconnect the P1 ECM connector.
STOP.
b. Fabricate a jumper wire that is long enough to
reach from a terminal at the ECM connector • Not OK – One of the following conditions exists:
to the engine ground stud. Crimp a connector The 171-3 diagnostic code is not active when the
socket to one end of the jumper wire. sensor signal wire is disconnected. The 171-4
diagnostic code is not active when the wire jumper
c. Remove the signal wire for the suspect sensor is installed.
from the P1 ECM connector. Install the jumper
wire into the terminal location for the signal wire Repair: Perform the following repair:
of the suspect sensor.
1. Make sure that the latest flash file for the
d. Connect the ECM connectors. application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.
e. Restore the electrical power to the ECM.
2. Remove all temporary jumpers and reconnect
f. Monitor the “Active Diagnostic Code” screen all connectors.
on the electronic service tool. Wait at least 30
seconds for activation of the code. 3. Contact the Technical Communicator.

An open circuit diagnostic code 171-3 will be Note: This consultation can greatly reduce the repair
active for the ambient air temperature sensor. time.

C. Check the operation of the ECM by creating a 4. If the Technical Communicator recommends the
short at the ECM. use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.
180 SENR9969-05
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5. Use the electronic service tool to recheck the If the fuel rail pump solenoid fails, it is likely that the
system for active diagnostic codes. fuel will not be pumped into the high pressure fuel
rail. The engine will shut down or the engine will fail
6. If the fault is eliminated with the test ECM, to start. The fuel rail pressure can be observed on
reconnect the suspect ECM. the status screen of the electronic service tool.

7. If the fault returns with the suspect ECM,

replace the ECM.

8. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP.

i03498422

Fuel Rail Pump Solenoid - Test

SMCS Code: 1251-038-OD; 5479-038-PX

System Operation Description:

Use this procedure to troubleshoot the system when

one of the following diagnostic codes is active or
easily repeated:

• 1779-05 Fuel Rail #1 Pressure Valve Solenoid

current below normal

• 1779-06 Fuel Rail #1 Pressure Valve Solenoid

current above normal

Note: The fuel rail pump is installed on the engine at

the factory. The fuel rail pump is not a serviceable
part. The fuel rail pump delivers fuel into the fuel rail
at very high pressure.

Use this procedure to troubleshoot the system when

there is a active diagnostic code or if a diagnostic
code can easily be activated.

The fuel rail pump solenoid is used to control the

output from the fuel rail pump. The solenoid receives
an electrical supply from the ECM. The fuel rail pump
solenoid is then energized when the fuel is required
to be pumped into the fuel rail. Varying the timing of
the voltage to the solenoid controls the fuel delivery
from the fuel rail pump.

When the fuel rail pump solenoid is deactivated, the

fuel that is not sent to the fuel rail is returned to the
fuel tank.

The fuel rail pump solenoid forms part of the closed

loop control system for the fuel rail pressure in
conjunction with the fuel rail pressure sensor, the
ECM and the software. The fuel rail pressure sensor
measures the fuel pressure in the high pressure fuel
rail. The signal from the fuel rail pressure sensor is
processed by the ECM and software. The measured
pressure is compared to the desired fuel rail pressure
for the given engine operating conditions.
SENR9969-05 181
Troubleshooting Section

g01803553
Illustration 72
Typical schematic of the circuit for the fuel rail pump solenoid

g01803554
Illustration 73
Typical view of the pin locations on theP2 connector for the fuel rail pump solenoid
(25) Fuel rail pump solenoid PWM signal (26) Fuel rail pump solenoid return

Test Step 1. Inspect the Electrical D. Check the harness for abrasions and for pinch
Connectors and the Harness points from the battery to the ECM. Check the
harness for abrasions and for pinch points from
the key switch to the ECM.

Electrical shock hazard. The fuel rail pump sole- E. Use the electronic service tool in order to perform
noid uses 63 to 73 volts. a “Wiggle Test”. The “Wiggle Test”is used to
identify intermittent connections.

A. Turn the keyswitch to the OFF position. Expected Result:

B. Thoroughly inspect the harness connector All connectors, pins, and sockets are completely
P2/J2 and the suspect connector P532. Refer to coupled and/or inserted. The harness is free of
Troubleshooting, “Electrical Connectors - Inspect” corrosion, of abrasion, and of pinch points.
for details.
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the solenoid connector P532 and the • OK – The connectors and the harness appear to
connector pins 25 and 26 that are associated with be OK. Proceed to Test Step 2.
the fuel rail pump solenoid. Refer to illustration 73.
182 SENR9969-05
Troubleshooting Section

• Not OK – There is a fault with the connectors Expected Result:

and/or the harness.
The nominal resistance is less than 2.0 Ohms.
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. Results:
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely • OK – The harness and the solenoid do not have
coupled. an open circuit.

Use the electronic service tool in order to clear all Repair: Check the high pressure fuel system for
logged diagnostic codes and then verify that the leaks. A mechanical relief valve is installed in the
repair has eliminated the fault. high pressure fuel rail. Check that there is no flow
of fuel from the mechanical relief valve. Refer to
STOP. the Operation and Maintenance Manual, “High
Pressure Fuel Lines”.
Test Step 2. Check for Active Diagnostic
Codes If the fuel system is not OK, repair the fuel system
and restart the diagnostic process.
A. Connect the electronic service tool to the
diagnostic connector. If the fuel system is OK, proceed to Test Step 4.

B. Turn the keyswitch to the ON position. • Not OK – There is an open circuit. Proceed to Test
Step 4.
C. Use the electronic service tool to verify if any
of the following diagnostic codes are active or Test Step 4. Check the Fuel Rail Pump
recently logged: Solenoid for an Open Circuit
• 1779-05 Fuel Rail #1 Pressure Valve Solenoid A. Turn the keyswitch to the OFF position.
current below normal
B. Disconnect the connector from the fuel rail pump
• 1779-06 Fuel Rail #1 Pressure Valve Solenoid solenoid.
current above normal
C. Measure the resistance of the fuel rail pump
Expected Result: solenoid.

One or more of the following diagnostic codes are Expected Result:

active or recently logged:
The nominal resistance is less than 1.0 Ohms.
• 1779-05 Fuel Rail #1 Pressure Valve Solenoid
current below normal Results:

• 1779-06 Fuel Rail #1 Pressure Valve Solenoid • OK – There is an open circuit or there is an
current above normal excessive resistance in the harness.

Results: Repair: Repair the connectors or the harness

and/or replace the connectors or the harness.
• 1779-05 – Proceed to Test Step 3.
Ensure that all of the seals are correctly in place
• 1779-06 – Proceed to Test Step 7. and ensure that all connectors are correctly
coupled.
• Not OK – No active diagnostic codes or recently
logged diagnostic codes are displayed. STOP. Use the electronic service tool in order to clear all
logged diagnostic codes.
Test Step 3. Check the Harness for an
Open Circuit Use the electronic service tool in order to perform
the fuel rail pump solenoid test.
A. Turn the keyswitch to the OFF position.
Verify that the repair eliminated the fault.
B. Disconnect P2 from the ECM.
STOP.
C. Measure the resistance between P2:25 and P2:26.
• Not OK – The fuel rail pump solenoid is faulty.
SENR9969-05 183
Troubleshooting Section

Repair: Temporarily connect a new fuel rail pump If the diagnostic code has been cleared, then install
to the harness, but do not install the fuel rail pump the new fuel rail pump to the engine. Refer to
to the engine. Disassembly and Assembly, “Fuel injection Pump
- Remove” and Disassembly and Assembly, “Fuel
Reconnect the P2 to the ECM. Check the screw injection Pump - Install”.
for the ECM connector for the correct torque of
5.0 N·m (44 lb in). STOP.

Use the electronic service tool in order to perform • Not OK – The harness has a short circuit or the
the fuel rail pump solenoid test. ECM has a short circuit. Proceed to Test Step 6.

Verify that the repair eliminated the fault. Test Step 6. Check the harness for the
Fuel Rail Pump Solenoid for a Short
If the diagnostic code has been cleared, install Circuit
the new fuel rail pump to the engine. Refer to
Disassembly and Assembly Manual, “Fuel Injection A. Turn the keyswitch to the OFF position.
Pump - Install”.
B. Disconnect the P532 connector from the fuel rail
STOP. pump solenoid.

Test Step 5. Check the Fuel Rail Pump C. Disconnect the P2 connector from the ECM.
Solenoid for a Short Circuit
D. Measure the resistance between P2:26 and P2:25.
A. Turn the keyswitch to the OFF position.
E. Measure the resistance between P2:25 and
B. Disconnect the connector from the fuel rail pump voltage +.
solenoid.
F. Measure the resistance between P2:25 and the
C. Turn the keyswitch to the ON position. voltage (-).

D. Use the electronic service tool in order to perform G. Measure the resistance between P2:26 and
the fuel rail pump solenoid test. voltage +.

Expected Result: H. Measure the resistance between P2:26 and

voltage (-).
A Current Below Normal diagnostic code is displayed.
The Current Above Normal diagnostic code is not Expected Result:
displayed.
The resistance is greater than 20,000 Ohms.
Results:
Results:
• OK – A Current Below Normal diagnostic code is
displayed. The harness has no shorts to supply or • OK – The harness has no short circuit to supply
ground. The fuel rail pump solenoid is faulty. or ground. The ECM is suspect. Proceed to Test
Step 7.
Repair: Temporarily connect a new fuel rail pump
to the harness, but do not install the fuel rail pump • Not OK – The harness has a short circuit.
to the engine.
Repair: Repair the harness and connectors or
Reconnect P2 to the ECM. Check the screw for the replace the faulty harness and connectors.
ECM connector for the correct torque of 5.0 N·m
(44 lb in). Connect the P532 connector to the fuel rail pump
solenoid.
Use the electronic service tool in order to clear all
logged diagnostic codes. Connect the P2 connector to the ECM.

Use the electronic service tool in order to perform Turn the keyswitch to the ON position.
the fuel rail pump solenoid test.
Use the electronic service tool in order to perform
Verify that the repair eliminates the fault. the fuel rail pump solenoid test.
184 SENR9969-05
Troubleshooting Section

Use the electronic service tool in order to clear all Repair: Perform the following procedure:
logged diagnostic codes and then verify that the
repair has eliminated the fault. 1. Reconnect the suspect ECM.

STOP. 2. If the fault returns with the suspect ECM,

replace the ECM.
Test Step 7. Check the ECM and the
Harness 3. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
A. Turn the keyswitch to the OFF position. the repair eliminates the fault.

B. Disconnect the P532 connector from the fuel rail STOP.

pump solenoid.
• Not OK
C. Insert a jumper wire across P532.
Repair: Repeat the test procedure from Test Step
D. Turn the keyswitch to the ON position. 1.

E. Use the electronic service tool in order to perform STOP.

the fuel rail pump solenoid test.
i03498683
F. Use the electronic service tool in order to monitor
the status screen. Idle Validation Switch Circuit
Expected Result: - Test
Diagnostic code 1779-6 is displayed. SMCS Code: 7332-038

Results: System Operation Description:

• OK – The ECM and the ECM connections function. Use this procedure if any of the following diagnostic
The solenoid is not an open circuit. Recheck the codes are active:
diagnostic codes. Proceed to Test Step 5.
• 0091-02 Throttle Position Sensor erratic,
• Not OK – The ECM is suspect. Proceed to Test intermittent, or incorrect
Step 8.
• 0774-02 Secondary Throttle Position Sensor
Test Step 8. Check the ECM Function erratic, intermittent, or incorrect

A. Make sure that the latest flash file for the The Idle Validation Switch (IVS) may be installed.
application is installed in the ECM. Refer to The IVS is required for mobile applications that use
Troubleshooting, “Flash Programming”. an analog throttle. The IVS is part of the analog
throttle demand sensor. The IVS is CLOSED when
B. Contact the Technical Communicator. the low idle is set.

Note: This consultation can greatly reduce the repair The demand settings for the analog throttle that are
time. valid for the IVS threshold are programmed into the
Electronic Control Module (ECM). Use the electronic
C. If the Technical Communicator recommends the service tool in order to display the demand settings
use of a test ECM, install a test ECM. Refer to for the analog throttle.
Troubleshooting, “Replacing the ECM”.
If the IVS operates outside of the programmed range
D. Use the electronic service tool to recheck the then the engine speed may not respond to changes
system for active diagnostic codes. in the throttle position.

Expected Result: The electronic service tool may be used for the
following:
The fault is eliminated.
• If necessary, reset the IVS threshold for an existing
Results: IVS.

• OK – The fault is eliminated with the test ECM.

SENR9969-05 185
Troubleshooting Section

• If necessary, view the IVS change point and reset

the IVS thresholds when a new throttle assembly
is installed.

g01803633
Illustration 74
Schematic of the idle validation switch (IVS) circuit

g01803694
Illustration 75
Typical view of the pin locations in the P1 connector for the idle validation switch
(35) Sensor Ground (GND) (44) Idle validation (IVS) 2 (45) Idle validation (IVS) 1

Test Step 1. Check the Operation of the B. Turn the keyswitch to the ON position.
Idle Validation Switch (IVS)
C. Use the electronic service tool in order to check
A. Connect the electronic service tool to the the current “Throttle Configuration”.
diagnostic connector.
186 SENR9969-05
Troubleshooting Section

D. Select the “SERVICE” option from the drop-down E. Select the “Throttle Configuration” option on the
menu of the electronic service tool. electronic service tool. Select the appropriate
analog “Throttle Configuration” summary from the
E. Select the “Throttle Configuration” option on the menu on the left of the screen. The IVS window
electronic service tool. Select the appropriate for the throttle will indicate “YES” if an IVS is
analog “Throttle Configuration” summary from the installed. Make a note of the “Idle Validation Min
menu on the left of the screen. The IVS window OFF Threshold” parameters that are displayed in
for the throttle will indicate “YES” if an IVS is the “Throttle Configuration” menu of the electronic
installed. Make a note of the “Idle Validation Min service tool. Make a note of the “Idle Validation
OFF Threshold” parameters that are displayed in Max ON Threshold” parameters that are displayed
the “Throttle Configuration” menu of the electronic in the “Throttle Configuration” menu of the
service tool. Make a note of the “Idle Validation electronic service tool.
Max ON Threshold” parameters that are displayed
in the “Throttle Configuration” menu of the F. To select the “Throttle status” function on the
electronic service tool. electronic service tool, select “Status” function and
then select “Throttles” function.
F. Select the “Throttle status” function on the
electronic service tool. Select “Status” function G. The throttle is set in the low idle position.
and then select “Throttles” function.
H. Operate the throttle slowly. The IVS status should
G. The throttle is set in the low idle position. change from CLOSED (ON) to OPEN (OFF).

