UENR4349-03 (en-us)

January 2018

Troubleshooting
C9.3 Marine Auxiliary and Generator
Set Engine
CA9 1-UP (Engine)
C93 1-UP (Generator)

SAFETY.CAT.COM
 i06558969

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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 you are authorized to perform this work, and 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. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury 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.
UENR4349-03 3
Table of Contents

Table of Contents Intake Manifold Air Temperature Is High.............. 131

Oil Consumption Is Excessive ............................ 133
Oil Contains Coolant ......................................... 135
Troubleshooting Section Oil Contains Fuel .............................................. 138
Oil Filter Differential Pressure Problem ............... 139
Oil Level Is Low................................................. 141
Introduction Oil Pressure Is Low ........................................... 142
General Information ..............................................4 Oil Temperature Is High ..................................... 146
Welding Precaution ...............................................5 Power Is Intermittently Low or Power Cutout Is
Electronic Service Tools.........................................5 Intermittent...................................................... 148
Service Information Report ..................................10 Sea Water Pump Pressure Problem ................... 151
Valve Lash Is Excessive .................................... 152
Electronic System Overview Valve Rotator or Spring Lock Is Free................... 154
System Overview ................................................12
Component Location ...........................................13 Circuit Tests
Engine Monitoring System ...................................13 Coolant Level - Test........................................... 156
Diagnostic Capabilities ........................................14 Data Link - Test ................................................. 159
Electrical Connectors ..........................................15 Electrical Power Supply - Test ............................ 166
Fuel Injection Pump - Test.................................. 169
Configuration Parameters Fuel Level - Test................................................ 174
Configuration Parameters ....................................19 Fuel Priming Pump - Test................................... 176
Injector Solenoid - Test ...................................... 182
Diagnostic Trouble Codes Relay - Test (Start Relay) ................................... 191
Diagnostic Trouble Codes....................................22 Sensor Calibration Required - Test ..................... 193
Sensor Signal (Analog, Active) - Test .................. 196
Symptom Troubleshooting Sensor Signal (Analog, Passive) - Test ............... 204
Acceleration Is Poor or Throttle Response Is Poor .33 Sensor Signal (PWM) - Test ............................... 208
Alternator Problem (Charging Problem and/or Noisy Sensor Supply - Test ......................................... 213
Operation) ........................................................36 Speed Control - Test.......................................... 217
Battery Problem ..................................................37 Speed/Timing - Test .......................................... 225
Coolant Contains Fuel .........................................38
Coolant Contains Oil ...........................................39 Service
Coolant Level Is Low ...........................................42 Cat ET Service Features.................................... 232
Coolant Pressure Is Low ......................................43 Cat ET Service Error Identifiers .......................... 251
Coolant Temperature Is High................................45 Customer Passwords ........................................ 253
Coolant Temperature Is Low ................................48 Factory Passwords............................................ 253
Crankcase Fumes Disposal Tube Has Oil Draining 51 ECM Will Not Accept Factory Passwords ............ 254
Crankcase Pressure Is High.................................53 Electronic Service Tool Does Not Communicate .. 255
Cylinder Is Noisy .................................................56 Test ECM Mode ................................................ 261
Engine Cranks but Does Not Start ........................58 Injector Trim File - Install .................................... 262
Engine Does Not Crank .......................................62 ECM Software - Install ....................................... 263
Engine Has Early Wear........................................64 ECM - Replace ................................................. 265
Engine Has Mechanical Noise (Knock) .................66 Timing - Calibrate .............................................. 266
Engine Misfires, Runs Rough or Is Unstable..........70
Engine Overcrank Occurrence .............................72
Engine Overspeeds.............................................76 Index Section
Engine Stalls at Low RPM....................................77
Engine Top Speed Is Not Obtained .......................79 Index................................................................ 272
Engine Vibration Is Excessive ..............................82
Exhaust Has Excessive Black Smoke ...................83
Exhaust Has Excessive White Smoke...................85
Exhaust System Contains Coolant........................88
Exhaust System Contains Oil ...............................89
Exhaust Temperature Is High ...............................91
Fuel Consumption Is Excessive............................94
Fuel Filter Is Restricted ........................................96
Fuel Pressure Is High ..........................................98
Fuel Pressure Is Low ......................................... 102
Fuel Rail Pressure Is Low .................................. 106
Fuel Rail Pressure Is Low While Cranking ........... 111
Fuel Rail Pressure Leakage Is High .................... 117
Fuel Temperature Is High................................... 122
Indicator Lamp Problem..................................... 127
Inlet Air Is Restricted ......................................... 127
Intake Manifold Air Pressure Is Low .................... 128
4 UENR4349-03
Introduction

Troubleshooting Section The ECM contains a flash file. The flash file is the
software for the ECM. The flash file contains the
operating maps. The operating maps define the
following characteristics of the engine:
Introduction • Horsepower

• Torque curves
• Engine speed (rpm)
i06066558
Refer to Troubleshooting, “System Overview” for
General Information additional information on the electronic control
system.
SMCS Code: 1000
Application Interface
Important Safety Information The ECM interfaces with the engine via software and
an electrical connector on the ECM. The software
Do not perform any procedures in this can be configured.
Troubleshooting Guide until you have read the
Operation and Maintenance Manual and you The application control system provides inputs to the
understand this information. Use only proper tools electrical connector on the ECM in order to indicate
and observe all precautions that pertain to the use of the status of switches. Correctly configure the ECM
those tools. Failure to follow these procedures can in order to interpret the inputs.
result in personal injury. The following procedures
should also be observed. The ECM provides outputs for the application control
system via the electrical connector in order to control
Work safely. Most accidents that involve product lamps, solenoids, and other devices. Correctly
operation, maintenance, and repair are caused by configure the ECM in order for the outputs to match
failure to observe basic safety rules or precautions. the configuration of the application control system.
An accident can often be avoided by recognizing
potentially hazardous situations before an accident Fault Detection and Reporting
occurs.
The ECM monitors inputs from the sensors and
A person must be alert to potential hazards. This inputs from the applications control system. Software
person should also have the necessary training, in the ECM interprets the inputs. The software
skills, and tools in order to perform these functions determines if the inputs are operating correctly. A
properly. diagnostic trouble code is activated when the
software detects a problem with an input.
Safety precautions and warnings are provided in this
publication and on the product. If these hazard The ECM broadcasts the codes on J1939. Cat ®
warnings are not heeded, bodily injury or death could Electronic Technician (Cat ET) must communicate on
occur to you or to other persons. Caterpillar cannot both data links in order to service the engine. If a
anticipate every possible circumstance that might problem is suspected with one of the data links, refer
involve a potential hazard. to Troubleshooting, “Data Link - Test”.
Therefore, the warnings in this publication and the The codes can be displayed on Cat ET and optional
warnings that are on the product are not all inclusive. operator interfaces. Refer to Troubleshooting,
“Diagnostic Trouble Codes” for additional information
Overview on diagnostic trouble codes and a complete list of
These engines are equipped with an electronic codes.
control system. The system consists of a computer,
sensors, and software. The system performs these Troubleshooting
functions: As a reference, simplified schematics for each of the
engine subsystems are included with each of the
• Control of the engine circuit tests that are in this manual. For an accurate
representation of the entire electrical schematic that
• Applications control system interface is for your application, refer to the Electrical System
Schematic.
• Fault detection and reporting

Electronic Control System

The Electronic Control Module (ECM) is a computer
that controls the operation of the engine.
UENR4349-03 5
Introduction

During troubleshooting, inspect all harness

connections before any component is replaced. If
these connections are not clean and tight, continuous
electrical problems or intermittent electrical problems
can result. Check that the wires are pushed into the
connectors completely. Make sure that the
connections are tight before other tests are made.
Failure of an electrical component may cause the
failure of other components. Always attempt to
correct the cause of an electrical failure before you
replace a component. If wire insulation is punctured,
repair the damage. Seal the damaged wires with
8T-0065 Silicone Sealant. Cover the sealant with
two layers of 1P-0810 Electrical Tape.

i06066570

Welding Precaution
SMCS Code: 1000
Proper welding procedures are necessary in
order to avoid damage to the A4 Electronic Illustration 1 g01143634
Control Module (ECM). Also consider Service welding guide (typical diagram)
components that are for the driven equipment.
Remove the component that requires welding. 5. When possible, connect the welder ground clamp
When welding on an engine that is equipped with
an ECM and removal of the component is not directly to the engine component that will be
possible, the following procedure must be welded. Place the clamp as close as possible to
followed. This procedure provides the minimum the weld. A close connection will reduce the
amount of risk to the electronic components. possibility of welding current damage to the engine
1. Stop the engine. Remove the electrical power from bearings, to the electrical components, and to
the ECM. other components.

2. Ensure that the fuel supply to the engine is turned 6. Protect the wiring harnesses from welding debris
off. and/or from the welding spatter.

3. Disconnect the negative battery cable from the 7. Use standard welding procedures to weld the
battery. If a battery disconnect switch is installed, materials together.
open the switch.
i06066601
4. Disconnect all electronic components from the
wiring harnesses. Electronic components include Electronic Service Tools
the following components:
SMCS Code: 0785
• Electronic components for the driven
equipment Service Tools
• A4 ECM Most of the tools that are listed in Table 1 are
required to enable a service technician to perform the
test procedures in this manual. Some of the devices
• Sensors may be specific to the type of Electronic Control
Module (ECM) that is being used.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
6 UENR4349-03
Introduction

Table 1
Service Tools Table 2
Part Number Description Optional Service Tools
Torque Wrench (capable of applying Part Number Description
N/A 1.5 N·m (13.3 lb in))
4C-4075 Crimp Tool (4-AWG TO 10-AWG)
1U-7563 4 mm Allen Wrench
Crimp Tool (12−AWG TO 18−AWG)
4C-8996 4mm Driver-Hex Ball
1U-5804
198-4240 Digital Pressure Indicator
Transducer
or or
6V-2197 114.3 mm (4.5 inch) Long X 6.35 mm
1U-5470 Engine Pressure Group
(0.25 inch)
4C-4911(1) Battery Load Tester
7X-1171 Transducer Mounting Adapter
5P-7277 Voltage Tester
7X-1695 Cable As
6V-9130(2) Temperature Adapter (MULTIMETER)
Multimeter Probe Gp
7X-1710 7X-1708 Multimeter Probe (Red) 8T-5319 Connector Tool Group
7X-1709 Multimeter Probe (Black)
152-7213 Electronic Testing Gp
7X-1715 Adapter Cable As (40-PIN BREAKOUT)
349-4199 AC/DC Current Probe
146-4080 Digital Multimeter Gp (RS232)
348-5430 Multi-Tool Gp
151-6320 Wire Removal Tool (14-GA TO 18-GA, RED)
386-2412 Tool Gp
Adapter Cable As (70-PIN BREAKOUT)
(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911 Bat-
(For ADEM 3 ECM (two 70-pin connectors) and
208-0059 tery Load Tester for 6, 8, and 12 v Lead Acid Batteries” and
for ADEM 4 ECM (one 70-pin connector and
Special Instructions, SEHS7633, “Battery Test Procedure”.
one 120-pin connector)) (2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130
Temperature Adapter Group”.
Adapter Cable As (120-PIN BREAKOUT)
257-8718 (For ADEM 4 ECM (one 70-pin connector and
one 120-pin connector)) Cat ®Electronic Technician (Cat ET)
326-4904 Adapter Cable As (3-PIN BREAKOUT) Cat ET can be used by the technician to help perform
Repair Kits for Connectors
the following procedures:

175-3700 Connector Repair Kit (DEUTSCH DT) • Diagnostic testing

362-3555 Connector Repair Kit (AMPSEAL) • Calibrations

Bypass Harnesses for the ECM • Flash programming
Wiring Harness (ECM BYPASS)
(The bypass harness connects to the battery.
• Configuration of the ECM
217-0113 The bypass harness is used with the following
harnesses for different types of electronic con-
• Print various reports
trol modules.)
Cat ET can display the following information:
Harness (ENGINE ECM BYPASS)
328-2292 • Status parameters
(For ADEM 3 ECM and ADEM 4 ECM)

• Diagnostic codes
Two short jumper wires may be needed to check the
continuity of some wiring harness circuits by shorting • ECM settings
two adjacent terminals together in a connector. A
long extension wire may also be needed to check the • Engine configuration
continuity of some wiring harness circuits.
Always use the latest revision of Cat ET. The media
Optional Service Tools is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 2 lists the optional service tools that may be
needed during testing or repair. Once you have downloaded Cat ET onto your PC,
you will need a license from your Caterpillar dealer in
order to use the software. Various licenses are
available for different users with different
requirements. Consult your Caterpillar dealer.
UENR4349-03 7
Introduction

Note: For more information regarding the use of Cat

ET and PC requirements, refer to the documentation
that accompanies your Cat ET software.

Connecting Cat ET

Connecting the Communication Adapter

Table 3 lists the standard hardware that is required in
order to connect Cat ET.
Table 3
Standard Hardware for Connecting with Cat ET

Part Number Description

N/A Personal Computer (PC)

317-7484 Communication Adapter Gp

Components of the 317-7484 Communication Adapter Gp

317-7485 Communication Adapter (3)

370-4617 Cable As (USB)

Cable As (DATALINK CABLE

457-6114
CA3)

Tool Operating Manual & Software CD ROM, NETG5057, “Com-

munication Adapter 3”

Follow the instructions for the communication

adapter. Use the following procedure in order to
connect Cat ET and the communication adapter to a
PC.
1. Remove the electrical power from the ECM.

Illustration 2 g02051513

(1) PC (3) 317-7485 Communication Adapter

(2) 353-5083 Computer Cable As (4) 327-8981 Cable As
8 UENR4349-03
Introduction

2. Connect cables (2) and (4) to communication Although changes can be made to the internal
adapter (3). settings of the 317-7493 Wireless Communication
Radio. Caterpillar recommends that the radio is
Note: The communication adapter will power up connected to a PC via 317-7496 Computer Cable
when the adapter is connected to a PC or to an ECM As (USB)Cable Assembly (8) and 317-7510 Radio
that is powered up. Cable Assembly (9).
Table 4
3. Connect cable (2) to the USB port of the PC.
Optional Hardware for the Use of Cat ET
4. Connect cable (4) to a service tool connector. Part Number Description
5. Restore electrical power to the ECM. Verify that N/A Personal Computer (PC)
the “POWER” indicator on the communication
adapter is illuminated. Make sure that the PC is
powered up.
6. Establish communication between Cat ET and the
ECM. If Cat ET indicates that there is more than
one ECM, select the engine ECM.
7. If Cat ET and the communication adapter do not
communicate with the ECM, refer to
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.
Refer to Troubleshooting, “Electronic Service Tool
Does Not Communicate” if any of the following
conditions exist:

• Cat ET displays a message that refers to a

Illustration 3 g03797181
communication problem.
(8) 317-7496 Computer Cable As (USB)
(9) 317-7510 Radio Cable Assembly C
• Cat ET displays “Error #142 The interface
hardware is not responding” .

• Cat ET displays a message that indicates that

the firmware in the communications adapter is
old.

Communicating with the Wireless

Communication Adapter (If so equipped)
A wireless communications adapter can be used in
order to allow Cat ET to communicate through a
wireless network with the equipment. Both the
wireless communications adapter and a
communication adapter must be installed on the
equipment in order for communication to take place.
This allows a technician to access information Illustration 4 g03797114
through Cat ET without being plugged directly into (9) 317-7510 Radio Cable Assembly
the equipment. (10) 317-7493 Wireless Communication Radio
(11) 326-9606 Antenna
For additional information regarding the setup and
operation of the wireless communications adapter, Note: Items (8), (9), (10), and (11) are part of the
refer to Tool Operating Manual, NEHS1081. 317-7492 Radio Kit and 349-1206 Radio Kit.
Table 4 lists the optional hardware that is needed in Use the following procedure in order to connect the
order to connect Cat ET by using a wireless wireless communication adapter for use with Cat ET.
connection.
1. Remove the electrical power from the ECM.
Note: Some applications cannot use a wireless
connection. Also, a dual data link cannot be used
with a wireless connection.
UENR4349-03 9
Introduction

2. Ensure that the computer has been correctly

configured for the 802.11a or 802.11b/g enabled
wireless card. Verify that the PC wireless is
installed and working correctly.
3. Connect cable (9) between communication radio
(8) and the service tool connector.
4. Restore the electrical power to the ECM. If Cat ET
and the communication radio do not communicate
with the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate with ECM”.
a. Install 326-9606 Antennas to the 317-7493
Wireless Communication Radio.
10 UENR4349-03
Introduction

PL1000E Communication ECM (If

Equipped)

Illustration 5 g01163897

The PL1000E is an ECM that provides the customer • Indicate if an event code was logged.
with the ability to integrate Caterpillar engines into
specific applications. The PL1000E enables • Indicate if a diagnostic code was logged. Also,
communication from a J1939 data link to a device record the codes that are logged.
that utilizes a MODBUS communication protocol. A
PC with Cat ET installed can be connected to the • Indicate the symptoms of engine operation that
PL1000E through the RS232 serial port of the PC. are present.
The PL1000E contains an embedded
communications adapter that will allow Cat ET to • Indicate the engine software part number.
communicate with the engine over the J1939 data
link. Be as specific as possible.
Refer to System Operation/Troubleshooting/Test and
Adjust, RENR8091, “PL1000E Communication ECM” Cause of Failure
for additional information.
Comments on the cause of failure include the
number of diagnostic codes that were logged.
i06127315
Comments also indicate if the code was an active
code. Indicate the source of the problem. Also
Service Information Report indicate the method that was used to discover the
problem. Examples of the methods that were used to
SMCS Code: 0336 discover the problem could be one of the following
methods:
After verifying that the correct repair has been
performed on the engine, provide brief, detailed • A specific procedure in the manual was followed.
information. This information is crucial and helps
Caterpillar better serve you and the customer. • A visual inspection indicated wire abrasion on the
engine harness.
Recommendations
• An engine dynamometer test indicated that the
power was below the specification at 1700 rpm.
Customers Complaint The power loss was due to the loss of the no. 4
Obtain as much information from the customer as injector. The engine dynamometer test indicated
possible. Investigate any written information that is that the power was below the specification at all
available and document any information that is engine speeds above 1700 rpm.
gathered from the customer. The following
information is of particular importance: Be as specific as possible.
UENR4349-03 11
Introduction

Repair Procedure
Comments on the repair procedure include the
following types of information:
• The wiring harness was repaired.

• The Full Load Setting (FLS) was changed per the

factory instructions.
Be as specific as possible.
12 UENR4349-03
Electronic System Overview

Electronic System The ECM adjusts timing for optimum engine

performance and for the fuel economy. Actual timing
Overview and desired timing cannot be viewed with Cat
Electronic Technician (ET). The ECM determines the
location of top center of the number one cylinder from
the signals that are provided by the engine speed/
timing sensors. The ECM determines when injection
i06067187 should occur relative to the top center. The ECM then
provides the signal to the injector at the desired time.
System Overview
Fuel Injection
SMCS Code: 1000; 1900
The C9.3 common rail fuel system is controlled by
The engine is designed for electronic control of most the ECM. The ECM gathers data from several
engine operating functions. The electronic system sensors on the engine. The ECM then uses this data
consists of an Electronic Control Module (ECM), the to adjust the quantity of fuel being delivered as well
wiring harness, switches, sensors, and fuel injectors. as the timing of the injection event. The injection
The engine ECM receives information from the event begins when the ECM sends a signal to the
sensors and the switches on the engine. The engine injector solenoid to actuate the 3 way valve inside the
ECM processes the information that is collected in injector. As the valve opens, the fuel flows from the
order to control the engine. By altering the fuel fuel rail, through the fuel line, and into the injector. As
delivery with the fuel injectors, the engine ECM the valve opening pressure is reached, the check is
controls the speed and the power that is produced by lifted and the fuel is delivered at a high pressure into
the engine. The engine is controlled by the A4E4 the combustion chamber.
ECM.
By controlling the timing and the duration of the high
The following information provides a general voltage signals, the ECM can control the following
description of the control system. Refer to the aspects of injection:
Systems Operation manual for detailed information
about the control system. • Injection timing

System Operation • Fuel delivery

The flash file inside the ECM establishes certain
Engine Governor limits on the amount of fuel that can be injected. The
“FRC Fuel Limit” is a limit that is based on the intake
The ECM governs the engine. The ECM determines manifold pressure. The “FRC Fuel Limit” is used to
the timing, the injection pressure, and the amount of control the air/fuel ratio for control of emissions.
fuel that is delivered to each cylinder. These factors When the ECM senses a higher intake manifold
are based on the actual conditions and on the pressure, the ECM increases the “FRC Fuel Limit” . A
desired conditions at any given time during starting higher intake manifold pressure indicates that there is
and operation. more air in the cylinder. When the ECM increases the
“FRC Fuel Limit” , the ECM changes the control
The ECM uses the throttle position sensor to signal to the injector. The signal will allow more fuel
determine the desired engine speed. The ECM into the cylinder.
compares the desired engine speed to the actual
engine speed. The actual engine speed is The “Rated Fuel Limit” is a limit that is based on the
determined through interpretation of the signals that power rating of the engine and on the engine rpm.
are received by the ECM from the engine speed/ The “Rated Fuel Limit” is like the rack stops and the
timing sensors. If the desired engine speed is greater torque spring on a mechanically governed engine.
than the actual engine speed, the ECM requests that The “Rated Fuel Limit” provides the power curves
more fuel is injected in order to increase engine and the torque curves for a specific engine family and
speed. a specific engine rating. All of these limits are
determined at the factory. These limits cannot be
Timing Considerations changed.

Once the ECM has determined the amount of fuel Other ECM Functions for
that is required, the ECM must determine the timing Performance
of the fuel injection.
The ECM may also provide enhanced control of the
engine for functions such as retarding the engine.
Refer to Troubleshooting, “Configuration Parameters”
for supplemental information about the systems that
can be monitored by the ECM.
UENR4349-03 13
Electronic System Overview

Programmable Parameters Refer to Troubleshooting, “Customer Passwords”

and Troubleshooting, “Factory Passwords” for
Certain parameters that affect engine operation may additional information on this subject.
be changed with Cat ET. The parameters are stored
in the ECM, and the parameters are protected from
unauthorized changes by passwords. These i06036406
parameters are either system configuration
parameters or customer parameters. Component Location
System configuration parameters are set at the SMCS Code: 1000; 1900
factory. System configuration parameters affect
emissions or power ratings within an engine family. Refer to the Schematic for the component location.
Factory passwords must be obtained and factory
passwords must be used to change the system i06132411
configuration parameters.
Some of the parameters may affect engine operation Engine Monitoring System
in an unusual way. An operator might not expect this
type of effect. Without adequate training, these SMCS Code: 1900
parameters may lead to power complaints or The Electronic Control Module (ECM) provides a
performance complaints even though the engines comprehensive, programmable engine monitoring
performance is to the specification. system for this engine. The ECM monitors specific
Customer parameters are variable. Customer engine operating parameters in order to detect
parameters can be used to affect the characteristics abnormal conditions that may develop. The ECM will
of the engine. Limits are set by the factory and by the generate an event code if a specific engine
monitoring system. parameter exceeds an acceptable range that is
defined by the engine monitoring system. The ECM
Customer passwords may be required to change will react with an action that is dependent on the
customer specified parameters. severity of the condition.

Refer to Troubleshooting, “Configuration Parameters” The following actions may be initiated by the ECM.
for additional information on this subject. These actions are dependent on the severity of the
condition.
Passwords • Illumination of a warning lamp or warning alarm
System configuration parameters are protected by
factory passwords. Factory passwords are calculated • Engine derate
on a computer system that is available only to
Caterpillar dealers. Since factory passwords contain • Engine shutdown
alphabetic characters, only Cat ET may change
system configuration parameters. Three possible responses may be available for each
parameter. Some of the responses are not available
Customer parameters can be protected by customer for some of the parameters. Refer to Table 5 .
passwords. The customer passwords are Table 5
programmed by the customer. Factory passwords
can be used to change customer passwords if Indicators
customer passwords are lost. Warning Category
Indicator Severity
(15) or (17) Least Severe

(16) or (18) Moderate Severity

(0) or (1) Most Severe

Use Caterpillar ® Electronic Technician (Cat ET) to

perform the following activities for the monitoring
system:
• Viewing parameters

• Parameter programming
• Set delay times
14 UENR4349-03
Electronic System Overview

The default settings for the parameters are Note: Factory passwords are only available to
programmed at the factory. To accommodate unique service technicians from an authorized Caterpillar
applications and sites, some of the parameters may Dealership. Customers of Caterpillar do not have
be reprogrammed with Cat ET. Use Cat ET to modify access to the Caterpillar Feature Protection System
the monitoring system parameters. (FPS).
Note: Some parameters do not require a password in
i06133243
order to be changed. Other parameters can be
changed with customer passwords. Some of the
parameters are protected by factory passwords. Diagnostic Capabilities
Some parameters cannot be changed. Some
applications do not allow any changes to the SMCS Code: 1900
programmable monitoring system. Parameters that
are protected by factory passwords can only be Diagnostic Codes
changed by dealer personnel.
The engines Electronic Control Module (ECM) can
monitor the circuitry between the ECM and the
Viewing or Changing the Settings engines components. The ECM can also monitor the
of the Monitoring System engines operating conditions. If the ECM detects a
problem, a code is generated.
Use the following procedure in order to view the
parameter settings and/or change the parameter There are two categories of codes:
settings:
• Diagnostic code
1. Select the “Service/Monitoring System” screen on
Cat ET. • Event code

Note: Ensure that you select the correct ECM for the Diagnostic Code – A diagnostic code indicates an
parameters that are being changed before electrical problem such as a short circuit or an open
circuit in the engines wiring or in an electrical
continuing. component.
2. Highlight the desired parameter. Then click the
“Change” button in the lower left corner of the Event Code – An event code is generated by the
screen. detection of an abnormal engine operating condition.
For example, an event code will be generated if the
The “Change Monitor System” screen will appear. oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Generally, event
3. Change the “State” of the parameter. codes indicate abnormal operating conditions or
mechanical problems rather than electrical problems.
4. Set the “Trip Point” and the “Delay Time” according
to the “Allowed Values” that are displayed in the
lower half of the screen. Codes can have two different states:

5. Click the “OK” button. • Active

If a password is required, the “Enter Passwords” • Logged
screen will appear. Enter the correct passwords
and then click the “OK” button.
Active Codes
Note: If a factory password is required, the “Enter
An active code indicates that a problem is present.
Factory Passwords” screen will appear. Refer to
Service the active code first. For the appropriate
Troubleshooting, “Factory Passwords” for information troubleshooting procedure for a particular code, refer
that is related to obtaining factory passwords. to the following troubleshooting procedure:
The new settings will be effective immediately. • Troubleshooting, “Diagnostic Trouble Codes”
• Troubleshooting, “Event Codes”
UENR4349-03 15
Electronic System Overview

Logged Codes active but the code may become logged.

The codes are logged and stored in the ECM Logged codes may not indicate that a repair is
memory. The problem may have been repaired and/ needed. The problem may have been temporary.
or the problem may no longer exist. If the system is Logged codes may be useful to help troubleshoot
powered, an active diagnostic code may be intermittent problems. Logged codes can also be
generated whenever a component is disconnected. If used to review the performance of the engine and of
the component is reconnected, the code is no longer the electronic system.

i06068247

Electrical Connectors
SMCS Code: 7553-WW

Connectors for the Electronic Control

Module (ECM)

Illustration 6 g06031486
Locations of the components at the Engine ECM A4 E4
(1) P2 ECM connector (ECM side) (2) P1 ECM connector (ECM side)
16 UENR4349-03
Electronic System Overview

(3) J2/P2 ECM connector (harness side) (4) J1/P1 ECM connector (harness side) (5) Engine ECM

Injector Connectors
Connectors at the Valve Cover

Illustration 7 g03820465

Connector at the Injector

Illustration 8 g03820496
Typical MR injector
UENR4349-03 17
Electronic System Overview

Sensor Connectors Connectors for the Termination Resistor

Analog Sensor Connector (active)

Illustration 9 g01240891

Analog Sensor Connector (passive)

Illustration 11 g01355248

Engine Speed/Timing Connector

Illustration 10 g01241538

Illustration 12 g03820559
18 UENR4349-03
Electronic System Overview

Ampseal Connector (typical) Deutsch Connectors (typical)

Illustration 13 g02219254
Refer to Special Instruction, REHS2556 for additional
information

Illustration 14 g02220494
Refer to Tool Operating Manual, SEHS9615,
“Servicing Deutsch HD and DT Style Connectors” for
additional information
UENR4349-03 19
Configuration Parameters

Configuration Parameters

i06068268

Configuration Parameters
SMCS Code: 1900
Use this procedure if the diagnostic code in Table 6 is
active.
Table 6
Codes That Relate to Configuration Parameters

Code Description
J1939 Code (code descriptions may vary) Comments
The engine Electronic Control Module
(ECM) detects that one or more of the pro-
grammable parameters have not been
Calibration Memory : Erratic, Intermittent, or
630-2 programmed.
Incorrect
The ECM may use a default torque map or
the ECM may limit the engine to low idle.
The code is active only.

Follow the troubleshooting procedure in order to identify the root cause of the problem.