H. Operate the throttle slowly. The IVS status should Expected Result:
change from CLOSED (ON) to OPEN (OFF).
The IVS switch operates between the “Idle Validation
Expected Result: Min OFF Threshold” and the “Idle Validation Max ON
Threshold” parameters. Use the electronic service
The IVS state changes from CLOSED (ON) to OPEN tool in order to view the parameters of the IVS switch.
(OFF).
Results:
Results:
• OK – The IVS switch operates within the “Idle
• OK – The IVS state changes from CLOSED (ON) Validation Min OFF Threshold” and the “Idle
to OPEN (OFF). Proceed to Test Step 2. Validation Max ON Threshold” parameters. Use
the electronic service tool in order to view the
• Not OK – The IVS does not operate. parameters of the IVS switch. STOP.

Repair: • Not OK – The IVS switch cannot operate within

the “Idle Validation Min OFF Threshold” and the
Proceed to Test Step 3. “Idle Validation Max ON Threshold” parameters.
Use the electronic service tool in order to view the
Test Step 2. Check the Idle Validation parameters of the IVS switch.
Switch (IVS) Threshold
Repair:
A. Connect the electronic service tool to the
diagnostic connector. Proceed to Test Step 7.

B. Turn the keyswitch to the ON position. Test Step 3. Inspect Electrical Connectors
and the Harness
C. Use the electronic service tool in order to check
the current “Throttle Configuration”. A. Inspect the P1/J1 connectors, the harness
and all of the connectors for the IVS. Refer to
D. Select the “SERVICE” option from the drop-down Troubleshooting, “Electrical Connectors - Inspect”
menu of the electronic service tool. for details.

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

wires in the ECM connector that are associated
with the suspect idle validation switch:

• P1:35
• P1:44
SENR9969-05 187
Troubleshooting Section

• P1:45 Results:

C. Check the screw for the ECM connector for the • OK – The jumper wire is connected. The electronic
correct torque of 5.0 N·m (44 lb in). service tool displays the IVS state in the ON
position. The jumper wire is disconnected. The
D. Check the harness for abrasion and pinch points electronic service tool displays the IVS state in
from the analog throttle switch to the ECM. the OFF position. The IVS is suspect. Proceed to
Test Step 6.
Expected Result:
• Not OK – The harness and/or the ECM are
All connectors, pins and sockets are completely suspect. Proceed to Test Step 5.
coupled and/or inserted and the harness is free of
corrosion, abrasion and pinch points. Test Step 5. Check the ECM function
Results: A. Disconnect the P1 connector.

• OK – Proceed to Test Step 4. B. If the IVS 2 is suspect, temporarily remove

connector P1:45. If the IVS 1 is suspect,
• Not OK temporarily remove P1:44.

Repair: Perform the following repair: C. Fabricate a jumper wire.

Repair the connectors or the harness and/or D. Turn the keyswitch to the ON position.
replace the connectors or the harness. Ensure that
all of the seals are correctly in place and ensure E. Install the jumper wire between the removed
that the connectors are completely coupled. connector pin on the P1 connector and P1:35.

Use the electronic service tool in order to clear all F. Use the electronic service tool in order to monitor
logged diagnostic codes and then verify that the the IVS status. Note the status of the IVS.
repair eliminates the fault.
G. Disconnect the jumper wire.
STOP.
H. Use the electronic service tool in order to monitor
Test Step 4. Check the Location of the the IVS status. Note the status of the IVS.
Fault
Expected Result:
A. Disconnect the IVS harness connector.
When the jumper wire is installed, the IVS state on
B. Install a jumper wire between the IVS connections the electronic service tool throttle status screen will
on the harness. display the ON position.

C. Turn the keyswitch to the ON position. When the jumper wire is disconnected, the IVS state
on the electronic service tool throttle status screen
D. Install a jumper wire between the IVS connections will display the OFF position.
on the harness. Use the electronic service tool in
order to check for diagnostic codes. Results:

E. Remove the jumper wire that is between the IVS • OK – When the jumper wire is connected, the
connections on the harness. Use the electronic electronic service tool shows the IVS state
service tool in order to check for diagnostic codes. in the ON position. When the jumper wire is
disconnected, the electronic service tool shows the
Expected Result: IVS state in the OFF position .

Connect the jumper wire. The IVS state on the Repair:

electronic service tool throttle status screen will
display the ON position. 1. Inspect the harness between the ECM and IVS.

Disconnect the jumper wire. The IVS state on the 2. Locate the fault.
electronic service tool throttle status screen will
display the OFF position. 3. Repair the harness and/or replace the harness.
188 SENR9969-05
Troubleshooting Section

4. Use the electronic service tool in order to clear Results:

all logged diagnostic codes and then verify that
the repair has eliminated the fault. • OK – The IVS indicates the resistance that is
shown in the test. No fault is indicated at this time.
STOP. Recheck the harness for intermittent connections.
STOP.
• Not OK – The ECM is suspect.
• Not OK – The IVS is not functioning correctly.
Repair: Perform the following repair:
Repair: Replace the IVS or replace the throttle
1. Make sure that the latest flash file for the sensor. Refer to OEM documentation for
application is installed in the ECM. Refer to information on the throttle sensor. Check the IVS
Troubleshooting, “Flash Programming”. calibration.

2. Contact the Technical Communicator. Refer to Test Step 7.

Note: This consultation can greatly reduce the repair • Verify that the repair has eliminated the fault. Clear
time. the logged diagnostic codes. – STOP.

3. If the Technical Communicator recommends the Test Step 7. Check the Idle Validation
use of a test ECM, install a test ECM. Refer to Switch (IVS) Calibration
Troubleshooting, “Replacing the ECM”.
A. Connect the electronic service tool to the
4. Use the electronic service tool to recheck the diagnostic connector.
system for active diagnostic codes.
B. Turn the keyswitch to the ON position.
5. If the fault is eliminated with the test ECM,
reconnect the suspect ECM. C. Select the “Throttle Configuration” option on the
electronic service tool. Select the appropriate
6. If the fault returns with the suspect ECM, analog “Throttle Configuration” summary from the
replace the ECM. menu on the left of the screen. The IVS window
for the throttle will indicate “YES” if an IVS is
7. Use the electronic service tool in order to clear installed. Make a note of the “Idle Validation Min
all logged diagnostic codes and then verify that OFF Threshold” parameters that are displayed in
the repair eliminates the fault. the “Throttle Configuration” menu of the electronic
service tool. Make a note of the “Idle Validation
STOP. Max ON Threshold” parameters that are displayed
in the “Throttle Configuration” menu of the
Test Step 6. Check the Idle Validation electronic service tool.
Switch (IVS) at the Sensor
D. Select the “Throttle status” function on the
A. Turn the keyswitch to the OFF position. electronic service tool. Select “Status” function
and then select “Throttles” function.
B. Disconnect the IVS.
E. Set the throttle to low idle.
C. Set the throttle to low idle.
F. Operate the throttle slowly toward high idle.
D. Check the resistance of the IVS. The raw percentage values for the throttle that
are shown on the electronic service tool should
E. Set the throttle to high idle. increase and the IVS status should change from
CLOSED (ON) to OPEN (OFF) position. Make
F. Check the resistance of the IVS. a note of the raw reading for the throttle when
the IVS reading changes from the CLOSED
Expected Result: position to the OPEN position. Repeat this step
in order to obtain accurate raw percentage
The IVS reading should be more than 20000 Ohms. values for the throttle. The noted value should
be within the previously noted “Idle Validation
The IVS reading should be less than 10 Ohms at Min OFF Threshold” and “Idle Validation Max ON
low idle. Threshold” limits.

G. The throttle is set to the full throttle position or the

high idle position.
SENR9969-05 189
Troubleshooting Section

H. Operate the throttle slowly toward low idle. The D. Turn the keyswitch to the OFF position. Turn the
raw percentage values for the throttle that are keyswitch to the ON position.
shown on the electronic service tool should
decrease and the IVS status should change E. Repeat Test Step 7. Check that the IVS operates
from OPEN (OFF) to CLOSED (ON) position. within the newly set threshold limits.
Make a note of the raw reading for the throttle
when the IVS reading changes from the OPEN Expected Result:
position to the CLOSED position. Repeat this
step in order to obtain accurate raw percentage The fault is cleared.
values for the throttle. The noted value should
be within the previously noted “Idle Validation Results:
Min OFF Threshold” and “Idle Validation Max ON
Threshold” limits. • OK – STOP.
Expected Result: • Not OK
The IVS operates within the “Idle Validation Min Repair: Perform the following repair:
OFF Threshold” and the “Idle Validation Max
ON Threshold” values that are shown on the Use the electronic service tool in order to clear all
“Configuration” menu of the electronic service tool. logged diagnostic codes and then verify that the
repair eliminates the fault.
Results:
STOP.
• OK – The IVS operates within the “Idle Validation
Min OFF Threshold” and the “Idle Validation Max
i03498803
ON Threshold” values that are shown on the
“Configuration” menu of the electronic service tool.
STOP.
Ignition Keyswitch Circuit and
Battery Supply Circuit - Test
• Not OK – Proceed to Test Step 8.
SMCS Code: 1401-038; 1553-038
Test Step 8. Use the Electronic Service
Tool to Reset the Idle Validation Switch System Operation Description:
(IVS) Threshold Limits
This procedure tests that the correct voltage is being
The electronic service tool can be used to reset the supplied to the Engine Control Module (ECM).
“Idle Validation Min OFF Threshold” and the “Idle
Validation Max ON Threshold” limits that are shown Use this procedure to troubleshoot the system when
in the current throttle configuration summary. one of the following diagnostic codes is active or
easily repeated:
A. Calculate the new “Idle Validation Min OFF
Threshold” limit . The “Idle Validation Min OFF • 0168-00 Electrical System Voltage high
Threshold” limit is 3% below the lowest raw values
that are noted in Test Step 7. • 0168-01 Electrical System Voltage low
Note: The default value for the “Idle Validation Min • 0168-02 Electrical System Voltage erratic,
OFF Threshold” is 10%. The lowest value that should intermittent, or incorrect
be set is 5%.
• 1834-02 Ignition Keyswitch loss of signal
B. Calculate the new “Idle Validation Max ON
Threshold” limit. The “Idle Validation Max ON The ECM receives electrical power (battery
Threshold” is 3% above the raw values that was voltage) through the wiring that is supplied by the
noted for the “Idle Validation Max ON Threshold” manufacturer of the application. Unswitched battery+
limit. The “Idle Validation Max ON Threshold” is voltage is supplied through P1: 7, 8, 15 and 16. The
3% above the highest raw % value that was noted battery- is supplied through P1: 1, 2, 3, 9 and 10.
in Test Step 7. The ECM receives the input from the keyswitch at
P1:40 when the keyswitch is in the ON position or in
Note: The default value for the “Idle Validation Max the START position. When the ECM detects battery
ON Threshold” is 25%. The maximum value that is voltage at this input, the ECM will power up. When
expected is 28%. battery voltage is removed from this input, the ECM
will power down.
C. Enter the new threshold limits into the electronic
service tool.
190 SENR9969-05
Troubleshooting Section

The cause of an intermittent power supply to the

ECM can occur on either the positive side or on the
negative side of the battery circuit. The connections
for the unswitched battery+ may be routed through a
dedicated protection device (circuit breaker).

Some applications may be equipped with an

engine protection shutdown system or an idle timer
shutdown system that interrupts electrical power
to the keyswitch. The engine protection shutdown
system can be an aftermarket device and the idle
timer shutdown system can be external to the ECM.
Some of these systems will not supply power to the
ECM until one of the following conditions is met:

• The engine is cranked.

• The engine oil pressure achieves acceptable limits.
• An override button is pressed.
These devices may be the cause of intermittent
power to the ECM. These devices may also shut
down the engine.

Usually, battery power to the diagnostic connector

is available and the battery power to the data link
connector is independent of the keyswitch. Therefore,
although it is possible to power up the electronic
service tool, there may be no communication with
the engine ECM. The engine ECM requires the
keyswitch to be in the ON position in order to maintain
communications. The ECM may power down a short
time after connecting the electronic service tool if the
keyswitch is in the OFF position. This is normal.

For intermittent faults such as intermittent shutdowns

that could be caused by the application wiring,
temporarily bypassing the application wiring may be
an effective means of determining the root cause. If
the symptoms disappear with the bypass wiring, the
application wiring is the cause of the fault. A means
of bypassing the application wiring is explained in
this test procedure. This is especially important for
applications that do not provide dedicated circuits
for the unswitched battery and the connections for
the keyswitch.
SENR9969-05 191
Troubleshooting Section

g01803755
Illustration 76
Schematic for the ignition keyswitch and battery supply circuit

g01803934
Illustration 77
View of the pin locations on the P1 connector for the ignition keyswitch and battery supply circuit
(1) Battery ground (GND) (8) Battery+ (16) Battery+
(2) Battery ground (GND) (9) Battery ground (GND) (40) Ignition key switch
(3) Battery ground (GND) (10) Battery ground (GND)
(7) Battery+ (15) Battery+
192 SENR9969-05
Troubleshooting Section

Test Step 1. Inspect Electrical Connectors Test Step 2. Check for Active Diagnostic
and Wiring Codes or Logged Diagnostic Codes
A. Thoroughly inspect the P1 connector, the battery A. Connect the electronic service tool to the
connections and the connections to the keyswitch. diagnostic connector.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. B. Turn the keyswitch to the ON position.

B. Perform a 45 N (10 lb) pull test on each of the C. Monitor the active diagnostic code screen on
wires in the ECM connector that are associated the electronic service tool. Check and record
with the following connections: any active diagnostic codes or logged diagnostic
codes.
• P1: 7, 8, 15, 16 (Unswitched Battery+)
Note: Wait at least 30 seconds in order for the
• P1: 1, 2, 3, 9, 10 (Battery-) diagnostic codes to become active.

• P1:40 (keyswitch) Expected Result:

C. Use the electronic service tool to perform a One of the following diagnostic codes is active or
“Wiggle Test”. Special attention must be paid to logged:
the following connections:
• 168-0 Electrical System Voltage high
• P1: 7, 8, 15, 16
• 168-1 Electrical System Voltage low
• P1: 1, 2, 3, 9, 10
• 168-2 Electrical System Voltage erratic,
• P1:40 intermittent, or incorrect

D. Check the ECM connector for the correct torque • 1834-2 Ignition Keyswitch loss of signal
of 5.0 N·m (44 lb in).
Note: Diagnostic code 1834-2 can be generated
E. Check the harness for abrasion and for pinch by rapidly cycling the keyswitch. If diagnostic code
points from the battery to the ECM, and from the 1834-2 is logged but not active, this may be the
keyswitch to the ECM. cause.

Expected Result: Results:

All connectors, pins and sockets are completely • OK – Diagnostic code 168-2 or diagnostic code
coupled and/or inserted and the harness is free of 1834-02 is active or logged. Proceed to Test Step
corrosion, of abrasion or of pinch points. 3.

Results: • Not OK – No diagnostic code is active.

• OK – The harness and connectors appear to be Repair: The fault is no longer present. If the fault
OK. Proceed to Test Step 2. is intermittent, refer to Troubleshooting, “Electrical
Connectors - Inspect”.
• Not OK – There is a fault with the connectors
and/or the harness. STOP.

Repair: Repair the connectors or the harness Test Step 3. Check the Battery Voltage at
and/or replace the connectors or the harness. the ECM Connector
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely A. Disconnect the P1 connector from the ECM.
coupled.
B. Turn the keyswitch to the ON position.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the C. Measure the voltage between P1:7 (Unswitched
repair eliminates the fault. Battery+) and P1:1 (Battery-).

STOP. D. Measure the voltage between P1:8 (Unswitched

Battery+) and P1:2 (Battery-).
SENR9969-05 193
Troubleshooting Section

E. Measure the voltage between P1:15 (Unswitched • Not OK - Battery voltage is out of range – Proceed
Battery+) and P1:9 (Battery-). to Test Step 4.

F. Measure the voltage between P1:16 (keyswitch) Test Step 4. Check the Batteries
and P1:10 (Battery-).
A. Load test the batteries. Use a suitable battery
G. Measure the voltage between P1:40 (keyswitch) load tester.
and P1:3 (Battery-).
Expected Result:
H. Turn the keyswitch to the OFF position.
The batteries pass the load test. For 12 Volt systems,
Expected Result: the measured voltage is at least 11.0 Volts DC. For
24 Volt systems, the measured voltage is at least
For 12 Volt Systems, the measured voltage is a 22.0 Volts DC.
constant 11.0 to 13.5 Volts DC with no suspected
intermittent faults at this time. Results:

For 24 Volt Systems, the measured voltage is a • OK – The batteries pass the load test. For 12
constant 22.0 to 27.0 Volts DC with no suspected Volt systems, the measured voltage is at least
intermittent faults at this time. 11.0 Volts DC. For 24 Volt systems, the measured
voltage is at least 22.0 Volts DC.
Results:
Repair: Refer to the service manual for the
• OK – The ECM is receiving the correct voltage. application for instructions on troubleshooting the
application harness. Troubleshoot the application
Repair: If an intermittent fault is suspected, refer to harness and repair the application harness, as
Troubleshooting, “Electrical Connectors - Inspect”. required.

STOP. Verify that the repairs eliminate the fault.

• Not OK - The ECM is not receiving the correct STOP.

voltage.
• Not OK – The batteries do not pass the load test.
Repair: Check for continuity in the harness for the For 12 Volt systems, the measured voltage is
keyswitch from P1:40 through the keyswitch circuit less than 11.0 Volts DC. For 24 Volt systems, the
to the batteries. Check the circuit protection for measured voltage is less than 22.0 Volts DC.
the circuit.
Repair: Recharge or replace the faulty batteries.
For intermittent faults such as intermittent
shutdowns that could be caused by the application Use the electronic service tool in order to clear all
wiring, temporarily bypassing the application wiring logged diagnostic codes and then verify that the
may be an effective means of determining the root repair eliminates the fault.
cause.
STOP.
Proceed to Test Step 5.
Test Step 5. Bypass the Application
• Not OK - No Voltage on P1: 7, 8, 15, 16 – No Harness
voltage was present on P1: 7, 8, 15, 16.

Repair: Check for continuity in the harness for the

unswitched Battery+ from the ECM to the batteries. Batteries give off flammable fumes which can ex-
Check the circuit protection for the circuit. Check plode.
for continuity in the harness for the Battery- from
the ECM to the batteries. To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a battery.
For intermittent faults such as intermittent
shutdowns that could be caused by the application
wiring, temporarily bypassing the application wiring NOTICE
may be an effective means of determining the root Do not connect the bypass harness to the battery un-
cause. til all of the in-line fuses have been removed from the
Battery+ line. If the fuses are not removed before con-
Proceed to Test Step 5. nection to the battery, a spark may result.
194 SENR9969-05
Troubleshooting Section

Note: This bypass harness is only for test

applications. This bypass harness must be removed
before the application is released to the customer.
The bypass harness can be used in order to
determine if the cause of the intermittent problem is
interruptions in battery power to the ECM or to the
keyswitch circuit.

g01803954
Illustration 78
Schematic for the bypass application harness

A. Turn the keyswitch to the OFF position. Expected Result:

B. Disconnect the P1 connector from the ECM. If the measured voltage between P2:46 and ground
is +5 Volts DC, installing the bypass has eliminated
C. Connect a bypass harness to the ECM. the fault.

D. Remove the fuses from the Battery+ wire of the Results:

bypass harness and connect the Battery+ and the
Battery- wires directly to the battery terminals. • OK – The symptoms disappear when the bypass
harness is installed. Also, the symptoms return
Note: This bypass directly connects the circuit for the when the bypass harness is removed. The fault
keyswitch to the ECM. The ECM will remain powered is in the wiring for the application that supplies
until the connection to the unswitched battery+ line power to the ECM. Check for aftermarket engine
is disconnected. Remove the fuses from the in-line protection switches that interrupt power. Send the
fuse holder to power down the ECM. Do not connect machine to the OEM dealer to repair. STOP.
the bypass to the battery terminals or do not remove
the bypass from the battery terminals without first • Not OK
removing the in-line fuses.
Repair: Perform the following procedure:
E. Use a multimeter to measure the voltage between
P2:46 and ground. The voltage should be +5 Volts 1. Connect the bypass to another battery and
DC. verify if the fault is resolved. If the fault is
resolved, the fault is with the batteries on the
Note: Remove the bypass harness and restore all application.
wiring to the original condition after testing.
SENR9969-05 195
Troubleshooting Section

2. If the fault still exists, make sure that the

latest flash file for the application is installed
in the ECM. Refer to Troubleshooting, “Flash
Programming”.

3. Contact the Technical Communicator.

Note: This consultation can greatly reduce the repair

time.

4. If the Technical Communicator recommends the

use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.

5. Use the electronic service tool to recheck the

system for active diagnostic codes.

6. If the fault is resolved with the test ECM,

reconnect the suspect ECM.

7. If the fault returns with the suspect ECM,

replace the ECM.

8. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP.

i03499040

Indicator Lamp Circuit - Test

SMCS Code: 7431-038

System Operation Description:

Use this procedure under the following circumstances:

• The lamps are not receiving battery voltage.

• The lamps are not operating correctly.
The following diagnostic lamps are available:

• Power Take Off (PTO) lamp

• Stop lamp
• Warning lamp
• Cold start (wait to start lamp)
• Low oil pressure lamp
The electronic service tool can be used as a
diagnostic aid in order to switch the individual lamps
ON and OFF.

Note: The diagnostic aid that switches the lamps

is contained in the “Override” section in the
“diagnostics” menu of the electronic service tool.
196 SENR9969-05
Troubleshooting Section

g01804053
Illustration 79
Typical schematic of the circuit for the indicator lamps

g01804073
Illustration 80
Typical example of the pin locations on the P1 connector for the indicator lamps
(1) Ground (GND) (7) Battery (+) (59) Warning lamp
(2) Ground (GND) (8) Battery (+) (60) Stop lamp
(3) Ground (GND) (15) Battery (+) (61) PTO lamp
(9) Ground (GND) (16) Battery (+) (62) Low oil pressure lamp
(10) Ground (GND) (40) Keyswitch (63) Cold start lamp

Test Step 1. Inspect Electrical Connectors C. Perform a 45 N (10 lb) pull test on each of the
and Wiring wires in the P1 connector that are associated with
the indicator lamps.
A. Turn the keyswitch to the OFF position.
D. Check the screw for the P1 connector for the
B. Thoroughly inspect the P1 connector and the lamp correct torque of 5.0 N·m (44 lb in).
connections. Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details. E. Check the harness for abrasions and for pinch
points from the battery to the ECM.
SENR9969-05 197
Troubleshooting Section

Results: Expected Result:

• OK – Proceed to Test Step 2. The voltage should be between 12.0 Volts DC and
24.0 Volts DC.
• Not OK
Results:
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. • OK – The voltage is between 12.0 Volts DC and
Ensure that all of the seals are correctly in place 24.0 Volts DC.
and ensure that the connectors are completely
coupled. Repair: Replace the bulb.

Verify that the repair eliminates the fault. Verify that the repair eliminates the fault.

STOP. If the fault persists, measure the resistance across

the 2 terminals of the lamp. If the resistance is
Test Step 2. Inspect the Lamp, the Fuse more than 2000 Ohms, the replacement bulb has
and the Power Supply failed. Replace the bulb and repeat the test.

A. Disconnect the lamp from the harness. Inspect the If the fault persists, proceed to Test Step 4.
lamp in order to determine if the lamp has failed.
• Not OK – The voltage is not in the range that is
B. Measure the resistance across the two terminals expected. Proceed to Test Step 5.
of the lamp. If the resistance is more than 2000
Ohms, the bulb has failed. Test Step 4. Test the Individual Lamp
Circuits
C. Check the battery by connecting a test lamp
across the terminal of the battery. A. Disconnect the P1 connector.

Expected Result: B. Temporarily disconnect the wire from the P1

connector socket that is connected to the suspect
The lamp has less than 2000 Ohms and the power lamp.
supply is OK.
C. By using a jumper wire, connect the removed wire
Results: to the battery-.

• OK – The lamp appears to be operating correctly D. Turn the keyswitch to the ON position and observe
at this time. Proceed to Test Step 3. the lamp.

• Not OK Expected Result:

Repair: Replace the suspect component or repair The diagnostic lamp comes on while the jumper is
the suspect component. Verify that the repairs connected. Also, the diagnostic lamp goes off when
have eliminated the fault. the jumper is removed.

STOP. Results:

Test Step 3. Measure the Input to the • OK – The circuit for the diagnostic lamp is
Lamp at the Lamp Socket functioning correctly. Proceed to Test Step 5.

A. Turn the keyswitch to the ON position. • Not OK – The lamp did not turn ON. The lamp
circuit is not functioning correctly. There is a fault in
B. Use the electronic service tool to select the the harness between the lamp and the ECM.
“override” function in order to switch individual
lamps ON and OFF. Repair: Repair the lamp circuit.

Note: The “Override” function is contained in the Verify that the repair eliminated the fault.
“Diagnostics” menu of the electronic service tool.
STOP.
C. Measure the voltage at the lamp socket.
Test Step 5. Check the Voltage at the ECM
A. Disconnect the P1 connector.
198 SENR9969-05
Troubleshooting Section

B. Temporarily disconnect the wire from the P1 7. Use the electronic service tool in order to clear
connector that supplies the suspect lamp. all logged diagnostic codes and then verify that
the repair eliminates the fault.
C. Fabricate the jumper wire with a suitable pin for
the P1 connector. STOP.

D. Install one end of the jumper wire into the P1

i03500121
connector socket that is connected to the suspect
lamp. Connect a voltage test bulb between the
battery+ and the jumper wire.
Injector Data Incorrect - Test
SMCS Code: 1290-038
E. Reinstall the P1 connector to the ECM.
System Operation Description:
F. Turn the keyswitch to the ON position. Use the
electronic service tool to select the override Use this procedure under the following situation:
function in order to switch individual lamps ON
and OFF. Use this procedure for any of the following diagnostic
codes:
Note: The “Override” function is contained in the
“Diagnostics” menu of the electronic service tool.
• 0001-02 Cylinder #1 Injector erratic, intermittent,
or incorrect
Expected Result:

The lamp should illuminate.

• 0002-02 Cylinder #2 Injector erratic, intermittent,
or incorrect
Results:
• 0003-02 Cylinder #3 Injector erratic, intermittent,
or incorrect
• OK – The ECM is operating correctly. There is a
fault in the wiring or the lamp. Repair the wiring
or the lamp, as required. Verify that the repair
• 0004-02 Cylinder #4 Injector erratic, intermittent,
or incorrect
eliminates the fault.

STOP.
• 0005-02 Cylinder #5 Injector erratic, intermittent, or
incorrect (C6.6 engine only)
• Not OK – The ECM is faulty. • 0006-02 Cylinder #6 Injector erratic, intermittent, or
incorrect (C6.6 engine only)
Repair: Perform the following repair:
The following background information is related
1. Make sure that the latest flash file for the to this procedure:
application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”. The engine has electronic unit injectors that are
controlled by the ECM. The Electronic Control
2. Contact the Technical Communicator. Module (ECM) sends a pulse to each injector
solenoid. The pulse is sent at the correct time and
Note: This consultation can greatly reduce the repair for the correct duration for a given engine load and
time. engine speed. Use this procedure to identify the
cause of the diagnostic code. Use this procedure to
3. If the Technical Communicator recommends the repair the system.
use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”. If an injector is replaced, then the correct trim file
for the injector must be programmed into the ECM.
4. Use the electronic service tool to recheck the The trim files for the injectors allow each individual
system for active diagnostic codes. injector to be fine tuned for optimum performance.
The ECM will generate the following diagnostic code
5. If the fault is resolved with the test ECM, if the injector codes are not programmed:
reconnect the suspect ECM.

6. If the fault returns with the suspect ECM,

• 0268-02 Programmed Parameter Fault erratic,
intermittent, or incorrect
replace the ECM.
Refer to Troubleshooting, “Injector Trim File” for
further information.
SENR9969-05 199
Troubleshooting Section

If the ECM is replaced then the replacement • 4-2 Cylinder #4 Injector erratic, intermittent, or
ECM must be correctly programmed. Refer to incorrect
Troubleshooting, “Replacing the ECM” for further
information. • 5-2 Cylinder #5 Injector erratic, intermittent, or
incorrect (C6.6 engine only)
Use the electronic service tool in order to perform the
“Fuel System Verification Test”. The “Fuel System • 6-2 Cylinder #6 Injector erratic, intermittent, or
Verification Test” is used to check that the system incorrect (C6.6 engine only)
operates correctly after a repair has been made.
Expected Result 2

On four cylinder engines, two injectors that share a

common supply indicate a diagnostic code.

Note: Injectors 1 and 4 share a common injector

driver circuit in the ECM. Injectors 2 and 3 share a
common driver circuit in the ECM. If two injectors that
share a common supply indicate a diagnostic code
then this is probably caused by a faulty ECM.

On six cylinder engines, three injectors that share a

common supply indicate a diagnostic code.

Note: Injectors 1, 2 and 3 share a common injector

driver circuit in the ECM. Injectors 4, 5 and 6 share a
common driver circuit in the ECM. If three injectors
that share a common supply indicate a diagnostic
code then this is probably caused by a faulty ECM.

Results:
g01336666
Illustration 81
• OK – Result 1 One or more diagnostic codes are
Typical example of the electronic unit injector logged. Proceed to Test Step 2.
Test Step 1. Check for Diagnostic Codes • OK – Result 2 On four cylinder engines, two
that are Related to this Procedure injectors that share a common supply indicate a
diagnostic code. On six cylinder engines, three
A. Connect the electronic service tool to the injectors that share a common supply indicate a
diagnostic connector. diagnostic code. Proceed to Test Step 3.
B. Turn the keyswitch to the ON position. • Not OK – No related diagnostic codes are logged.
STOP.
C. Check for diagnostic codes that are related to this
procedure. Test Step 2. Check the Faulty Cylinder
Numbers
D. Make a note of the diagnostic codes.
A. Use the electronic service tool in order to identify
Expected Result: the diagnostic codes.
Expected Result 1 B. Use the diagnostic codes in order to check the
cylinders for faulty injectors.
One or more of the following diagnostic codes are
logged or active: Expected Result:
• 1-2 Cylinder #1 Injector erratic, intermittent, or The diagnostic codes indicate the cylinder numbers
incorrect that have faulty injectors.
• 2-2 Cylinder #2 Injector erratic, intermittent, or Results:
incorrect
• OK – No related diagnostic codes are logged.
• 3-2 Cylinder #3 Injector erratic, intermittent, or STOP.
incorrect
200 SENR9969-05
Troubleshooting Section

• Not OK – The diagnostic codes indicate the 1. Reconnect the suspect ECM.
cylinder numbers that have faulty injectors.
2. Use the electronic service tool in order to
Repair: Replace the faulty injectors. perform the “Fuel System Verification Test”.