The Cat ® Electronic Technician (Cat ET) can be used

to view certain parameters that can affect the
operation of the engine. Cat ET can also be used to
change certain parameters. Some parameters
cannot be changed and some applications do not
allow any changes to the programmable monitoring
system. The parameters are stored in the Electronic
Control Module (ECM). Some of the parameters are
protected from unauthorized changes by passwords.
Parameters that can be changed have a tattletale
number. The tattletale number shows if a parameter
has been changed.
The parameters are divided into two different types:
Customer Specified Parameters – Customer
passwords may be required to change the values of
customer specified parameters.
System Configuration Parameters – System
configuration parameters affect the emissions of the
engine or the power of the engine. Factory
passwords may be required to change the values of
system configuration parameters.
20 UENR4349-03
Configuration Parameters

Illustration 15 g02161343
Typical configuration screen

1. Connect to Cat ET.

2. Select the Service tab.
3. Select the Configuration tab to view the
configuration parameters.
If an ECM is replaced, the appropriate parameters
must be copied from the old ECM. Copy the
parameters with the “Copy Configuration” feature of
the Cat ET. The “Copy Configuration” tab is below the
“Configuration” tab. Alternatively, the settings can be
recorded on paper and then programmed into the
configuration screen that is for the new module.

NOTICE
Changing the parameters during engine operation
can cause the engine to operate erratically and can
cause engine damage.
Only change the settings of the parameters when the
engine is STOPPED.
UENR4349-03 21
Configuration Parameters

Check Programmable Parameters

(630-2)

Illustration 16 g06034118

If a programmable parameter has not been

programmed, the ECM will generate a 268-2 or 630-2
diagnostic code. The programmable parameter that
is not programmed will be listed under the code.
Illustration 16 shows the parameters that are not
programmed under the 268-2 code. The
unprogrammed parameters will be set to default.
Certain aspects of the engines performance and
engine monitoring may be affected.
If “Injector Trim” is displayed below a 630-2
diagnostic code on Cat ET, refer to Troubleshooting,
“Injector Trim File - Install”.
22 UENR4349-03
Diagnostic Trouble Codes

Diagnostic Trouble Codes

i07272818

Diagnostic Trouble Codes

SMCS Code: 1900
Table 7 lists the diagnostic trouble codes that apply to
the engines that are covered in this manual. Use the
Caterpillar Electronic Technician (ET) in order to
determine the codes that are active or logged. Then
refer to the appropriate troubleshooting procedure for
more information.
Further explanations of diagnostic codes are
explained after Table 7 .
Portions of this material are reprinted with permission
from SAE J1939DA_201607© 2016 SAE
International. SAE International is not responsible for
any use or translation of this material, in whole or in
part. Contact SAE International to obtain a complete
copy of SAE J1939DA_201607, the official definitive
source of this standard.
Note: A requirement for all troubleshooting is that the
troubleshooting is based on active and/or passive
diagnostic trouble codes. Do not troubleshoot based
on flash codes alone.
Table 7
Cross-Reference from Diagnostic Trouble Codes to Functional Test or Procedure

J1939 Code and Description Troubleshooting Procedure Flash Codes

28-3
Accelerator Pedal Position #3 : Voltage Above Troubleshooting, “Speed Control - Test” N/A
Normal
28-4
Accelerator Pedal Position #3 : Voltage Below Troubleshooting, “Speed Control - Test” N/A
Normal
29-3
Accelerator Pedal Position 2 : Voltage Above Troubleshooting, “Speed Control - Test” N/A
Normal
29-4
Accelerator Pedal Position 2 : Voltage Below Troubleshooting, “Speed Control - Test” N/A
Normal
29-8
Accelerator Pedal Position 2 : Abnormal Fre- Troubleshooting, “Speed Control - Test” N/A
quency, Pulse Width, or Period

91-3
Accelerator Pedal Position 1 : Voltage Above Troubleshooting, “Speed Control - Test” N/A
Normal

(continued)
UENR4349-03 23
Diagnostic Trouble Codes

(Table 7, contd)
91-4
Accelerator Pedal Position 1 : Voltage Below Troubleshooting, “Speed Control - Test” N/A
Normal
91-8
Accelerator Pedal Position 1 : Abnormal Fre- Troubleshooting, “Speed Control - Test” N/A
quency, Pulse Width, or Period

94-16
Engine Fuel Delivery Pressure : High - moderate Troubleshooting, “Fuel Pressure Is High” N/A
severity (2)

96-3
Troubleshooting, “Fuel Level - Test” N/A
Fuel Level : Voltage Above Normal

96-4
Troubleshooting, “Fuel Level - Test” N/A
Fuel Level : Voltage Below Normal

96-17 Add fuel to the fuel tank. Refer to the literature that is pro-
N/A
Fuel Level : Low - least severe (1) vided by the OEM of the vessel for the correct procedure.

98-1
Troubleshooting, “Oil Level Is Low” N/A
Engine Oil Level : Low - most severe (3)

98-17
Troubleshooting, “Oil Level Is Low” N/A
Engine Oil Level : Low - least severe (1)

98-18
Troubleshooting, “Oil Level Is Low” N/A
Engine Oil Level : Low - moderate severity (2)

100-1
Troubleshooting, “Oil Pressure Is Low” N/A
Engine Oil Pressure : Low - most severe (3)

100-3
Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Engine Oil Pressure : Voltage Above Normal

100-4
Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Engine Oil Pressure : Voltage Below Normal

100-17
Troubleshooting, “Oil Pressure Is Low” N/A
Engine Oil Pressure : Low - least severe (1)

100-18
Troubleshooting, “Oil Pressure Is Low” N/A
Engine Oil Pressure : Low - moderate severity (2)

101-3
Engine Crankcase Pressure : Voltage Above Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal
101-4
Engine Crankcase Pressure : Voltage Below Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal
101-13
Troubleshooting, “Sensor Calibration Required - Test” N/A
Engine Crankcase Pressure : Calibration Required

102-18
Engine Intake Manifold #1 Pressure : Low - moder- Troubleshooting, “Intake Manifold Air Pressure Is Low” N/A
ate severity (2)

105-0
Troubleshooting, “Intake Manifold Air Temperature Is
Engine Intake Manifold #1 Temperature : High - N/A
High”
most severe (3)

105-3
Engine Intake Manifold #1 Temperature : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Above Normal

(continued)
24 UENR4349-03
Diagnostic Trouble Codes

(Table 7, contd)
105-4
Engine Intake Manifold #1 Temperature : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Below Normal
105-15
Troubleshooting, “Intake Manifold Air Temperature Is
Engine Intake Manifold #1 Temperature : High - N/A
High”
least severe (1)

105-16
Troubleshooting, “Intake Manifold Air Temperature Is
Engine Intake Manifold #1 Temperature : High - N/A
High”
moderate severity (2)

109-1
Engine Coolant Pressure : Data Low - Most Severe Troubleshooting, “Coolant Pressure Is Low” N/A
(3)

109-3
Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Engine Coolant Pressure : Voltage Above Normal

109-4
Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Engine Coolant Pressure : Voltage Below Normal

109-17
Troubleshooting, “Coolant Pressure Is Low” N/A
Engine Coolant Pressure : Low - least severe (1)

109-18
Engine Coolant Pressure : Low - moderate severity Troubleshooting, “Coolant Pressure Is Low” N/A
(2)

110-0
Engine Coolant Temperature : High - most severe Troubleshooting, “Coolant Temperature is High” N/A
(3)

110-3
Engine Coolant Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 133
Normal
110-4
Engine Coolant Temperature : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 133
Normal
110-15
Engine Coolant Temperature : High - least severe Troubleshooting, “Coolant Temperature is High” N/A
(1)

110-16
Engine Coolant Temperature : High - moderate se- Troubleshooting, “Coolant Temperature is High” N/A
verity (2)

110-17
Engine Coolant Temperature : Low - least severe Troubleshooting, “Coolant Temperature is Low” N/A
(1)

111-1
Troubleshooting, “Coolant Level Is Low” N/A
Engine Coolant Level : Low - most severe (3)

111-17
Troubleshooting, “Coolant Level Is Low” N/A
Engine Coolant Level : Low - least severe (1)

111-18
Troubleshooting, “Coolant Level Is Low” N/A
Engine Coolant Level : Low - moderate severity (2)

157-3
Engine Injector Metering Rail #1 Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” 133
Above Normal

(continued)
UENR4349-03 25
Diagnostic Trouble Codes

(Table 7, contd)
157-4
Engine Injector Metering Rail #1 Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” 133
Below Normal
157-17
Engine Injector Metering Rail #1 Pressure : Low - Troubleshooting, “Fuel Rail Pressure Is Low” N/A
least severe (1)

168-3
Battery Potential / Power Input 1 : Voltage Above Troubleshooting, “Electrical Power Supply - Test” 422
Normal
168-4
Battery Potential / Power Input 1 : Voltage Below Troubleshooting, “Electrical Power Supply - Test” 422
Normal
172-3
Engine Air Inlet Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 133
Normal
172-4
Engine Air Inlet Temperature : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 133
Normal
173-0
Engine Exhaust Gas Temperature : High - most se- Troubleshooting, “Exhaust Temperature is High” N/A
vere (3)

173-3
Engine Exhaust Gas Temperature : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
Normal
173-4
Engine Exhaust Gas Temperature : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
Normal
173-8
Engine Exhaust Gas Temperature : Abnormal Fre- Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
quency, Pulse Width, or Period

173-15
Engine Exhaust Gas Temperature : High - least se- Troubleshooting, “Exhaust Temperature is High” N/A
vere (1)

173-16
Engine Exhaust Gas Temperature : High - moder- Troubleshooting, “Exhaust Temperature is High” N/A
ate severity (2)

174-0
Engine Fuel Temperature 1 : High - most severe Troubleshooting, “Fuel Temperature is High” N/A
(3)

174-3
Engine Fuel Temperature 1 : Voltage Above Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 165
Normal
174-4
Engine Fuel Temperature 1 : Voltage Below Troubleshooting, “Sensor Signal (Analog, Passive) - Test” 165
Normal
174-15
Troubleshooting, “Fuel Temperature is High” N/A
Engine Fuel Temperature 1 : High - least severe (1)

174-16
Engine Fuel Temperature 1 : High - moderate se- Troubleshooting, “Fuel Temperature is High” N/A
verity (2)

(continued)
26 UENR4349-03
Diagnostic Trouble Codes

(Table 7, contd)
175-0
Troubleshooting, “Engine Oil Temperature is High” N/A
Engine Oil Temperature 1 : High - most severe (3)

175-3
Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
Engine Oil Temperature 1 : Voltage Above Normal

175-4
Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
Engine Oil Temperature 1 : Voltage Below Normal

175-15
Troubleshooting, “Engine Oil Temperature is High” N/A
Engine Oil Temperature 1 : High - least severe (1)

175-16
Engine Oil Temperature 1 : High - moderate se- Troubleshooting, “Engine Oil Temperature is High” N/A
verity (2)

190-0
Troubleshooting, “Engine Overspeeds” N/A
Engine Speed : High - most severe (3)

190-8
Engine Speed : Abnormal Frequency, Pulse Width, Troubleshooting, “Speed/Timing - Test” 141
or Period
190-15
Troubleshooting, “Engine Overspeeds” N/A
Engine Speed : High - least severe (1)

411-3
Engine Exhaust Gas Recirculation Differential Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Pressure : Voltage Above Normal

441-0 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Temperature #1 : High - most severe (3) bleshooting procedure will depend on the symptoms.

441-3 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Temperature #1 : Voltage Above Normal bleshooting procedure will depend on the symptoms.

441-4 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Temperature #1 : Voltage Below Normal bleshooting procedure will depend on the symptoms.

441-15 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Temperature #1 : High - least severe (1) bleshooting procedure will depend on the symptoms.

441-16
Troubleshooting, “Symptom Troubleshooting” The trou-
Auxiliary Temperature #1 : High - moderate se- N/A
bleshooting procedure will depend on the symptoms.
verity (2)

630-2
Calibration Memory : Erratic, Intermittent, or Troubleshooting, “Configuration Parameters” 527
Incorrect
631-2
Calibration Module : Erratic, Intermittent, or Troubleshooting, “ECM Software - Install” N/A
Incorrect
637-11
Troubleshooting, “Timing - Calibrate” 143
Engine Timing Sensor : Other Failure Mode

637-13
Troubleshooting, “Timing - Calibrate” 143
Engine Timing Sensor : Calibration Required

639-9
Troubleshooting, “Data Link - Test” N/A
J1939 Network #1 : Abnormal Update Rate

639-14
Troubleshooting, “Data Link - Test” N/A
J1939 Network #1 : Special Instruction

(continued)
UENR4349-03 27
Diagnostic Trouble Codes

(Table 7, contd)
651-2
Engine Injector Cylinder #01 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 111/139
or Incorrect
651-5
Engine Injector Cylinder #01 : Current Below Troubleshooting, “Injector Solenoid - Test” 111/139
Normal
651-6
Engine Injector Cylinder #01 : Current Above Troubleshooting, “Injector Solenoid - Test” 111/139
Normal
651-7
Engine Injector Cylinder #01 : Not Responding Troubleshooting, “Injector Solenoid - Test” 111/139
Properly

652-2
Engine Injector Cylinder #02 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 112/139
or Incorrect
652-5
Engine Injector Cylinder #02 : Current Below Troubleshooting, “Injector Solenoid - Test” 112/139
Normal
652-6
Engine Injector Cylinder #02 : Current Above Troubleshooting, “Injector Solenoid - Test” 112/139
Normal
652-7
Engine Injector Cylinder #02 : Not Responding Troubleshooting, “Injector Solenoid - Test” 112/139
Properly

653-2
Engine Injector Cylinder #03 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 113/139
or Incorrect
653-5
Engine Injector Cylinder #03 : Current Below Troubleshooting, “Injector Solenoid - Test” 113/139
Normal
653-6
Engine Injector Cylinder #03 : Current Above Troubleshooting, “Injector Solenoid - Test” 113/139
Normal
653-7
Engine Injector Cylinder #03 : Not Responding Troubleshooting, “Injector Solenoid - Test” 113/139
Properly

654-2
Engine Injector Cylinder #04 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 114/139
or Incorrect
654-5
Engine Injector Cylinder #04 : Current Below Troubleshooting, “Injector Solenoid - Test” 114/139
Normal
654-6
Engine Injector Cylinder #04 : Current Above Troubleshooting, “Injector Solenoid - Test” 114/139
Normal
654-7
Engine Injector Cylinder #04 : Not Responding Troubleshooting, “Injector Solenoid - Test” 114/139
Properly

655-2
Engine Injector Cylinder #05 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 115/139
or Incorrect

(continued)
28 UENR4349-03
Diagnostic Trouble Codes

(Table 7, contd)
655-5
Engine Injector Cylinder #05 : Current Below Troubleshooting, “Injector Solenoid - Test” 115/139
Normal
655-6
Engine Injector Cylinder #05 : Current Above Troubleshooting, “Injector Solenoid - Test” 115/139
Normal
655-7
Engine Injector Cylinder #05 : Not Responding Troubleshooting, “Injector Solenoid - Test” 115/139
Properly

656-2
Engine Injector Cylinder #06 : Erratic, Intermittent, Troubleshooting, “Injector Solenoid - Test” 116/139
or Incorrect
656-5
Engine Injector Cylinder #06 : Current Below Troubleshooting, “Injector Solenoid - Test” 116/139
Normal
656-6
Engine Injector Cylinder #06 : Current Above Troubleshooting, “Injector Solenoid - Test” 116/139
Normal
656-7
Engine Injector Cylinder #06 : Not Responding Troubleshooting, “Injector Solenoid - Test” 116/139
Properly

677-5
Engine Starter Motor Relay : Current Below Troubleshooting, “Relay - Test” N/A
Normal
677-6
Engine Starter Motor Relay : Current Above Troubleshooting, “Relay - Test” N/A
Normal
678-3
Troubleshooting, “Sensor Supply - Test” N/A
ECU 8 Volts DC Supply : Voltage Above Normal

678-4
Troubleshooting, “Sensor Supply - Test” N/A
ECU 8 Volts DC Supply : Voltage Below Normal

723-8
Engine Speed Sensor #2 : Abnormal Frequency, Troubleshooting, “Speed/Timing - Test” N/A
Pulse Width, or Period

931–5
Engine Fuel Supply Pump Actuator: Current Below Troubleshooting, “Fuel Priming Pump- Test” N/A
Normal
931–6
Engine Fuel Supply Pump Actuator: Current Above Troubleshooting, “Fuel Priming Pump- Test” N/A
Normal
The monitoring system override switch has been acti-
971-31
vated. Engine derates are prevented when this event is N/A
Engine Derate Switch
active.
974-5
Remote Accelerator Pedal Position : Current Below Troubleshooting, “Speed Control - Test” N/A
Normal
974-6
Remote Accelerator Pedal Position : Current Troubleshooting, “Speed Control- Test” N/A
Above Normal
1208-3
Engine Pre-filter Oil Pressure : Voltage Above Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal

(continued)
UENR4349-03 29
Diagnostic Trouble Codes

(Table 7, contd)
1208-4
Engine Pre-filter Oil Pressure : Voltage Below Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal
The Engine Shutdown Override Switch is used to keep
the engine running when the ECM is commanding that the
engine be shutdown for reasons other than inducement-
1237-31
related events. If this code is present, there may be dam- N/A
Engine Shutdown Override Switch
age to the engine. This code indicates that the operator
chose to keep the engine running in conditions that typi-
cally can damage the engine.

1239-0
Troubleshooting, “Fuel Rail Pressure Leakage Is High” N/A
Engine Fuel Leakage 1 : High - most severe (3)

1239-31
Troubleshooting, “Fuel Rail Pressure Leakage Is High” N/A
Engine Fuel Leakage 1

1347-5
Engine Fuel Pump Pressurizing Assembly #1 : Troubleshooting, “Fuel Injection Pump - Test” N/A
Current Below Normal

1347-6
Engine Fuel Pump Pressurizing Assembly #1 : Troubleshooting, “Fuel Injection Pump - Test” N/A
Current Above Normal

1348-5
Engine Fuel Pump Pressurizing Assembly #2 : Troubleshooting, “Fuel Injection Pump - Test” N/A
Current Below Normal

1348-6
Engine Fuel Pump Pressurizing Assembly #2 : Troubleshooting, “Fuel Injection Pump - Test” N/A
Current Above Normal

1381-3
Engine Fuel Supply Pump Inlet Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Above Normal

1381-4
Engine Fuel Supply Pump Inlet Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Below Normal

1387-0 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Pressure #1 : High - most severe (3) bleshooting procedure will depend on the symptoms.

1387-3 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Pressure #1 : Voltage Above Normal bleshooting procedure will depend on the symptoms.

(continued)
30 UENR4349-03
Diagnostic Trouble Codes

(Table 7, contd)

1387-4 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Pressure #1 : Voltage Below Normal bleshooting procedure will depend on the symptoms.

1387-15 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Pressure #1 : High - least severe (1) bleshooting procedure will depend on the symptoms.

1387-16 Troubleshooting, “Symptom Troubleshooting” The trou-

N/A
Auxiliary Pressure #1 : High - moderate severity (2) bleshooting procedure will depend on the symptoms.

1656-2
Engine Automatic Start Enable Switch : Erratic, In- Troubleshooting, “Engine Control Switch - Test” N/A
termittent, or Incorrect

1664-31
Troubleshooting, “Engine Overcrank Occurrence” N/A
Engine Automatic Start Failed

2435-3
Seawater Pump Outlet Pressure : Voltage Above Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal
2435-4
Seawater Pump Outlet Pressure : Voltage Below Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Normal
2435-17
Seawater Pump Outlet Pressure : Low - least se- Troubleshooting, “Sea Water Pump Pressure Problem” N/A
vere (1)

2630-1
Engine Charge Air Cooler Outlet Temperature : Troubleshooting, “Sensor Signal (Analog, Passive) - Test” N/A
Voltage Above Normal

2648-5
N/A N/A
Maintenance Lamp : Current Below Normal

2648-6
N/A N/A
Maintenance Lamp : Current Above Normal

3509-3
Troubleshooting, “Sensor Supply - Test” 516
Sensor Supply Voltage 1 : Voltage Above Normal

3509-4
Troubleshooting, “Sensor Supply - Test” 516
Sensor Supply Voltage 1 : Voltage Below Normal

3510-3
Troubleshooting, “Sensor Supply - Test” 516
Sensor Supply Voltage 2 : Voltage Above Normal

3510-4
Troubleshooting, “Sensor Supply - Test” 516
Sensor Supply Voltage 2 : Voltage Below Normal

3563-3
Engine Intake Manifold #1 Absolute Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test” 197
Voltage Above Normal

3563-4
Engine Intake Manifold #1 Absolute Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test” 197
Voltage Below Normal

(continued)
UENR4349-03 31
Diagnostic Trouble Codes

(Table 7, contd)
3563-13
Engine Intake Manifold #1 Absolute Pressure : Cal- Troubleshooting, “Sensor Calibration Required - Test” 197
ibration Required

3563-21
Engine Intake Manifold #1 Absolute Pressure : Da- Troubleshooting, “Sensor Supply - Test” N/A
ta Drifted Low
5578-3
Engine Fuel Delivery Absolute Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Above Normal
5578-4
Engine Fuel Delivery Absolute Pressure : Voltage Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Below Normal
5578-21
Engine Fuel Delivery Absolute Pressure : Data Troubleshooting, “Sensor Supply - Test” N/A
Drifted Low
5580-3
Engine Filtered Fuel Delivery Absolute Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Voltage Above Normal

5580-4
Engine Filtered Fuel Delivery Absolute Pressure : Troubleshooting, “Sensor Signal (Analog, Active) - Test” N/A
Voltage Below Normal

5580-17
Engine Filtered Fuel Delivery Absolute Pressure : Troubleshooting, “Fuel Pressure Is Low” N/A
Low - least severe (1)

5580-21
Engine Filtered Fuel Delivery Absolute Pressure : Troubleshooting, “Sensor Supply - Test” N/A
Data Drifted Low
5584-15
Engine Fuel Filter Degradation : High - least severe Troubleshooting, “Fuel Filter Is Restricted” N/A
(1)

5584-16
Engine Fuel Filter Degradation : High - moderate Troubleshooting, “Fuel Filter Is Restricted” N/A
severity (2)

5585-17
Troubleshooting, “Fuel Rail Pressure Is Low While
Engine Injector Metering Rail #1 Cranking Pres- N/A
Cranking”
sure : Low - least severe (1)

7471-15
Engine Oil Filter Differential Pressure : High - least Troubleshooting, “Oil Filter Differential Pressure Problem” N/A
severe (1)

Diagnostic Codes Failure Mode Identifier (FMI) – The FMI indicates

the type of failure.
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes are also used by the service technician to Refer to Table 7 for a complete list of the diagnostic
identify the nature of the problem. Cat ® Electronic codes and the appropriate troubleshooting
Technician (ET) is a software program that runs on a procedure.
personal computer. The software can be used by the
service technician to view the diagnostic code Note: Do not confuse diagnostic codes with event
information for an ECM. The diagnostic code will be codes. Event codes alert the operator that an
displayed as a two-element code. The following abnormal operating condition such as low oil
terms describe the elements of the code: pressure or high coolant temperature has been
detected. If an event code is active, refer to
Suspect Parameter Number (SPN) – The SPN is a Troubleshooting, “Event Codes”.
code which is assigned to each component to identify
data. Illustration 17 is an example of the operating range of
a sensor.
32 UENR4349-03
Diagnostic Trouble Codes

Logged Diagnostic Codes

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

• The hour of the last occurrence of the code

• The number of occurrences of the code
This information is a valuable indicator for
troubleshooting intermittent problems.
A code is cleared from memory when one of the
following conditions occur:
• The service technician manually clears the code.

• The code does not recur for 100 hours.

• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that did
not result in complaints. The most likely cause of an
intermittent problem is a faulty connection or
damaged wiring. The next likely cause is a
component failure. The least likely cause is the
failure of an electronic module. Diagnostic codes that
are logged repeatedly may indicate a problem that
needs special investigation.

Illustration 17 g01365757 Note: Always clear logged diagnostic codes after

Example of the typical operating range of a sensor investigating and correcting the problem which
generated the code.
(1) This area represents the normal operating range of the engine
parameter.
(2) In these areas, the engine is operating in an unsafe operating
range of the monitored parameter. An event code will be
generated for the monitored parameter. The sensor circuit
does not have an electronic problem. Refer to Troubleshooting,
“Event Codes” for additional information on event codes.
(3) In these areas, the signal from the sensor is outside of the
operating range of the sensor. The sensor circuit has an
electronic problem. A diagnostic code will be generated for the
sensor circuit.

Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.
When the ECM generates an active diagnostic code.
The “Active Alarm” indicator ( “Control Alarm Status”
on Cat ET) is activated to alert the operator. If the
condition that generated the code is momentary, the
message disappears from the list of active diagnostic
codes. The diagnostic code becomes logged.
UENR4349-03 33
Symptom Troubleshooting

Symptom Troubleshooting

i06068577

Acceleration Is Poor or
Throttle Response Is Poor
SMCS Code: 1000-035
Download the “Warranty Report” from the engine
ECM before performing any troubleshooting or
clearing diagnostic trouble codes. Check Caterpillar ®
Electronic Technician (Cat ET) for any associated
codes that are listed in Table 8 . Troubleshoot any
active codes before continuing with this procedure.
Table 8
Associated Diagnostic Trouble Codes

157-17
5580-18
5584-15
5584-16

Probable Causes
• Codes
• Parameters

• Throttle Signal
• Inlet air restriction

• Exhaust restriction
• Fuel System
• Engine Load

• Valve Lash

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
speed, full load, and engine operating temperature.
Troubleshooting the symptoms under other
conditions can give misleading results.
34 UENR4349-03
Symptom Troubleshooting

Table 9
Troubleshooting Test Steps Values Results

1. Engine Derate or Active Codes Result: A diagnostic code is present.

Engine Derate
A. Certain diagnostic codes and/or event codes may cause poor or Active Codes Repair: Troubleshoot the code and then reset the
performance. Refer to the histogram information for engine de- histogram.
rates in Cat ET. Check for the following histograms:
Result: A diagnostic code is not present.
1. High Exhaust Temperature Prevention Derate Time Histogram
Proceed to Test Step 2.
2. High Turbo Speed Prevention Derate Time Histogram

B. If the histograms contain derates and no diagnostic codes are

present, then the engine is operating normally. The following list
contains conditions that can cause derates:

1. Elevated altitude

2. Elevated inlet air temperature

3. Elevated ambient temperature

2. Check for Incorrect Configuration Parameters Result: The parameters are correct.
Parameters
A. Connect Cat ET to the service tool connector. verify that the Proceed to Test Step 3.
correct parameters are being used.
Result: The parameters are not correct.
B. Use Cat ET to verify that the correct parameters are being
used. Repair: Input the correct parameters. Refer to Trouble-
shooting, “Configuration Parameters” for additional
information.

If the problem is not resolved, proceed to Test Step 3.

3. Check the Throttle Signal Result: The throttle signal is stable.

Throttle Signal Proceed to Test Step 4.
A. Monitor the status for “Throttle Position” on Cat ET. Verify that
the status for “Throttle Position” is stable and that the engine is Result: The throttle signal is not stable.
able to reach high idle speed.
Repair: Make the necessary repairs, Refer to the appro-
priate circuit test.

If the problem is not resolved, proceed to Test Step 4.

4. Check for Restriction in the Air Inlet System Result: The inlet air restriction is OK.
Restrictions
A. Check for an air filter restriction indicator. Refer to the Opera- Proceed to Test Step 5.
tion and Maintenance Manual for additional information.
Result: The inlet air restriction is NOT OK. An imbalance
B. Measure the inlet air restriction for the turbocharger. Refer to in the system is discovered.
Troubleshooting, “Inlet Air Is Restricted” for additional
information. Repair: Repair or replace damaged inlet air system com-
ponents. Equalize the inlet air restriction for the
turbocharger.

If the problem is not resolved, proceed to Test Step 5.

(continued)
UENR4349-03 35
Symptom Troubleshooting

(Table 9, contd)
5. Check for a Restriction in the Exhaust System Result: The exhaust restriction measurement is OK.
Restrictions
A. Measure the exhaust restriction during engine operation with a Proceed to Test Step 6.
load. For data that is specific to your engine, refer to the Technical
Marketing Information (TMI). Result: The exhaust restrictions not OK.

Repair: Repair or replace damaged exhaust system

components.

If the problem is not resolved, proceed to Test Step 6.

6. Inspect the Fuel System Result: The fuel pressure is OK.

Fuel system
Refer to Systems Operation/Testing and Adjusting, “Fuel System Proceed to Test Step 7.
Inspection” for additional information.
Result: The fuel pressure is not OK.
A. Visually check the fuel level in the fuel tank. Do not rely on the
fuel gauge only. Repair: Replace the fuel filters. Clean the primary filter/
water separator of debris. Refer to the Operation and
B. Ensure that the vent in the fuel cap is not filled with debris. Maintenance Manual for details.

C. Ensure that the fuel supply valve (if equipped) is in the full If the problem is not resolved, proceed to Test Step 7.
OPEN position.

Note: Cold weather adversely affects the characteristics of the

fuel. Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
cold-weather operation. Cold mode (if applicable) is activated
whenever the engine coolant temperature falls below a predeter-
mined value. Monitor the status screen on Cat ET in order to veri-
fy that the engine has exited cold mode. Observe the reading for
coolant temperature on the Cat ET.

D. Inspect the fuel system. Refer to Systems Operation/Testing

and Adjusting, “Fuel System - Inspect” for additional information.