Use the electronic service tool in order to program 3. If the fault returns with the suspect ECM,
the trim file for the replacement injector . Refer replace the ECM.
to Troubleshooting, “Injector Trim File” for further
information. 4. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
Use the electronic service tool in order to clear the the repair eliminates the fault.
logged codes.
STOP.
Turn the keyswitch to the ON position.
• Not OK – The test ECM did not eliminate the fault.
Start the engine.
Repair: Repeat this test procedure from Test Step
Use the electronic service tool in order to perform 1.
the “Fuel System Verification Test”. If the cylinders
indicate “PASS”, then the fault has been cleared. STOP.

Verify that the repair eliminates the fault.

i03500164

STOP. Injector Solenoid Circuit - Test

Test Step 3. Check the ECM SMCS Code: 1290-038
A. Make sure that the latest flash file for the System Operation Description:
application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”. Use this procedure to troubleshoot any suspect faults
with the injector solenoids.
B. Contact the Technical Communicator.
Use this procedure for the following diagnostic codes:
Note: This consultation can greatly reduce the repair
time.
• 0001-05 Cylinder #1 Injector current below normal
C. If the Technical Communicator recommends the
use of a test ECM, install a test ECM. Refer to
• 0001-06 Cylinder #1 Injector current above normal
Troubleshooting, “Replacing the ECM”.
• 0002-05 Cylinder #2 Injector current below normal
D. Use the electronic service tool in order to perform
the “Fuel System Verification Test”. Verify that the
• 0002-06 Cylinder #2 Injector current above normal
test eliminates the fault.
• 0003-05 Cylinder #3 Injector current below normal
Note: The “Fuel System Verification Test” will indicate
if the cylinder has a “Pass” or “Fail”. If the cylinders
• 0003-06 Cylinder #3 Injector current above normal
indicate “Pass” then the fault has been cleared.
• 0004-05 Cylinder #4 Injector current below normal
E. If the test ECM eliminates the fault, reconnect the
suspect ECM.
• 0004-06 Cylinder #4 Injector current above normal

F. Use the electronic service tool in order to perform

• 0005-05 Cylinder #5 Injector current below normal
(C6.6 engine only)
the “Fuel System Verification Test”.

Expected Result:
• 0005-06 Cylinder #5 Injector current above normal
(C6.6 engine only)
The test ECM clears the fault.
• 0006-05 Cylinder #6 Injector current below normal
(C6.6 engine only)
Results:
• 0006-06 Cylinder #6 Injector current above normal
• OK – The test ECM eliminates the fault. (C6.6 engine only)
Repair: Perform the following procedure:
SENR9969-05 201
Troubleshooting Section

Perform this procedure under conditions that are

identical to the conditions that exist when the fault
occurs. Typically, faults with the injector solenoid
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads).

These engines have Electronic Unit Injectors (EUI)

that are mechanically actuated and electronically
controlled. The Engine Control Module (ECM) sends
a pulse to each injector solenoid. The pulse is sent at
the correct time and at the correct duration for a given
engine load and speed. The solenoid is mounted on
top of the fuel injector body.

If an open circuit is detected in the solenoid circuit, a

diagnostic code is generated. The ECM continues to
try to fire the injector. If a short circuit is detected, a
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will periodically try
to fire the injector. If the short circuit remains this
sequence of events will be repeated until the fault
is corrected.

“Injector Solenoid Test”

Use the “Injector Solenoid Test” in the electronic

service tool to aid in diagnosing an open circuit or
a short circuit diagnostic code while the engine is
not running. The “Injector Solenoid Test” will send
a signal to each solenoid. The electronic service
tool will indicate the status of the solenoid as “OK”,
“Open”, or “Short”.

g01336666
Illustration 82
Typical example of the fuel injector
202 SENR9969-05
Troubleshooting Section

g01805273
Illustration 83
Schematic of the circuit for the injector solenoids in the C4.4 engine

g01805296
Illustration 84
View of the pin locations on the P2 connector for the injector solenoids in the C4.4 engine
(57) Injector Cylinder (No. 1) (7) Injector (No. 2 Cylinder Return) (58) Injector Cylinder (No. 4)
(35) Injector (No. 1 Cylinder Return) (64) Injector Cylinder (No. 3) (34) Injector (No. 4 Cylinder Return)
(63) Injector Cylinder (No. 2) (8) Injector (No. 3 Cylinder Return)
SENR9969-05 203
Troubleshooting Section

g01805313
Illustration 85
Schematic of the circuit for the injector solenoids in the C6.6 engine

g01171366
Illustration 86
View of the pin locations on the P2 connector for the injector solenoids in the C6.6 engine
(57) Injector Cylinder (No. 1) (59) Injector Cylinder (No. 3) (63) Injector Cylinder (No. 5)
(35) Injector (No. 1 Cylinder Return) (33) Injector (No. 3 Cylinder Return) (7) Injector (No. 5 Cylinder Return)
(58) Injector Cylinder (No. 2) (64) Injector Cylinder (No. 4) (62) Injector Cylinder (No. 6)
(34) Injector (No. 2 Cylinder Return) (8) Injector (No. 4 Cylinder Return) (6) Injector (No. 6 Cylinder Return)
204 SENR9969-05
Troubleshooting Section

g01237524
Illustration 87
Typical example of the harness connector for the fuel injector

g01237558
Illustration 88
Typical example of the connector in the valve mechanism cover

Test Step 1. Inspect Electrical Connectors Expected Result:

and Wiring
All connectors, pins, and sockets are completely
coupled and/or inserted and the harness is free of
corrosion, of abrasion and of pinch points.
Electrical shock hazard. The electronic unit injec- Results:
tor system uses 67-73 volts.
• OK – The harness is OK. Proceed to Test Step 2.
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch • Not OK – There is a fault in the connectors and/or
is not turned OFF. the harness.

B. Thoroughly inspect the P2 connector. Thoroughly Repair: Repair the connectors or the harness
inspect the connectors at the valve cover base. and/or replace the connectors or the harness.
Refer to Troubleshooting, “Electrical Connectors - Ensure that all of the seals are correctly in place
Inspect” for details. and ensure that the connectors are completely
coupled.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated Use the electronic service tool in order to clear all
with injector solenoids. logged diagnostic codes and then verify that the
repair eliminates the fault.
D. Check the screw for the ECM connector for the
correct torque of 5.0 N·m (44 lb in). STOP.

E. Check the harness and wiring for abrasion and for

pinch points from the injectors to the ECM.
SENR9969-05 205
Troubleshooting Section

Test Step 2. Check for Logged Diagnostic D. Turn the keyswitch to the ON position.
Codes that are Related to the Injector
Solenoids E. Access the “Injector Solenoid Test” by accessing
the following display screens in order:
A. Connect the electronic service tool to the
diagnostic connector. • “Diagnostics”
B. Turn the keyswitch to the ON position. • “Diagnostic Tests”
C. Check for logged diagnostic codes that are related • “Injector Solenoid Test”
to the injector solenoids on the electronic service
tool. F. Activate the test.

Expected Result: Note: Do not confuse the “Injector Solenoid Test”

with the “Cylinder Cutout Test”. The “Cylinder Cutout
One or more diagnostic codes that are related to the Test” is used to shut off fuel to a specific cylinder
injector solenoids have been logged: while the engine is running. The “Injector Solenoid
Test” is used to actuate the injector solenoids while
• 1-5 Cylinder #1 Injector current below normal the engine is not running. This allows the click of the
injector solenoids to be heard while the engine is
• 1-6 Cylinder #1 Injector current above normal not operating in order to determine that the circuit is
functioning correctly.
• 2-5 Cylinder #2 Injector current below normal
G. As each solenoid is energized by the ECM, an
• 2-6 Cylinder #2 Injector current above normal audible click can be heard at the valve cover.

• 3-5 Cylinder #3 Injector current below normal Expected Result:

• 3-6 Cylinder #3 Injector current above normal All cylinders indicate “OK”.

• 4-5 Cylinder #4 Injector current below normal Results:

• 4-6 Cylinder #4 Injector current above normal • OK – There is not an electronic fault with the
injectors at this time.
• 5-5 Cylinder #5 Injector current below normal (C6.6
engine only) Repair: If the “Cylinder Cutout Test” returned a
“Not OK” for any injector, refer to Troubleshooting,
• 5-6 Cylinder #5 Injector current above normal “Engine Misfires, Runs Rough or Is Unstable”.
(C6.6 engine only)
STOP.
• 6-5 Cylinder #6 Injector current below normal (C6.6
engine only) • Not OK - Open – Note the cylinders that indicate
“Open”. Proceed to Test Step 5.
• 6-6 Cylinder #6 Injector current above normal
(C6.6 engine only) • Not OK - Short – Note the cylinders that indicate
“Short”. Proceed to Test Step 4.
Results:
Test Step 4. Check the Variation of the
• OK – One or more diagnostic codes have been Injectors between Cylinders
logged. Proceed to Test Step 3.
A. Start the engine.
• Not OK – No diagnostic codes have been logged.
Proceed to Test Step 3. B. Allow the engine to warm up to normal operating
temperature.
Test Step 3. Use the “Injector Solenoid
Test” C. After the engine is warmed to operating
temperature, access the “Cylinder Cutout Test” by
A. Start the engine. accessing the following display screens in order:

B. Allow the engine to warm up to the normal • “Diagnostics”

operating temperature.
• “Diagnostic Tests”
C. Stop the engine.
206 SENR9969-05
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• “Cylinder Cutout Test” D. Fabricate a jumper wire 100 mm (4 inch) long with
terminals on both ends of the wire.
D. Select the start button at the bottom of the screen
for the cylinder cutout test on the electronic E. Insert one end of the jumper wire into the terminal
service tool. for the supply to the suspect injector. Insert the
other end of the jumper wire into the terminal for
E. Select the “Cylinder Cutout Test”. the return circuit for the suspect injector.

F. Follow the instructions that are provided in the F. Perform the “Injector Solenoid Test” at least two
cylinder cutout test. The cylinder cutout tests are times.
interactive so the procedure is guided to the finish.
G. Repeat this test for each suspect injector. Stop
Note: The “Manual Cylinder Cutout Test” is also the “Injector Solenoid Test” before handling the
available. Access the manual test by selecting the jumper wires.
“Change” button on the screen for the cylinder cutout
test. The “Cylinder Cutout Test” is the recommended Expected Result:
starting procedure. The automated tests run twice
collecting data. The two sets of data are analyzed The electronic service tool displays “Current Above
and an “OK” or “Not OK” result is displayed. Normal” for the cylinder with the jumper wire.

G. Check for active diagnostic codes and for logged Results:

diagnostic codes that are related to the injector
solenoids. • OK – The harness between the ECM and the
valve cover base is OK. Proceed to Test Step 6.
Expected Result:
• Not OK – There is a fault between the ECM and
All cylinders indicate “OK” on the electronic service the valve cover base. Proceed to Test Step 7.
tool.
Test Step 6. Check the Injector Harness
Results: Under the Valve Cover
• OK – All cylinders indicate “OK”.
Repair: If the engine is misfiring or if the Electrical shock hazard. The electronic unit injec-
engine has low power, refer to Troubleshooting, tor system uses 67-73 volts.
“Engine Misfires, Runs Rough or Is Unstable”
and Troubleshooting, “Low Power/Poor or No
Response to Throttle”. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
If a diagnostic code results from running the is not turned OFF.
cylinder cutout test, proceed to Test Step 3.
B. Remove the valve cover.
• Not OK – One or more cylinders displayed “Not
OK” during the test. Proceed to Test Step 5. C. On four cylinder engines, disconnect the harness
from the suspect injector. Disconnect the harness
Test Step 5. Check the Harness between from the injector that shares the same supply
the ECM and the Valve Cover Base for an circuit as the suspect injector.
Open Circuit
Note: On four cylinder engines, injectors 1 and 4
share a common injector driver circuit in the ECM.
Injectors 2 and 3 share a common injector driver
circuit in the ECM. If the two injectors that share a
Electrical shock hazard. The electronic unit injec- common supply indicate “Open Circuit Fault Codes”,
tor system uses 67-73 volts. the open circuit is probably caused by a faulty ECM.

A. Turn the keyswitch to the OFF position. A strong D. On six cylinder engines, disconnect the harness
electrical shock hazard is present if the keyswitch from the suspect injector. Disconnect the harness
is not turned OFF. from the injectors that shares the same supply
circuit as the suspect injector.
B. Disconnect the connectors from the valve cover
base.

C. Turn the keyswitch to the ON position.

SENR9969-05 207
Troubleshooting Section

Note: On six cylinder engines, injectors 1, 2, and 3 Test Step 7. Check the ECM for an Open
share a common injector driver circuit in the ECM. Circuit
Injectors 4, 5, and 6 share a common injector driver
circuit in the ECM. If three injectors that share a
common supply indicate “Open Circuit Fault Codes”,
the open circuit is probably caused by a faulty ECM. Electrical shock hazard. The electronic unit injec-
tor system uses 67-73 volts.
E. On four cylinder engines, thoroughly clean the
terminals on the two injectors and on the harness
connectors. A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
F. On six cylinder engines, thoroughly clean the is not turned OFF.
terminals on the three injectors and on the harness
connectors. B. Disconnect connector P2 from the ECM.

G. On four cylinder engines, exchange the harness C. Remove the supply wire and the return wire for
between the two injectors that share the common the suspect injector from the P2 connector. Install
driver. a jumper wire into the P2 connector in order to
provide a short between the supply and the return
H. On six cylinder engines, exchange the harness of the suspect injector.
between two of the injectors that share the
common driver. D. Reinstall the P2 connector to the ECM.

I. Turn the keyswitch to the ON position. E. Turn the keyswitch to the ON position.

J. Perform the “Injector Solenoid Test” at least two F. Perform the “Injector Solenoid Test” at least two
times. times.

Expected Result: Expected Result:

Exchanging the harness between the two injectors The electronic service tool displays “Current Above
causes the fault to move to the other injector. Normal” for the cylinder with the jumper wire.

Results: Note: On four cylinder engines, shorting a shared

supply will affect the status of two injectors. Ignore
• OK – There is a fault with the injector harness the status of the other injector that is on the shared
under the valve cover. supply.

Repair: Repair the injector harness or replace the Note: On six cylinder engines, shorting a shared
injector harness under the valve cover. supply will affect the status of three injectors. Ignore
the status of the other injectors that are on the shared
Use the electronic service tool in order to clear all shared supply.
logged diagnostic codes and then verify that the
repair eliminates the fault. Results:

STOP. • OK – The ECM is OK.

• Not OK – The injector may be faulty. Repair: On four cylinder engines, if two injectors
that share a supply indicate “Open Circuit” fault
Repair: Replace the faulty injector. Refer to codes, the open circuit is probably caused by a
Disassembly and Assembly, “Electronic Unit faulty ECM.
Injector - Remove” and Disassembly and
Assembly, “Electronic Unit Injector - Install”. On six cylinder engines, if three injectors that share
a supply indicate “Open Circuit” fault codes, the
Restore the wiring to the correct injectors. open circuit is probably caused by a faulty ECM.

Perform the “Injector Solenoid Test”. Repair the engine harness or replace the engine
harness, as required.
Verify that the repair eliminates the fault.

STOP.
208 SENR9969-05
Troubleshooting Section

Use the electronic service tool in order to clear all Expected Result:
logged diagnostic codes and then verify that the
repair eliminates the fault. All cylinders indicate “Current Below Normal”.

STOP. Results:

• Not OK – There may be a fault with the ECM. • OK – All cylinders indicate “Current Below
Normal”. Proceed to Test Step 10.
Repair: Perform the following repair:
• Not OK – One or more cylinders indicate “Current
1. Make sure that the latest flash file for the Above Normal”. Note the cylinders that indicate
application is installed in the ECM. Refer to “Current Above Normal”. Proceed to Test Step 9.
Troubleshooting, “Flash Programming”.
Test Step 9. Check the ECM for a Short
2. Contact the Technical Communicator. Circuit
Note: This consultation can greatly reduce the repair
time.
Electrical shock hazard. The electronic unit injec-
3. If the Technical Communicator recommends the tor system uses 67-73 volts.
use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.
A. Turn the keyswitch to the OFF position. A strong
4. Remove the jumper wire from the P2 connector electrical shock hazard is present if the keyswitch
and reinstall the injector wires. is not turned OFF.

5. Perform the “Injector Solenoid Test”. B. Disconnect the P2 connector from the ECM and
check for evidence of moisture entry.
6. If the fault is eliminated with the test ECM,
reconnect the suspect ECM. C. Turn the keyswitch to the ON position.

7. If the fault returns with the suspect ECM, D. Perform the “Injector Solenoid Test” at least two
replace the ECM. times.

8. Use the electronic service tool in order to clear Expected Result:

all logged diagnostic codes and then verify that
the repair eliminates the fault. All cylinders indicate “Current Below Normal” when
connector P2 is disconnected from the ECM.
STOP.
Note: When the engine harness is disconnected,
Test Step 8. Check the Harness between all of the diagnostic codes for supply voltage to the
the ECM and the Valve Cover Base for a sensors will be active. This is normal. Clear all of the
Short Circuit logged diagnostic codes after completing this test
step.

Results:
Electrical shock hazard. The electronic unit injec-
tor system uses 67-73 volts. • OK – The short circuit is in the engine harness.
Repair: The fault is most likely to be in one of
A. Turn the keyswitch to the OFF position. A strong the wires to the injector. Inspect the connectors
electrical shock hazard is present if the keyswitch for moisture and for corrosion. Also, check the
is not turned OFF. wire insulation for damage and for strands that
are exposed.
B. Disconnect the connectors from the valve cover
base. Repair the engine harness or replace the engine
harness, as required. Clear all diagnostic codes
C. Turn the keyswitch to the ON position. after completing this test step.

D. Perform the “Injector Solenoid Test” at least two Verify that the repair eliminates the fault.
times.
STOP.
SENR9969-05 209
Troubleshooting Section

• Not OK – There may be a fault with the ECM. Results:

Repair: Perform the following repair: • OK – All of the injectors that were disconnected
indicate “Current Below Normal”.
1. Make sure that the latest flash file for the
application is installed in the ECM. Refer to Repair: Leave the injector wires disconnected.
Troubleshooting, “Flash Programming”. The supply wire is not shorted to the engine.

2. Contact the Technical Communicator. Proceed to Test Step 11.

Note: This consultation can greatly reduce the repair • Not OK – One or more of the injectors that were
time. disconnected indicate “Current Above Normal”.

3. If the Technical Communicator recommends the Repair: The fault is most likely in the supply to the
use of a test ECM, install a test ECM. Refer to injector. Inspect the connectors for moisture and for
Troubleshooting, “Replacing the ECM”. corrosion. Also, check the supply wire's insulation
for damage and for strands that are exposed.
4. Remove the jumper wire from the P2 connector
and reinstall the injector wires. Repair the injector harness or replace the injector
harness under the valve cover.
5. Perform the “Injector Solenoid Test”.
Use the electronic service tool in order to clear all
6. If the fault is eliminated with the test ECM, logged diagnostic codes and then verify that the
reconnect the suspect ECM. repair eliminates the fault.

7. If the fault returns with the suspect ECM, STOP.

replace the ECM.
Test Step 11. Check for a Short Circuit in
8. Use the electronic service tool in order to clear the Return Wire
all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP. Electrical shock hazard. The electronic unit injec-

tor system uses 67-73 volts.
Test Step 10. Check the Engine Harness
Under the Valve Cover for a Short Circuit
A. Turn the keyswitch to the OFF position. A strong
electrical shock hazard is present if the keyswitch
is not turned OFF.
Electrical shock hazard. The electronic unit injec-
B. Disconnect the P2 connector from the ECM.
tor system uses 67-73 volts.
C. Locate the terminal for the supply of the faulty
A. Turn the keyswitch to the OFF position. A strong injector in the P2 connector. Measure the
electrical shock hazard is present if the keyswitch resistance from the terminal to the engine ground
is not turned OFF. stud.

B. Remove the valve cover. Expected Result:

C. Disconnect each of the injectors that indicate a The resistance is greater than 10 Ohms.
“Short” from the wiring harness. Ensure that each
of the connectors from the disconnected injector Results:
harness does not touch any other components.
• OK – The resistance is greater than 10 Ohms.
D. Turn the keyswitch to the ON position.
Repair: Reconnect the P2 connector.
E. Perform the “Injector Solenoid Test” at least two
times. Replace the faulty injector.

Expected Result: Use the electronic service tool in order to clear all
logged diagnostic codes.
All of the injectors that were disconnected indicate
“Current Below Normal”. Perform the “Injector Solenoid Test”.
210 SENR9969-05
Troubleshooting Section

Verify that the repair eliminates the fault.

STOP.

• Not OK – There is a short in the return line.

Repair: Disconnect the connectors from the valve
cover base.

Measure the resistance of the return wire between

the P2 connector and the engine ground stud.

If the resistance is less than 10 Ohms, the fault is

in the return wire between the ECM and the valve
cover base.

If the resistance is greater than 10 Ohms, the fault

is in the return wire under the valve cover.

Repair the injector harness or replace the injector

harness.

Use the electronic service tool in order to clear

all logged diagnostic codes and then perform the
“Injector Solenoid Test” in order to verify that the
repair eliminates the fault.

STOP.

i03503902

Mode Selection Circuit - Test

SMCS Code: 7332-038

System Operation Description:

Use this procedure under the following circumstances:

• Diagnostic code 1743-02 has been generated.

• Check if the mode selector switch operates
correctly.

The mode selector switch inputs provide the operator

with the ability to select a maximum of four different
modes of operation. Different modes of operation
can be used in a particular situation by giving the
operator a means to select the most efficient method
of completing the required work.

Each mode has a single fuel limit map, a rated speed,

and a matched fuel delivery. Each mode also has a
specific droop value for throttle 1 and throttle 2.

For C4.4 engines, refer to table 59 for a list of

examples of different modes of operation.

For C6.6 engines, refer to table 60 for a list of

examples of different modes of operation. Refer to
table 61 for a list of mode switch connections.
SENR9969-05 211
Troubleshooting Section

Table 59
Switch 2 Switch 1 Mode C4.4 Engine Rating Droop (%)(1)
Number
Throttle 1 Throttle Torque
2 Speed
Control
Open Open 1 80 KW @ 2200 RPM 10 10 10
Open Closed 2 80 KW @ 2200 RPM 5 2 0
Closed Open 3 100 KW @2200 RPM 10 10 10
Closed Closed 4 100 KW @ 2200 RPM 5 5 0
(1) Throttle droop can be configured in 1% increments.

Table 60
Switch 2 Switch 1 Mode C6.6 Engine Rating Droop (%)(1)
Number
Throttle 1 Throttle Torque
2 Speed
Control
Open Open 1 100 KW @ 2200 RPM 10 10 10
Open Closed 2 100 KW @ 2200 RPM 5 2 0
Closed Open 3 120 KW @2200 RPM 10 10 10
Closed Closed 4 120 KW @ 2200 RPM 5 5 0
(1) Throttle droop can be configured in 1% increments.

Table 61
Function P1 Connector Pin
Assignment
Mode Switch 1 39
Mode Switch 2 46
Switch return (Ground) 35

g01805358
Illustration 89
Typical schematic for the mode selector switches
212 SENR9969-05
Troubleshooting Section

g01805359
Illustration 90
View of the pin locations on the P1 connector for the circuit for mode selection
(35) Mode switch return (GND) (39) Mode switch 1 (46) Mode switch 2

Test Step 1. Inspect Electrical Connectors Use the electronic service tool in order to clear all
and Wiring logged diagnostic codes and then verify that the
repair eliminates the fault.
A. Turn the keyswitch OFF.
STOP.
B. Thoroughly inspect the P1 connector. Thoroughly
inspect the mode switch connectors, plugs • – If the fault has not been eliminated proceed to
and interconnections on the harness. Refer to Test Step 2.
Troubleshooting, “Electrical Connectors - Inspect”
for details. Test Step 2. Check the Status of the Mode
Selector Switch
C. Perform a 45 N (10 lb) pull test on each of the
wires in the P1 connector that are associated with A. Turn the keyswitch to the OFF position.
the mode selector switches.
B. Connect the electronic service tool to the
D. Check the screw for the ECM connector for the diagnostic connector.
correct torque of 5.0 N·m (44 lb in).
C. Turn the keyswitch to the ON position.
E. Check the harness for abrasions and for pinch
points from the battery to the ECM. D. Monitor the status screen on the electronic service
tool. Cycle the mode switch to the ON position
Results: and to the OFF position.

• OK – Proceed to Test Step 2. Expected Result:

• Not OK The switch status should change as you cycle the

mode switches. When the switch is in the OFF
Repair: Repair the connectors or the harness position, the switch is open. When the switch is in the
and/or replace the connectors or the harness. ON position, the switch is closed.
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely Results:
coupled.
• OK
SENR9969-05 213
Troubleshooting Section

Repair: Verify that the status of the switch changes Expected Result:
as the switch is cycled.
The resistance is less than 10 Ohms in the mode
STOP. switch ON position.

• Not OK – There is a fault with the circuit for the The resistance is more than 4000 Ohms in the mode
mode selector switch. Proceed to Test Step 3. switch OFF position.

Test Step 3. Insert a Jumper at the Results:

Suspect Mode Switch
• OK – There is no faults in the harness. Proceed
A. Turn the keyswitch to the OFF position. to Test Step 5.

B. Perform the following procedure to test the circuit • Not OK – The fault is in the harness between the
of mode selector switch No. 1. Place a jumper sensor connector and the P1 connector.
wire across the contacts of switch No. 1.
Repair: Repair the connector or replace the
C. Perform the following procedure to test the circuit connector.
of mode selector switch No. 2. Place a jumper
wire across the contacts of switch No. 2. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
D. Turn the keyswitch to the ON position. Monitor repair has eliminated the fault.
the status screen on the electronic service tool.
Connect the jumper wire and then disconnect the Proceed to Test Step 5 if the fault has not been
jumper wire. eliminated.

Expected Result: Test Step 5. Test the ECM

When the jumper wire is connected the switch should A. Turn the keyswitch to the OFF position.
be in the CLOSED position.
B. Temporarily disconnect the P1 connector from the
Results: ECM. Remove the pins 35, 39 and 46 from the
P1 connector.
• OK
C. Reconnect the P1 connector.
Repair: Verify that the jumper wire has been
removed. The suspect mode selector switch is D. Turn the keyswitch to the ON position. Monitor the
faulty. Replace the switch and verify that the repair status screen of the electronic service tool.
has eliminated the fault.
E. Turn the keyswitch to the OFF position.
STOP.
F. Disconnect the P1 from J1.
• Not OK – Proceed to Test Step 4.
G. Insert a jumper wire between the suspect switch
Test Step 4. Measure the Resistance of socket and P1:35.
the Wire Harness at the ECM
H. Turn the keyswitch to the ON position. Monitor the
A. Turn the keyswitch to the OFF position. status screen of the electronic service tool.

B. Disconnect P1 from J1. I. Turn the keyswitch to the OFF position.

C. Measure the resistance between P1:35 switch Expected Result:

return and the following ECM pins:
When the connections are removed from the
• P1:46 Mode Switch No. 2 P1 connector, the mode switch indication on the
electronic service tool will be in the OFF position. The
• P1:39 Mode Switch No. 1 switch will indicate an open condition.

D. Cycle each mode switch to the OFF position and When the jumper is connected to the P1 connector,
to the ON position. the mode switch indication on the electronic service
tool will be in the ON position. The switch will indicate
a closed condition.
214 SENR9969-05
Troubleshooting Section

Results: • No speed (no PTO control)

• OK – The ECM is operating correctly. STOP. The PTO switches are listed below:

• Not OK – The fault has not been eliminated. • P1:52 PTO Control ON or P1
Repair: Perform the following repair: • P1:50 PTO Raise/Resume
1. Make sure that the latest flash file for the • P1:51 PTO Set or Lower
application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”. • P1:49 (Clutch or Brake) PTO Disengage Switches
2. Contact the Technical Communicator. An indicator lamp is used to indicate the status of
the PTO.
Note: This consultation can greatly reduce the repair
time.

3. If the Technical Communicator recommends the

use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.

4. Use the electronic service tool to recheck the

system for active diagnostic codes.

5. If the fault is resolved with the test ECM,

reconnect the suspect ECM.

6. If the fault returns with the suspect ECM,

replace the ECM.

7. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP.

i03504040

PTO Switch Circuit - Test

SMCS Code: 7332-038

System Operation Description:

Use this procedure under the following circumstances:

• The correct supply voltage to the PTO switches

is suspect.

• Operation of the PTO switches is suspect.

Note: Some applications may only have one PTO
switch.

The PTO switches provide the operator with the

ability to select the desired engine speed. Engine
speed will decrease with increasing load. The PTO
switches can be used to control the engine speed.