F. Check fuel quality. Refer to Systems Operation/Testing and Ad-

justing, “Fuel Quality - Test” for additional information. Check the
fuel tank for debris or foreign objects which may block the fuel
supply.

G. Check for the proper operation of the fuel transfer pump. Refer
to Systems Operation/Testing and Adjusting, “Fuel System” for
test information.

7. Engine Load Engine loads Result: There is not a parasitic load.

A. Check accessories and parasitic loads on the engine. Proceed to Test Step 8.

Result: There is a parasitic load.

Repair: Remove the parasitic load.

If the problem is not resolved, proceed to Test Step 8.

8. Check the Valve Lash Valve lash Result: The valve lash is NOT OK.

Note: The valve lash can affect the performance of the engine. Repair:Reset the valve lash. Refer to Testing and Adjust-
ing, “Engine Valve Lash - Inspect/Adjust” for additional
information.
36 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i05988725

Alternator Problem
(Charging Problem and/or Noisy
Operation)
SMCS Code: 1405-035

Probable Causes
• Alternator
• Charging Circuit

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Table 10
Troubleshooting Test Steps Values Results

1. Condition of the Alternator Drive Belts Drive Belt Result: The alternator drive belts are in good condition and
the belt tension is correct.
A. Inspect the condition of the alternator drive belts.
Proceed to Test Step 2.
B. Check the belt tension. If the engine is equipped with an
automatic belt tensioner, check the automatic belt tensioner. Result: The alternator drive belts are not in good condition
or the belt tension is incorrect.
Excessive belt tension can result in damage to the alternator.
Repair: If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and Assembly for
the correct procedure.

If necessary, replace the automatic belt tensioner. Refer to

Disassembly and Assembly for the correct procedure.

2. Condition of the Alternator Drive Pulley Alternator Drive Result: There is excessive wear on the alternator drive
Pulley pulley.
A. Check the condition of the alternator drive pulley. Look for
deep grooves that have been worn into the pulley by the belt. Repair: Replace the pulley.
Check that the nut for the pulley has not become loose.
Result: The alternator drive pulley nut was loose.

Repair: Tighten the nut.

Result: There is not excessive wear on the alternator drive

pulley.

Proceed to Test Step 3.

(continued)
UENR4349-03 37
Symptom Troubleshooting

(Table 10, contd)

Troubleshooting Test Steps Values Results

3. Wear of the Alternator Bearings Alternator Bearings Result: The alternator bearings are OK.

A. Check the alternator bearings for signs of wear. Proceed to Test Step 4.

Result: The alternator bearings are not OK.

Repair: Repair the alternator or replace the alternator, as

needed. Refer to Disassembly and Assembly for the cor-
rect procedure.

4. Operation of the Alternator or Regulator Regulator and Result: The regulator and alternator are operating
Alternator properly.
A. Verify that the alternator or the regulator is operating cor-
rectly. Refer to Special Instruction, REHS0354, “Charging Proceed to Test Step 5.
System Troubleshooting” for the proper testing procedures.
Result: The regulator and alternator are not operating
properly.

Repair: Repair the alternator and regulator or replace the

alternator and regulator, as needed. Refer to Disassembly
and Assembly for the correct procedure.

5. Inspection of the Charging Circuit Charging Circuit Result: The charging circuit is not working properly.

A. Inspect the battery cables, wiring, and connections in the Repair: Clean all connections and tighten all connections.
charging circuit. Replace any faulty parts.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06990105

Battery Problem
SMCS Code: 1401-035
Use this procedure to troubleshoot a problem with
the battery.

Probable Causes
• Battery
• Switched battery circuit
38 UENR4349-03
Symptom Troubleshooting

Recommended Actions
Table 11
Troubleshooting Test Steps Values Results

1. Check the Battery Battery Result: The battery is OK.

A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 2.
to Testing and Adjusting, “Battery - Test” for additional information.
Result: The battery is NOT OK.

Repair: Replace the battery. Refer to Disassembly and As-

sembly for the correct procedure.

If the problem is not resolved, proceed to Test Step 2.

2. Check the Switched Battery Circuit Switched Result: The switched battery circuit drained the battery by
Battery being left in the ON position.
A. Verify that a switched battery circuit drained the battery by Circuit
being left in the ON position. Repair: Charge the battery. Verify that the battery is able to
maintain a charge. Refer to Testing and Adjusting, “Battery -
Test” for additional information.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06926334

Coolant Contains Fuel

SMCS Code: 1250-035; 1395-035

Probable Causes
• Leaking injector sleeve and/or damaged seal

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 39
Symptom Troubleshooting

Table 12
Troubleshooting Test Steps Values Results
1. Leaking injector sleeve and/or damaged seal
Injector
A. Remove the valve mechanism covers. Sleeve Result: The injector sleeve is leaking.

B. Remove the fuel injectors from the cylinder head. Remove the injector sleeve that is leaking. Carefully inspect
the sleeve for damage. If there are visible signs of damage to
Refer to the Disassembly and Assembly manual for details. the injector sleeve, replace the sleeve. Replace the O-ring
seals for the injector sleeve and reinstall the sleeve. Replace
Do not allow the pressure on the cooling system to exceed any damaged components.
103 kPa (15 psi) during the test. Damage to the cooling
system may result from applying excessive pressure. Coolant may also be contaminating the fuel system. After the
engine is shutdown, the retention of pressure in the cooling
C. Pressurize the cooling system in order to identify the injector system may cause the transfer of coolant into the fuel system.
sleeve that is leaking. Closely inspect the sealing joint around Visually inspect the fuel tank for coolant. The contamination of
the top of the injector sleeve. Small amounts of coolant will be coolant in the fuel system may damage injectors and other fuel
dripping from the injector sleeve that is leaking. system components. Ensure that all the fuel system compo-
nents are in good repair prior to returning the engine to
Coolant may also be contaminating the fuel system. After the service.
engine is shutdown, the retention of pressure in the cooling
system may cause the transfer of coolant into the fuel system. Do not crank the engine if a cylinder is full of fluid. Cata-
Visually inspect the fuel tank for coolant. The contamination of strophic damage can occur to the engine.
coolant in the fuel system may damage injectors and other fuel
system components. Ensure that all the fuel system compo- Evacuate all cylinders of fluid before trying to start the engine.
nents are in good repair prior to returning the engine to service.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Deal
Solutions Network (DSN).

i06926343

Coolant Contains Oil

SMCS Code: 1348-035; 1395-035

Probable Causes
• Engine Oil Cooler
• Marine Transmission Oil Cooler (if equipped)

• Water-Cooled Turbocharger (if equipped)

• Cylinder Head Gasket

• Block
The procedures have been listed in order of
probability. Complete the procedures in order.
Verify the presence of oil in the coolant with a
scheduled oil sample. Verification must be made
before performing the procedure.

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
40 UENR4349-03
Symptom Troubleshooting

Table 13
Troubleshooting Test Steps Values Results

1. Leak in the Engine Oil Cooler Oil Cooler Result: A leak is found in the engine oil cooler.

A. Check for leaks in the engine oil cooler. Refer to Testing Repair: Install a new oil cooler core. Refer to the Disas-
and Adjusting for the proper procedure. sembly and Assembly manual.

Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.

Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the crankcase with the proper oil after
the leak has been repaired. Refer to the Operation and
Maintenance Manual for the correct oil capacities and
viscosity.

Result: A leak was not found in the engine oil cooler.

Proceed to Test Step 2.

2. Leak in the Marine Transmission Oil Cooler (If Marine Transmis- Result: A leak is found in the marine transmission oil
Equipped) sion Oil Cooler cooler.

A. Check for leaks in the power train oil cooler. Refer to Test- Repair: Install a new oil cooler core. Refer to the Disas-
ing and Adjusting for the proper procedure sembly and Assembly manual.

Flush the cooling system. Refer to the Operation and

Maintenance Manual for the proper flushing procedure.
Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.

Check the oil for coolant. If coolant is found in the oil, drain
the crankcase. Refill the oil after the leak has been re-
paired. Refer to the Operation and Maintenance Manual
for the correct oil capacities and viscosity.

Result: A leak was not found in the marine transmission

oil cooler.

Proceed to Test Step 3.

(continued)
UENR4349-03 41
Symptom Troubleshooting

(Table 13, contd)

Troubleshooting Test Steps Values Results

3. Water-Cooled Turbocharger (if equipped) Turbocharger Result: The turbocharger is cracked.

A. Inspect the turbocharger for cracks. Repair: Replace the turbocharger. Refer to the engine Dis-
assembly and Assembly for the correct procedure.
B. Remove the oil drain line from the turbo and pressurize the
cooling system, Refer to Testing and Adjusting, “Cooling Sys- Flush the cooling system, Refer to the Operation and
tem - Test”. Maintenance Manual for the correct procedure.

C. Check the turbocharger for coolant leakage. Refill the cooling system with the proper coolant. Refer to
the Operation and Maintenance Manual for the correct
coolant and capacities.

Check the oil for coolant. If coolant is found in the oil, drain
the oil. Refill the oil after the leak has been repaired. Refer
to the Operation and Maintenance Manual for the correct
oil capacities.

Result: The turbocharger is not cracked.

Proceed to Test Step 4.

4. Cylinder Head Gasket Cylinder Head Result: New cylinder head gasket and water seals were
Gasket installed.
A. Remove the cylinder head. Refer to the Disassembly and
Assembly manual. Proceed to Test Step 5.

B. Check the cylinder liner projection. Refer to the Systems

Operation/Testing and Adjusting manual.

C. Install a new cylinder head gasket and new water seals in

the spacer plate. Refer to the Disassembly and Assembly
manual.

5. Cylinder Head Cylinder Head Result: A crack is found in the cylinder head.

A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head and/or replace the cylin-
on the cylinder head. Refer to System Operation, Testing and der head. Refer to the Disassembly and Assembly
Adjusting for the proper procedure for checking the cylinder manual.
head.
Result: A crack is not found in the cylinder head.

Proceed to Test Step 6.

Result: A crack is found in the cylinder block.

6. Cylinder Block Cylinder Block
Repair: Repair the cylinder block or replace the cylinder
A. Inspect the cylinder block for cracks. block. Inspect the top deck. Refer to the Reuse and Sal-
vage Guidelines for the proper inspection procedure.
42 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Deal
Solutions Network (DSN).

i06684440

Coolant Level Is Low

SMCS Code: 1395-035
Use this procedure to troubleshoot low coolant level
or use this procedure if one of the following codes is
active. Refer to Troubleshooting, “Event Codes” for
information about event codes. Refer to
Troubleshooting, “Diagnostic Trouble Codes” for
information about diagnostic codes. Access the
monitoring system on Cat ® Electronic Technician
(Cat ET) to view the current trip points for these
codes. For information on the engine monitoring
system, refer to Troubleshooting, “Engine Monitoring
System”.
Note: Some of the following codes may not be
applicable for certain applications.

Table 14
Diagnostic Trouble Codes

J1939 Code and Description System Response

The engine has been running for 30 seconds. The engine coolant lev-
111-1 el has fallen below the coolant level sensor for the specified delay
Engine Coolant Level : Low - most severe (3) time.
Engine power is shutdown. The code is logged.

The engine has been running for 30 seconds. The engine coolant lev-
111-17 el has fallen below the coolant level sensor for the specified delay
Engine Coolant Level : Low - least severe (1) time.
The code is logged.

The engine has been running for 30 seconds. The engine coolant lev-
111-18 el has fallen below the coolant level sensor for the specified delay
Engine Coolant Level : Low - moderate severity (2) time.
Engine power is derated. The code is logged.

Probable Causes
• Low Coolant Level and/or Coolant Leakage

• Coolant level sensor

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 43
Symptom Troubleshooting

Table 15
Troubleshooting Test Steps Values Results

1. Low Coolant Level and/or Coolant Leakage Coolant Result: The engine coolant level is OK.
Level
A. Inspect the coolant level. Proceed to Test Step 2.

Result: The engine coolant level is not OK.

Repair: Troubleshoot the cause of the incorrect coolant

level.

1. Check for the correct mixture of antifreeze and water. Re-

fer to Operation and Maintenance Manual.

2. Check the cooling system for leaks. Refer to Systems Op-

eration/Testing and Adjusting, “Cooling System - Test” for
the correct procedure. Repair any leaks immediately.

3. Check for combustion gas in the cooling system. Refer to

Systems Operation/Testing and Adjusting, “Testing the Cool-
ing System” for the correct procedure.

If the problem is not resolved, proceed to Test Step 2.

2. Faulty Sensor Coolant Lev- Result: The coolant level sensor is not operating properly.
el Sensor
A. If an electrical problem with the coolant level sensor is sus- Repair: Replace the coolant level sensor.
pected, refer to Troubleshooting, “Coolant Level - Test” for informa-
tion that is related to troubleshooting an electrical problem with the Verify that the repair eliminated the problem.
coolant level sensor.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046183

Coolant Pressure Is Low

SMCS Code: 1395-035
Use this procedure to troubleshoot the coolant flow or
coolant pressure switch. Use this procedure if any of
the diagnostic codes in Table 16 are active or easily
repeated.
Table 16
J1939 Code and Description Comments
109-1 The engine coolant pressure is lower than expected for an extended period.
Engine Coolant Pressure : Low - most severe (3) Engine power is shut down. The code is logged.

109-17 The engine coolant pressure is lower than expected for an extended period.
Engine Coolant Pressure : Low - least severe (1) The code is logged.

109-18 The engine coolant pressure is lower than expected for an extended period.
Engine Coolant Pressure : Low - moderate severity (2) Engine power is derated. The code is logged.

Complete the procedure in the order in which the

steps are listed.
44 UENR4349-03
Symptom Troubleshooting

Table 17
Troubleshooting Test Steps Values Results

1. Verify the Coolant Level Coolant Level Result: The coolant level is correct.

A. Verify that the coolant is filled to the correct level. If the Proceed to Test Step 2.
coolant level is too low, air will get into the cooling system.
Combustion gas in the cooling system will cause a reduc- Result: The coolant level is not correct.
tion in coolant flow and pressure.
Repair: Determine the cause of the low coolant level. Refer
B. Check the cooling system for coolant leaks. to Troubleshooting, “Coolant Level Is Low”. Verify that the
problem has been corrected.

2. Check the Cooling System Hose Routing Leaks or Kinks Result: The coolant clamps and hoses are installed properly.

A. Check the cooling system clamps and hoses to make Proceed to Test Step 3.
sure that they are installed in the proper location and the
clamps are tight. Result: The coolant clamps and hoses are not installed
properly.
B. Ensure that there are no kinks or tight bends that may
cause excessive restriction. Repair: Repair or replace the damaged cooling system com-
ponent. Verify that the problem has been corrected. Return
C. Check to make sure that the hoses are routed correctly. the unit to service.

3. Check the Expansion Tank (if equipped) Shunt Line Result: The shunt line is properly installed and there are no
restrictions.
A. Check the shunt line for a restriction. A restriction of the
shunt line from the expansion tank to the inlet of the jacket For a 109 code, proceed to Test Step 4.
water pump will cause a reduction of water pump efficiency.
Result: The shunt line is not properly installed or there are
B. Inspect the expansion tank for a restriction that blocks restrictions.
the port to the shunt line.
Repair: Install the shunt line correctly or replace the line if
Note: The expansion tank may be integrated into the design necessary. Remove any restrictions that are found.
of the radiator top tank and may not be separate.
Verify that the problem has been corrected. Return the unit to
service.

4. Check the Coolant Pressure Sensor For Accuracy Coolant Pressure Result: The pressure difference between the mechanical
Sensor gauge and the reading in Cat ET is less than 14 kPa (2 psi).
A. Install a mechanical pressure gauge in the coolant jacket
near the coolant pressure sensor. Proceed to Test Step 5.

B. Start the engine. Result: The pressure difference between the mechanical
gauge and the reading in Cat ET is greater than 14 kPa
C. Connect to the engine ECM using Cat ® Electronic Tech- (2 psi).
nician (Cat ET).
Repair: Replace the coolant pressure sensor.
D. Allow the engine to run and record the pressure on the
mechanical gauge. Verify that the problem has been corrected. Return the unit to
service.
E. Check the pressure reading at various engine speeds.

(continued)
UENR4349-03 45
Symptom Troubleshooting

(Table 17, contd)

Troubleshooting Test Steps Values Results

5. Check the Water Pump Damaged Impeller Result: The water pump impeller is not damaged or loose
and there are no restrictions.
A. Remove the water pump and check for a damaged or
loose impeller, or a restriction in the water pump inlet or out- Proceed to Test Step 6.
let ports.
Result: The water pump impeller is damaged or loose, or
there are restrictions.

Repair: Replace the water pump.

Verify that the problem has been corrected. Return the unit to
service.

6. Check the Radiator or Heat Exchanger Restrictions Result: There were deposits or restrictions in the radiator or
heat exchanger.
A. Check the radiator or heat exchanger for a restriction.
Check internally for dirt, debris, or deposits on the radiator Repair: Clean or replace the radiator or heat exchanger.
core.
Verify that the problem has been corrected. Return the unit to
service.

Result: There were no deposits or restrictions in the radiator

or heat exchanger.

Proceed to Test Step 7.

7. Check the Oil Cooler Restrictions Result: There was debris or restrictions in the oil cooler.

A. Check the inlet side of the oil cooler for debris or Repair: Clean or replace the oil cooler.
blockage.
Verify that the problem has been corrected. Return the unit to
service.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06926350

Coolant Temperature Is High

SMCS Code: 1395-035
Use this procedure in order to troubleshoot high
coolant temperature or use this procedure if one of
the following event codes is active. Refer to
Troubleshooting, “Event Codes” for information about
event codes. Access the monitoring system on
Caterpillar ® Electronic Technician (Cat ET) in order
to view the current trip points for these codes.
46 UENR4349-03
Symptom Troubleshooting

Table 18
J1939 Code and Description Comments
The engine coolant temperature has exceeded the trip point and the
110-0 delay time has expired.
Engine Coolant Temperature High - Most Severe (3) Engine power is derated.
The code is logged.

The engine coolant temperature has exceeded the trip point and de-
110-15
lay time has expired.
Engine Coolant Temperature High- Least Severe (1)
The code is logged.

The engine coolant temperature has exceeded the trip point and the
110-16
delay time has expired.
High Engine Coolant Temperature High - Moderate Severity (2)
The code is logged.

Probable Causes
• Low Coolant Level and/or Coolant Leakage
• Coolant Temperature Sensor

• Water Temperature Regulator and/or Pressure

Relief Valve
• Radiator

• Heat Exchanger
• Engine Cooling Fan (if equipped)

• Coolant Pump
• Cylinder Head Gasket

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 47
Symptom Troubleshooting

Table 19
Troubleshooting Test Steps Values Results

1. Coolant Engine Cool- Result: The engine coolant level is OK.

ant Level
A. Inspect the coolant level. Proceed to Test Step 2.

Result: The engine coolant level is not OK.

Repair: Check the cooling system for leaks. Refer to Trou-

bleshooting, “Coolant Level is Low” for additional informa-
tion. Repair any leaks immediately.

2. Coolant Temperature Sensor and/or the Circuit Coolant Tem- Result: The temperature sensor is working properly.
perature
A. Check the reading of the coolant temperature on Cat ET. The Sensor Proceed to Test Step 3.
temperature should rise steadily as the engine is warmed. Ensure
that the temperature is reasonable. Result: The temperature sensor is not working properly.

Repair: Troubleshoot the circuit and the coolant tempera-

ture sensor. Refer to Troubleshooting, “Sensor Signal
(Analog, Passive) - Test”.

3. Water Temperature Regulator and/or Pressure Relief Valve Temperature Result: The pressure relief valve and/or the water temper-
Regulator ature regulator are operating properly.
A. Pressure-test the cooling system. Refer to Systems Operation/
Testing and Adjusting for the correct procedure. Proceed to Test Step 4.

B. Check that the seating surfaces of the pressure relief valve and Result: The pressure relief valve and/or the water temper-
the radiator cap are clean and undamaged. ature regulator are not operating properly.

C. Check operation of the pressure relief valve and/or the water Repair: Clean the components and/or replace the
temperature regulator. components.

4. Radiator Radiator Result : The radiator fins are not damaged and the radia-
tor does not have an internal blockage.
A. Check the radiator fins for dirt, debris, and/or damage.
Proceed to Test Step 5.
B. Check for collapsed hoses and/or other restrictions.
Result : The radiator fins are damaged.
C. Check the radiator for internal blockage.
Repair: Remove any dirt and/or debris and straighten any
Ensure that the radiator size is sufficient. An undersized radiator bent fins.
does not have enough area for the effective release of heat. An un-
dersized radiator may cause the engine to run at a temperature Result : The radiator has internal blockage.
that is higher than normal. The normal temperature is dependent
on the ambient temperature. Repair: Remove the blockage.

(continued)
48 UENR4349-03
Symptom Troubleshooting

(Table 19, contd)

Troubleshooting Test Steps Values Results

5. Heat Exchanger Heat Result : The flow of cooling water is sufficient.

Exchanger
A. Check for sufficient flow and temperature of the cooling water Proceed to Test Step 6.
through the heat exchanger.
Result : The flow of cooling water is not sufficient.

Repair: Determine the location of the obstruction. If the

temperature of the cooling water is too high, determine the
cause. Ensure that the size of the heat exchanger is suffi-
cient. Make the necessary repairs.

6. Faulty Engine Cooling Fan (if equipped) Fan Belt or Result : The fan belt is tensioned correctly.
Clutch
A. If the fan is belt driven, check for loose drive belts. Proceed to Test Step 7.

A loose fan drive belt will cause a reduction in the air flow across Result : The fan belt is not tensioned correctly.
the radiator.
Repair: Adjust the tension of the fan drive belt, if neces-
sary. Refer to Operation and Maintenance Manual.

7. Inspection of the Coolant Pump Coolant Pump Result : The coolant pump is operating correctly.

A. Inspect the impeller of the coolant pump for damage and/or Proceed to Test Step 8.
erosion.
Result : The coolant pump is not operating correctly.
B. Make sure that the drive gear is not loose on the drive shaft of
the coolant pump. Repair: If necessary, replace the coolant pump. Refer to
Disassembly and Assembly for the correct procedure.

Result : The cylinder head was checked for leaks and the
8. Cylinder Head Gasket Head Gasket gasket was replaced.

A. Remove the cylinder head. Refer to the Disassembly and As- Verify that the problem was corrected.
sembly manual.

B. Check the cylinder liner projection. Refer to the Systems Opera-

tion/Testing and Adjusting manual.

C. Pressure test the head for leaks.

D. Install a new cylinder head gasket and new water seals in the
spacer plate. Refer to the Disassembly and Assembly manual.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Deal
Solutions Network (DSN).

i07034932

Coolant Temperature Is Low

SMCS Code: 1395-035
Use this procedure to troubleshoot a low coolant
temperature. Also, use this procedure if one of the
following event codes is active or logged.
UENR4349-03 49
Symptom Troubleshooting

Table 20
J1939 Code and Description Comments
110-17 The coolant temperature did not rise above a temperature threshold
Engine Coolant Temperature : Low - least severe (1) after an extended period of operation under load.

Probable Causes
• Jacket water heater
• Sensor

• Connectors and wiring

• Temperature regulators

Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.
50 UENR4349-03
Symptom Troubleshooting

Recommended Actions
Table 21
Troubleshooting Test Steps Values Results

1. Check for Codes Codes Result: An associated code is active.

A. Connect Cat ® Electronic Technician (ET) to the service tool Repair: Troubleshoot any associated codes before continu-
connector. ing with this test.

B. Look for active codes that are associated with the system Result: A code is active or logged.
for the event code.
Proceed to Test Step 2.

2. Check the Water Temperature Regulators Regulators Result: The temperature regulators are NOT OK.

Note: The water temperature regulators should not begin to Repair: Replace the water temperature regulators.
open until jacket water reaches opening temperature for the
regulators. Verify that the repair eliminated the problem.

A. Allow the engine to cool and then start the engine. Check If the problem is not resolved, proceed to Test Step 3.
the hose at the outlet for the jacket water. If the hose is warm
and normal operating temperature is not achieved yet, a regu-
lator may be stuck open.

B. If the water temperature regulators are malfunctioning,

check the water temperature regulators. Refer to Testing and
Adjusting, “Testing the Cooling System” for additional
information.

(continued)
UENR4349-03 51
Symptom Troubleshooting

(Table 21, contd)

3. Check the Coolant Temperature Sensor Sensor Result: The temperature sensor is OK.

Note: The sensor may be indicating an incorrect temperature Proceed to Test Step 4.
that is within the normal range of the sensor.
Result: The temperature sensor is NOT OK.
A. Connect Cat ET.
Proceed to Test Step 4.
B. Use Cat ET to monitor the following temperature:

- Coolant temperature

Note: The temperature should rise steadily as the engine is

warmed.

C. Ensure that the temperature is reasonable.

D. Reference the reading to another temperature indicator

when possible. Refer to Testing and Adjusting, “Testing the
Cooling System” for additional information.

4. Inspect the Electrical Connectors and the Wiring Connectors and Result: The connectors and wiring appear to be OK.
Wiring
A. Turn the main disconnect switch to the OFF position. Repair: Replace the sensor.

B. Thoroughly inspect the connectors. Refer to Troubleshoot- Verify that the repair eliminated the problem.
ing, “Electrical Connectors-Inspect” for additional information.
Result: There is a problem with the connectors and/or
C. Perform a 45 N (10 lb) pull test on the connector wires. wiring.

D. Check the harness for abrasions and pinch points. Repair: Repair or replace the connectors or wiring. Ensure
that all the seals are properly in place and ensure that the
connectors are coupled.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07060188

Crankcase Fumes Disposal

Tube Has Oil Draining
SMCS Code: 1000-035-BBY; 1317-035

Probable Cause
• Breather Filter

• Engine Oil Level

• One-Way Level

• Excessive Blow-By
Illustration 18 g03806023
(1) Crankcase Filter Housing
(2) Fumes Disposal Tube
52 UENR4349-03
Symptom Troubleshooting

Illustration 19 g03806044
(3) Crankcase Pressure Sensor
(4) Oil Drain Tube

Illustration 20 g06213438
Left-Hand Side
(5) Check Valve

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 53
Symptom Troubleshooting

Table 22
Troubleshooting Test Steps Values Results

1. Check Valve Check Valve Result: The check valve was replaced.

The check valve at the bottom of the oil drain tube has failed. Verify the repair.

A. Replace check valve (5).

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07044471

Crankcase Pressure Is High

SMCS Code: 1201-035-PX
The engine is equipped with a closed crankcase
ventilation (CCV) system. Refer to Illustration 22 .
The pressure sensor monitors the level of crankcase
pressure. The CCV system contains a filter element
(if equipped). Tubing routes the blowby from the CCV
system to the filter housing (if equipped). The filter
housing (if equipped) contains a filter element. The
filter element filters the blowby. Refer to the
Operation and Maintenance Manual for the
replacement of the filter.
Table 23
Diagnostic Trouble Codes

J1939 Code and Description Comments

The crankcase pressure is higher than the trip point and the delay
101-15
time has expired.
Engine Crankcase Pressure : High - least severe (1)
The code is logged.

The crankcase pressure is higher than the trip point and the delay
101-16 time has expired. Engine power is derated.
Engine Crankcase Pressure : High - moderate severity (2) Engine power is derated.
The code is logged.

Troubleshooting Procedure
Reset all active codes and clear all logged codes.
54 UENR4349-03
Symptom Troubleshooting

Illustration 21 g03806104 Illustration 23 g06213438

(1) Crankcase Filter housing (If Equipped) Left-Hand Side
(2) Fumes Disposal Tube
(5) Check Valve

Probable Causes
• Engine oil level
• Plugged CCV system

• Faulty check valve

• Faulty sensor
• Worn engine components

Recommended Actions
Complete the procedure in the order in which the
steps are listed.

Illustration 22 g03806044
(3) Crankcase Pressure Sensor
(4) Oil Drain Tube
UENR4349-03 55
Symptom Troubleshooting

Table 24
Troubleshooting Test Steps Values Results

1. Check the Engine Oil Level Engine Oil Result: The engine oil level is OK.
Level
Proceed to Test Step 2.

Result: The engine oil level is high.

Repair: Troubleshoot the cause of the incorrect oil level.

If the problem is not resolved, proceed to Test Step 2.

2. Plugged CCV System Plugged Result: The CCV is not plugged.

CCV
A plugged CCV system will cause excessive crankcase pressure. Proceed to Test Step 3.

A. Check the CCV for plugging. Result: The CCV is plugged.

Repair: Replace the fumes disposal filter (if equipped) ac-

cording to the Operation and Maintenance Manual, “Fumes
Disposal Filter Element - Replace”.

If the problem is not resolved, proceed to Test Step 3.

3. Faulty Check Valve Check Valve Result: The check valve was replaced.

A faulty check valve can cause excessive crankcase pressure. A Verify that the problem is resolved.
faulty check valve will not allow the crankcase to vent properly.
If the problem is not resolved, Proceed to Test Step 4.
A. Replace the check valve.

4. Plugged Oil Disposal Tube Plugged Oil Result The oil disposal tube is not obstructed.
Disposal
A plugged disposal tube will not allow the crankcase to vent Tube Proceed to Test Step 5.
properly.
Result The oil disposal tube is obstructed.
A. Check the disposal tube for obstructions.
Repair: Clean any obstructions from the tube.

If the problem is not resolved, proceed to Test Step 5.

(continued)
56 UENR4349-03
Symptom Troubleshooting

(Table 24, contd)

Troubleshooting Test Steps Values Results

5. Faulty Sensor Crankcase Result The crankcase pressure reading is 0 kpa (0 inH2O) ±
Pressure .5 kpa (2 inH2O).
A. Connect Caterpillar ® Electronic Technician (Cat ET) to the serv- Sensor
ice tool connector. Proceed to Test Step 6.

B. Turn the keyswitch to the ON position. Do not start the engine. Result The crankcase pressure reading is not 0 kpa (0 in-
H2O) ± .5 kpa (2 inH2O).
C. Remove the oil filler cap.
Repair: Replace the crankcase pressure sensor.
D. Monitor the crankcase pressure in Cat ET.
If the problem is not resolved, proceed to Test Step 6.

6. Internal Engine Problem Damaged or Result There are worn or damaged engine parts.
Worn Engine
Damaged pistons or rings can cause too much pressure in the Parts Repair: Repair or replace the worn or damaged parts.
crankcase. This condition will cause the engine to run rough.
There will be more than the normal quantity of fumes (blowby) en- Verify that the repair eliminated the problem.
tering the CCV system. The CCV system can then more quickly
become restricted, causing oil leakage at gaskets and seals that
would not normally have leakage. Blowby can also be caused by
worn valve guides or by a failed turbocharger seal.

A. To determine whether the piston rings leak, measure the crank-

case blowby. Use the following service tools, along with Software
License, NETG5044:

1. 285-0900 Blowby Tool Gp (SMALL ENGINE)

2. 348-5430 Multi-Tool Gp

If the procedure did not correct the issue, contact Recommended Actions
your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Not: The procedures have been listed in order of
Dealer Solutions Network (DSN). probability. Complete the procedures in order.

i06090558
Complete the procedure in the order in which the
steps are listed.
Cylinder Is Noisy
SMCS Kodu: 1223-035

Probable Causes
• Active codes and logged codes

• Low quality fuel

• Injectors
• Lack of lubrication

• Valve train components

• Gear train and components of the lower end
UENR4349-03 57
Symptom Troubleshooting

Tablo 25
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: A diagnostic trouble code is not active or logged.

A. Establish communication between Caterpillar Electronic Techni- Proceed to Test Step 2.

cian (Cat ET) and the Electronic Control Module (ECM).
Result: A diagnostic trouble code is active or logged.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Repair: Troubleshoot the active or logged codes.
codes.
If the problem is not resolved, proceed to Test Step 2.

2. Low Quality Fuel Fuel Result: The fuel quality is OK.

A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 3.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing and
Adjusting, Fuel System Quality Test for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.

If the problem is not resolved, proceed to Test Step 3.

3. Injectors Injector Sole- Result: The test was successful.

noid Test or
A. Perform the “Fuel System Verification Test” in the “Diagnostic Fuel System Proceed to Test Step 4.
Tests” under the “Diagnostics” menu. Verification
Test Result: The test was not successful.

Repair: Diagnose the problem and then repair the

problem.

Reset all active codes and clear all logged codes.

Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 4.

4. Lack of Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.

If the problem is not resolved, proceed to Test Step 5.

(devamı var)
58 UENR4349-03
Symptom Troubleshooting

(Tablo 25, devamı)

Troubleshooting Test Steps Values Results

5. Valve Train Components Valve train Result: The valve train components are not damaged.

A. Remove the valve mechanism cover and the camshaft covers. Proceed to Test Step 6.

B. Check the valve lash. Refer to Troubleshooting, Valve Lash Is Result: The valve train components are damaged.
Excessive.
Repair: Make the necessary repairs, Verify that the repair
C. Check the following valve train components for damage: eliminated the problem.

1. Camshaft If the problem is not resolved, proceed to Test Step 6.

2. Valve rotocoil

3. Valve springs

4. Camshaft followers

5. Rocker shaft

6. Bridges

7. Pushrods

8. Injectors

D. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.

6. Inspect the Gear Train Gear Train Result: The gear train or lower end components are
damaged.
A. Check the following gear train for damage:
Repair: Repair or replace damaged gear train compo-
- Crankshaft gear nents. Refer to Disassembly and Assembly and the Reuse
- Camshaft drive gear and Salvage Guidelines manual for additional information.

B. Verify that the crankshaft and the camshaft drive gears are set Verify that the repair eliminated the problem.
with the proper orientation for engine timing.

If the procedure did not correct the issue, contact Note: If the symptom is intermittent and the symptom
your Cat dealer Technical Communicator (TC). For cannot be repeated, refer to Troubleshooting, “Power
further assistance, your TC can confer with the Is Intermittently Low or Power Cutout Is Intermittent”.
Dealer Solutions Network (DSN). If the symptom is consistent and the symptom can be
repeated, continue with this procedure.
i06090630
Download the “Warranty Report” from the engine
Engine Cranks but Does Not Electronic Control Module (ECM) before performing
any troubleshooting or clearing diagnostic trouble
Start codes. Check Cat ® Electronic Technician (Cat ET)
for any associated codes that are listed in Table 26 .
SMCS Code: 1000-035; 1450-035 Troubleshoot any active codes before continuing with
this procedure.
Use this procedure in order to troubleshoot an engine
that cranks but does not start.
UENR4349-03 59
Symptom Troubleshooting

Table 26
Associated Diagnostic Trouble Codes

J1939 Code Descriptions

157 Common Rail - Low Fuel Rail Pressure

5584 Fuel Filter Restriction
1347 Common Rail Solenoid
1348 Fuel Rail #1 Pressure Valve Solenoid
5580 Low Fuel Pressure

Probable Causes
• Diagnostic Codes
• Event Codes

• Fuel Supply
• Engine shutdown switches (if applicable)

• Starting aids (if equipped)

• Engine Speed/Timing

• Fuel Pressure
60 UENR4349-03
Symptom Troubleshooting

Recommended Actions
Table 27
Troubleshooting Test Steps Values Results

1. Inspection of the Fuel Supply Fuel Level Result : The fuel level is OK.

A. Visually check the fuel level in the fuel tank. Do not rely Proceed to Test Step 2.
on the fuel gauge only.
Result : The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the
full OPEN position. Repair : Fill the tank.

If the problem is not resolved, proceed to Test Step 2.

2. Check the Engine Shutdown Switches (if applicable) Engine Shutoff Result : The switches are in the OFF position.
Switches
A. The engine shutdown switches must be in the OFF Proceed to Test Step 3.
position.
Result : The switches are not in the OFF position.
B. Use Caterpillar ®Electronic Technician (Cat ET) to verify
the status of the engine shutdown switches. When a shut- Repair : Turn the switches to the OFF position.
down occurs, the keyswitch must be turned to the OFF po-
sition for at least 15 seconds before restarting the engine. If the problem is not resolved, proceed to Test Step 3.

3. Check the Engine Starting Aids (if applicable) Starting Aids Result : The starting aid is operating correctly.

A. If cold ambient conditions exist, check the operation of Proceed to Test Step 4.
the starting aids. Verify that the starting aid is operating
correctly. Result: The starting aid is not operating correctly.

Repair : Refer to the appropriate circuit test in order to trou-

bleshoot the starting aid.

If the problem is not resolved, proceed to Test Step 4.

4. Restrictions in the Air Inlet and Exhaust System Air and Exhaust Result : There are no system restrictions.
System
A. Check for an air filter restriction indicator. Restrictions Proceed to Test Step 5.

B. Check the air inlet and exhaust system for restrictions Result : There are system restrictions.
and/or leaks.
Refer to Testing and Adjusting, “Air Inlet and Exhaust System
- Inspect” for more information on air system restrictions.

Repair : Replace plugged air filters. Refer to the Operation

and Maintenance Manual for the correct procedure.

If the problem is not resolved, proceed to Test Step 5.

(continued)
UENR4349-03 61
Symptom Troubleshooting

(Table 27, contd)

Troubleshooting Test Steps Values Results

5. Check for Activation of the Theft Deterrent System (if Theft Deterrent Result : The theft deterrent system is not active.
applicable) System
Proceed to Test Step 6.
A. Verify that the theft deterrent system is not active.
Result : The theft deterrent system is active.

Repair : Turn the theft deterrent system OFF.

If the problem is not resolved, proceed to Test Step 6.

6. Check the Engine Speed/Timing Signal for Proper Timing Signal Result : The timing sensor is operating properly.
Operation
Proceed to Test Step 7.
A. Crank the engine and observe the engine speed on the
Cat ET status screen. Refer to Troubleshooting, “Speed/ Result : The timing sensor is not operating properly.
Timing - Test” for additional information.
Repair : Refer to Troubleshooting, “Speed/Timing - Test” for
Upon initial cranking, the status for engine speed may indi- troubleshooting information.
cate that the engine speed signal is abnormal. This mes-
sage will be replaced with an engine speed once the ECM If the problem is not resolved, proceed to Test Step 7.
is able to calculate a speed from the signal.

7. Inspect the Low-Pressure Fuel System Low-Pressure Fuel Result : The low-pressure fuel system is operating properly.
System
A. Inspect the fuel system. Refer to Systems Operation/ Proceed to Test Step 8.
Testing and Adjusting, “Fuel System” for additional
information. Result : The low-pressure fuel system is not operating
properly.
B. Cold weather adversely affects the characteristics of the
fuel. Refer to the engines Operation and Maintenance Man- Repair : Make the necessary repairs. Return the engine to
ual for information on improving the characteristics of the service.
fuel during cold-weather operation.
If the problem is not resolved, proceed to Test Step 8.
C. Check fuel quality. Refer to Systems Operation/Testing
and Adjusting, “Fuel System” for the proper procedure.
Check the fuel tank for debris or foreign objects which may
block the fuel supply.

D. Check the filtered fuel pressure while the engine is being

cranked. Refer to Systems Operation/Testing and Adjust-
ing, “Fuel System” for the test procedure and for the correct
pressure values.
If the fuel pressure is low, replace the fuel filters. Clean the
primary filter/water separator of debris. Refer to the Opera-
tion and Maintenance Manual for details.

E. Check for the proper operation of the fuel transfer pump.

Refer to Systems Operation/Testing and Adjusting, “Fuel
System” for test information.

8. Inspect the High-Pressure Fuel System High-pressure Fuel Result : The high-pressure fuel system is not operating
System properly.
A. Perform the Testing and Adjusting, “Injector Bypass Fuel
Flow - Test” to test the high-pressure fuel system. Repair : Make the necessary repairs. Return the engine to
service.
62 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06094990

Engine Does Not Crank

SMCS Code: 1000-035; 1450-035
Use this procedure to troubleshoot an engine that will
not crank.
Complete the procedure in the order in which the
steps are listed.
Table 28
Troubleshooting Test Steps Values Results

1. Inspection of the Batteries and Battery Cables Batteries Result The batteries and cables are OK.

A. Inspect the main power switch, battery posts, and battery ca- Proceed to Test Step 2.
bles for loose connections and for corrosion. If the battery ca-
bles are corroded, remove the battery cables and clean the Result The batteries and cables are not OK.
battery cables. Tighten any loose connections.
Repair: Make the necessary repairs.
B. Inspect the batteries.
If the problem is not resolved, proceed to Test Step 2.
C. Charge the batteries. Refer to Special Instruction,
SEHS7633, “Battery Test Procedure” for additional information.

D. Load-test the batteries. Refer to Special Instruction,

SEHS9249, “Use of 4C-4911 Battery Load Tester for 6 v, 8 v,
and 12 v Lead Acid Batteries”.

2. Switches and/or Circuit Breakers (if applicable) Switches and/or Result The switches and/or circuit breakers are OK.
Circuit Breakers
A. If equipped, check any switches and/or circuit breakers that Proceed to Test Step 3.
may interfere with the engine cranking. Refer to the applications
electrical schematic for additional information. Result The switches and/or circuit breakers are not OK.

Repair: Make the necessary repairs.

If the problem is not resolved, proceed to Test Step 3.

3. Starting Motor Solenoid and Starting Circuit Starting Motor Result The starting motor solenoid and circuit are OK.
Solenoid and
Test the operation of the starting motor circuit. Refer to Systems Circuit Proceed to Test Step 4.
Operation/Testing and Adjusting, “Electrical System” for addi-
tional information. Result The starting motor solenoid and circuit are not OK.

Repair: Make the necessary repairs.

If the problem is not resolved, proceed to Test Step 4.

(continued)
UENR4349-03 63
Symptom Troubleshooting

(Table 28, contd)

Troubleshooting Test Steps Values Results

4. Inspect the Starter Pinion and Flywheel Ring Gear Starter Pinion Result The starter pinion and flywheel ring gear are OK.
and Flywheel
A. Test the operation of the starting motor. Ring Gear Proceed to Test Step 5.

B. Check the pinion clearance. Inspect the pinion and the fly- Result The starter pinion and flywheel ring gear are not
wheel ring gear for damage. Refer to Systems Operation/Test- OK.
ing and Adjusting, “Electrical System” for additional information.
Repair: Make the necessary repairs.

If the problem is not resolved, proceed to Test Step 5.

5. Inspect Engine Accessories and the Transmission (if Engine Accesso- Result The engine accessories and transmission are OK.
applicable) ries and
Transmission Proceed to Test Step 6.
A. Ensure free movement of the driveline.
Result The engine accessories and transmission are not
B. Remove any engine accessories that may lock up the engine OK.
and inspect any engine accessories that may lock up the
engine. Repair: Make the necessary repairs.

The following list illustrates examples of engine accessories that If the problem is not resolved, proceed to Test Step 6.
may lock up the engine:

1. Hydraulic pump that is driven from the rear gear group

2. Air compressor

3. Engine oil pump

4. Other components that are driven by the engine

6. Hydraulic Cylinder Lock Hydraulic Cylin- Result The engine has hydraulic cylinder lock.
der Lock
A. If an injector has been replaced, evacuate any fluids from the Repair: Make the necessary repairs.
cylinder and attempt to start the engine. Fuel will flow from the
cylinder head into the cylinders when a unit injector is removed. Verify that the repair eliminated the problem.

B. If the engine will not start, check for fluid in the cylinders (hy-
draulic cylinder lock) by removing the individual unit injectors.
Check for damaged seals. Determine the type of fluid that
locked up the cylinder.

C. If there was a coolant leak, determine the cause of the leak.

Check the exhaust (NRS) cooler for leaks. Refer to Testing and
Adjusting, “Exhaust Cooler (NRS) - Test”.

D. If there was excessive fuel in the cylinder, replace the seals

and reinstall the injector. Drain any excess fuel from the cylinder
head.

E. If a mechanical problem is suspected, disassemble the en-

gine. Refer to the Disassembly and Assembly manual. Inspect
the internal components for the following conditions:

1. Seizure

2. Broken components

3. Bent components
64 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06095075

Engine Has Early Wear

SMCS Code: 1000-035; 1200-035

Probable Causes
• Incorrect maintenance intervals and/or incorrect
oil

• Contaminated engine oil

• Low oil pressure

• Leaks in the air system

• Inspect the fuel filters for contamination.

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
UENR4349-03 65
Symptom Troubleshooting

Table 29
Troubleshooting Test Steps Values Results

1. Incorrect Maintenance Intervals and/or Incorrect Oil Maintenance Result: The engine oil was changed at the interval that is
Intervals recommended by the engines Operation and Mainte-
A. Use engine oil that is recommended and change the engine oil nance Manual.
at the interval that is recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.

Result: The engine oil was not changed at the interval

that is recommended by the engines Operation and Main-
tenance Manual.

Use at least the minimum grade of Cat oil.

Repair: Change the engine oil at the interval that is rec-

ommended. Repair or replace any damaged parts.

If the problem is not resolved, proceed to Test Step 2.

2. Contaminated Engine Oil Contamination Result: The oil is not contaminated.

A. Obtain an S-O-S oil analysis. The analysis will contribute to a Proceed to Test Step 3.
better understanding of oil contamination.
Result: The oil is contaminated.
B. Check the oil filter bypass valve.
Repair: Determine the reason for any contamination of
- Weak or broken spring the engine oil and make the necessary repairs. Drain the
crankcase and refill the crankcase with clean engine oil.
Operating correctly Install new engine oil filters. Refer to the engines Opera-
tion and Maintenance Manual.
Note: If the oil filter bypass valve is open, the oil will not be fil-
tered. Check the oil filter bypass valve for a weak spring or for a If the problem is not resolved, proceed to Test Step 3.
broken spring. If the spring is broken, replace the spring. Verify
that the oil bypass valve is operating correctly. Refer to the Disas-
sembly and Assembly manual. Refer to the Caterpillar guidelines
for “Reusability and Salvage/Repair” for determining if the re-
placement of parts is necessary in order to perform a quality
repair.

3. Low Oil Pressure Restriction Result: The inlet tube does not have a restriction.

A. Engine oil that is contaminated with another liquid can cause Proceed to Test Step 4.
low engine oil pressure. High engine oil level can be an indication
of contamination. Obtain an analysis of the engine oil.
Result: The inlet tube has a restriction.
B. The inlet screen of the suction tube for the engine oil pump can
have a restriction. This restriction will cause cavitation and a loss Repair: Clear the obstruction. Repair or replace inlet
of engine oil pressure. Check the inlet screen on the suction tube tube.
and remove any material that may be restricting engine oil flow.
If the problem is not resolved, proceed to Test Step 4.
When some components of the engine show wear in a short time,
the cause can be a restriction in a passage for engine oil. An indi-
cator for the engine oil pressure may indicate sufficient pressure,
but a component is worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil supply to the compo-
nent. Refer to Systems Operation/Testing and Adjusting, “Lubrica-
tion System” for additional information.

(continued)
66 UENR4349-03
Symptom Troubleshooting

(Table 29, contd)

Troubleshooting Test Steps Values Results

4. Check the Inlet Air System for Leaks Air Leak Result: There are no air leaks.

Note: A leak in the air intake system may allow unfiltered air into Proceed to Test Step 5.
the engine.
A. Inspect the air intake system for streaks which may indicate a Result: There are air leaks.
leakage of unfiltered air. Inspect all of the gaskets and the
connections. Repair: Repair or replace damaged inlet air system
components.

If the problem is not resolved, proceed to Test Step 5.

5. Inspect the Fuel Filters for Contamination Fuel Filters Result: The fuel filters has contamination.

A. Remove the fuel filters. Inspect the fuel filters for contamina- Repair: Determine the cause of any contamination and
tion. Obtain a fuel analysis. make the necessary repairs.

B. Obtain a fuel analysis. Repair: Install new fuel filters. Refer to the Operation and
Maintenance Manual.
Note: Contaminants in the fuel such as hydrogen sulfide and sul-
fur can lead to the formation of acids in the crankcase. Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06095311

Engine Has Mechanical Noise

(Knock)
SMCS Code: 1000-035

Probable Causes
• Active codes and logged codes

• Electrical connections
• Fuel injection

• Fuel quality
• Proper lubrication

• Isolate the source of the noise.

• Valve train components
• Gear train and lower end components

• Crankshaft

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
UENR4349-03 67
Symptom Troubleshooting

Table 30
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: There are no active codes.

A. Establish communication between Caterpillar ® Electronic Tech- Proceed to Test Step 2.

nician (Cat ET) and the Electronic Control Module (ECM). Refer to
Troubleshooting, “Electronic Service Tools”, if necessary. Result: There are active codes.

B. Download the “Warranty Report” from the engine ECM before Repair: Troubleshoot any active codes before continuing
performing any troubleshooting or clearing diagnostic trouble with this procedure.
codes.
If the problem is not resolved, proceed to Test Step 2.

2. Electrical Connections Connectors Perform the “Wiggle Test” on Cat ET.

A. Check for the correct installation of the ECM J1/P1 and the J2/ Result: There are no suspect connectors.
P2 connectors. Check for correct installation of the fuel injector
connectors. Proceed to Test Step 3.

Result: There are suspect connectors.

Repair: Repair connectors that are suspect or replace con-

nectors that are suspect.

If the problem is not resolved, proceed to Test Step 3.

3. Fuel Injection Injector Sole- Result: The test was successful.

noid Test or
A. Perform the “Fuel System Verification Test” in the “Diagnostic Fuel System Proceed to Test Step 4.
Tests” under the “Diagnostics” menu. Verification
Test Result: The test was not successful.

Repair: Diagnose the problem and then repair the problem.

Reset all active codes and clear all logged codes.

Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 4.

4. Fuel Quality Fuel Result: The fuel quality is OK.

A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 5.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing
and Adjusting, “Fuel System Quality Test” for the proper Repair: Replace the fuel. Verify that the repair eliminated
procedure. the problem.

If the problem is not resolved, proceed to Test Step 5.

(continued)
68 UENR4349-03
Symptom Troubleshooting

(Table 30, contd)

Troubleshooting Test Steps Values Results

5. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check
for sufficient lubrication between the injector tappets and the rock- Proceed to Test Step 6.
er arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
If the problem is not resolved, proceed to Test Step 6.
D. Obtain an S-O-S oil analysis. The analysis will contribute to a
better understanding of oil contamination and the origin of the
contamination.

6. Isolate the Source of the Noise Engine Result An engine accessory is not the source of the noise.
Accessory
A. If the source of the noise is the engine accessory, remove the Proceed to Test Step 7.
suspect engine accessory. Inspect the suspect engine accessory.
Result An engine accessory is the source of the noise.

Repair: Repair the engine accessory and/or replace the en-

gine accessory, if necessary.

If the problem is not resolved, proceed to Test Step 7.

(continued)
UENR4349-03 69
Symptom Troubleshooting

(Table 30, contd)

Troubleshooting Test Steps Values Results

7. Valve Train Components Valve Train Result: The valve train components are not damaged.

A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 8.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair: Make the necessary repairs, Verify that the repair
for damage: eliminated the problem.

1. Camshaft If the problem is not resolved, proceed to Test Step 8.

2. Valve rotocoil

3. Valve springs

4. Camshaft followers

5. Rocker shaft

6. Bridges

7. Pushrods

8. Injectors

Refer to the Disassembly and Assembly for additional information.

C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.

8. Gear Train and Components of the Lower End Gear Train Result: The gear train or lower end components are not
damaged.
A. Inspect the gear train and lower end components.
Proceed to Test Step 9.

Result: The gear train or lower end components are

damaged.

Repair: Replace any damaged parts.

If the problem is not resolved, proceed to Test Step 9.

9. Crankshaft Crankshaft Result: The crankshaft or the related components are dam-
aged or worn.
A. Inspect the crankshaft and the related components. Look for
worn thrust plates and wear on the crankshaft. Repair: Repair or replace any damaged parts.

B. Inspect the connecting rod bearings and the bearing surfaces Verify that the repair eliminated the problem.
on the crankshaft. Make sure that the bearings are in the correct
position.

C. Check the counterweight bolts.

70 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06095413

Engine Misfires, Runs Rough

or Is Unstable
SMCS Code: 1000-035

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Probable Causes
• Active codes and logged codes
• Low quality fuel
• Fuel injectors

• Lack of lubrication
• Valve train components

• Gear train and components of the lower end

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
UENR4349-03 71
Symptom Troubleshooting

Table 31
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: There are no active codes.

A. Establish communication between Caterpillar ® Electronic Tech- Proceed to Test Step 2.

nician (Cat ET) and the Electronic Control Module (ECM). Refer to
Troubleshooting, “Electronic Service Tools”, if necessary. Result: There are active codes.

B. Download the “Warranty Report” from the engine ECM before Repair: Troubleshoot any active codes before continuing
performing any troubleshooting or clearing diagnostic trouble with this procedure.
codes.
If the problem is not resolved, proceed to Test Step 2.
Troubleshoot any active codes before continuing with this
procedure.

2. Fuel Quality Fuel Result: The fuel quality is OK.

A. Refer to Operation and Maintenance Manual for information on Proceed to Test Step 3.
the proper characteristics of the fuel for the engine. If necessary,
obtain a fuel analysis in order to confirm that the correct fuel is Result: The fuel quality is not OK.
being used for the engine. Refer to Systems Operation/Testing
and Adjusting, “Fuel Quality - Test” for the proper procedure. Repair: Replace the fuel. Verify that the repair eliminated
the problem.

If the problem is not resolved, proceed to Test Step 3.

3. Fuel Injectors Injector Sole- Result: The test was successful.

noid Test or
A. Use Cat ET to ensure that there are not any active diagnostic Fuel System Proceed to Test Step 4.
codes for the injector solenoids. Perform the “Cylinder Cutout Test” Verification
in order to check for a misfiring cylinder. Refer to Troubleshooting, Test Result: The test was not successful.
“Injector Solenoid - Test” for information that is related to the test.
Repair: Diagnose the problem and then repair the problem.
Use Cat ET to perform the “Fuel System Verification Test” in order
to check the mechanical condition of the fuel injectors. Refer to Reset all active codes and clear all logged codes.
Troubleshooting, “Injector Solenoid - Test” for information that is
related to the test. Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 4.

4. Proper Lubrication Lubrication Result: The oil passages are not blocked and the engine
has proper lubrication.
A. Check for proper lubrication of the valve components. Check for
sufficient lubrication between the injector tappets and the rocker Proceed to Test Step 5.
arms.
Result: The oil passages are blocked or the engine does
B. Check for blocked oil passages. Oil passages must be clean. not have proper lubrication.
Clean any oil passages that are questionable. Refer to the Disas-
sembly and Assembly for additional information. Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.
C. Inspect the engine oil filters for ferrous material.
If the problem is not resolved, proceed to Test Step 5.
D. Obtain an S·O·S oil analysis. The analysis will contribute to a
better understanding of oil contamination and the origin of the
contamination.

(continued)
72 UENR4349-03
Symptom Troubleshooting

(Table 31, contd)

Troubleshooting Test Steps Values Results

5. Valve Train Components Valve Train Result: The valve train components are not damaged.

A. Check the valve lash. Refer to Troubleshooting, “Valve Lash Is Proceed to Test Step 6.
Excessive”.
Result: The valve train components are damaged.
B. Check for damage to valve train components. Remove the
valve cover from the suspect cylinders. Check the following items Repair: Make the necessary repairs, Verify that the repair
for damage: eliminated the problem.

1. Camshaft If the problem is not resolved, proceed to Test Step 6.

2. Valve rotocoil

3. Valve springs

4. Camshaft followers

5. Rocker shaft

6. Bridges

7. Pushrods

8. Injectors

Refer to the Disassembly and Assembly for additional information.

C. Check for valves that do not move freely. Remove the cylinder
head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.

6. Gear Train and Components of the Lower End Gear Train Result: The gear train or lower end components are
damaged.
A. Inspect the gear train and lower end components.
Repair: Replace any damaged parts.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07044435

Engine Overcrank Occurrence

SMCS Code: 1450-035; 1900-035
Use this procedure if the following event code is
active. Refer to Troubleshooting, “Event Codes” for
information about event codes.

Note: The following code may not be applicable for

certain applications.
UENR4349-03 73
Symptom Troubleshooting

Table 32
Diagnostic Trouble Codes

J1939 Code and Description Comments

An attempt from the automatic start system failed to start the engine due
to an overcrank condition. The starting attempt has exceeded the time
1664-31 that is programmed for the “Crank Duration” parameter. Activation of this
Engine Automatic Start Failed code latches an engine shutdown condition. The power to the ECM must
be cycled prior to any additional attempts to start the engine.
The fuel is shut off. Engine cranking is prevented.

Probable Causes
• Diagnostic Codes

• Starting Aids (if applicable)

• Load

• Fuel Supply
• Battery

• Charging Circuit
• Starter

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
74 UENR4349-03
Symptom Troubleshooting

Table 33
Troubleshooting Test Steps Values Results

1. Check for Codes Associated Result: An associated diagnostic trouble code is not active
Codes or logged.
A. Establish communication between the Caterpillar Electronic
Technician (ET) and the ECM. Refer to Troubleshooting, “Elec- Proceed to Test Step 2.
tronic Service Tools”, if necessary.
Result: An associated code is active or logged.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Repair: Troubleshoot the associated codes before continu-
codes. ing with this procedure.

Troubleshoot any associated diagnostic codes that are present Refer to Troubleshooting, “Diagnostic Trouble Codes” in or-
before continuing with this procedure. der to troubleshoot the associated diagnostic code.

If the problem is not resolved, proceed to Test Step 2.

2. Starting Aids (if applicable) Starting Aids Result: The starting aid is operating correctly.

A. If cold ambient conditions exist, check the operation of the Proceed to Test Step 3.
starting aids.
Result: The starting aid is not operating correctly.
B. Verify that the starting aid is operating correctly.
Repair: Refer to the appropriate circuit test in order to trou-
bleshoot the starting aid.

If the problem is not resolved, proceed to Test Step 3.

3. Excessive Loads Excessive Result: The are not excessive loads on the engine.
Load
A. Check for an excessive load on the engine. Proceed to Test Step 4.

B. If necessary, disengage the driven equipment and test the Result: The are excessive loads on the engine.
engine.
Repair: Reduce the load on the engine. Return the unit to
service.

If the problem is not resolved, proceed to Test Step 4.

(continued)
UENR4349-03 75
Symptom Troubleshooting

(Table 33, contd)

Troubleshooting Test Steps Values Results

4. Inspection of the Fuel Supply Fuel Level Result: The fuel level is OK.

A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 5.
the fuel gauge only.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Fill the tank.

C. Check the fuel quality. If necessary, add fuel. If the engine has been run out of fuel,
purge the air from the fuel system.
Make sure that the fuel meets the requirements of Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids If the problem is not resolved, proceed to Test Step 5.
Recommendations”.

D. Inspect the fuel system.

Refer to Systems Operation/Testing and Adjusting, “Fuel Sys-

tem” for additional information.