The engine has the following options of set speed

control:

• Single speed
SENR9969-05 215
Troubleshooting Section

g01805393
Illustration 91
Schematic for the PTO switches

g01805477
Illustration 92
View of the pin locations on the P1 connector for the PTO mode switches
(35) Switch Ground (GND) (50) PTO mode - raise/resume (52) PTO mode - ON/OFF
(49) PTO mode - disengage (51) PTO mode - set/lower

Test Step 1. Inspect Electrical Connectors E. Check the screw for the ECM connector for the
and Wiring correct torque of 5.0 N·m (44 lb in).

A. Turn the keyswitch to the OFF position. F. Check the harness for corrosion, abrasion and
pinch points from the PTO mode switches to the
B. Thoroughly inspect the J1/P1 connectors on the ECM.
Electronic Control Module (ECM), the switch
connections and battery connections. Refer to Expected Result:
Troubleshooting, “Electrical Connectors - Inspect”
for details. All connectors, pins, and sockets should be
completely inserted and coupled. The harness should
C. Perform a 45 N (10 lb) pull test on each of the be free of corrosion, abrasion, and pinch points.
wires in the sensor connector and the ECM
connector that are associated with the active Results:
diagnostic code. Refer to illustration 92.
• OK – Proceed to Test Step 2.
D. Verify that the latch tab of the connector is
correctly latched. Also verify that the latch tab of • Not OK
the connector has returned to the fully latching
position. Repair: Repair the circuit.
216 SENR9969-05
Troubleshooting Section

Use the electronic service tool in order to clear all Note: The “PTO mode lamp” will flash when the
logged diagnostic codes and then verify that the “PTO mode” is switched ON. The PTO mode lamp
repair eliminates the fault. should change from flashing to ON when the PTO
mode Set/Lower switch is CLOSED. The PTO mode
STOP. lamp should change from flashing to ON when the
PTO mode Raise/Resume switch is CLOSED.
Test Step 2. Check the “PTO Mode
Switches” on the Electronic Service Tool Results:

A. Turn the keyswitch to the OFF position. • OK – The PTO mode switches operate correctly.
STOP.
B. Connect the electronic service tool to the
diagnostic connector. • Not OK – Proceed to Test Step 3.
C. Turn the keyswitch to the ON position. Test Step 3. Check the Status of the PTO
Mode Disengage Switches
D. Observe the status of the PTO mode switch on
the electronic service tool while you operate the A. Use the electronic service tool in order to observe
“PTO ON/OFF switch” from the ON position to the the switch status while the PTO mode disengage
OFF position. switches are operated OFF and ON.

E. Use the electronic service tool in order to observe Note: The PTO mode disengage switches usually
the status of the PTO mode switch while you function by the operation of the brake, clutch or the
operate the “PTO Set/Lower switch” from the OFF operator switch. These switches should be operated
position to the ON position. separately for this test.

F. Use the electronic service tool in order to observe Expected Result:

the status of the PTO mode switch while you
operate the “PTO Raise/Resume switch” from the When the PTO mode is switched ON, the electronic
OFF position to the ON position. service tool will show that the “PTO mode disengage
switches” are in the “ENGAGED” position. If the “PTO
Expected Result: mode disengage switches” is activated, the electronic
service tool will show the status of the “PTO mode
Result 1 The electronic service tool will show that the disengage switches”. If the “PTO mode disengage
“PTO mode ON/OFF switch” is in the OPEN condition switches” are activated, the electronic service tool
when the control switch is OFF. will show that the “PTO mode disengage switches”
are in the “DISENGAGED” position.
The electronic service tool will show that the “PTO
mode ON/OFF switch” is in the CLOSED condition Results:
when the control switch is ON.
• OK – The “PTO mode disengage switches”
Note: The PTO mode lamp should be OFF when the operate correctly. STOP.
switch is in the OFF position. The lamp should be
flashing when the switch is in the ON position. • Not OK – Proceed to Test Step 4.
Result 2 When the “PTO mode Set/Lower switch” is Test Step 4. Check the Suspect PTO
in the OFF position the switch should be in the OPEN Switch
position.
A. Turn the keyswitch to the OFF position.
When the “PTO mode Set/Lower switch” is in the ON
position the “PTO mode Set/Lower switch” should be B. Remove the two wires from the suspect switch.
in the CLOSED position. Use a suitable jumper in order to join the two
wires together.
Result 3 When the “PTO mode Raise/Resume
switch” is in the OFF position the display screen C. Turn the keyswitch to the ON position.
should show an OPEN condition.
D. Monitor the status screen on the electronic service
When the “PTO mode Raise/Resume switch” is in tool while the jumper wire is being disconnected
the ON position the display screen should show a and reconnected.
CLOSED condition.
SENR9969-05 217
Troubleshooting Section

Expected Result: Test Step 6. Test the Engine ECM

When the jumper wire is connected the status of the A. Turn the keyswitch to the OFF position.
PTO mode switches should be “CLOSED”.
B. Disconnect the P1 connector from the ECM.
When the jumper wire is disconnected the status of
the PTO mode switches should be “OPEN”. C. By using a suitable pin removal tool, temporarily
remove the wires from the suspect switch socket.
Results: By using a suitable pin removal tool, temporarily
remove the wires from the P1:35.
• OK – The switch is faulty.
D. Insert a jumper wire between the suspect switch
Repair: Replace the switch. socket and P1:35.

Use the electronic service tool in order to clear all E. Turn the keyswitch to the ON position.
logged diagnostic codes and then verify that the
repair has eliminated the problem. F. Monitor the status screen on the electronic service
tool while the jumper wire is being disconnected
STOP. and reconnected.

• Not OK – There is a fault with the harness between Expected Result:

the PTO mode switches and the engine ECM.
Proceed to Test Step 5. The status screen should display an OPEN condition
with the switch in the OFF position.
Test Step 5. Measure the Resistance of
the Cables at the ECM The status screen should display a CLOSED
condition with the switch in the ON position.
A. Turn the keyswitch to the OFF position.
Results:
B. Connect the cables to the suspect switch.
• OK – The ECM is working correctly. STOP.
C. Disconnect the P1 connector from the ECM.
• Not OK – The ECM is not working correctly.
D. Measure the resistance between P1:35 and
the appropriate pin on the P1 connector for the Repair: Perform the following repair:
suspect switch. Refer to illustration 91.
1. Make sure that the latest flash file for the
E. Repeat the procedure for each of the PTO mode application is installed in the ECM. Refer to
switches. Troubleshooting, “Flash Programming”.

Expected Result: 2. Contact the Technical Communicator.

The measured resistance should be less than 10 Note: This consultation can greatly reduce the repair
Ohms with the switch ON. time.

The measured resistance should be more than 3. If the Technical Communicator recommends the
20,000 Ohms with the switch OFF. use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.
Results:
4. Use the electronic service tool to recheck the
• OK – Proceed to Test Step 6. system for active diagnostic codes.

• Not OK – There is a fault with the wires between 5. If the fault is resolved with the test ECM,
the suspect switch and the P1 connector. reconnect the suspect ECM.

Repair: Repair the wires or replace the wires. 6. If the fault returns with the suspect ECM,
replace the ECM.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the 7. Use the electronic service tool in order to clear
repair has eliminated the fault. all logged diagnostic codes and then verify that
the repair eliminates the fault.
STOP.
STOP.
218 SENR9969-05
Troubleshooting Section

i03504268

Starting Aid (Glow Plug) Relay

Circuit - Test
SMCS Code: 4493-038

System Operation Description:

Use this procedure when there is an active fault for

the current consumption on the glow plug start aid
relay.

Use this procedure for the following diagnostic codes:

• 2246-06 Glow Plug Start Aid Relay Current Above

Normal

The following background information is related

to this procedure:

The starting aid is used to improve the engine starting

when the engine is cold. With the keyswitch in the
ON position, the engine Electronic Control Module
(ECM) will monitor the coolant temperature and the
air temperature in the engine intake manifold in order
to decide if the glow plugs are required to be switched
ON. If the glow plugs are required, then the ECM will
activate the starting aid relay for a controlled period
of time. While the glow plug start aid relay is activated
the glow plug start aid relay will supply power to the
glow plugs. If a “Wait To Start” lamp is installed then
this will be illuminated in order to indicate the “Wait
To Start” period.

“Wait to Start/Start Aid Active Lamp”

This feature may be included as an option.

On a cold start, when the ECM determines that

it is necessary for the glow plugs to be activated
prior to starting, a lamp output will indicate that the
operator needs to “Wait to Start”. It is possible that
starting aids may be used during the cranking of the
engine. Starting aids may be used if the engine has
previously been started. The “Wait to Start” lamp will
not be active in these conditions.

Electronic Service Tool Test Aid

The electronic service tool includes the test “Glow

Plug Start Aid Override Test”. This test will assist the
analysis of the cold starting aid.

Overview of the Glow Plug Start Aid Override Test

This glow plug start aid override test switches on the

cold starting aid when the engine is not running. The
glow plug start aid override test aids the analysis of
the circuit for the glow plug start aid relay.
SENR9969-05 219
Troubleshooting Section

g01839594
Illustration 93
Typical schematic for the starting aid switch

g01805855
Illustration 94
View of the pin locations on the P1 connector for the starting aid circuit
(1) Ground (GND) (9) Ground (GND) (63) Cold start lamp
(2) Ground (GND) (10) Ground (GND)
(3) Ground (GND) (57) Start aid control
220 SENR9969-05
Troubleshooting Section

Test Step 1. Inspect Electrical Connectors C. Use the electronic service tool to select the “Glow
and Wiring Plug Start Aid Override Test” in order to turn on
the power for the glow plugs.
A. Inspect the following connectors:
D. Check for active diagnostic codes or recently
• P1 connector logged diagnostic codes.

• P2 connector Expected Result:

B. Inspect the terminal connections on the glow The following diagnostic code is active or recently
plug start aid relay. Refer to Troubleshooting, logged:
“Electrical Connectors - Inspect” for details.
• 2246-06 Glow Plug Start Aid Relay Current Above
C. Perform a 45 N (10 lb) pull test on each of the Normal
wires in the ECM connector that are associated
with the glow plug starting aid. Results:

D. Check the screw for the ECM connector for the • OK – The expected diagnostic code is active or
correct torque of 5.0 N·m (44 lb in). recently logged. Proceed to Test step 3.

E. Check the harness for abrasion and pinch points • Not OK – An active diagnostic code or a recently
from the glow plugs back to the ECM. logged diagnostic code was not displayed.

F. Check that the fuses are not blown. Repair: Perform one of the following procedures:

Expected Result: • If an intermittent fault is suspected, use the

electronic service tool to perform a “Wiggle Test”
All connectors, pins and sockets are correctly coupled in order to locate intermittent connections.
and/or inserted. The harness is free of corrosion,
abrasion and pinch points. The fuses are not blown. • If there is a fault on the glow plug or a fault on
the starting aid and a diagnostic code is not
Results: displayed then there may be a fault with the glow
plug switched power circuit or there may be an
• OK – The harness and the connectors appear to open circuit in the relay coil circuit. The ECM
be OK. Proceed to Test Step 2. does not monitor the status of these tests. Refer
to Testing and Adjusting, “Glow Plugs - Test”.
• Not OK – There is a fault with the harness and
connectors. STOP.

Repair: Repair the connectors or the harness Test Step 3. Check the Wiring for a Short
and/or replace the connectors or the harness. Circuit
Ensure that all of the seals are correctly in place
and ensure that the connectors are completely A. Turn the keyswitch to the OFF position.
coupled. Replace blown fuses.
B. Remove the P1 connector from the ECM.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the C. Check the connector, pins and the sockets for
repair has eliminated the fault. corrosion or damage.

STOP. D. Check the resistance between P1:57 and each of

the pins on the P1 connector.
Test Step 2. Check for Active Diagnostic
Codes Expected Result:

A. Connect the electronic service tool to the The resistance between P1:57 and P1:63 is
diagnostic connector. approximately 2,000 Ohms.

B. Turn the keyswitch to the ON position. The resistance between P1:57 and each of the
remaining pins on the P1 connector is more than
Note: Do not start the engine. 10,000 Ohms.
SENR9969-05 221
Troubleshooting Section

Results: Expected Result:

• OK – The harness connects the ECM to the glow The keyswitch is in the OFF position. The voltage
plug start aid relay and there are no shorts to other should be 0 Volts DC.
circuits. The ECM or the glow plug start aid relay is
suspect. Proceed to Test Step 4. The keyswitch is in the ON position. The measured
voltage for a 12 Volt system is a constant 10.5 to 13.5
• Not OK – The harness is faulty. Volts DC. The measured voltage for a 24 Volt system
is a constant 21.0 to 27.0 Volts DC.
Repair: If the resistance between P1:57 and P1:63
is less than 2,000 Ohms then there is a short circuit Results:
or high resistance in the connection to another
wire. If the resistance between P1:57 and each • OK – The glow plug start aid relay is operating
of the remaining pins on the J1 connector is less correctly. Reconnect the connection to pin 2 on the
than 10,000 Ohms then there is a short circuit or glow plug start aid relay. Proceed to Test Step 5.
high resistance in the connection to another wire.
Locate the open circuit, the short circuit or high • Not OK – The glow plug start aid relay is faulty.
resistance in the connection in the harness. Repair
the connectors or the harness and/or replace the Repair: Replace the glow plug start aid relay.
connectors or the harness. Ensure that all of the Use the electronic service tool in order to clear all
seals are correctly in place and ensure that the logged diagnostic codes and then verify that the
connectors are correctly coupled. Replace any repair eliminates the fault.
fuses that may be open circuit.
If the fault still exists, proceed to Test step 5.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the Test Step 5. Check the ECM
repair has eliminated the fault.
A. Make sure that the latest flash file for the
If the fault still exists, proceed to Test Step 4. application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.
Test Step 4. Bypass the ECM In Order to
Check the Operation of the Glow Plug B. Contact the Technical Communicator.
Start Aid Relay
Note: This consultation can greatly reduce the repair
A. Turn the keyswitch to the OFF position. time.

B. Disconnect the connection from pin 2 on the C. If the Technical Communicator recommends the
socket for the glow plug start aid relay. use of a test ECM, install a test ECM. Refer to
Troubleshooting, “Replacing the ECM”.
C. Connect a suitable multimeter between battery+
and each power terminal on the glow plug start D. Use the electronic service tool in order to clear all
aid relay. One terminal will read 0 Volts DC. logged diagnostic codes.
This is Test Point A. The other terminal will read
approximately 12 Volts DC or 24 Volts DC. This is E. Use the electronic service tool in order to perform
Test Point B. Refer to Figure 94. a “Glow Plug Start Aid Override Test”.

D. Connect a jumper wire between the pin 2 on the Expected Result:

glow plug start aid relay and battery-.
The replacement ECM functions correctly. Performing
E. Connect a multimeter between Test Point “B” the “Glow Plug Start Aid Override Test” energizes
on the glow plug start aid relay and the battery the glow plugs.
ground.
Results:
F. Measure the voltage from the battery ground and
Test Point “B” on the glow plug start aid relay. • OK
G. Turn the keyswitch to the ON position. Repair: Perform the following procedure:

Note: Do not start the engine. 1. Reconnect the suspect ECM.