Cold weather adversely affects the characteristics of the fuel.

Refer to the engine Operation and Maintenance Manual for in-
formation on improving the characteristics of the fuel during
cold-weather operation.

5. Worn Battery Battery Result: The battery will hold a charge.

A. Verify that the battery is no longer able to hold a charge. Refer Proceed to Test Step 6.
to Systems Operation/Testing and Adjusting for the correct
procedure. Result: The battery will no longer hold a charge.

Repair: Replace the battery. Refer to Disassembly and As-

sembly for the correct procedure.

If the problem is not resolved, proceed to Test Step 6.

6. Switched Battery Circuit Battery Circuit Result: The battery circuit is OK.

A. Inspect the battery cables, wiring, and connections in the Proceed to Test Step 7.
charging circuit.
Result: The battery circuit is not OK.
B. Verify that a switched battery circuit drained the battery by
being left in the ON position. Repair: Clean all connections and tighten all connections.
Replace any faulty parts, if necessary.
C. Charge the battery. Verify that the battery is able to maintain
a charge. Refer to Systems Operation/Testing and Adjusting for If the problem is not resolved, proceed to Test Step 7.
the correct procedure.

(continued)
76 UENR4349-03
Symptom Troubleshooting

(Table 33, contd)

Troubleshooting Test Steps Values Results
Alternator
7. Alternator Result: The condition of the alternator is OK.

A. Inspect the condition of the alternator. Refer to Troubleshoot- Proceed to Test Step 8.
ing, “Alternator Problem” for the correct procedure.
Result: The condition of the alternator is not OK.

Repair: Replace or repair the alternator.

If the problem is not resolved, proceed to Test Step 8.

Starter
8. Starter Engagement Engagement Result: The relay for the starting motor indicates that the en-
gine should crank and cranking occurs.
A. Attempt to start the engine while you observe the status of
the relay for the starting motor on Caterpillar Electronic Proceed to Test Step 9.
Technician.
Result: The relay for the starting motor indicates that the en-
gine should crank but no cranking occurs.

Repair: Troubleshoot the starting circuit.

If the problem is not resolved, proceed to Test Step 9.

Crank Cycle
9. Crank Cycle Result: The engine cannot be cranked for a sufficient
amount of time.
A maximum of one crank cycle per overcrank is recommended.
Repair: Use Cat ET to check the “Cycle Crank Time” and the
A. Make sure that the engine can be cranked for a sufficient “Overcrank Time” parameters. Remember that the purge
amount of time. cycle is part of the total crank cycle. Reprogram the parame-
ters, if necessary.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046273

Engine Overspeeds
SMCS Code: 1915-035
Use this procedure in order to troubleshoot an engine
overspeed or use this procedure if the following event
code is active. Refer to Troubleshooting, “Event
Codes” for information about event codes. For
information on the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
Note: Some of the following codes may not be
applicable for certain applications.
UENR4349-03 77
Symptom Troubleshooting

Table 34
Diagnostic Trouble Codes

J1939 Code and Description Comments

190-0
The code requires factory passwords to be cleared.
Engine Speed : High - most severe (3)

190-15
The code is logged.
Engine Speed : High - least severe (1)

Probable Causes
• Proper operation of the turbocharger

• Intake air
• Starting aids that are not operating properly

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.

Table 35
Troubleshooting Test Steps Values Results

1. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is not leaking oil into the inlet.

A. Check for proper operation of the turbocharger. Proceed to Test Step 3.

B. Check for any oil that may be leaking into the air inlet. Result: The turbocharger is leaking oil into the inlet.

Repair: Repair or replace the turbocharger.

If the problem is not resolved, proceed to Test Step 2.

2. Intake Air Air Quality Result: The atmosphere has combustible gases.

A. Check for combustible gases in the surrounding Repair: Do not operate the engine in an environment with
atmosphere. combustible gases.

B. Check for proper operation of starting aids (if equipped). Verify that the repair eliminated to problem.

If the procedure did not correct the issue, contact Probable Causes
your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the • Active codes and logged codes
Dealer Solutions Network (DSN).
• Incorrect parameters
i06095830
• Low-pressure fuel system
Engine Stalls at Low RPM • Fuel injectors
SMCS Code: 1000-035; 1900-035 • Engine accessories
Note: Refer to Troubleshooting, “Cat ET Service • Parasitic loads
Features” for information about service features.
Recommended Actions
Complete the procedure in the order in which the
steps are listed.
78 UENR4349-03
Symptom Troubleshooting

Table 36
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Diagnostic Result: A code is not active or logged.
Code
A. Establish communication between Caterpillar ® Electronic Techni- Proceed to Test Step 2.
cian (Cat ET) and the Electronic Control Module (ECM) . Refer to
Troubleshooting, “Electronic Service Tools”, if necessary. Result: A code is active or logged.

B. Determine if a code is active or logged. Repair: Troubleshoot any active codes before continuing
with this procedure.

If the problem is not resolved, proceed to Test Step 2.

2. Incorrect Parameters Parameters Result: The correct parameters are being used.

A. Use Cat ET to verify that the correct parameters are being used. Proceed to Test Step 3.
Refer to Troubleshooting, “Configuration Parameters” for additional
information. Result: The correct parameters are not being used.

Configure the correct parameters.

If the problem is not resolved, proceed to Test Step 3.

3. Low Pressure Fuel System Fuel System Result: The fuel system is operating properly.

A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 4.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for additional information. If the problem is not resolved, proceed to Test Step 4.

Cold weather adversely affects the characteristics of the fuel. Refer

to the engines Operation and Maintenance Manual for information
on improving the characteristics of the fuel during cold-weather
operation.

D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.

E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.

(continued)
UENR4349-03 79
Symptom Troubleshooting

(Table 36, contd)

Troubleshooting Test Steps Values Results

4. Fuel Injectors Injector Sole- Result: The test was successful.

noid Test or
A. Use Cat ET to ensure that there are not any active diagnostic co- Fuel System Proceed to Test Step 6.
des for the injector solenoids. Perform the “Cylinder Cutout Test” in Verification
order to check for a misfiring cylinder. Refer to Troubleshooting, “In- Test Result: The test was not successful.
jector Solenoid - Test” for information that is related to the test.
Repair: Diagnose the problem and then repair the
Use Cat ET to perform the “Fuel System Verification Test” in order problem.
to check the mechanical condition of the fuel injectors. Refer to
Troubleshooting, “Injector Solenoid - Test” for information that is re- Reset all active codes and clear all logged codes.
lated to the test.
Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 5.

5. Engine Accessories Engine Result: An engine accessory is creating an excessive

Accessories load.
A. Inspect any engine accessories and the transmission (if
applicable). Repair: Repair the engine accessory.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046276

Engine Top Speed Is Not

Obtained
SMCS Code: 1915-035

Note: If this fault occurs only under load, refer to

Troubleshooting, “Acceleration Is Poor or Throttle
Response Is Poor”.

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.
Table 37
J1939 Code and Description Comments
5580-17
The fuel pressure after the secondary fuel filter is lower than expected
Engine Filtered Fuel Delivery Absolute Pressure : Low - least severe
while the engine is running.
(1)

5580-18
The fuel pressure after the secondary fuel filter is lower than expected
Engine Filtered Fuel Delivery Absolute Pressure : Low - moderate se-
while the engine is running.
verity (2)

Probable Causes • Accessory and/or parasitic loads

• Active codes and logged codes • Incorrect flash file

• Incorrect parameters • Restriction in the air inlet and exhaust system

80 UENR4349-03
Symptom Troubleshooting

• Proper operation of the turbocharger

• Low-pressure fuel system

• Fuel injectors

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
Table 38
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Codes Result: There are no active codes.

A. Establish communication between Caterpillar ® Electronic Proceed to Test Step 2.

Technician (Cat ET) and the Electronic Control Module
(ECM). Refer to Troubleshooting, “Electronic Service Tools”, Result: There are active codes.
if necessary.
Repair: Troubleshoot any active codes before continuing with
B. Download the “Warranty Report” from the engine ECM be- this procedure.
fore performing any troubleshooting or clearing diagnostic
trouble codes. If the problem is not resolved, proceed to Test Step 2.

Troubleshoot any active codes before continuing with this

procedure.

2. Check for Incorrect Configuration Parameters Parameters Result: The parameters are configured correctly.

A. Use Cat ET to verify that the correct engine parameters Proceed to Test Step 3.
are being used. Refer to Troubleshooting, “Configuration Pa-
rameters” for additional information. Result: The parameters are not configured correctly.

B. Verify that all of the parameters for parasitic loads are Repair: Correctly configure the parameters.
correct.
Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 3.

3. Accessory and/or Parasitic Loads Parasitic Loads Result: There is not an excessive load on the engine.

Proceed to Test Step 4.

A. Check all accessory equipment for problems that may cre-
ate excessive load on the engine. Result: There is an excessive load on the engine.

B. Check for any excess parasitic load on the engine. Repair: Diagnose the problem and then repair the problem.

Verify that the repair eliminated the problem.

If the problem is not resolved, proceed to Test Step 4.

(continued)
UENR4349-03 81
Symptom Troubleshooting

(Table 38, contd)

Troubleshooting Test Steps Values Results

4. Incorrect Flash File Flash File Result: The latest flash file is installed in the ECM.

A. Verify that the latest flash file is installed in the Electronic Proceed to Test Step 5.
Control Module (ECM). Refer to Troubleshooting, “ECM Soft-
ware - Install” for the proper procedure. Result: The latest flash file is not installed in the ECM.

Repair: Install the latest flash file. Verify that the repair elimi-
nated the problem.

If the problem is not resolved, proceed to Test Step 5.

5. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are no restrictions in the air inlet or exhaust
system.
A. Check the air filter restriction indicator, if equipped. Clean
plugged air filters or replace plugged air filters. Refer to the Proceed to Test Step 6.
Operation and Maintenance Manual.
Result: There are restrictions in the air inlet or exhaust
B. Check the air inlet and exhaust system for restrictions system.
and/or leaks.
Repair: Make the necessary repairs, Verify that the repair
eliminated the problem.

If the problem is not resolved, proceed to Test Step 6.

6. Proper Operation of the Turbocharger Turbocharger Result: The turbocharger is operating properly.

A. Check for proper operation of the turbocharger. Proceed to Test Step 7.

Result: The turbocharger is not operating properly.

Repair: Repair or replace the turbocharger. Verify that the re-

pair eliminated the problem.

If the problem is not resolved, proceed to Test Step 7.

(continued)
82 UENR4349-03
Symptom Troubleshooting

(Table 38, contd)

Troubleshooting Test Steps Values Results

7. Low-Pressure Fuel System Fuel System Result: The fuel system is operating properly.

A. Visually check the fuel level in the fuel tank. Do not rely on Proceed to Test Step 8.
the fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Make the necessary repairs. Verify that the repair
eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Test-
ing and Adjusting, “Fuel System - Inspect” for additional If the problem is not resolved, proceed to Test Step 8.
information.

Cold weather adversely affects the characteristics of the fuel.

Refer to the engines Operation and Maintenance Manual for
information on improving the characteristics of the fuel during
cold-weather operation.

D. Check fuel quality. Check the fuel tank for debris or foreign
objects which may block the fuel supply.

E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low”
for the proper testing procedure.

8. Fuel Injectors Injector Solenoid Result: The test was successful.

Test or Fuel Sys-
A. Use Cat ET to ensure that there are not any active diag- tem Verification Return the unit to service.
nostic codes for the injector solenoids. Perform the “Cylinder Test
Cutout Test” in order to check for a misfiring cylinder. Refer to Result: The test was not successful.
Troubleshooting, “Injector Solenoid - Test” for information that
is related to the test. Repair: Diagnose the problem and then repair the problem.

Use Cat ET to perform the “Fuel System Verification Test” in Reset all active codes and clear all logged codes.
order to check the mechanical condition of the fuel injectors.
Refer to Troubleshooting, “Injector Solenoid - Test” for infor- Verify that the repair eliminated the problem.
mation that is related to the test.

If the procedure did not correct the issue, contact Recommended Actions
your Cat dealer Technical Communicator (TC). For Complete the procedure in the order in which the
further assistance, your TC can confer with the steps are listed.
Dealer Solutions Network (DSN).

i06096892

Engine Vibration Is Excessive

SMCS Code: 1000-035; 1152-035; 3252-035

Probable Causes
• Inspect the vibration damper.

• Engine Supports
• Driven Equipment

• Engine Misfiring
• Running Rough
UENR4349-03 83
Symptom Troubleshooting

Table 39
Troubleshooting Test Steps Values Results

1. Inspect the Vibration Damper Damper Result: The vibration damper or the mounting bolts are not
damaged.
A. Clean any debris from around the damper. Check the vibration
damper for damage. Proceed to Test Step 2.

B. Inspect the mounting bolts for damage and/or for wear. Refer to Result: The vibration damper or the mounting bolts are
the Disassembly and Assembly manual. damaged.

Repair: Replace the damaged vibration damper or the dam-

aged mounting bolts.

If the problem is not resolved, proceed to Test Step 2.

2. Engine Supports Engine Result: The mounts and brackets are not loose and/or
Supports broken.
A. Inspect the mounts and the brackets while you run the engine
through the speed range. Look for mounts and brackets that are Proceed to Test Step 3.
loose and/or broken.
Result: The mounts and brackets are loose and/or broken.
B. Check the alignment of the following before operating the en-
gine under load for any length of time: Repair: Replace the mounts and brackets that are loose
and/or broken.
1. Mounts
If the problem is not resolved, proceed to Test Step 3.
2. Coupling

3. Driven Equipment Driven Result: The driven equipment and the alignment are OK.
Equipment
A. Inspect the mounting bolts for the driven equipment. Inspect the Repair: Refer to Troubleshooting, “Engine Misfires, Runs
alignment and the balance of the driven equipment. Rough, or Is Unstable”, for more troubleshooting
information.
B. Inspect the coupling.
Result The driven equipment and the alignment are not OK.

Repair: Repair or replace the driven equipment.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact Recommended Actions
your Caterpillar dealer Technical Communicator (TC). Complete the procedure in the order in which the
For further assistance, your TC can confer with the steps are listed.
Dealer Solutions Network (DSN).

i06096938

Exhaust Has Excessive Black

Smoke
SMCS Code: 1088-035; 1250-035
Check for the following problems if there is excessive
black exhaust smoke.
Note: Refer to Troubleshooting, “Cat ET Service
Features” for information about service features.
84 UENR4349-03
Symptom Troubleshooting

Table 40
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Codes Result: There are no codes present.

A. Check for any logged or active codes associated with high Proceed to Test Step 2.
soot loading.

Result: There are codes present.

Repair: Troubleshoot the codes before continuing with this

procedure.

If the problem is not resolved, proceed to Test Step 2.

2. Perform the Automatic Cylinder Cutout Test using Cat Cylinder Cutout Result: The test was successful.
ET. Test
Proceed to Test Step 3.

Result: The test was not successful.

Repair: Diagnose the problem. Repair or replace damaged

components.

If the problem is not resolved, proceed to Test Step 3.

3. Check for Boost Pressure Leaks Leaks Result: There are no leaks found.

Proceed to Test Step 4.

Result: There are leaks found.

Repair: Diagnose and repair the boost pressure leaks.

If the problem is not resolved, proceed to Test Step 4.

4. Inspect the Turbocharger Turbocharger Result: The turbocharger is not OK.

A. Check for boost pressure leaks. Repair: Replace the turbocharger.

Refer to Testing and Adjusting, “Turbocharger - Inspect” for Verify that the repair eliminated the problem.
additional information.
UENR4349-03 85
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06097162

Exhaust Has Excessive White

Smoke
SMCS Code: 1088-035; 1250-035

Note: Some white smoke may be present during cold

start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a
problem.

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Probable Causes
• Active codes
• Oil in the exhaust system

• Cold mode operation (if applicable). Refer to

"Cold Mode Operation" within the Systems
Operation, “General Information”.

• Starting aids (if applicable)

• Noncurrent flash file

• Cooling system
• Unstable fuel supply

• Unstable fuel injection

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
86 UENR4349-03
Symptom Troubleshooting

Table 41
Troubleshooting Test Steps Values Results

1. Active Codes and Logged Codes Diagnostic Code Result: A code is not active or logged.

A. Establish communication between Caterpillar ® Electronic Tech- Proceed to Test Step 2.

nician (Cat ET) and the Electronic Control Module (ECM) . Refer
to Troubleshooting, “Electronic Service Tools”, if necessary. Result: A code is active or logged.

B. Determine if a code is active or logged. Repair: Troubleshoot any active codes before continu-
ing with this procedure.

If the problem is not resolved, proceed to Test Step 2.

2. Oil in the Exhaust System Oil in the Exhaust Result: The exhaust system contains oil.
System
A. Check for oil in the exhaust system. Repair: Determine the cause of oil in the exhaust sys-
tem and make the necessary repairs.

Proceed to Test Step 3.

Result: The exhaust system does not contain oil.

Proceed to Test Step 4.

3. Clean Oil from the Exhaust System Oil in the Exhaust Result: Oil has been cleaned from the exhaust system
System and the white smoke has dissipated.
A. Remove excess oil from piping with a clean cloth.
Return the unit to service.
B. Inhibit regeneration with the inhibit switch.
Result: Oil has been cleaned from the exhaust system
C. Operate the engine at elevated idle (1500 RPM) for 10 but the white smoke did not dissipate.
minutes.
Proceed to Test Step 4.

4. Cold Mode Operation (if applicable) Cold Mode Result: The engine is operating in cold mode.

During cold mode operation, condensation may be present and is This is normal operation. Return the engine to service.
normal.
Result: The engine is not operating in cold mode.
A. Cold mode is activated whenever the engine coolant tempera-
ture falls below a predetermined value. Monitor the status screen Proceed to Test Step 5.
on Cat ET in order to verify that the engine has exited cold mode.
Observe the reading for coolant temperature on the Cat ET.

5. Starting Aids (If Applicable) Starting Aid Result: The starting aid is operating correctly.

A. If cold ambient conditions exist, check operation of starting Proceed to Test Step 6.
aids. Verify that the starting aid is operating correctly. Refer to the
appropriate circuit test for information that is related to trouble- Result: The starting aid is not operating correctly.
shooting the starting aid.
Repair: Make the necessary repairs. Verify that the re-
If ether bottles are not installed, check the configuration screen on pair corrected the problem.
Cat ET in order to verify that ether is not enabled.
If the problem is not resolved, proceed to Test Step 6.

(continued)
UENR4349-03 87
Symptom Troubleshooting

(Table 41, contd)

Troubleshooting Test Steps Values Results

6. Noncurrent Flash File Flash File Result: The latest flash file is installed.

A. Verify that the latest flash file is installed in the ECM. Refer to Proceed to Test Step 7.
Troubleshooting, “ECM Software - Install” for the proper
procedure. Result: The latest flash file is not installed.

Repair: Install the latest flash file. Verify that the repair
eliminates the problem.

If the problem is not resolved, proceed to Test Step 7.

7. Cooling System Internal Coolant Result: There is not an internal coolant leak.
Leak
A. Check for an internal coolant leak into the cylinder and/or the Proceed to Test Step 8.
exhaust. Refer to Systems Operation/Testing and Adjusting,
“Cooling System”. Result: There is an internal coolant leak.

Repair: Make the necessary repairs. Verify that the re-

pair eliminated the problem.

If the problem is not resolved, proceed to Test Step 8.

(continued)
88 UENR4349-03
Symptom Troubleshooting

(Table 41, contd)

Troubleshooting Test Steps Values Results

8. Unstable Fuel Supply Fuel System Result: The fuel system is operating properly.

A. Visually check the fuel level in the fuel tank. Do not rely on the Proceed to Test Step 9.
fuel gauge only.
Result: The fuel system is not operating properly.
B. Ensure that the fuel supply valve (if equipped) is in the full
OPEN position. Repair: Make the necessary repairs. Verify that the re-
pair eliminates the problem.
C. Inspect the fuel system. Refer to Systems Operation/Testing
and Adjusting, “Fuel System - Inspect” for additional information. If the problem is not resolved, proceed to Test Step 9.

Cold weather adversely affects the characteristics of the fuel. Re-

fer to the engines Operation and Maintenance Manual for informa-
tion on improving the characteristics of the fuel during cold-
weather operation.

D. Check fuel quality. Check the fuel tank for debris or foreign ob-
jects which may block the fuel supply.

E. Check the filtered fuel pressure while the engine is being

cranked. Refer to Troubleshooting, “Fuel Pressure Is Low” for the
proper testing procedure.

9. Fuel Injectors
Injector Solenoid Result: The test was successful.
If service has been performed on the engine fuel system recently, Test or Fuel Sys-
verify that the injector trim files are correct. Use Cat ET to check tem Verification Return the unit to service.
that the injector trim files are correct for the injectors that are in- Test
stalled on the engine. Result: The test was not successful.

A. Use Cat ET to ensure that there are not any active diagnostic Repair: Diagnose the problem and then repair the
codes for the injector solenoids. Perform the “Cylinder Cutout problem.
Test” in order to check for a misfiring cylinder. Refer to Trouble-
shooting, “Injector Solenoid - Test” for information that is related to Reset all active codes and clear all logged codes.
the test.
Verify that the repair eliminated the problem.
Use Cat ET to perform the “Fuel System Verification Test” in order
to check the mechanical condition of the fuel injectors. Refer to
Troubleshooting, “Injector Solenoid - Test” for information that is
related to the test.

If the procedure did not correct the issue, contact • Cylinder head leak
your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Recommended Actions
Dealer Solutions Network (DSN).
Note: The procedures have been listed in order of
i06101376 probability. Complete the procedures in order.

Exhaust System Contains

Coolant
SMCS Code: 1050-035; 1395-035
Use the following procedure to troubleshoot a
problem with coolant in the exhaust system.

Probable Causes
• Cylinder head gasket leak
UENR4349-03 89
Symptom Troubleshooting

Table 42
Troubleshooting Test Steps Values Results

1. Cylinder head gasket leak Cylinder Head Result : The cylinder head gasket is not leaking.
Gasket
A. Check the cylinder head gasket for leaks. Refer to the Sys- Proceed to Test Step 2.
tems Operation/Testing and Adjusting for the proper proce-
dure for checking the cylinder head. Result : The cylinder head gasket is leaking.

Repair: Replace the cylinder head gasket. Refer to the Disas-

sembly and Assembly manual.

If the problem is not resolved, proceed to Test Step 2.

2. Cylinder head Cylinder Head Result : A crack is found in the cylinder head.

A. Check for cracks in the cylinder head. Perform a leak test Repair: Repair the cylinder head and/or replace the cylinder
on the cylinder head. Refer to the Systems Operation/Testing head. Refer to the Disassembly and Assembly manual.
and Adjusting for the proper procedure for checking the cylin-
der head. Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact If white smoke does not dissipate, Contact your Cat
your Cat dealer Technical Communicator (TC). For dealer Technical Communicator (TC). For further
further assistance, your TC can confer with the assistance, your TC can confer with the Dealer
Dealer Solutions Network (DSN). Solutions Network (DSN).

i06101379
Complete the procedure in the order in which the
steps are listed.
Exhaust System Contains Oil
SMCS Code: 1050-035; 1348-035

Probable Causes
• Failed turbocharger seals

• Worn valve guide seals or faulty valve guide seals

• Worn valve guides

• Worn piston rings and/or liners

• Extended idle times

Recommended Actions
Note: After the repair has been made, the oil should
be cleaned from the exhaust system. To clean the oil
from the exhaust system, perform the following
procedure:

1. Remove excess oil from piping with a clean cloth.

2. Inhibit regeneration with the inhibit switch.
3. Operate the engine at elevated idle (1500 RPM)
for 10 minutes.
If blue smoke dissipates, return machine to work.
90 UENR4349-03
Symptom Troubleshooting

Table 43
Troubleshooting Test Steps Values Results

1. Failed Turbocharger Seals Turbo Seals Result: Oil is not present in the inlet or exhaust manifold.

A. Check the inlet manifold and the exhaust manifold for oil. Proceed to Test Step 2.

Result: Oil is present in the inlet or exhaust manifold.

Repair: Replace the turbocharger. Verify the repair.

If the problem is not resolved, proceed to Test Step 2.

2. Worn Valve Guide Seals or Faulty Valve Guide Seals Valve Guide Result: The valve guide seals are not damaged.
Seals
A. Inspect the valve guide seals for wear and for damage. Proceed to Test Step 3.

Result: The valve guide seals are damaged.

Repair: Replace the valve guide seals. Verify the repair.

If the problem is not resolved, proceed to Test Step 3.

3. Worn Valve Guides and Valves Valve Guides Result: The valve guides and valves are not worn.

A. Inspect the valve guides and valves for wear. Refer to the Spec- Proceed to Test Step 4.
ification manual for the maximum permissible wear of the valve
guides and valves. Result: The valve guides and valves are worn.

Repair: If necessary, recondition the cylinder head. Verify

the repair.

If the problem is not resolved, proceed to Test Step 4.

4. Worn Piston Rings and Cylinder Liners Piston Rings Result The piston rings are not worn.

A. Piston rings or cylinder liners that have excessive wear can Proceed to Test Step 5.
cause too much pressure in the crankcase. The additional pres-
sure in the crankcase will cause more than the normal amount of Result The piston rings and or liners are worn.
crankcase blowby from the crankcase breather. Use the following
service tools, along with Software License, NETG5044: Repair: Replace the piston rings. Verify the repair.

1. 285-0900 Blowby Tool Gp (SMALL ENGINE) If the problem is not resolved, proceed to Test Step 5.

2. 348-5430 Multi-Tool Gp

B. Inspect piston rings

5. Extended Idle Times Idle Times Result The idle times are extensive.

A. Extended idle times will allow oil to pass into the exhaust Repair: Reduce the idle times.
system.
Verify that the repair eliminated the problem.
UENR4349-03 91
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046288

Exhaust Temperature Is High

SMCS Code: 1088-035-TA; 7498-035
The Engine Control Module (ECM) monitors the
following parameters:
• Barometric pressure

• Intake manifold air temperature

• Engine speed
Certain operating conditions may cause the exhaust
temperature to increase to a level that may damage
engine components. If a high exhaust temperature
occurs, the ECM derates the engine to reduce the
exhaust temperature. The engine is derated only to a
level that allows the exhaust temperature to return to
an acceptable level.
Table 44
Diagnostic Trouble Codes

J1939 Code and Description System Response

173-0 The exhaust gas temperature is higher than expected for the engine op-
Engine Exhaust Gas Temperature : High - most severe (3) erating conditions.
The code is logged.

173-15 The exhaust gas temperature is higher than expected for the engine op-
Engine Exhaust Gas Temperature : High - least severe (1) erating conditions.
The code is logged.

173-16 The exhaust gas temperature is higher than expected for the engine op-
Engine Exhaust Gas Temperature : High - moderate severity (2) erating conditions.
The code is logged.

Probable Causes
• Associated codes
• Boost Leak

• Engine operating conditions

• Obstructed aftercooler
92 UENR4349-03
Symptom Troubleshooting

Table 45
Troubleshooting Test Steps Values Results

1. Check for Associated Diagnostic Codes Associated Di- Result: An associated diagnostic code is not active or
agnostic logged.
A. Establish communication between Cat ET and the ECM . Refer Codes
to Troubleshooting, “Electronic Service Tools”, if necessary. Proceed to Test Step 2.

B. Determine if a code is active or logged. Result: An associated diagnostic code is active or logged.

Repair: Troubleshoot the associated code. Refer to Trou-

bleshooting, “Diagnostic Trouble Codes” to troubleshoot the
associated diagnostic code.

If the problem is not resolved, proceed to Test Step 2.

Table 46
DTC with associ- Data logged in this Interpretation
ated derate? histogram?

Derate was probably

caused by the ex-
No Yes
haust temperature
derate.
There may be multi-
ple causes for de-
rate since this
exhaust tempera-
ture histogram only
logs data when it
has the largest de-
Yes Yes
rate ( another derate
may have been ac-
tive due to a diag-
nostic trouble code,
but a larger exhaust
temperature derate
was applied).

Derate was probably

not caused by the
Yes No
exhaust tempera-
ture derate.
UENR4349-03 93
Symptom Troubleshooting

Illustration 24 g06034140
Example of Cat ET screenshot of the histogram. This histogram is populated when the engine system has
calculated a condition in which high exhaust temperatures are present. A fault code will not be logged when the
system calculates a high exhaust temperature condition, but will activate a de-rate to the engine to protect the
engine system. This action is normal under most circumstances and no additional troubleshooting is necessary.

Note: Information from this histogram is to be used

with active and logged diagnostic trouble codes. This
histogram is informational if no diagnostic codes are
active or logged.
Complete the procedure in the order in which the
steps are listed.
94 UENR4349-03
Symptom Troubleshooting

Table 47
Troubleshooting Test Steps Values Results

2. Check for Boost Leakage Boost Leaks Result: Boost leakage was not found.

A. Apply a light load to the engine and check for boost leakage. Proceed to Test Step 3.

Result: Boost leakage was found.

Repair: Repair the leaks. Return the unit to service.

If the problem is not resolved, proceed to Test Step 3.

3. Check the Engine Operating Conditions Normal Result: The code was not logged during a heavy load.
Operation
A. Check the histogram to determine if the high exhaust tempera- Proceed to Test Step 4.
ture was due to normal operation.
When possible, interview the operator. Determine if the engine is Result: The code was logged during a heavy load.
being operated under heavy load. Ensure that the engine is being
operated at the proper engine speed. Repair: Reduce the load on the engine. Return the unit to
service.
If derates are suspected, reset histogram and return the unit to
service. If the histogram repopulates without fault codes, derate If the problem is not resolved, proceed to Test Step 4.
was under normal engine operation.