H. Measure the voltage from the battery ground and 2. If the fault returns with the suspect ECM,
Test Point “B” on the glow plug start aid relay. replace the ECM.
222 SENR9969-05
Troubleshooting Section

3. Use the electronic service tool in order to clear

all logged diagnostic codes and then verify that
the repair eliminates the fault.

STOP.

• Not OK
Repair: Repeat this test procedure from Test Step
1.

STOP.

i03505285

Throttle Switch Circuit - Test

SMCS Code: 7332-038

System Operation Description:

Use this procedure to troubleshoot the system under

the following conditions:

• There is an active diagnostic code or a recently

logged diagnostic code that is related to the
following:

• 0091-02 Throttle Position Sensor erratic,

intermittent, or incorrect

• 0774-02 Secondary Throttle Position Sensor

erratic, intermittent, or incorrect

Check that the software configuration in the Electronic

Control Module (ECM) is correct for a multi-position
throttle .

If the engine has an analog throttle with an Idle

Validation Switch (IVS), then refer to Troubleshooting,
“Idle Validation Switch Circuit - Test”.

The throttle switch provides the operator with the

ability to select the desired engine speed. The throttle
switch configuration may be selected between 0 to 4
switches. A multi-position rotary switch may be used.

The throttle switch is typically connected to the four

throttle inputs of the ECM. Each position generates
a specific ON/OFF pattern on the throttle inputs. A
diagnostic code is generated if a pattern that does
not correspond with any of the switch positions is
detected.

Once a diagnostic code is generated, the ECM

ignores the throttle input signals. The desired engine
speed is set to low idle if no alternative throttle is
detected.

Voltage at the throttle inputs to the ECM should be

13.8 ± 0.5 Volts DC when the throttle inputs are open.
The voltage should be less than 0.5 Volts DC when
the throttle inputs are closed.
SENR9969-05 223
Troubleshooting Section

g01806833
Illustration 95
Schematic for the circuit for the throttle switch

g01806834
Illustration 96
Typical view of the pin locations on the P1 connector for the throttle switch
(35) Switch return (50) Throttle position switch 3 (52) Throttle position switch 1
(49) Throttle position switch 4 (51) Throttle position switch 2

Test Step 1. Inspect Electrical Connectors E. Check the screw for the ECM connector for the
and Wiring correct torque of 5.0 N·m (44 lb in).

A. Turn the keyswitch to the OFF position. F. Check the harness for corrosion, abrasion, and
pinch points from the throttle switch to the ECM.
B. Thoroughly inspect the P1 connector and
any other connectors that are included in the Expected Result:
application for this throttle switch. Refer to
Troubleshooting, “Electrical Connectors - Inspect” All connectors, pins, and sockets should be
for details. completely inserted and coupled. The harness should
be free of corrosion, abrasion and pinch points.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the sensor connector and the ECM Results:
connector that are associated with the active
diagnostic code. Refer to illustration 96. • OK – Proceed to Test Step 2.
D. Verify that the latch tab of the connector is • Not OK
correctly latched. Also verify that the latch tab of
the connector has returned to the fully latching Repair: Repair the circuit.
position.
224 SENR9969-05
Troubleshooting Section

Use the electronic service tool in order to clear all Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the logged diagnostic codes and then verify that the
repair eliminates the problem. repair eliminates the fault.

STOP. STOP.

Test Step 2. Check “Throttle Cab Switch • Not OK – Proceed to Test Step 4.
Position” on the Electronic Service Tool
Test Step 4. Check for Shorts in the
A. Connect the electronic service tool to the Harness
diagnostic connector.
A. Turn the keyswitch to the OFF position.
B. Turn the keyswitch to the ON position.
B. Disconnect the P1 connector and the P503
C. Observe the status of the throttle switch and the connector.
throttle inputs on the electronic service tool while
you operate the throttle switch in each position. C. Measure the resistance between engine ground
and the terminal for the suspect throttle input at
Results: the P503 connector.

• OK – The throttle switch is functioning correctly D. Measure the resistance between the terminal for
at this time. the suspect throttle input on the P503 connector
and the remaining terminals at the connector.
Repair: Refer to Troubleshooting, “Electrical
Connectors - Inspect” if the fault is intermittent. Expected Result:

STOP. Resistance should be greater than 20,000 Ohms for

each reading.
• Not OK – Record the suspect input. Proceed to
Test Step 3. Results:

Test Step 3. Jumper the Switch Input at • OK – Proceed to Test Step 5.

the Throttle Switch Connector
• Not OK – There is a short in the harness between
A. Disconnect the P503 connector for the throttle the ECM and the throttle switch.
switch.
Repair: Repair the circuit.
B. Observe the status of the suspect throttle input on
the electronic service tool. Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the
C. Use a suitable jumper wire to short P503:1 to the repair eliminates the fault.
terminal for the suspect throttle input at throttle
switch connector P503. STOP.

D. Observe the status of the suspect throttle input on Test Step 5. Check Resistance through
the electronic service tool. the Harness
E. Remove the jumper wire. A. Use a jumper wire to short P503:1 to the terminal
of the suspect throttle input at the P503 connector.
Expected Result:
B. Measure the resistance between P1:35 and the
The status of the suspect throttle input should be terminal for the suspect throttle input at ECM
OFF when throttle switch connector J503/P503 is connector P1 connector.
disconnected. The status should be ON when the
jumper wire is installed. Expected Result:

Results: Resistance should be less than 10 Ohms.

• OK – The harness and the ECM are OK. Results:

Repair: Replace the throttle switch. • OK – Proceed to Test Step 6.

SENR9969-05 225
Troubleshooting Section

• Not OK – There is an open circuit or excessive Repair: Repair the circuit.

resistance in the harness.
Use the electronic service tool in order to clear all
Repair: Repair the circuit. logged diagnostic codes and then verify that the
repair eliminates the fault.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the STOP.
repair eliminates the fault.
• Not OK – The switch signal appears at the ECM.
STOP. The ECM is not reading the switch correctly.

Test Step 6. Check the Harness and the Repair: Perform the following repair:
ECM
1. Make sure that the latest flash file for the
A. Turn the keyswitch to the OFF position. application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.
B. Disconnect the P1 connector and remove the
wire for the suspect throttle input from the P1 2. Contact the Technical Communicator.
connector.
Note: This consultation can greatly reduce the repair
C. Reconnect all of the connectors. time.

D. Turn the keyswitch to the ON position. 3. If the Technical Communicator recommends the
use of a test ECM, install a test ECM. Refer to
E. Observe the status of the suspect throttle input on Troubleshooting, “Replacing the ECM”.
the electronic service tool.
4. Use the electronic service tool to recheck the
F. Turn the keyswitch to the OFF position. system for active diagnostic codes.

G. Disconnect P1 connector and remove the wire 5. If the fault is resolved with the test ECM,
from P1:35. reconnect the suspect ECM.

H. Fabricate a jumper wire with pins at both ends. 6. If the fault returns with the suspect ECM,
Insert the jumper wire at P1:35 and the suspect replace the ECM.
throttle input at ECM connector P1 connector.
7. Use the electronic service tool in order to clear
I. Reconnect all of the connectors. all logged diagnostic codes and then verify that
the repair eliminates the fault.
J. Turn the keyswitch to the ON position.
STOP.
Note: Additional diagnostic codes will be generated
because P1:35 will no longer be connected to other
i03505560
sensors and switches. Ignore the codes and clear the
codes when you complete this test. Wastegate Solenoid - Test
K. Observe the status of the suspect throttle input on SMCS Code: 5479-038
the electronic service tool.
System Operation Description:
L. Turn the keyswitch to the OFF position.
Use this procedure under the following
M. Remove the jumper wire from the P1 connector conditions:
and reconnect all wires and connectors.
Use this procedure if any of the following diagnostic
Expected Result: codes are active:
The status of the suspect throttle input should be
• 0526-05 Turbo Wastegate Drive current below
OFF when the throttle input is open. The status normal
should be ON when the jumper wire is installed.
• 0526-06 Turbo Wastegate Drive current above
Results: normal
• OK – There is a fault in the harness between the • 0526-07 Turbo Wastegate Drive not responding
ECM and the throttle switch. properly
226 SENR9969-05
Troubleshooting Section

Some engine models will have a turbocharger with

an electronically controlled wastegate. Typically, the
wastegate is a mechanical valve that is used in the
turbocharger in order to regulate the intake manifold
pressure to a set value.

The control system for the electronically controlled

wastegate precisely regulates the intake manifold
pressure by using a wastegate regulator to control
the wastegate.

The required intake manifold pressure is calculated

by the software that is contained in the Electronic
Control Module (ECM). The ECM uses the wastegate
regulator to control the wastegate in order to provide
the precise value of intake manifold pressure. The
solenoid in the wastegate regulator is controlled by a
PWM signal from the ECM.

Table 62
Pin Connections
Sensor Pin Function P2 Pin Connection
1 Ground 44
2 Signal 17

g01806857
Illustration 97
Schematic for the wastegate regulator
SENR9969-05 227
Troubleshooting Section

g01806859
Illustration 98
Typical view of the pin locations on the P1 connector for the wastegate regulator
(17) Wastegate pulse width modulation
(PWM) signal
(44) Wastegate return

g01806858 g01806873
Illustration 99 Illustration 100
Connector for the wastegate regulator Wastegate regulator
(1) Ground (GND) (1) Wastegate regulator
(2) Signal (SIG)
Test Step 1. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.

B. Connect the electronic service tool to the

diagnostic connector.

C. Turn the keyswitch to the ON position. Start the

electronic service tool.

D. Monitor the electronic service tool for active

diagnostic codes and/or logged diagnostic codes.

Expected Result:

One or more diagnostic codes are active or logged.

228 SENR9969-05
Troubleshooting Section

Results: • “Low current” (open circuit)

• 526-xx diagnostic codes are active and/or logged – • “High current” (short circuit)
Proceed to Test Step 2.
Expected Result:
• No Codes – The fault seems to be resolved.
The electronic service tool displays no diagnostic
Repair: For intermittent faults, refer to codes.
Troubleshooting, “Electrical Connectors - Inspect”.
Results:
STOP.
• OK – There are no active codes.
Test Step 2. Inspect Electrical Connectors
and Wiring Repair: The original codes may have been caused
by a loose connector. If this is an intermittent fault,
A. Thoroughly inspect the P2/J2 ECM connector and refer to Troubleshooting, “Electrical Connectors -
the P511 connector for the wastegate regulator. Inspect”.
Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details. STOP.

B. Perform a 45 N (10 lb) pull test on each of the • Not OK – Diagnostic code 526-5 is active at this
wires that are associated with the wastegate time. Proceed to Test Step 4.
solenoid.
• Not OK – Diagnostic code 526-6 is active at this
C. Check the screw for the ECM connector for the time. Proceed to Test Step 6.
correct torque of 5.0 N·m (44 lb in).
• Not OK – Diagnostic code 526-7 is active at this
Expected Result: time. Proceed to Test Step 4.

All connectors, pins, and sockets are completely Test Step 4. Create a Short Circuit in the
coupled and/or inserted and the harness is free of Harness at the Solenoid
corrosion, abrasion, and pinch points.
A. Turn the keyswitch to the OFF position.
Results:
B. Disconnect the P511 connector for the wastegate
• OK – The harness is OK. Proceed to Test Step 3. regulator.

• Not OK – There is a fault in the connectors and/or C. Fabricate a jumper wire and then install the wire
the harness. between P511:1 and P511:2 in order to create a
short circuit.
Repair: Repair the connectors or the harness
and/or replace the connectors or the harness. D. Turn the keyswitch to the ON position. Access the
Ensure that all of the seals are correctly in place “Diagnostics Tests” on the electronic service tool.
and ensure that the connectors are completely Activate the “Turbo Wastegate Solenoid Test”.
coupled. Wait at least 30 seconds in order for the result to
be displayed.
Use the electronic service tool in order to clear all
logged diagnostic codes and then verify that the E. Check for active diagnostic codes on the electronic
repair eliminates the fault. service tool.

STOP. F. Remove the jumper wire from the P511 connector.

Test Step 3. Determine the Diagnostic Expected Result:

Code that is Active
Diagnostic code 526-6 is active while the jumper wire
A. Turn the keyswitch to the ON position. Access the is installed.
“Diagnostics Tests” on the electronic service tool.
Activate the “Turbo Wastegate Solenoid Test”. Results:
Wait at least 30 seconds in order for the result to
be displayed. • OK – Diagnostic code 526-6 is active when the
jumper wire is installed. There is a fault in the
B. Determine if the fault is related to either of the solenoid.
following:
SENR9969-05 229
Troubleshooting Section

Repair: Perform the following procedure: Use the electronic service tool in order to clear all
logged diagnostic codes.
1. Temporarily connect a replacement wastegate
regulator. STOP.

2. Turn the keyswitch to the ON position. Access • Not OK – There is still an open circuit diagnostic
the “Diagnostics Tests” on the electronic service code.
tool. Activate the “Turbo Wastegate Solenoid
Test”. Wait at least 30 seconds in order for the Repair: Perform the following repair:
result to be displayed.
1. Make sure that the latest flash file for the
3. Diagnostic code 526-6 is no longer active. application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.
4. If the fault is eliminated, reconnect the suspect
wastegate regulator. If the fault returns, 2. Contact the Technical Communicator.
permanently install the replacement wastegate
regulator. Note: This consultation can greatly reduce the repair
time.
STOP.
3. If the Technical Communicator recommends the
• Not OK – The low current diagnostic code (open use of a test ECM, install a test ECM. Refer to
circuit) is still active. Proceed to Test Step 5. Troubleshooting, “Replacing the ECM”.

Test Step 5. Create a Short Circuit at the 4. Use the electronic service tool to recheck the
ECM system for active diagnostic codes.

A. Turn the keyswitch to the OFF position. 5. If the fault is resolved with the test ECM,
reconnect the suspect ECM.
B. Temporarily remove the wires from P2:17 and
P2:44. 6. If the fault returns with the suspect ECM,
replace the ECM.
C. Fabricate a jumper wire and then install the wire
between P2:17 and P2:44 in order to create a 7. Use the electronic service tool in order to clear
short circuit. all logged diagnostic codes and then verify that
the repair eliminates the fault.
Note: P2/J2 must be connected during the next step.
STOP.
D. Turn the keyswitch to the ON position. Access
the “Special Tests” under the “Diagnostics” menu Test Step 6. Disconnect the Solenoid in
on the electronic service tool. Activate the “Turbo order to Create an Open Circuit
Wastegate Solenoid Output” on the electronic
service tool. Wait at least 30 seconds for activation A. Turn the keyswitch to the OFF position.
of the diagnostic codes.
B. Disconnect the P511 connector from the
E. Check for active diagnostic codes on the electronic wastegate regulator in order to create an open
service tool. circuit.

F. Remove the jumper wire from the P1 connector. C. Turn the keyswitch to the ON position. Access the
“Diagnostics Tests” on the electronic service tool.
Expected Result: Activate the “Turbo Wastegate Solenoid Test”.
Wait at least 30 seconds in order for the result to
Diagnostic code 526-6 is active when the jumper is be displayed.
installed.
D. Check for active diagnostic codes on the electronic
Results: service tool.