4. Check for an Obstructed Aftercooler Obstructed Result: The engine aftercooler was obstructed.
Aftercooler
A. The intake manifold air temperature can increase if the flow Repair: Clear any obstructions. Return the unit to service.
through the aftercooler is obstructed. Check the aftercooler for
obstructions or debris. Ensure that the flow of air or coolant Verify that the repair eliminated the problem.
through the aftercooler is adequate.

If the procedure did not correct the issue, contact • Air inlet and exhaust system
your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the • Check for damaged accessory equipment
Dealer Solutions Network (DSN).
Recommended Actions
i07060213
Complete the procedure in the order in which the
steps are listed.
Fuel Consumption Is
Excessive
SMCS Code: 1250-035

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Probable Causes
• Engine operation

• Diagnostic codes, event codes and derates

• Fuel quality

• Fuel injection
• Engine speed/timing
UENR4349-03 95
Symptom Troubleshooting

Table 48
Troubleshooting Test Steps Values Results

1. Engine Operation Operation Result: Excessive idling is indicated.

Use Caterpillar® Electronic Technician (Cat ET) to check the “Cur- Repair: Make the necessary changes. Ensure that the
rent Totals” for excessive idle time and/or for a high load factor. Ex- problem is resolved.
cessive idle time and/or for a high load factor would be indicative of
poor operating habits. Result: Excessive idling is not indicated.

Note: Fuel consumption may also be affected by environmental Proceed to Test Step 2.
conditions such as wind, rough seas, and water current.

2. Diagnostic Codes, Event Codes and Derates Codes and Result: No codes are active.
Derates
Certain diagnostic codes and/or event codes may cause poor Proceed to Test Step 3.
performance.
Result: Codes are active.
A. Connect Cat ET and download the “Warranty Report” from the
engine Electronic Control Module (ECM) before performing any Repair: Troubleshoot the codes that are present.
troubleshooting or clearing diagnostic trouble codes.
Proceed to Test Step 3.
B. Wait at least 30 seconds in order for any codes to become
active.

Note: Certain failure modes of a sensor may produce an output sig-

nal that does not represent an accurate measurement. The inaccu-
rate measurement can occur when the signal is in the operational
range of the sensor. Use Cat ET to check that the pressures and
the temperatures are fluctuating normally. Also check that the val-
ues are reasonable for the conditions that are present.

3. Fuel Quality Poor Fuel Quality Result Fuel quality is desirable.

A. Check fuel quality. Proceed to Test Step 4.

Cold weather adversely affects the characteristics of the fuel. Result: Fuel quality is undesirable.

Repair: Refer to the Operation and Maintenance Man-

ual for information on improving the characteristics of
the fuel during cold-weather operation.

If the problem is not resolved, proceed to Test Step 4.

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
96 UENR4349-03
Symptom Troubleshooting

Table 49
Troubleshooting Test Steps Values Results

4. Fuel Injection Fuel Injection Result The “Fuel System Verification Test” completed
successfully.
A. Perform the “Fuel System Verification Test” in Cat ET. Refer to
Troubleshooting, “Injector Solenoid - Test”. Proceed to Test Step 5.

Result The “Fuel System Verification Test” failed.

Repair: Diagnose the problem and then repair the

problem. Clear all logged diagnostic codes.

If the problem is not resolved, proceed to Test Step 5.

5. Engine Speed/Timing Engine Speed/ Result The speed/timing sensor calibration failed.
Timing
A. Perform a speed/timing sensor calibration. Refer to the calibra- Repair: Resolve the issue. Ensure that the problem is
tion procedure Troubleshooting, “Timing - Calibrate”. resolved.

Result The speed/timing sensor calibration completed

successfully.

Proceed to Test Step 6.

6. Air Inlet and Exhaust System Air inlet and Ex- Result The air inlet and exhaust system is not func-
haust System tioning correctly.
A. Inspect the air filter for a restriction. If the air filter shows signs
of plugging, clean the air filter or replace the air filter. Repair: Make the proper repairs. Ensure that the
problem is resolved.
B. Check the air inlet and exhaust system for restrictions and/or for
leaks. Refer to Systems Operation/Testing and Adjusting. Result The air inlet and exhaust system is functioning
correctly.

Proceed to Test Step 7.

7. Check for Damaged Accessory Equipment Damaged Acces- Result Problems have been found with the accessory
sory Equipment equipment.
A. Check all accessory equipment for problems that may create
excessive load on the engine. Repair: Repair any damaged components or replace
any damaged components.

Result No problems have been found with the acces-

sory equipment.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact Use this procedure if one of the following codes is
your Cat dealer Technical Communicator (TC). For active. Refer to Troubleshooting, “Diagnostic Codes”
further assistance, your TC can confer with the for information about diagnostic codes. For
Dealer Solutions Network (DSN). information on the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
i07037885
Note: Some of the following codes may not be
applicable for certain applications.
Fuel Filter Is Restricted
SMCS Code: 1261-035
The Electronic Control Module (ECM) detects an
abnormal fuel filter differential pressure.
UENR4349-03 97
Symptom Troubleshooting

Table 50
Diagnostic Trouble Codes

J1939 Diagnostic Code and Description Comments

The code is logged.
5584-15
The filter is becoming clogged. Change the filter at the next regular
Engine Fuel Filter Degradation : High - least severe (1)
maintenance.
The code is logged.
The difference between the filtered fuel pressure and the unfiltered
5584-16
fuel pressure is greater than the trip point pressure.
Engine Fuel Filter Degradation : High - moderate severity (2)
The engine ECM will derate engine power.
Change the fuel filter.

Probable Causes
Fuel Filter
• Fuel filter
Note: Change the primary filter, the secondary filter,
and the tertiary filter at the same time. Use clean fuel
on the stud threads of filter base to reduce friction.
Note: Do not fill the canister or the fuel filter
before installation. The fuel can carry debris into
the fuel filter and the fuel system may be
damaged. The electric priming pump is designed
to purge the trapped air in the new filters.
Complete the procedure in the order in which the
steps are listed.
Table 51
Troubleshooting Test Steps Values Results

1. Change the fuel filters Fuel Filter Result: The code is no longer active
Change
A. Reset all active codes and clear all logged codes by cycling the Result: The event code becomes active after changing
keyswitch to the OFF position. Change the primary fuel filter. the fuel filters.

B. Prime the system with the electric priming pump. Repair: The problem may be electrical. Refer to Trouble-
shooting, “Sensor Signal (Analog, Active) - Test” for the
C. Start the engine and allow the engine to idle for few minutes. procedure to troubleshoot the circuit.

D. Turn the engine OFF and change the secondary fuel filter.

E. Prime the system with the electric priming pump.

F. Start the engine and allow the engine to idle for few minutes.

G. Turn the engine OFF and change the tertiary fuel filter.

H. Prime the system with the electric priming pump.

J. Restart the engine.

98 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issues, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07047405

Fuel Pressure Is High

SMCS Code: 1250-035
The probable causes of high fuel pressure:
• Fuel pressure sensors
• Fuel lines

• Fuel transfer pump

• Fuel return pressure regulator
Use this procedure in order to troubleshoot high fuel
pressure. Use this procedure if the following event
code is active. Refer to Troubleshooting, “Event
Codes” for information about event codes. For
information on the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
Table 52
J1939 Code and Description Comments

94-16 The code is logged.

Engine Fuel Delivery Pressure : High - moderate severity (2) The fuel pressure is above the trip point pressure.

Table 53
Associated Diagnostic Trouble Codes

J1939 Code Code Description

5584 Fuel Filter Restriction

Complete the procedure in the order in which the

steps are listed.
Table 54
Troubleshooting Test Steps Values Results

1. Determine the Code Codes Result: A 94-16 code is present.

A. Connect Caterpillar ® Electronic Technician (Cat ET) to the service Proceed to Test Step 2.
tool connector. Refer to Troubleshooting, “Electronic Service Tools”,
if necessary. Result: A code other than 94-16 code is present.

B. Download the “Warranty Report” from the engine Electronic Con- Repair: Troubleshoot the code. Refer to the proper trou-
trol Module (ECM) before performing any troubleshooting or clearing bleshooting procedure.
diagnostic trouble codes.

C. Determine if a diagnostic trouble code is present.

UENR4349-03 99
Symptom Troubleshooting

Illustration 25 g03811888

(1) Fuel Pressure Outlet Sensor (3) Fuel Pressure Inlet Sensor
(2) Fuel Temperature Sensor (4) Fuel filter base

Table 55
Troubleshooting Test Steps Values Results

2. Check Fuel Pressure Sensor (3) Pressure Result: The gauge value of the fuel pressure is within
Sensor 69 kPa (10 psi) of the unfiltered fuel pressure reading
A. Record the unfiltered fuel pressure from Cat ET. Record the value shown in Cat ET.
in Table 57 .
Proceed to Test Step 3.
B. Remove fuel pressure sensor (3).
Result: The gauge value of the fuel pressure is not with-
C. Install a 5P-1318 Adapter into the port of the pressure sensor in 69 kPa (10 psi) of the unfiltered fuel pressure reading
(3). shown in Cat ET.

D. Install the 123-0783 Fluid Sampling Valve Gp onto the Repair: Replace the pressure sensor. Verify that the
5P-1318 Adapter. problem has been resolved.

E. Install a 8T-0855 Pressure Gauge onto a 6V-3990 Coupler. If the problem is not resolved, proceed to Test Step 3.

F. Install the 6V-3990 Coupler onto the 123-0783 Fluid Sampling

Valve Gp.

G. Record the fuel pressure from the pressure gauge. Record the
pressure in Table 57 .

Table 56 Table 57
Required Tooling for Pressure Sensor “ A”” Engine RPM Unfiltered fuel pres- Fuel pressure
sure from Cat ET from the mechani-
5P-1318 Adapter cal gauge
123-0783 Fluid Sampling Valve Gp 800 - -
8T-0855 Pressure Gauge 1800 - -

6V-3990 Coupler
100 UENR4349-03
Symptom Troubleshooting

Illustration 26 g03812246 Illustration 28 g03812369

Simplex Fuel Supply Lines Duplex Fuel Filters and Supply Lines Rear View (If
Equipped)

Illustration 27 g03812355
Duplex Fuel Filters and Supply Lines Front View (If Illustration 29 g03812185
Equipped) Fuel Return Line
UENR4349-03 101
Symptom Troubleshooting

Table 58
Troubleshooting Test Steps Values Results

3. Inspect the Fuel Supply and Return Lines Inspect Lines Result: The fuel lines and the cooler (if equipped) are
OK.
A. Visually inspect the fuel lines between the primary filter base and
the inlet to the fuel injection pump. Also, inspect the fuel cooler, if Proceed to Test Step 4.
equipped. Inspect the fuel return line from the head to the fuel tank.
Inspect the lines for restrictions, pinching, and swelling. Refer to Sys- Result: The fuel lines and the cooler (if equipped) are
tems Operation/Testing and Adjusting, “Fuel System - Inspect” for not OK.
additional information.
Repair: Make the necessary repairs. Verify that the prob-
lem has been resolved.

If the problem is not resolved, proceed to Test Step 4.

Illustration 30 g03811936
(8) Return Fuel Pressure Regulator

Table 59
Troubleshooting Test Steps Values Results

4. Replace the Return Fuel Pressure Regulator Pressure Result: The regulator was replaced. Verify that the prob-
Regulator lem is resolved.

If the problem is not resolved, proceed to Test Step 5.

102 UENR4349-03
Symptom Troubleshooting

Illustration 31 g03812410
Typical Fuel Transfer Pump
(9) Relief Valve

Table 60
Troubleshooting Test Steps Values Results

5. Inspect the Relief Valve for the Fuel Transfer Pump Transfer Result: The relief valve is stuck CLOSED.
Pump
A. Inspect the relief valve for the transfer pump. The spring must Repair: Replace the fuel transfer pump. Verify that the
move freely. problem has been resolved.

Result: The relief valve is OK.

Repair: Clean the relief valve and reinstall the relief

valve. Verify that the problem has been resolved.

If the procedure did not correct the issue, contact Note: Some of the following codes may not be
your Cat dealer Technical Communicator (TC). For applicable for certain applications.
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07037875

Fuel Pressure Is Low

SMCS Code: 1250-035

Note: The 5580 code may activate when the water

separator is being drained. Disregard the code and
toggle the keyswitch to clear the code.
Use this procedure in order to troubleshoot a low fuel
pressure. Use this procedure if one of the following
event codes is active. Refer to Troubleshooting,
“Event Codes” for information about event codes. For
information on the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
UENR4349-03 103
Symptom Troubleshooting

Table 61
Diagnostic Trouble Codes

J1939 Diagnostic Code and Description Comments

5580-17
Engine Filtered Fuel Delivery Absolute Pressure : Low - least severe The code is logged.
(1)

5580-18 The code is logged.

Engine Filtered Fuel Delivery Absolute Pressure : Low - moderate se- The engine power is derated.
verity (2) The Electronic Control Module (ECM) will illuminate the action lamp.

Table 62
Associated Diagnostic Trouble Codes

J1939 Code CDL Code

5584-15 E390 (1)

5584-16 E390 (2)

Table 63
Troubleshooting Test Steps Values Results

1. Determine the Code Codes Result: A 5580 code is present.

A. Connect Caterpillar Electronic Technician (ET) to the service tool Proceed to Test Step 2.
connector. Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Result: An associated code is present.

B. Download the “Warranty Report” from the engine ECM before Repair: Troubleshoot the associated code. Refer to the
performing any troubleshooting or clearing diagnostic trouble proper troubleshooting procedure.
codes.

C. Determine if a diagnostic trouble code is present or an associ-

ated code is present.

2. Check the Fuel Level in the Tank Fuel Level Result: The fuel level is OK.

A. Visually inspect the fuel level in the fuel tank. Ensure that the fuel Proceed to Test Step 3.
tank contains enough fuel in order to operate the engine.
Result: The fuel level is not OK.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position. Repair: Fill the tank. Verify that the problem has been
resolved.

If the problem is not resolved, proceed to Test Step 3.

3. Inspect the Fuel System for Leaks Leaks in the Result: No leaks were found.
Fuel System
A. Perform a visual inspection of the fuel system. Verify that there Proceed to Test Step 4.
are no fuel leaks. Inspect the fuel lines from the fuel transfer pump
to the secondary fuel filter base for restrictions. Refer to Systems Result: Leaks were found in the fuel system.
Operation/Testing and Adjusting, “Fuel System - Inspect” for addi-
tional information. Repair: Repair the leaks. Verify that the problem is
resolved.

If the problem is not resolved, proceed to Test Step 4.

104 UENR4349-03
Symptom Troubleshooting

Note: Cold weather adversely affects the

characteristics of the fuel. Refer to the engine
Operation and Maintenance Manual for information
on improving the characteristics of the fuel during
cold-weather operation.
Table 64
Required Tooling for Fuel Pressure Sensor

8t-7860 Connector
110-6349 Fitting As

8t-0855 Pressure Gauge

6v-3990 Coupler

Illustration 32 g03758136
C9.3 Engines
(1) Fuel temperature sensor (3) Fuel pressure sensor
(2) Unfiltered fuel pressure sensor (4) Fuel filter base

Note: Do not use location (2) for measuring the fuel

pressure. Follow the steps below.
UENR4349-03 105
Symptom Troubleshooting

Table 65
Troubleshooting Test Steps Values Results

4. Check the Fuel Pressure Sensor Pressure Result: The gauge value of the fuel pressure is within
Sensor 69 kPa (10 psi) of the fuel pressure reading shown in ET.
A. Record the fuel pressure from Cat ET. Record the value in Table
66 . Proceed to Test Step 5.

B. Remove the fuel pressure sensor . Result: The gauge value of the fuel pressure is not within
69 kPa (10 psi) of the fuel pressure reading shown in ET.
C. Install a 8t-7860 Connector into the port of the pressure sen-
sor . Repair: Replace the pressure sensor. Verify that the
problem has been resolved.
D. Install the 110-6349 Fitting As onto the 8t-7860 Connector.
If the problem is not resolved, proceed to Test Step 5.
E. Install a 8t-0855 Pressure Gauge onto a 6v-3990 Coupler.

F. Install the 6v-3990 Coupler onto the 110-6349 Fitting As.

G. Record the fuel pressure from Cat ET and on the pressure

gauge. Record the data in Table 66 .

Table 66
Engine RPM Fuel pressure from Fuel pressure
Cat ET from the mechani-
cal gauge

800
1800

Table 67
Troubleshooting Test Steps Values Results

5. Replace the Fuel Filters Fuel Filters Result: The problem has been resolved.

A. Replace the primary filter, the secondary filter, and the tertiary Return the engine to service.
fuel filters.
The fuel system will need to be primed after the filters are
replaced. Result: The problem has not been resolved.

B. Reset all active codes by cycling the keyswitch to the OFF posi- Proceed to Test Step 6.
tion for 2 minutes.

6. Check for Air in the Fuel System Air in the Result: Air is in the system.
System
A. Check for air in the fuel. Refer to Systems Operation/Testing and Repair: Refer to Systems Operation/Testing and Adjust-
Adjusting, “Air in Fuel - Test” for the proper procedure ing, “Air in Fuel - Test” for the proper repairs.

Result: Air is not in the system.

Proceed to Test Step 7.

106 UENR4349-03
Symptom Troubleshooting

Illustration 33 g03429826
C9.3 Engines
(9) Anti-drain check valve (10) Fuel return pressure regulator

Table 68
Troubleshooting Test Steps Values Results

7. Replace the Fuel Return Pressure Regulator Replace Pres- Result: The problem has been resolved
sure Regulator
A. Replace the fuel return pressure regulator. Return the engine to service.

B. Inspect the anti-drain check valve for proper operation. Result: The problem has not been resolved.

Proceed to Test Step 8.

8. Replace the Transfer Pump Transfer Pump Result: The transfer pump was replaced.

A. Replace the transfer pump. Repair: Reset all active codes and clear all logged codes
For information about testing the transfer pump, Refer to Testing by using Cat® ET.
and Adjusting, “Fuel System Pressure - Test”.
Verify that the problem has been resolved.

If the procedure did not correct the issue, contact Use this procedure in order to troubleshoot low fuel
your Cat dealer Technical Communicator (TC). For rail pressure or use this procedure if the following
further assistance, your TC can confer with the event code is active. Refer to Troubleshooting,
Dealer Solutions Network (DSN). “Event Codes” for information about event codes. For
information on the engine monitoring system, refer to
i07046309
Troubleshooting, “Engine Monitoring System”.

Note: Some of the following codes may not be

Fuel Rail Pressure Is Low applicable for certain applications.
SMCS Code: 127A-035 Note: The 157-17 code may activate when the water
separator is being drained. Disregard the code and
Note: Refer to Troubleshooting, “Cat ET Service toggle the keyswitch to clear the code.
Features” for information about service features.
UENR4349-03 107
Symptom Troubleshooting

Table 69
Diagnostic Trouble Codes

J1939 Code and Description Comments

The fuel rail pressure is below an acceptable level.
157-17
The code is logged.
Engine Injector Metering Rail #1 Pressure : Low - least severe (1)
The check engine light will illuminate.

Table 70
Associated Diagnostic Trouble Codes
J1939 Code Code Description

157-3 Engine Injector Metering Rail #1 Pressure : Voltage Above Normal

157-4 Engine Injector Metering Rail #1 Pressure : Voltage Below Normal

1347-5 Engine Fuel Pump Pressurizing Assembly #1 : Current Below Normal

1347-6 Engine Fuel Pump Pressurizing Assembly #1 : Current Above Normal

1348-5 Engine Fuel Pump Pressurizing Assembly #2 : Current Below Normal

1348-6 Engine Fuel Pump Pressurizing Assembly #2 : Current Above Normal

5580-17 Engine Filtered Fuel Delivery Absolute Pressure : Data Low - Least Se-
vere (1)

5580-18 Engine Filtered Fuel Delivery Absolute Pressure : Data Low - Moder-
ately Severe (2)

5584-15 Engine Fuel Filter Degradation : Data High - Least Severe (1)

5584-16 Engine Fuel Filter Degradation : Data High - Moderately Severe (2)

Troubleshooting Procedure
Complete the procedure in the order in which the
steps are listed.
108 UENR4349-03
Symptom Troubleshooting

Table 71
Troubleshooting Test Steps Values Results

1. Check for Associated Codes Associated Codes Result: An associated code is not active or logged.

A. Establish communication between Caterpillar ® Proceed to Test Step 2.

Electronic Technician (Cat ET) and the Engine Elec-
tronic Control Module (ECM). Result: An associated code is active or logged.

B. Download the “Warranty Report” from the engine Repair: Troubleshoot the associated codes before continuing with
ECM before performing any troubleshooting or clearing this procedure.
diagnostic trouble codes.

C. If any of the associated codes in Table 70 are

logged, troubleshoot the codes before continuing with
this procedure.

2. Inspect the Fuel System Fuel System Result: Problems were not found with the fuel system.
Problems
A. Inspect the fuel system. Refer to Systems Opera- Proceed to Test Step 3.
tion/Testing and Adjusting, “Fuel System - Inspect” for
inspection of the high-pressure fuel lines and the fuel Result: Problems were found with the fuel system.
rail.
Repair: Repair the components or replace the components that
are damaged. Verify that the problem is resolved.

If the problem is not resolved, proceed to Test Step 3.

Result: The pressure dropped below 5,000 kPa (725 psi) after
3. Check the Fuel Rail Sensor Rail pressure less the engine was shut off for 10 minutes.
than 5,000 kPa
A. Allow the engine to be OFF for 10 minutes. (725 psi) Proceed to Test Step 4.

B. Turn the keyswitch to the ON position, do not start Result: The pressure did not drop below 5,000 kPa (725 psi)
the engine. after the engine was shut off for 10 minutes.

C. Connect to the Engine ECM using Cat ET. Repair: Replace the fuel rail pressure sensor. If the problem has
been corrected, return the unit to service.
D. Using Cat ET, check the status of the “Fuel Rail
Pressure (absolute)” . If the problem is not resolved, proceed to Test Step 4.

Result: The engine will start.

4. Start the Engine Engine will Start
Proceed to Test Step 5.
A. Try to start the engine.
Result: The engine will not start.

Repair: Refer to Systems Operations/Testing and Adjusting, “In-

jector Bypass Fuel Flow”.
UENR4349-03 109
Symptom Troubleshooting

Illustration 34 g03812708
Location of the “Fuel System Functional Test” in the “Diagnostic Service Test” menu
110 UENR4349-03
Symptom Troubleshooting

Illustration 35 g03383456
If 157-17 Low Fuel Rail Pressure fault is active, the “Fuel System Functional Test – Pretest” will not be able to run.
Uncheck the “Fuel System Functional Test – Pretest” box and proceed to the “Fuel System Functional Test”
UENR4349-03 111
Symptom Troubleshooting

Table 72
Troubleshooting Test Steps Values Results

5. Perform the “ Fuel System Functional Test”” Test Passed Result: The test failed for an $1120 - Fuel Pump Not Timed
Correctly.
A. Start the engine.
Repair: Remove the high-pressure fuel pump. Refer to Disas-
B. Connect to the Engine ECM using Cat ET. sembly and Assembly for the correct procedures. Pin the engine
to TDC. Time the pump and then reinstall the high-pressure fuel
C. Perform the “Fuel System Functional Test” in Cat ET. pump. Then, run the “Fuel System Functional Test” in order to ver-
Cat ET will display an error message that indicates the ify that the pump is timed correctly.
problem. Follow the repair procedure for the error mes-
sage. If the test aborts for an active diagnostic make Result: The test failed for an $111F - Fuel Flow Too Low.
sure to troubleshoot the code first.
Repair: Replace the high-pressure fuel pump. Refer to Disassem-
If a 157-17 Low Fuel Rail Pressure fault is active, bly and Assembly for the correct procedure. Then, run the “Fuel
the “ Fuel System Functional Test – Pretest”” will not System Functional Test” again in order to verify that the problem
be able to run. Uncheck the box and proceed to the is resolved.
“ Fuel System Functional Test”” .
Result: The test failed for an $111D - Fuel Rail High Pressure De-
cay Too High.

Repair: Replace the relief valve. Refer to Disassembly and As-

sembly for the correct procedure. Then, run the “Fuel System
Functional Test” again in order to verify that the problem is re-
solved. If the problem is not resolved, torque all the quill tubes
again, then perform the “Fuel System Functional Test” . If the test
passed, return the unit to service. If the test failed, perform the “In-
jector Bypass Fuel Flow - Test” . Refer to Systems Operation/Test-
ing and Adjusting, “Injector Bypass Fuel Flow - Test”.

Result: The test failed for an $111E - Fuel Rail Low Pressure De-
cay Too High.

Repair: Torque all the quill tubes again, then perform the “Fuel
System Functional Test” . If the test passed, return the unit to
service. If the test failed, perform the “Injector Bypass Fuel Flow -
Test” . Refer to Systems Operation/Testing and Adjusting, “Injec-
tor Bypass Fuel Flow - Test”.

Result: The test passed successfully.

If the procedure did not correct the issue, contact • The fuel pressure must be above 210 kPa
your Cat dealer Technical Communicator (TC). For (30 psi).
further assistance, your TC can confer with the
Dealer Solutions Network (DSN). • The fuel temperature must be above 10° C
(50° F).
i07046325
Use this procedure in order to troubleshoot low fuel
rail pressure while the engine is cranking. Also, use
Fuel Rail Pressure Is Low this procedure if the diagnostic code in Table 73 is
While Cranking active or logged.

SMCS Code: 127A-035

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Note: The following conditions must be met before

continuing with this procedure.

• The minimum engine speed or cranking speed

must be at least 150 RPM.
112 UENR4349-03
Symptom Troubleshooting

Table 73
Diagnostic Trouble Codes

J1939 Code and Description Comments

5585-17
Engine Injector Metering Rail #1 Cranking Pressure : Low - least se- The code is logged.
vere (1)

Table 74
Associated Diagnostic Trouble Codes

J1939 Code Code Description

157-3 Engine Injector Metering Rail #1

Pressure : Voltage Above
Normal
157-4 Engine Injector Metering Rail #1
Pressure : Voltage Below
Normal
190-8 Engine Speed : Abnormal Fre-
quency, Pulse Width, or Period

723-8 Engine Speed Sensor #2 : Ab-

normal Frequency, Pulse Width,
or Period
1347-5 Engine Fuel Pump Pressurizing
Assembly #1 : Current Below
Normal
1347-6 Engine Fuel Pump Pressurizing
Assembly #1 : Current Above
Normal
1348-5 Engine Fuel Pump Pressurizing
Assembly #2 : Current Below
Normal
1348-6 Engine Fuel Pump Pressurizing
Assembly #2 : Current Above
Normal
5580-17 Engine Filtered Fuel Delivery
Absolute Pressure : Data Low -
Least Severe (1)

5580-18 Engine Filtered Fuel Delivery

Absolute Pressure : Data Low -
Moderately Severe (2)

Complete the procedure in the order in which the

steps are listed.
UENR4349-03 113
Symptom Troubleshooting

Table 75
Troubleshooting Test Steps Values Results

1. Check for Associated Codes Associated Result: An associated code is not active or logged.
Codes
A. Establish communication between Caterpillar ® Electronic Techni- Proceed to Test Step 2.
cian (Cat ET) and the Engine Electronic Control Module (ECM).
Result: An associated code is active or logged.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble codes. Repair: Troubleshoot the associated codes before
continuing with this procedure.
C. If any of the associated codes in Table 74 are logged, trouble-
shoot the codes before continuing with this procedure. If the problem is not resolved, proceed to Test Step 2.

2. Inspect the Fuel System Fuel System Result: Problems were not found with the fuel
Problems system.
A. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for inspection of the high-pres- Proceed to Test Step 3.
sure fuel lines and the fuel rail.
Result: Problems were found with the fuel system.

Repair: Repair the components or replace the compo-

nents that are damaged. Verify that the problem is
resolved.

If the problem is not resolved, proceed to Test Step 3.

Result: The pressure dropped below 5,000 kPa

3. Check the Fuel Rail Sensor Rail Pressure (725 psi) after the engine was shut off for 10 minutes.
less than
A. Allow the engine to be OFF for 10 minutes. 5,000 kPa Proceed to Test Step 4.
(725 psi)
B. Turn the keyswitch to the ON position, do not start the engine. Result: The pressure did not drop below 5,000 kPa
(725 psi) after the engine was shut off for 10 minutes.
C. Connect to the Engine ECM using Cat ET.
Repair: Replace the fuel rail pressure sensor. If the
D. Using Cat ET, check the status of the “Fuel Rail Pressure (abso- problem has been corrected, return the unit to service.
lute)” .
If the problem is not resolved, proceed to Test Step 4.

Result: The engine will start.

4. Start the Engine Engine will Start
Proceed to Test Step 5.
A. Try to start the engine.
Result: The engine will not start.

Repair: Refer to Systems Operations/Testing and Ad-

justing, “Injector Bypass Fuel Flow”

If the problem is not resolved, proceed to Test Step 5.