• OK – Diagnostic code 526-6 is active when the Expected Result:

jumper wire is installed. There is a fault in the
harness between the ECM and the solenoid. Diagnostic code 526-5 is now active.

Repair: Repair the harness or replace the harness. Results:

• OK – Diagnostic code 526-5 is now active.

230 SENR9969-05
Troubleshooting Section

Repair: There is a short in the solenoid. Note: This consultation can greatly reduce the repair
time.
1. Temporarily connect a replacement wastegate
regulator. 3. If the Technical Communicator recommends the
use of a test ECM, install a test ECM. Refer to
2. If the fault is eliminated, reconnect the suspect Troubleshooting, “Replacing the ECM”.
wastegate regulator. If the fault returns,
permanently install the replacement wastegate 4. Use the electronic service tool to recheck the
regulator. system for active diagnostic codes.

STOP. 5. If the fault is resolved with the test ECM,

reconnect the suspect ECM.
• Not OK – There is still a 526-06 diagnostic code.
Proceed to Test Step 7. 6. If the fault returns with the suspect ECM,
replace the ECM.
Test Step 7. Create an Open Circuit at the
ECM 7. Use the electronic service tool in order to clear
all logged diagnostic codes and then verify that
A. Turn the keyswitch to the OFF position. the repair eliminates the fault.

B. Remove the wires from P2:17 and P2:44 in order STOP.

to create an open circuit at the ECM.

C. Turn the keyswitch to the ON position. Access the

“Diagnostics Tests” on the electronic service tool.
Activate the “Turbo Wastegate Solenoid Test”.
Wait at least 30 seconds in order for the result to
be displayed.

D. Check for active diagnostic codes on the electronic

service tool.

E. Reconnect the removed wires.

Expected Result:

Diagnostic code 526-5 is active when the wires are

removed.

Results:

• OK – Diagnostic code 526-5 is active when the

wires are removed. There is a short circuit in the
harness between the ECM and the solenoid.

Repair: Repair the harness or replace the harness.

Use the electronic service tool in order to clear all

logged diagnostic codes.

STOP.

• Not OK – Diagnostic code 526-6 is still present.

Repair: Perform the following repair:

1. Make sure that the latest flash file for the

application is installed in the ECM. Refer to
Troubleshooting, “Flash Programming”.

2. Contact the Technical Communicator.

SENR9969-05 231
Index Section

Index
Numerics CID 0100 FMI 04 ................................................... 95
CID 0100 FMI 10 ................................................... 96
5 Volt Sensor Supply Circuit - Test ...................... 121 CID 0110 FMI 03 ................................................... 96
CID 0110 FMI 04 ................................................... 97
CID 0168 FMI 00 ................................................... 97
A CID 0168 FMI 01 ................................................... 97
CID 0168 FMI 02 ................................................... 98
Alternator Noise..................................................... 46 CID 0171 FMI 03 ................................................... 98
Probable Causes ............................................... 46 CID 0171 FMI 04 ................................................... 99
Recommended Actions...................................... 46 CID 0172 FMI 03 ................................................... 99
Alternator Will Not Charge..................................... 46 CID 0172 FMI 04 ................................................. 100
Probable Causes ............................................... 46 CID 0190 FMI 08 ................................................. 100
Recommended Actions...................................... 46 CID 0247 FMI 09 ................................................. 100
Analog Throttle Position Sensor Circuit - Test ..... 128 CID 0247 FMI 12 ................................................. 101
CID 0253 FMI 02 ................................................. 101
CID 0261 FMI 11 ................................................. 101
B CID 0262 FMI 03 ................................................. 102
CID 0262 FMI 04 ................................................. 102
Battery ................................................................... 47 CID 0268 FMI 02 ................................................. 102
Probable Causes ............................................... 47 CID 0342 FMI 08 ................................................. 103
Recommended Actions...................................... 47 CID 0526 FMI 05 ................................................. 103
CID 0526 FMI 06 ................................................. 104
CID 0526 FMI 07 ................................................. 104
C CID 0774 FMI 02 ................................................. 105
CID 0774 FMI 03 ................................................. 105
CAN Data Link Circuit - Test................................ 133 CID 0774 FMI 04 ................................................. 106
Can Not Reach Top Engine RPM .......................... 47 CID 0774 FMI 08 ................................................. 106
Probable Causes ............................................... 47 CID 1639 FMI 09 ................................................. 107
Recommended Actions...................................... 47 CID 1743 FMI 02 ................................................. 107
CID 0001 FMI 02 ................................................... 81 CID 1779 FMI 05 ................................................. 108
CID 0001 FMI 05 ................................................... 82 CID 1779 FMI 06 ................................................. 108
CID 0001 FMI 06 ................................................... 82 CID 1785 FMI 03 ................................................. 108
CID 0001 FMI 07 ................................................... 83 CID 1785 FMI 04 ................................................. 109
CID 0002 FMI 02 ................................................... 83 CID 1785 FMI 10 ................................................. 109
CID 0002 FMI 05 ................................................... 83 CID 1797 FMI 03 .................................................. 110
CID 0002 FMI 06 ................................................... 84 CID 1797 FMI 04 .................................................. 110
CID 0002 FMI 07 ................................................... 84 CID 1834 FMI 02 .................................................. 110
CID 0003 FMI 02 ................................................... 85 CID 2246 FMI 06 .................................................. 111
CID 0003 FMI 05 ................................................... 85 Coolant in Engine Oil............................................. 49
CID 0003 FMI 06 ................................................... 86 Probable Causes ............................................... 49
CID 0003 FMI 07 ................................................... 86 Recommended Actions...................................... 49
CID 0004 FMI 02 ................................................... 86 Coolant Temperature Is Too High .......................... 49
CID 0004 FMI 05 ................................................... 87 Probable Causes ............................................... 49
CID 0004 FMI 06 ................................................... 87 Recommended Actions...................................... 50
CID 0004 FMI 07 ................................................... 88 Customer Specified Parameters............................ 40
CID 0005 FMI 02 ................................................... 88 Configurable Inputs............................................ 41
CID 0005 FMI 05 ................................................... 89 ECM Identification Parameter ............................ 40
CID 0005 FMI 06 ................................................... 89 Engine Rating Parameter................................... 40
CID 0005 FMI 07 ................................................... 90 J1939 Continuous Fault Handling...................... 41
CID 0006 FMI 02 ................................................... 90 Low/High Idle Parameters.................................. 40
CID 0006 FMI 05 ................................................... 90 Miscellaneous .................................................... 41
CID 0006 FMI 06 ................................................... 91 PTO and Throttle Lock Parameters ................... 40
CID 0006 FMI 07 ................................................... 91 Customer Specified Parameters Table .................. 43
CID 0041 FMI 03 ................................................... 92 Customer Specified Parameters Worksheet ......... 44
CID 0041 FMI 04 ................................................... 92
CID 0091 FMI 02 ................................................... 92
CID 0091 FMI 03 ................................................... 93 D
CID 0091 FMI 04 ................................................... 94
CID 0091 FMI 08 ................................................... 94 Data Link Circuit - Test ........................................ 136
CID 0100 FMI 03 ................................................... 95 Diagnostic Code Cross Reference ........................ 79
232 SENR9969-05
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Diagnostic Functional Tests................................. 121 Engine Will Not Crank ........................................... 62

Digital Throttle Position Sensor Circuit - Test ...... 142 Probable Causes ............................................... 62
Recommended Repairs ..................................... 62
Engine Wiring Information ..................................... 26
E Harness Wire Identification ................................ 26
Schematic Diagrams.......................................... 28
E172 High Air Filter Restriction ............................ 113 Event Codes ......................................................... 112
E194 High Exhaust Temperature.......................... 114 Active Event Codes........................................... 112
E2143 Low Engine Coolant Level ....................... 120 Clearing Event Codes ....................................... 113
E232 High Fuel/Water Separator Water Level ..... 115 Logged Event Codes ........................................ 113
E360 Low Engine Oil Pressure............................. 115 Troubleshooting ................................................ 113
E361 High Engine Coolant Temperature .............. 117 Excessive Black Smoke ........................................ 63
E362 Engine Overspeed ...................................... 118 Probable Causes ............................................... 63
E396 High Fuel Rail Pressure .............................. 118 Recommended Actions...................................... 63
E398 Low Fuel Rail Pressure ............................... 119 Excessive Engine Oil Consumption....................... 65
E539 High Intake Manifold Air Temperature......... 119 Probable Causes ............................................... 65
ECM Harness Connector Terminals ...................... 30 Recommended Actions...................................... 65
Removal and Installation of the Harness Connector Excessive Fuel Consumption ................................ 66
Terminals.......................................................... 31 Probable Causes ............................................... 66
ECM Memory - Test............................................. 149 Recommended Actions...................................... 66
ECM Will Not Accept Factory Passwords.............. 51 Excessive Valve Lash............................................ 68
Probable Causes ............................................... 51 Probable Causes ............................................... 68
Recommended Actions...................................... 51 Recommended Actions...................................... 68
ECM Will Not Communicate with Other Systems or Excessive White Smoke ........................................ 68
Display Modules .................................................. 51 Probable Causes ............................................... 69
Probable Causes ............................................... 51 Recommended Actions...................................... 69
Recommended Actions...................................... 51
Electrical Connectors - Inspect............................ 150
Electronic Service Tool Will Not Communicate with F
ECM..................................................................... 51
Probable Causes ............................................... 51 Factory Passwords ................................................ 32
Recommended Actions...................................... 52 Flash Programming ............................................... 33
Electronic Service Tools ........................................ 12 Flash Programming a Flash File ........................ 33
Caterpillar Electronic Technician (ET)................ 13 Fuel Rail Pump Solenoid - Test ........................... 180
Optional Service Tools ....................................... 12
Required Service Tools ...................................... 12
Electronic Troubleshooting ...................................... 5 G
Engine Cranks but Will Not Start ........................... 52
Probable Causes ............................................... 52 Glossary .................................................................. 8
Recommended Actions...................................... 53
Engine Has Early Wear ......................................... 56
Probable Causes ............................................... 56 I
Recommended Actions...................................... 56
Engine Misfires, Runs Rough or Is Unstable......... 57 Idle Validation Switch Circuit - Test...................... 184
Probable Causes ............................................... 57 Ignition Keyswitch Circuit and Battery Supply Circuit -
Recommended Actions...................................... 57 Test .................................................................... 189
Engine Oil in Cooling System ................................ 59 Important Safety Information ................................... 2
Probable Causes ............................................... 59 Indicator Lamp Circuit - Test................................ 195
Recommended Actions...................................... 59 Indicator Lamps ..................................................... 15
Engine Pressure Sensor Open or Short Circuit - Color of Lamps................................................... 15
Test .................................................................... 154 Flash Codes....................................................... 16
Engine Speed Does Not Change .......................... 59 Functions of the Lamps...................................... 15
Probable Causes ............................................... 60 Indicator Lamps ................................................. 15
Recommended Repairs ..................................... 60 Operation of the Indicator Lamps....................... 16
Engine Speed/Timing Sensor Circuit - Test ......... 161 Injector Data Incorrect - Test ............................... 198
Engine Stalls at Low RPM ..................................... 60 Injector Solenoid Circuit - Test............................. 200
Probable Causes ............................................... 60 Injector Trim File.................................................... 34
Recommended Actions...................................... 60 Intake Air Temperature Is Too High ....................... 70
Engine Temperature Sensor Open or Short Circuit - Probable Causes ............................................... 70
Test ............................................................ 169, 175 Recommended Actions...................................... 70
Engine Vibration .................................................... 61 Intermittent Engine Shutdown ............................... 71
Probable Causes ............................................... 61 Probable Causes ............................................... 71
Recommended Actions...................................... 61 Recommended Actions...................................... 71
SENR9969-05 233
Index Section

Intermittent Low Power or Power Cutout............... 72 Sensors and Electrical Connectors ....................... 19
Probable Causes ............................................... 72 Starting Aid (Glow Plug) Relay Circuit - Test ....... 218
Recommended Actions...................................... 72 System Configuration Parameters......................... 45
“ECM Software Release Date”........................... 45
“Engine Serial Number” ..................................... 45
L “Full Load Setting”.............................................. 45
“Full Torque Setting”........................................... 45
Low Engine Oil Pressure ....................................... 73 “Rating” .............................................................. 45
Probable Causes ............................................... 73 System Overview..................................................... 5
Recommended Actions...................................... 73 Diagnostic Codes................................................. 7
Low Power/Poor or No Response to Throttle ........ 74 Passwords ........................................................... 8
Probable Causes ............................................... 74 Programmable Parameters.................................. 7
Recommended Actions...................................... 75 System Operation ................................................ 5

M T

Mechanical Noise (Knock) in Engine..................... 77 Table of Contents..................................................... 3

Probable Causes ............................................... 77 Test ECM Mode ..................................................... 32
Recommended Actions...................................... 77 Throttle Setup ........................................................ 35
Mode Selection Circuit - Test............................... 210 Idle Validation..................................................... 36
Mode Switch Setup................................................ 34 Idle Validation Maximum On (Closed)
Enabled.............................................................. 35 Threshold ......................................................... 37
Mode Selection Number .................................... 35 Idle Validation Minimum Off (Open) Threshold .. 36
Mode Selection Switch Input 2 and Mode Selection Initial Lower Position Limit ................................. 38
Switch Input 1................................................... 35 Initial Upper Position Limit ................................. 38
Number of Switch Inputs.................................... 34 Lower Dead Zone .............................................. 38
Rated Speed (RPM)........................................... 35 Lower Diagnostic Limit....................................... 37
Rating Number................................................... 35 Lower Position Limit........................................... 38
Throttle 1 Droop Percentage.............................. 35 Upper Dead Zone .............................................. 38
Throttle 2 Droop Percentage.............................. 35 Upper Diagnostic Limit....................................... 37
TSC1 Droop Percentage.................................... 35 Upper Position Limit........................................... 38
Multiposition Switch Setup..................................... 38 Throttle Switch Circuit - Test................................ 222
Engine Speed (in RPM) ..................................... 39 Troubleshooting Section.......................................... 5
Input 4, Input 3, Input 2, Input 1 ......................... 39 Troubleshooting with a Diagnostic Code ............... 79
Logical Position.................................................. 39 Troubleshooting with an Event Code.................... 112
Number of Switch Inputs.................................... 38 Troubleshooting without a Diagnostic Code .......... 46
Physical Position................................................ 38
Physical Position Enabled.................................. 39
W

N Wastegate Solenoid - Test................................... 225

No Diagnostic Codes Detected ............................. 81

Noise Coming from Cylinder.................................. 77
Probable Causes ............................................... 77
Recommended Actions...................................... 77

Programming Parameters ..................................... 32

PTO Switch Circuit - Test..................................... 214

Replacing the ECM................................................ 18

Self-Diagnostics..................................................... 19
234 SENR9969-05
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SENR9969-05 235
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