114 UENR4349-03
Symptom Troubleshooting

Illustration 36 g03814248
Location of the “Fuel System Functional Test” in the “Diagnostic Service Test” menu
UENR4349-03 115
Symptom Troubleshooting

Illustration 37 g03383456
If a 5585-17 Low Fuel Rail Pressure fault is active, the “Fuel System Functional Test – Pretest” will not be able to
run. Uncheck the “Fuel System Functional Test – Pretest” box and proceed to the “Fuel System Functional Test”
116 UENR4349-03
Symptom Troubleshooting

Table 76
Troubleshooting Test Steps Values Results

5. Perform the “ Fuel System Functional Test”” Test Passed Result: The test failed for an $1120 - Fuel Pump Not
Timed Correctly.
A. Start the engine.
Repair: Remove the high-pressure fuel pump. Refer
B. Connect to the Engine ECM using Cat ET. to Disassembly and Assembly for the correct proce-
dures. Pin the engine to TDC. Time the pump and
C. Perform the “Fuel System Functional Test” in Cat ET. Cat ET will then reinstall the high-pressure fuel pump. Then, run
display an error message that indicates the problem. Follow the re- the “Fuel System Functional Test” in order to verify
pair procedure for the error message. If the test aborts for an active that the pump is timed correctly.
diagnostic make sure to troubleshoot the code first.
Result: The test failed for an $111F - Fuel Flow Too
If a 5585-17 Low Fuel Rail Pressure fault is active, the “ Fuel Low.
System Functional Test – Pretest”” will not be able to run. Un-
check the box and proceed to the “ Fuel System Functional Repair: Replace the high-pressure fuel pump. Refer
Test”” . to Disassembly and Assembly for the correct proce-
dure. Then, run the “Fuel System Functional Test”
again in order to verify that the problem is resolved.

Result: The test failed for an $111D - Fuel Rail High

Pressure Decay Too High.

Repair: Replace the relief valve. Refer to Disassem-

bly and Assembly for the correct procedure. Then, run
the “Fuel System Functional Test” again in order to
verify that the problem is resolved. If the problem is
not resolved, torque all the quill tubes again, then per-
form the “Fuel System Functional Test” . If the test
passed, return the unit to service. If the test failed, per-
form the “Injector Bypass Fuel Flow - Test” . Refer to
Systems Operation/Testing and Adjusting, “Injector
Bypass Fuel Flow - Test”.

Result: The test failed for an $111E - Fuel Rail Low

Pressure Decay Too High.

Repair: Torque all the quill tubes again, then perform

the “Fuel System Functional Test” . If the test passed,
return the unit to service. If the test failed, perform the
“Injector Bypass Fuel Flow - Test” . Refer to Systems
Operation/Testing and Adjusting, “Injector Bypass
Fuel Flow - Test”.

Result: The test passed successfully.

UENR4349-03 117
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046331

Fuel Rail Pressure Leakage Is

High
SMCS Code: 127A-035
Use this procedure if the following event code is
active. Refer to Troubleshooting, “Event Codes” for
information about event codes. For information on
the engine monitoring system, refer to
Troubleshooting, “Engine Monitoring System”.
Note: Refer to Troubleshooting, “Cat ET Service
Features” for information about service features.
Complete the procedure in the order in which the
steps are listed.
Table 77
Diagnostic Trouble Codes

J1939 Code and Description Comments

1239-0 The fuel rail pressure is below an acceptable level.
Engine Fuel Leakage 1 : Data High - Most Severe (3) The code is logged.

1239-31
Condition Exists
Engine Fuel Leakage 1 : Condition Exists

Table 78
Associated Diagnostic Trouble Codes

J1939 Code Code Description

Engine Injector Metering Rail #1

157-17 Pressure : Data Low - Least Se-
vere (1)

Engine Filtered Fuel Delivery

5580-18 Absolute Pressure : Data Low -
Moderately Severe (2)
118 UENR4349-03
Symptom Troubleshooting

Table 79
Troubleshooting Test Steps Values Results

1. Check for Associated Codes Associated Result: An associated code is not active or logged.
Codes
A. Establish communication between Caterpillar ® Electronic Techni- Proceed to Test Step 2.
cian (Cat ET) and the Engine Electronic Control Module (ECM).
Result: An associated code is active or logged.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble codes. Repair: Troubleshoot the associated codes before
continuing with this procedure.
C. If any of the associated codes in Table 78 are logged, trouble-
shoot the codes before continuing with this procedure. If the problem is not resolved, proceed to Test Step 2.

2. Inspect the Fuel System Fuel System Result: Problems were not found with the fuel
Problems system.
A. Inspect the fuel system. Refer to Systems Operation/Testing and
Adjusting, “Fuel System - Inspect” for inspection of the high-pres- Proceed to Test Step 3.
sure fuel lines and the fuel rail.
Result: Problems were found with the fuel system.

Repair: Repair the components or replace the compo-

nents that are damaged. Verify that the problem is
resolved.

If the problem is not resolved, proceed to Test Step 3.

Result: The pressure dropped below 5,000 kPa

3. Check the Fuel Rail Sensor Rail Pressure (725 psi) after the engine was shut off for 10 minutes.
less than
A. Allow the engine to be OFF for 10 minutes. 5,000 kPa Proceed to Test Step 4.
(725 psi)
B. Turn the keyswitch to the ON position, do not start the engine. Result: The pressure did not drop below 5,000 kPa
(725 psi) after the engine was shut off for 10 minutes.
C. Connect to the Engine ECM using Cat ET.
Repair: Replace the fuel rail pressure sensor. If the
D. Using Cat ET, check the status of the “Fuel Rail Pressure (abso- problem has been corrected, return the unit to service.
lute)” .
If the problem is not resolved, proceed to Test Step 4.
UENR4349-03 119
Symptom Troubleshooting

Illustration 38 g03814419
Location of the “Fuel System Functional Test” in the “Diagnostic Service Test” menu
120 UENR4349-03
Symptom Troubleshooting

Illustration 39 g03383456
If a 1239-0 Low Fuel Rail Pressure fault is active, the “Fuel System Functional Test – Pretest” will not be able to run.
Uncheck the “Fuel System Functional Test – Pretest” box and proceed to the “Fuel System Functional Test”
UENR4349-03 121
Symptom Troubleshooting

Table 80
Troubleshooting Test Steps Values Results

4. Perform the “ Fuel System Functional Test”” Test Passed Result: The test failed for an $1120 - Fuel Pump Not
Timed Correctly.
A. Start the engine.
Repair: Remove the high-pressure fuel pump. Refer
B. Connect to the Engine ECM using Cat ET. to Disassembly and Assembly for the correct proce-
dures. Pin the engine to TDC. Time the pump and
C. Perform the “Fuel System Functional Test” in Cat ET. Cat ET will then reinstall the high-pressure fuel pump. Then, run
display an error message that indicates the problem. Follow the re- the “Fuel System Functional Test” in order to verify
pair procedure for the error message. If the test aborts for an active that the pump is timed correctly.
diagnostic make sure to troubleshoot the code first.
Result: The test failed for an $111F - Fuel Flow Too
If a 1239-0 Low Fuel Rail Pressure fault is active, the “ Fuel Sys- Low.
tem Functional Test – Pretest”” will not be able to run. Uncheck
the box and proceed to the “ Fuel System Functional Test”” . Repair: Replace the high-pressure fuel pump. Refer
to Disassembly and Assembly for the correct proce-
dure. Then, run the “Fuel System Functional Test”
again in order to verify that the problem is resolved.

Result: The test failed for an $111D - Fuel Rail High

Pressure Decay Too High.

Repair: Replace the relief valve. Refer to Disassem-

bly and Assembly for the correct procedure. Then, run
the “Fuel System Functional Test” again in order to
verify that the problem is resolved. If the problem is
not resolved, torque all the quill tubes again, then per-
form the “Fuel System Functional Test” . If the test
passed, return the unit to service. If the test failed, per-
form the “Injector Bypass Fuel Flow - Test” . Refer to
Systems Operation/Testing and Adjusting, “Injector
Bypass Fuel Flow - Test”.

Result: The test failed for an $111E - Fuel Rail Low

Pressure Decay Too High.

Repair: Torque all the quill tubes again, then perform

the “Fuel System Functional Test” . If the test passed,
return the unit to service. If the test failed, perform the
“Injector Bypass Fuel Flow - Test” . Refer to Systems
Operation/Testing and Adjusting, “Injector Bypass
Fuel Flow - Test”.

Result: The test passed successfully.

122 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07044489

Fuel Temperature Is High

SMCS Code: 1250-035-TA
Use this procedure in order to troubleshoot high fuel
temperature. Use this procedure if one of the
following event codes is active. Refer to
Troubleshooting, “Event Codes” for information about
event codes. For information on the engine
monitoring system, refer to Troubleshooting, “Engine
Monitoring System”.

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.
Table 81
J1939 Code and Description Comments

174-0 The fuel temperature sensor on the secondary filter head is higher than
Engine Fuel Temperature 1 : Data High - Most Severe (3) expected.

174–15 The fuel temperature sensor on the secondary filter head is higher than
Engine Fuel Temperature 1 : Data High - Least Severe (1) expected.

174–16 The fuel temperature sensor on the secondary filter head is higher than
Engine Fuel Temperature 1 : Data High - Moderately Severe (2) expected.

Table 82
Associated Diagnostic Trouble Codes

J1939 Code Code Description

94 Engine Fuel Delivery Pressure

5580 Engine Filtered Fuel Delivery Absolute Pressure

Probable Causes
Probable causes of high fuel temperature.

• Associated codes
• Fuel level in the tank

• Restriction in the fuel lines

• Fuel cooler (if equipped)
• Fuel temperature sensor

• Fuel return pressure regulator

• Fuel injector

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 123
Symptom Troubleshooting

Table 83
Troubleshooting Test Steps Values Results

1. Determine the Code Codes Result: An associated code is not active or logged.

A. Establish communication between Caterpillar ® Electronic Tech- Proceed to Test Step 2.

nician (CET) and the Electronic Control Module (ECM) . Refer to
Troubleshooting, “Electronic Service Tools”, if necessary. Result: An associated code is active or logged.

B. Download the “Warranty Report” from the engine ECM before Repair: Troubleshoot any active codes before continuing
performing any troubleshooting or clearing diagnostic trouble co- with this procedure.
des. Check for active codes and check for logged codes on Cat ET.
If the problem is not resolved, proceed to Test Step 2.
C. Check Cat ET for any associated codes that are listed in Table
82 . Troubleshoot any active codes before continuing with this
procedure.

2. Check the Fuel Level in the Fuel Tank Fuel Level Result: The fuel level is acceptable.

A. Check the fuel level in the fuel tank. Proceed to Test Step 3.

Result: The fuel level is not acceptable.

Repair: Fill the tank. Verify that the problem has been
resolved.

If the problem has not been resolved, proceed to Test

Step 3.

Illustration 40 g03814805 Illustration 41 g03814817

Fuel supply lines for inspection Duplex Fuel Filters and Supply Lines Front View (If
Equipped)
124 UENR4349-03
Symptom Troubleshooting

Illustration 42 g03814819 Illustration 44 g03814884

Duplex Fuel Filters and Supply Lines Rear View (If Fuel return line to be inspected
Equipped)

Illustration 43 g02163246
Cooling line from fuel high-pressure pump to injectors

Table 84
Troubleshooting Test Steps Values Results

3. Inspect the Fuel Supply Lines Fuel Supply Result: The fuel lines and the cooler (if equipped) are
Lines OK.
A. Visually inspect the fuel lines between the priming pump and the
inlet to the cylinder head. Also, inspect the fuel cooler (if equipped) Proceed to Test Step 4.
for dirt, debris, or damage. Inspect the fuel return line from the head
to the fuel tank. Inspect the lines for restrictions, pinching, and swel- Result: The fuel lines and the cooler (if equipped) are
ling. Refer to Systems Operation/Testing and Adjusting, “Fuel Sys- not OK.
tem - Inspect” for additional information.
Repair: Replace damaged fuel lines and/or fuel cooler.
B. Inspect the fuel cooler for dirt, debris, or damage. Remove dirt or debris from fuel cooler fins. Verify that the
problem has been resolved.

If the problem has not been resolved, proceed to Test

Step 4.
UENR4349-03 125
Symptom Troubleshooting

Illustration 45 g03832486
Fuel cooler

Illustration 46 g03814893
(1) Fuel temperature sensor

Table 85
Troubleshooting Test Steps Values Results

4. Replace the Temperature Sensor Fuel Tempera- Result: A 174 code is active or logged.
ture Sensor
A. Replace fuel temperature sensor (1). Proceed to Test Step 5.

B. Check for active codes or logged codes. Result: A 174 code is not active or logged. Return the
unit to service.

If the problem is not resolved, proceed to Test Step 5.

126 UENR4349-03
Symptom Troubleshooting

Illustration 47 g03814986
(5) Fuel return pressure regulator

Table 86
Troubleshooting Test Steps Values Results

5. Replace the Fuel Return Pressure Regulator Fuel Pressure Result: The problem has not been resolved.
Regulator
A. Replace the fuel return pressure regulator (5). Verify that the Proceed to Test Step 6.
problem has been resolved.
Result: The problem has been resolved. Return the unit
to service.

6. Perform a Fuel System Verification Test Fuel System Result: The “Fuel System Verification Test” was not
verification Test successful.
A. Perform a “Fuel System Verification Test” in Cat ET.
Repair: Replace the identified injectors. Verify that all
trim files are installed into the ECM correctly. Refer to
Troubleshooting, “Injector Trim File - Install”. Repeat the
“Fuel System Verification Test” after making the neces-
sary repairs. Repeat the process until all the injectors are
operating properly.

Result: The “Fuel System Verification Test” was suc-

cessful. Return the unit to service.
UENR4349-03 127
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06119141

Indicator Lamp Problem

SMCS Code: 7431-035

Probable Causes
• Burned out bulb
• Problem with the lamp circuit

• A system on the power train data link

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
Table 87
Troubleshooting Test Steps Values Results

1. Check the Circuit for the Lamp Lamp Circuit Result: The electrical circuit is OK.

A. Check the electrical circuit for the lamp. Proceed to Test Step 2.

B. Refer to Troubleshooting, “Indicator Lamp - Test”. Result: The electrical circuit is not OK.

Repair: Repair the circuit. Verify the repair.

If the problem is not resolved, proceed to Test Step 2.

2. Check the Systems on the Power Train Data Link Power Train Result: A system that is connected to the power train da-
Data Link ta link is illuminating the lamp.
A. A system that is connected to the power train data link may be illu-
minating the lamp. Check the systems that are connected to the Repair: Troubleshoot the system causing the illumina-
power train data link. tion of the lamp.

B. Obtain the necessary equipment, when possible. Monitor the ap- Verify that the repair eliminated the problem.
propriate parameters while the machine is experiencing problems.
Determine if the condition is normal operation.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06119868

Inlet Air Is Restricted

SMCS Code: 1087-035
Complete the procedure in the order in which the
steps are listed.
128 UENR4349-03
Symptom Troubleshooting

Table 88
Troubleshooting Test Steps Values Results

1. Check the Air Filter Element Plugged Air Filter Result: The air filter is not clogged.

A. Check the air intake system for plugged air filters or for dam- Proceed to Test Step 2.
aged air filters. If the engine is equipped with an air intake pre-
cleaner, verify the proper operation of the air intake precleaner. Result: The air filter is clogged.

Repair: Clean or replace the air filter. Verify that the

problem is resolved.

If the problem is not resolved, proceed to Test Step

2.

2. Check the Air Inlet Piping Damaged Air Inlet Result: The air inlet piping does not have damage
Piping or restrictions.
A. Check the air inlet piping for damage or restrictions.
Proceed to Test Step 3.

Result: The air inlet piping is damaged or has

restrictions.

Repair: Repair the piping or replace the piping. Veri-

fy that the problem is resolved.

If the problem is not resolved, proceed to Test Step

3.

3. Check the Enclosure Ventilation Enclosure Ventilation Result: The engine does not have sufficient
ventilation.
A. Check that the engine has been installed in an enclosure that is
sufficiently ventilated. Repair: Repair the ventilation for the enclosure.

Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07035000

Intake Manifold Air Pressure Is

Low
SMCS Code: 1058-035-PX
Table 89 lists the diagnostic trouble code for low
intake manifold air pressure.

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.
UENR4349-03 129
Symptom Troubleshooting

Table 89
J1939 Code and Description Comments
102-18 The code is logged.
Engine Intake Manifold #1 Pressure : Low - moderate severity (2) Engine power is derated.

2630-1
The code is logged due to a restriction in the intake manifold that can be
Engine Charge Air Cooler Outlet Temperature : Low - most severe
causes by icing.
(3)

Table 90
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Codes Result: An associated code is active.

A. Connect to Cat ® Electronic Technician (ET). Repair: Refer to Troubleshooting, “Diagnostic Trouble Co-
des” in order to troubleshoot the associated diagnostic code.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Result: An associated code is not active or logged.
codes.
Proceed to Test Step 2.
C. Determine if an associated code listed in Table 90 is active or
logged. Table 90 lists associated diagnostic codes. Result: A 102-18 code is active.

Proceed to Test Step 2.

2. Check the Air Inlet System for Restrictions Restrictions Result: The air filter is clean and a restriction is not found.

A. Visually inspect the air filter for cleanliness on engines without Proceed to Test Step 3.
an electronic monitoring system on the inlet air system. A me-
chanical indicator may be used to monitor inlet air restrictions. Result: The inlet air system is restricted.
Use the indicator to determine the cleanliness of the inlet air sys-
tem. Also, inspect the piping for restrictions. Repair: Clean the filter or replace the filter. Remove all ob-
structions in the inlet air piping. Verify that the problem has
been resolved. If the problem still exists, proceed to Test Step
3.
130 UENR4349-03
Symptom Troubleshooting

Illustration 48 g06203703
Typical points of inspection

Table 91
Troubleshooting Test Steps Values Results

3. Inspect the Air Piping and Connections Connections Result: The piping or hose connections were damaged.

A. Inspect the piping and the hose connections from the turbo- Repair: Replace the damaged piping or hose connections.
charger compressor outlet to the charge air cooler inlet. Verify that the problem has been resolved.

If the problem still exists, proceed to Test Step 4.

Result: The piping was not damaged.

Proceed to Test Step 4.

4. Inspect the Turbocharger Turbocharger Result: The turbocharger wheels are damaged.

A. Remove the connection for the inlet air and the exhaust con- Repair: Replace the turbocharger. Return the unit to
nection to the turbocharger. Verify that the compressor wheel service.
and the turbine wheel are spinning freely. Verify that the com-
pressor wheel and the turbine wheel are not damaged.
UENR4349-03 131
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046360

Intake Manifold Air

Temperature Is High
SMCS Code: 1058-035-TA
Table 92 lists the diagnostic trouble codes for high
intake manifold air temperature.
Note: Some of the following codes may not be
applicable for certain applications.

Table 92
J1939 Code and Description Comments
The code indicates that the temperature of the intake air into the engine
105-0 has risen above a predetermined threshold. The value is obtained from a
Engine Intake Manifold #1 Temperature : Data High - Most Severe virtual sensor. For information on virtual sensors, refer to System Opera-
(3) tions and Testing and Adjusting.
Engine power may be shut down.

The code indicates that the temperature of the intake air into the engine
105-15
has risen above a predetermined threshold. The value is obtained from a
Engine Intake Manifold #1 Temperature : Data High - Least Severe
virtual sensor. For information on virtual sensors, refer to System Opera-
(1)
tions and Testing and Adjusting.

The code indicates that the temperature of the intake air into the engine
105-16 has risen above a predetermined threshold. The value is obtained from a
Engine Intake Manifold #1 Temperature : Data High - Moderately virtual sensor. For information on virtual sensors, refer to System Opera-
Severe (2) tions and Testing and Adjusting.
Engine power may be derated.

Complete the procedure in the order in which the

steps are listed.
Table 93
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Codes Result: A code is not active or logged.

A. Establish communication between Caterpillar ® Electronic Proceed to Test Step 2.

Technician (Cat ET) and the Electronic Control Module (ECM) .
Refer to Troubleshooting, “Electronic Service Tools”, if necessary. Result: An associated code is active.

B. Download the “Warranty Report” from the engine ECM before Repair: Refer to Troubleshooting, “Diagnostic Trouble Co-
performing any troubleshooting or clearing diagnostic trouble des” to troubleshoot the associated diagnostic code.
codes.
Result: An associated code is not active or logged.
C. Determine if an associated code is active or logged. Table 93
lists associated diagnostic codes. Proceed to Test Step 2.

Result: A 105-0 diagnostic code is active.

Proceed to Test Step 2.

132 UENR4349-03
Symptom Troubleshooting

Illustration 49 g03821086
Inspection point

Table 94
Troubleshooting Test Steps Values Results

2. Check the Aftercooler for Leaks or Restrictions Restrictions Result: The exterior of the aftercooler is not damaged.

A. Inspect the exterior surface of the aftercooler for leaks. Proceed to Test Step 3.

B. Inspect the aftercooler core for any restrictions. Result: The aftercooler core has an excessive buildup of
dirt or debris.

Repair: Clean the aftercooler. Refer to the engine Test

and Adjust manual. Verify that the problem has been
resolved.

If the problem still exists, proceed to Test Step 3.

Result: The aftercooler core is damaged.

Repair: Replace the aftercooler core.

If the problem still exists, proceed to Test Step 3.

(continued)
UENR4349-03 133
Symptom Troubleshooting

(Table 94, contd)

3. Check the Radiator for Leaks or Restrictions Radiator Result: The exterior and fins of the Radiator does not
contain any restrictions or have any leaks.
A. Inspect the exterior surface of the Radiator for excessive build-
up of dirt or debris. Also verify that the fins of the Radiator are not Proceed to Test Step 4.
damaged.
Result: The exterior and/or fins of the Radiator contains
debris or has a leak.

Repair: Clean the debris or restrictions from the Radiator

or replace if Radiator is damaged.

If the problem still exists, proceed to Test Step 4.

4. Check the Operation of the Charge Air Cooler Outlet Tem- Sensor Result: The value of the charge air cooler outlet tempera-
perature Sensor ture sensor is within ± −9° C (±15° F) of the ambient
temperature.
A. Remove the charge air cooler outlet temperature sensor. Allow
the charge air cooler outlet temperature sensor to rest in ambient Repair: Reinstall the sensor. Torque the sensor to the
air for 2 minutes. proper specifications. Return the unit to service.

B. Connect to the engine ECM by using Cat ET. Result: The value of the charge air cooler outlet tempera-
ture sensor is not within ± −9° C (±15° F) of the ambient
C. Monitor the value of the charge air cooler outlet temperature temperature.
sensor on Cat ET.
Repair: Replace the charge air cooler outlet temperature
sensor. Return the unit to service.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06120071

Oil Consumption Is Excessive

SMCS Code: 1348-035

Probable Causes
• Incorrect oil level in the crankcase
• Oil leaks on the outside of the engine

• Oil leaks in the combustion area of the cylinders

• Oil leakage at the injector

• Incorrect oil viscosity

• Condition of turbocharger

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
134 UENR4349-03
Symptom Troubleshooting

Table 95
Troubleshooting Test Steps Values Results

1. Excessive Oil in the Crankcase Oil Level Result: The oil level is correct.

A. Check the engine oil level. Too much oil in the engine crankcase Proceed to Test Step 2.
can cause the engine to consume oil.
Result: The oil level is high.
B. Ensure that the dipstick is properly calibrated and/or that the dip-
stick is correct for the application. Calibrate the dipstick and/or re- Repair: Remove excessive engine oil from the
place the dipstick. Refer to Systems Operation/Testing and crankcase.
Adjusting, “Lubrication System” for calibration of the dipstick gauge.
If the problem is not resolved, proceed to Test Step 2.

2. Oil Leaks on the Outside of the Engine Oil Leaks Result: There are no oil leaks on the outside of the
engine.
A. Check for oil leaks on the outside of the engine. Refer to Sys-
tems Operation/Testing and Adjusting, “Lubrication System”. Proceed to Test Step 3.

Result: There are oil leaks on the outside of the engine.

Repair: Find the source of the oil leaks and make the
necessary repairs.

If the problem is not resolved, proceed to Test Step 3.

3. Oil Leaks in the Combustion Area of the Cylinder Oil Leaks Result: There are no oil leaks in the combustion area of
the cylinder.
A. Check for oil leaks in the combustion area of the cylinders.
Proceed to Test Step 4.
B. Check for excessive engine blowby. Excessive engine blowby
will cause unnecessary oil consumption. Excessive engine blowby Result: There are oil leaks in the combustion area of the
can also cause unnecessary engine wear. cylinder.

Repair: Make the necessary repairs. Replace parts, if

necessary.

If the problem is not resolved, proceed to Test Step 4.

4. Oil Viscosity Viscosity Result: The engine oil viscosity is correct.

A. Excessive consumption of engine oil can also result if engine oil Proceed to Test Step 6.
with the wrong viscosity is used. Engine oil with a thin viscosity can
be caused by fuel leakage into the crankcase or by increased en- Result: The engine oil viscosity is not correct.
gine temperature. Refer to the Operation and Maintenance Manual
for additional information. Repair: Replace the engine oil, Refer to the Operation
and Maintenance Manual for additional information.

If the problem is not resolved, proceed to Test Step 5.

5. Condition of Turbocharger Turbocharger Result: The turbocharger has leakage.

A. Check the turbocharger for leakage. Repair: Make the necessary repairs. Replace parts, if
necessary.

Verify that the repair eliminated the problem.

UENR4349-03 135
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06120284

Oil Contains Coolant

SMCS Code: 1348-035; 1395-035
Emulsion is a mixture of oil and water. The water
occurs when condensation forms in the engine during
certain operating and seasonal conditions. The
emulsion may appear light in color. Emulsion may be
found in the following areas:
• Engine oil filler

• Engine oil level gauge

• Valve cover

• Crankcase ventilation system

The emulsion should disappear with increased
engine operating temperatures at higher load
conditions.

Probable Causes
• Leaks in the core of oil cooler
• Cracks in the turbocharger housing or center
section
• Leaks in the cylinder head gasket

• Damaged water seals

• Cracks in the cylinder head
• Cracks in a cylinder liner

• Liner seals
• Cracks in the cylinder block

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
136 UENR4349-03
Symptom Troubleshooting

Table 96
Troubleshooting Test Steps Values Results

1. Leaks in Core of Oil Cooler Oil Cooler Result: The oil cooler is not leaking.

A. Check for leaks in the oil cooler core. Proceed to Test Step 2.

Result: The oil cooler is leaking.

Repair: Repair or replace the oil cooler.

Proceed to Test Step 9.

2. Liquid Cooled Turbochargers Turbocharger Result The turbocharger housing or center section does not
have cracks.
A. Inspect the turbocharger housing and center section for
cracks. Proceed to Test Step 3.

Result The turbocharger housing or center section has

cracks.

Repair: Make any repairs, as required.

Proceed to Test Step 9.

3. Leaks in the Cylinder Head Gasket Head Gasket Result The cylinder head gasket is not leaking.

A. Inspect the cylinder head gasket for leaks. Proceed to Test Step 4.

Result The cylinder head gasket is leaking.

Repair: Replace the cylinder head gasket.

Proceed to Test Step 9.

4. Damaged Water Seals Water Seals Result The water seal is not damaged.

A. Inspect the water seal for damage. Proceed to Test Step 5.

Result The water seal is damaged.

Repair: Repair or replace the damaged seal.

Proceed to Test Step 9.

5. Cracks in the Cylinder Head Cylinder Head Result The cylinder head is not damaged.

A. Check for cracks in the cylinder head. Proceed to Test Step 6.

Result The cylinder head is damaged.

Repair: Repair or replace the damaged cylinder head.

Proceed to Test Step 9.

(continued)
UENR4349-03 137
Symptom Troubleshooting

(Table 96, contd)

Troubleshooting Test Steps Values Results

6. Cracks in a Cylinder Liner Cylinder Liner Result The cylinder liner or seal is not damaged or cracked.
and Seals
A. Check for cracked cylinder liners. Proceed to Test Step 7.

B. Check the liner seals for damage. Result The cylinder liner or seal is damaged or cracked.

Repair: Repair or replace the damaged cylinder liner and

seal.

Proceed to Test Step 9.

7. Cracks in the Cylinder Block Cylinder Block Result: The cylinder block is not cracked.

A. Inspect the cylinder block for cracks. Repair: Proceed to Test Step 8.

Result The cylinder block is cracked.

Repair: Repair or replace the damaged cylinder block.

Proceed to Test Step 9.

9. Pressurize the Cooling System Leaks Result: The test indicates that there is not a drop in
pressure.
A. Pressurize the cooling system. Refer to Systems Operation/
Testing and Adjusting, “Cooling System - Test”. Proceed to Test Step 10.

Result: The test indicates a drop in pressure.

The leak still exists.

Make any repairs, as required.

Proceed to Test Step 10.

Result: The engine oil was changed.

10. Change the Engine Oil Oil
Verify that the repair eliminated the problem.
A. Drain the engine oil.
Return the unit to service.
B. Refill the engine with clean oil.

C. Run the engine until the engine is at normal operating

temperature.

D. Drain the engine oil, replace the oil filters, and refill the en-
gine with clean oil.
138 UENR4349-03
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06120382

Oil Contains Fuel

SMCS Code: 1250-035; 1348-035

Note: For additional information, refer to Special

Instruction, REHS3007, “Determining the Cause of
Fuel Dilution of Engine Oil”.

Note: Refer to Troubleshooting, “Cat ET Service

Features” for information about service features.

Probable Causes
• Fuel injector O-ring seals
• Fuel injector tip

• Fuel transfer pump seal

• High-pressure fuel pump

• Cracked cylinder head

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
Table 97
Troubleshooting Test Steps Values Results

1. Fuel Injector Seals (Leaking) O-ring Seal Result: The injector O-ring seal is not damaged.

A. Remove the injector from the affected cylinder and visually in- Proceed to Test Step 2.
spect the injector O-ring seals for damage.
Result: The injector O-ring seal is damaged.
If leakage is found and the O-rings are in good repair, there may
be a problem with the injector. Replace the injector. Ensure that Repair: Replace the damaged seals. Install the injector onto
the new trim files are installed. Refer to Troubleshooting, “Injector the engine and confirm that the repair has resolved the
Trim File - Install” for details. Use Caterpillar ® Electronic Techni- problem.
cian (ET) to perform a “Fuel System Verification Test” . Refer to
Troubleshooting, “Injector Solenoid - Test” for details. If the problem is not resolved, proceed to Test Step 2.

If the leakage is not located, add the appropriate dye to the fuel
tanks. Run the engine at high idle for several minutes. Shut down
the engine and remove the valve covers. Use a black light to
check for traces of dye around each injector.

(continued)
UENR4349-03 139
Symptom Troubleshooting

(Table 97, contd)

2. Fuel Injector Tip Injector Tip Result: The fuel injector tip is not damaged.

A. Use Cat ET to perform the “Cylinder Cutout Test” in order to Proceed to Test Step 3.
identify any cylinders that may be overfueled.
Result: The fuel injector tip is damaged.
B. A fuel injector tip that is broken or fractured is a possible cause
of a cylinder that is being overfueled. If a cylinder is identified by Repair: Replace the suspect injector.
the test, Remove the injector and check the injector tip for dam-
age. Check the fuel injector tip for cracks or breakage. If the problem is not resolved, proceed to Test Step 3.

3. Fuel Transfer Pump Seal Pump Seal Result There is not fuel leakage around the shaft seal.

A. Check for fuel leakage around the shaft seal for the fuel transfer Proceed to Test Step 4.
pump. Ensure that the weep hole is not plugged.
Result: There is fuel leakage around the shaft seal.

Repair: Replace the fuel transfer pump.

If the problem is not resolved, proceed to Test Step 4.

4. High-pressure fuel pump Defective Result No leak is detected.

Pump
A. Remove the plug from the bottom of the high-pressure fuel Proceed to Test Step 5.
pump. Remove the plug from the bottom of the fuel pump adapter.
Expect that a small amount of engine oil will drain from the Result A leak is detected.
openings.
Repair: Replace the high-pressure fuel pump.
B. Use the manual override for the fuel priming pump to run the
pump in order to pressurize the fuel system. Allow the pump to run If the problem is not resolved, proceed to Test Step 5.
for at least 5 minutes while you monitor the drain holes in the
pump and the adapter for leakage.

5. Cracked Cylinder Head Cracked Result The internal passages for the fuel supply to the injec-
Head tors are damaged.
A. Look for signs of damage to the internal passages for the fuel
supply to the injectors in the cylinder head. Check for pin hole Repair: Repair or replace the cylinder head.
leaks. Refer to Disassembly and Assembly.
Verify that the repair eliminated the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07272815

Oil Filter Differential Pressure

Problem
SMCS Code: 1308-035-PX

Note: This procedure is only applicable to units that

have an oil filter inlet pressure sensor.
Use this procedure in order to troubleshoot abnormal
oil filter differential pressure or use this procedure if
the following event code is active.
140 UENR4349-03
Symptom Troubleshooting

Table 98
J1939 Code and Description Comments
7471-15 The difference between the filtered oil pressure and the unfiltered oil
Engine Oil Filter Differential Pressure : High - least severe (1) pressure is greater than the trip point pressure.

The code is logged.

Probable Causes
• Diagnostic codes
• Fuel filter element

• Sensor

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in the order of
the listed test steps.

Table 99
Troubleshooting Test Step Value Result

1. Diagnostic Codes 7471-15 Result: An associated code is present.

A. Connect the electronic service tool to the diagnostic connector. Repair: Troubleshoot any associated codes before con-
Refer to Troubleshooting, “Electronic Service Tools”. tinuing with this test.

B. Check for 7471-15 diagnostic codes. Result: A 7471-15 code is present.

D. Check for active diagnostic codes that are associated with the Proceed to the Test Step 2.
oil filter pressure sensors.
Result: There are no active diagnostic codes.

Return the unit to service.

2. Oil Filter Oil filter Result: After starting the engine, the 7471-15 code is no
longer active for the filter that was changed.
A. Replace the active engine oil filter. Refer to the Operation and
Maintenance Manual, “Engine Oil and Filter - Change”. Return the unit to service.

Result: After starting the engine, the 7471-15 code is still

active for the filters that were changed.

Proceed to Test Step 3.

3. Oil Pressure Sensors Oil pressure Result: A sensor does not read atmospheric pressure
sensors while the engine is off.
A. Use the electronic service tool to compare the status of the fol-
lowing parameters with the engine not running: Troubleshoot the sensor circuit. Refer to Troubleshooting,
“Sensor Signal (Analog Active) - Test”.
- Pre-filter Oil Pressure
- Post-filter Oil Pressure Result: The sensors read atmospheric pressure while
the engine is off.

Contact the Technical Communicator at a Cat dealer.

UENR4349-03 141
Symptom Troubleshooting

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07035255

Oil Level Is Low

SMCS Code: 1348-035-LO
Use this procedure to troubleshoot low engine oil
level. Also, use this procedure if one of the following
event codes is active or logged.
Table 100
J1939 Code and Description Comments
The engine oil level has dropped below the level of the switch for the
98-1 time specified in the ECM.
Engine Oil Level : Low - most severe (3) The code is logged.
The engine is derated and may stop.

98–17
The warning lamp is lit and the code is logged
Engine Oil Level : Low - least sever (1)

The engine oil level has dropped below the level of the switch for the
98-18 time specified in the ECM.
Engine Oil Level : Low - moderate severity (2) The code is logged.
The engine is derated.

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
142 UENR4349-03
Symptom Troubleshooting

Table 101
Troubleshooting Test Steps Values Results

1. Low Engine Oil Level Engine oil level Result: The engine oil level is low.

A. Check the engine oil level. Refer to the Operation and Repair: Add engine oil, as necessary.
Maintenance Manual, “Engine Oil Level - Check”.
If engine oil consumption is considered excessive, refer to
Troubleshooting, “Oil Consumption Is Excessive”.

Proceed to Test Step 2.

2. Electrical Connections or Wiring Electrical connec- Result: There is a fault in an electrical connection or the
tors and wiring wiring.
A. Inspect the electrical connectors and all the wiring for the
switch. Refer to Troubleshooting, “Electrical Connectors - In- Repair: Repair or replace the faulty item.
spect” and refer to the electrical Schematic.
Result: The electrical connections and wiring are OK.

Proceed to Test Step 3.

3. Test the Oil Level Switch Oil level switch Result: The correct results are not obtained or if the switch
does not close.
Note: The engine oil level switch must be closed in order for
the engine to operate. The switch is normally open. The Repair: Replace the switch.
switch must be submerged in fluid to become closed.
Result: The correct results are obtained and the switch
A. Disconnect the switch and remove the switch. closes correctly.

B. Connect an ohmmeter to the switch terminals and meas- Contact the Dealer Solutions Network (DSN).
ure the continuity. The correct continuity for the normally
open switch is greater than 20,000 Ohms.

C. Continue to monitor the ohmmeter and submerge the

switch in water. The correct continuity for the closed switch is
less than 5 Ohms.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07044531

Oil Pressure Is Low

SMCS Code: 1348-035-PX
Use this procedure in order to troubleshoot low oil
pressure. Also, use this procedure if one of the
following event codes is active or logged.
UENR4349-03 143
Symptom Troubleshooting

Table 102
J1939 Code and Description Comments
100-1 The engine is shutdown.
Engine Oil Pressure : Low - most severe (3) The code is logged.

100-17 The code is logged.

Engine Oil Pressure : Low - least severe (1)

100-18 The code is logged.

Engine Oil Pressure : Low - moderate severity (2)

If the engine shuts down due to a low oil pressure,

power to the Electronic Control Module (ECM) must
be cycled before restarting the engine.

Probable Causes
• Codes

• Oil level
• Oil aeration

• Oil viscosity
• Oil filter

• Oil pump
• Sensors

• Bypass valve
• Oil cooler
• Suction tube

• Worn engine components

144 UENR4349-03
Symptom Troubleshooting

Recommended Actions
Table 103
Troubleshooting Test Steps Values Results

1. Check for Codes Codes Result: An associated code is active.

A. Connect Caterpillar ® Electronic Technician (Cat ET) to the Repair: Troubleshoot any associated codes before continuing
service tool connector. with this test.

B. Look for active codes that are associated with the system for Result: A code is active or logged.
the event code.
Proceed to Test Step 2.

2. Check the Engine Oil Level Oil Level Result: The engine oil level is OK.

A. Refer to the Operation and Maintenance Manual, “Engine Proceed to Test Step 3.
Oil Level - Check” for calibration of the dipstick gauge. The oil
level can possibly be too far below the oil pump supply tube. Result: The engine oil level is low.
The oil pump cannot supply enough lubrication to the engine
components. Repair: Add engine oil in order to obtain the correct engine oil
level. Refer to Operation and Maintenance Manual, “Engine
Oil” for the recommendations of engine oil.

Start the engine. Inspect the exterior of the engine for oil
leaks.

If the problem is not resolved, proceed to Test Step 3.

3. Check the Engine Oil for Aeration Aeration Result: The oil is aerated.

Note: Foamy oil on the dipstick is a good indication of aeration. Proceed to Test Step 10.

Result: The oil is not aerated.

Proceed to Test Step 4.

4. Ensure that the Engine Oil Viscosity is Correct Oil Viscosity Result: The engine oil viscosity is correct.

A. Obtain an S·O·S Oil Analysis to determine the characteris- Proceed to Test Step 5.
tics of the oil.
Result: The engine oil viscosity is not correct, or the oil is
contaminated.

Repair: Replace the engine oil. Refer to Operation and Main-

tenance Manual, “Engine Oil” for the recommendations of en-
gine oil.

Repair the cause of any engine oil contamination.

If the problem is not resolved, proceed to Test Step 5.

(continued)
UENR4349-03 145
Symptom Troubleshooting

(Table 103, contd)

Troubleshooting Test Steps Values Results

5. Replace the Oil Filter Filter Result: Replace the engine oil filter.

Repair: The oil filter was replaced.

If the problem is not resolved, proceed to Test Step 6.

6. Check the Oil Pump Pressure Oil Pressure Result: The oil pressure meets specifications.

A. Manually check the engine oil pressure. Refer to Testing and Proceed to Test Step 7.
Adjusting, “Engine Oil Pressure - Test” for additional
information. Result: The oil pressure does not meet specifications.

Repair: Repair or replace the oil pump.

If the problem is not resolved, proceed to Test Step 7.

7. Check the Engine Oil Pressure Sensor Sensor Result The pressure is within ±13.8 kPa (±2 psi).

A. Remove the oil pressure sensor. Proceed to Test Step 8.

B. Install a pipe “T” in the pressure sensor port. Result The pressure is not within ±13.8 kPa (±2 psi).

C. Install a manual gauge on one side of the pipe “T” . Install Repair: Replace the sensor.
the oil pressure sensor on the other side of the pipe “T” .
If the problem is not resolved, proceed to Test Step 8.
D. Start the engine and compare the two readings. The pres-
sure reading must be within ±13.8 kPa (±2 psi).

8. Check the Oil Cooler for a Restriction Restriction Result: There was not debris or restrictions in the oil cooler.

A. Check the inlet side of the oil cooler for debris or blockage. Proceed to Test Step 9.

Result: There was debris or restrictions in the oil cooler.

Repair: Clean or replace the oil cooler.

If the problem is not resolved, proceed to Test Step 9.

(continued)
146 UENR4349-03
Symptom Troubleshooting

(Table 103, contd)

Troubleshooting Test Steps Values Results

9. Check the Suction Tube Suction Tube Result: The suction tube and seal are OK.

A. Remove the oil pan. Proceed to Test Step 10.

B. Inspect the suction tube. Check the joints of the tube for Result: The suction tube and seal are not OK.
cracks or for a damaged O-ring seal at the connection to the
pump. Repair: Clear the obstruction. Repair or replace damaged
suction tube components.
C. Inspect the inlet screen of the suction tube for a restriction.
This restriction will cause cavitation and a loss of engine oil If the problem is not resolved, proceed to Test Step 10.
pressure.

10. Check for Worn Engine Components Damaged or Result: Excessive clearance was identified for an engine
Worn Engine component.
A. Check for excessive clearance for the following: Components
Repair: Replace the worn engine components.
- Oil pump gears
- Camshaft bearings Verify that the repair eliminated the problem.
- Crankshaft bearings
- Rocker arm to rocker arm shaft

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046370

Oil Temperature Is High

SMCS Code: 1348-035-TA
Use this procedure in order to troubleshoot high oil
temperature or use this procedure if one of the
following event codes is active.
Table 104
Diagnostic Trouble Codes

J1939 Code and Description Comments

175-15
The code is logged.
Engine Oil Temperature 1 : Data High - Least Severe (1)

175-16 The code is logged.

Engine Oil Temperature 1 : Data High - Moderately Severe (2) Engine power is derated.

175-0 The code is logged.

Engine Oil Temperature 1 : Data High - Most Severe (3) The engine is shut down.

If the engine is shut down due to a high engine oil

temperature, the power to the engine Electronic
Control Module (ECM) must be cycled in order to
restart the engine.
UENR4349-03 147
Symptom Troubleshooting

Table 105
Associated Codes

J1939 Code Code Description

110-0 Engine Coolant Temperature : Data High - Most Severe (3)

110-15 Engine Coolant Temperature : Data High - Least Severe (1)

110-16 Engine Coolant Temperature : Data High - Moderately Severe (2)

175-3 Engine Oil Temperature 1 : Voltage Above Normal

175-4 Engine Oil Temperature 1 : Voltage Below Normal

Probable Causes
• Diagnostic codes and event codes
• Coolant temperature is high

• Oil level is low

• Oil cooler bypass valve

• Oil cooler core problem

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in the order of
the listed test steps.

Table 106
Troubleshooting Test Steps Values Results

1. Check for Associated Diagnostic Trouble Codes Associated Result: A 175-0, 175-15 or 175-16 code is present.
Code
A. Connect Caterpillar ® Electronic Technician (Cat ET) to the Proceed to Step 2.
service tool connector. Refer to Troubleshooting, “Electronic
Service Tools”, if necessary. Result: An associated code is present.

B. Download the “Product Status Report” from the engine ECM Repair: Troubleshoot any associated codes before continu-
before performing any troubleshooting or clearing diagnostic ing with this procedure.
trouble codes.

C. Determine if an associated diagnostic code is present.

2. Check the Engine Oil Level Level Result: The engine oil level is OK.

Proceed to Step 3.

Result: The level is NOT OK.

Repair: Add oil and repair any leaks.

If the problem is not resolved, Proceed to Step 3.

(continued)
148 UENR4349-03
Symptom Troubleshooting

(Table 106, contd)

Troubleshooting Test Steps Values Results

3. Check the Engine Oil Cooler Bypass Valve Valve Result: The valve is OK.

A. Ensure that the bypass valve is not stuck in the open position. Proceed to the next step.
Clean the bore for the valve.
Inspect the components of the engine oil cooler bypass valve for Result: The valve is NOT OK.
damage.
Repair: Free the valve or replace the valve.

If the problem is not resolved, Proceed to Step 4.

4. Check the Engine Oil Cooler Core Cooler Result: The cooler core is NOT OK.

Check the engine oil cooler core for damage and for plugging. Repair: Clean the engine oil cooler core or replace the en-
Clean the engine oil cooler core or replace the engine oil cooler gine oil cooler core, if necessary.
core, if necessary.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06121618

Power Is Intermittently Low or

Power Cutout Is Intermittent
SMCS Code: 1000-035-PWR

Note: Use this procedure only if the engine does not

shut down completely.
Note: Refer to Troubleshooting, “Cat ET Service
Features” for information about service features.

Probable Causes
• Check for diagnostic trouble codes

• Electrical connections not properly connected.

• Intermittent throttle signal
• Fuel system components

• Fuel supply pressure

• Restriction in the air inlet and exhaust system

• Excessive temperature of the turbocharger that

causes engine derate

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 149
Symptom Troubleshooting

Table 107
Troubleshooting Test Steps Values Results

1. Diagnostic Codes Diagnostic Result: A diagnostic code is active or logged.

Codes
A. Certain codes may derate engine power. Connect Caterpillar ® Repair: Troubleshoot any codes that are present before
Electronic Technician (Cat ET) and check for active codes and/or for continuing with this procedure.
logged codes.
Result: A diagnostic code is not active or logged.

Proceed to Test Step 2.

2. Electrical Connections Electrical Result: The connectors are installed correctly.

Connectors
A. Verify that the following connectors are installed correctly: Proceed to Test Step 3.

1. Electrical connectors for the ECM Result: The connectors are not installed correctly.

2. Connectors for the wiring harness under the valve cover Repair: Install the connectors correctly. Refer toTrouble-
shooting, “Electrical Connectors - Inspect” for the proper
3. Connectors for the engine speed/timing sensors troubleshooting procedure.

3. Check for Intermittent Diagnostic Codes Intermittent Result: Intermittent codes are present.
Codes
A. Certain diagnostic codes may cause poor performance. Connect Repair: Troubleshoot any codes that are present before
Cat ET and check for active codes and/or for logged codes. continuing with this procedure.

Result: Intermittent codes are not present.

Proceed to Test Step 4.

4. Intermittent Throttle Signal Throttle Signal Result: The status for “Throttle Position” is stable.

A. Monitor the status for “Throttle Position” on Cat ET. Proceed to Test Step 5.

B. Verify that the status for “Throttle Position” is stable and that the Result: The status for “Throttle Position” is not stable.
engine is able to reach high idle speed.
Repair: Make the necessary repairs. Refer to Trouble-
Refer to Troubleshooting, “Speed Control - Test”. shooting, “Speed Control - Test”.

5. Fuel System Fuel System Result: The “Fuel System Verification Test” was
Verification successful.
A. Ensure that the fuel system is operating properly. Test
Proceed to Test Step 6.
B. Start the engine.
Result: The “Fuel System Verification Test” was not
C. Perform the “Fuel System Verification Test” on Cat ET. successful.

Repair: Repair the cylinders that failed the “Fuel System

Verification Test” . Reset all active codes and clear all
logged codes. Verify that the repair has eliminated the
problem in the cylinder.

(continued)
150 UENR4349-03
Symptom Troubleshooting

(Table 107, contd)

Troubleshooting Test Steps Values Results

6. Fuel Supply Pressure Fuel Supply Result: The fuel supply is stable.

A. Check the fuel pressure. Ensure that the fuel is stable. Refer to Proceed to Test Step 7.
Systems Operation/Testing and Adjusting for the procedure to check
the fuel pressure manually. Result: The fuel supply is not stable.

B. Visually check the fuel level. Do not rely on the fuel gauge only. If Make the necessary repairs.
necessary, add fuel. If the engine has been run out of fuel, purge the
air from the fuel system. Verify that the repair eliminates the problem.

C. Ensure that the fuel supply valve (if equipped) is in the full OPEN
position.

D. Check the fuel lines for the following problems:

1. Restrictions

2. Collapsed lines

3. Pinched lines

4. Loose connections

E. Prime the fuel system if any of the following procedures have

been performed:

1. Replacement of the fuel filters

2. Service on the low-pressure fuel supply circuit

3. Replacement of unit injectors

F. Check the fuel tank for foreign objects which may block the fuel
supply.

G. Check the fuel filters.

H. Check the fuel quality. Make sure that the fuel meets the require-
ments of Special Publication, SEBU6250, “Caterpillar Machine Flu-
ids Recommendations ”.

Cold weather adversely affects the characteristics of the fuel. Refer

to the Operation and Maintenance Manual for information on improv-
ing the characteristics of the fuel during cold-weather operation.

7. Restriction in the Air Inlet and Exhaust System Restrictions Result: There are restrictions in the air inlet or exhaust
system.
Inlet air restrictions or exhaust system restrictions can cause a high
exhaust temperature. Repair: Repair the restrictions or remove the
restrictions.
The Engine Control Module (ECM) monitors the following parame-
ters in order to calculate an exhaust temperature:
· Barometric pressure
· Intake manifold air temperature
· Engine speed

Certain operating conditions may cause the calculated exhaust tem-

perature to increase to a level that may damage engine

(continued)
UENR4349-03 151
Symptom Troubleshooting

(Table 107, contd)

Troubleshooting Test Steps Values Results
components. If a high exhaust temperature occurs, the ECM derates
the engine in order to reduce the calculated exhaust temperature.
The engine is derated only to a level that allows the calculated ex-
haust temperature to return to an acceptable level.

Refer to the High Exhaust Temperature Prevention Derate Time His-

togram for derate information.

A. Ensure that the turbocharger is operating correctly. Periodic in-

spection and cleaning are recommended for the turbocharger com-
pressor housing (inlet side).

B. Check the air filter restriction indicator. Clean plugged air filters or
replace plugged air filters.

C. Check the air inlet and exhaust system for restrictions and/or
leaks.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046437

Sea Water Pump Pressure

Problem
SMCS Code: 1371-035
This procedure is only applicable to applications with
a raw water cooling system.
The following code is associated with low sea water
pump outlet pressure:
Table 108
J1939 Code and Description Comments
The ECM detects that the outlet pressure of the sea water pump is below
2435-17
the trip point for 10 seconds.
Seawater Pump Outlet Pressure : Low - least severe (1)
The warning lamp is lit and the code is logged.

Probable Causes
• Diagnostic code
• Pump inlet blocked

• Pump impeller damaged

Recommended Actions
Note: The procedures have been listed in order of
probability. Complete the procedures in order.
152 UENR4349-03
Symptom Troubleshooting

Table 109
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Codes Diagnostic Result: There are active or logged codes.
codes
A. Establish communication between the electronic service Repair: Troubleshoot any codes before continuing with this
tool and the Electronic Control Module (ECM). Refer to Trou- procedure.
bleshooting, “Electronic Service Tools”, if necessary.
Result: A 2435-17 code is active or recently logged.
B. Download the “Warranty Report” from the engine ECM be-
fore performing any troubleshooting or clearing diagnostic Proceed to Test Step 2.
trouble codes.

2. Check the Inlet Pipe for the Sea Water Pump Inlet pipe Result: The inlet pipe is blocked, restricted, damaged, or
loose.
A. Disconnect the inlet pipe from the sea water pump.
Repair: Make all necessary repairs to the inlet pipe.
B. Check the inlet pipe for the following defects:
Confirm that the fault has been eliminated.
· Blockages
· Restrictions Result: The inlet pipe is OK.
· Damage to the pipe
· Lose connections Do not reconnect the pipe. Proceed to Test Step 3.

3. Check the Sea Water Pump Impeller Pump impeller Result: The sea water pump impeller is damaged.

A. Crank the engine by hand and check the sea water pump Repair: Replace the impeller. Refer to Disassembly and As-
impeller for damage. sembly, “Auxiliary Water Pump - Disassemble” and Disassem-
bly and Assembly, “Auxiliary Water Pump - Assemble”.

Confirm that the fault has been eliminated.

Result: The sea water pump impeller is OK.

Contact the Technical Communicator at a Cat dealer.

If the procedure did not correct the issue, contact Recommended Actions
your Cat dealer Technical Communicator (TC). For Complete the procedure in the order in which the
further assistance, your TC can confer with the steps are listed.
Dealer Solutions Network (DSN).

i06122035

Valve Lash Is Excessive

SMCS Code: 1105-035

Probable Causes
• Valve lash setting is not at factory specifications.
• Worn rocker arms

• Worn valve springs or broken valve springs

• Bent pushrods
• Worn camshaft

• Valve seat wear

UENR4349-03 153
Symptom Troubleshooting

Table 110
Troubleshooting Test Steps Values Results

1. Valve Lash Setting Valve Lash Result: The valve lash cannot be set to specifications.

A. Check the engine valve lash. If necessary, adjust the engine Proceed to Test Step 2.
valve lash. Refer to Systems Operation/Testing and Adjusting
for information on adjusting the engine valve lash. Result: The valve lash is set to specifications.

Return the unit to service.

2. Rocker Arms Rocker Arms Result: The rocker arms are not damaged.

A. Inspect rocker arms for pitting or spalling on the roller. Proceed to Test Step 3.

B. Check the rocker arm for a missing button. Result: The rocker arms are damaged.

Repair: Replace parts, if necessary.

If the problem has been corrected, return the unit to service.

If the problem is not resolved, proceed to Test Step 8.

3. Valve Springs Valve Springs Result: The valve springs are not broken or cracked.

A. Check for cracked valve springs or broken valve springs. Proceed to Test Step 4.

Result: The valve springs are broken or cracked.

Repair: Replace parts, if necessary.

If the problem has been corrected, return the unit to service.

If the problem is not resolved, proceed to Test Step 4.

4. Pushrods Pushrods Result: The pushrods are not worn or bent.

A. Check the pushrods for wear and straightness. Proceed to Test Step 5.

B. Roll the pushrods on a flat surface in order to determine the Result: The pushrods are worn or bent.
straightness of the rod.
Repair: Replace parts, if necessary. If the symptom remains,
Proceed to Test Step 5.

If the problem has been corrected, return the unit to service.

(continued)
154 UENR4349-03
Symptom Troubleshooting

(Table 110, contd)

5. Camshaft Camshaft Result: The camshaft measured within specifications.

A. Remove the camshaft in order to inspect the camshaft. Proceed to Test Step 6.

B. Inspect the camshaft for large grooves. Result: The camshaft did not measure within specifications.

C. Measure the camshaft in order to determine if the camshaft Repair: Make the necessary repairs, If the symptom remains,
is in specifications. Refer to Reuse and Salvage Guidelines for proceed to Test Step 6. If you replace the camshaft, replace
the correct measurements. the valve lifters.

If the problem has been corrected, return the unit to service.

6. Cylinder Head Engine Result There are worn or damaged engine components.
Components
A. Remove the cylinder head. Refer to the Reuse and Salvage Repair: Replace parts, if necessary. Check the Reuse and
Guidelines for the reusability specifications. Salvage Guidelines for the reusability of existing engine
components.
B. Inspect the piston and valve for damage.

C. Inspect the valve seat for wear.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06123428

Valve Rotator or Spring Lock

Is Free
SMCS Code: 1109-035
Use this procedure in order to troubleshoot a problem
with the valve rotators or spring locks.

Probable Cause
• Valve Components

Recommended Actions
Complete the procedure in the order in which the
steps are listed.
UENR4349-03 155
Symptom Troubleshooting

Table 111
Troubleshooting Test Steps Values Results

1. Valve Components Damaged Result: The valve components are damaged.

Components
A. Inspect the following components for damage: Repair: Replace the damaged components.

1. Valve rotators A valve rotator that is cracked or a valve rotator that is

broken is an indication of an engine overspeed. Deter-
2. Spring locks mine the cause of the engine overspeed. Repair the
condition.
3. Valve springs

4. Valves

B. Ensure that the valve has not contacted the piston. If the
valve has contacted the piston, check the exhaust system for
debris.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).
156 UENR4349-03
Circuit Tests

Circuit Tests

i06123497

Coolant Level - Test

SMCS Code: 1395-038; 1439-038-CLT; 7422-038-
CLT
Use this procedure to troubleshoot any suspect
problems with the circuit for the coolant level sensor.
The coolant level sensor monitors the engine coolant
level in order to warn the operator when the coolant
level is low.

Illustration 50 g01150024
Components of the coolant level sensor
(1) Sensor
(2) Sensor probe (brass dowel)
(3) Outer coating

When the probe is not immersed in coolant,

approximately +5 VDC is sourced to the sensor
signal wire. When this condition is detected by the
Electronic Control Module (ECM), an event code is
activated.
Prior to troubleshooting any problems with the
coolant level sensor, use Caterpillar ® Electronic
Technician (Cat ET) to check the installation status
for the sensor. The coolant level sensor configuration
parameter must be set to “Installed” in order for the
ECM to monitor the signal from the sensor.
The activation of an event code and/or a warning
lamp is probably caused by a low coolant level. The
next likely cause is a problem with the wiring
harness, a connector, or the sensor.
UENR4349-03 157
Circuit Tests

Illustration 51 g03816533

Complete the procedure in the order in which the

steps are listed.
Table 112
Troubleshooting Test Steps Values Results

1. Check the Coolant Level Coolant Level Result: The coolant is at the proper level.

Allow the engine to cool prior to removal of the cooling system Proceed to Test Step 2.
pressure cap.
Result: The coolant level is low.
A. Remove electrical power from the ECM.
Repair: Add coolant according to the procedure in the
B. Check the coolant level. Refer to the Operation and Maintenance Operation and Maintenance Manual.
Manual for the proper procedure to check the coolant level.
There may be a leak in the cooling system. Identify the
source of the coolant leak. Repair the leak. Refer to
Systems Operation/Testing and Adjusting, “Cooling
System” for additional information.

If the problem is not resolved, proceed to Test Step 2.

2. Verify that the “ Coolant Level Sensor”” Parameter is Pro- Parameter Result: The “Coolant Level Sensor” parameter is pro-
grammed Correctly Programmed grammed correctly.

A. Connect Cat ET to the service tool connector. Proceed to Test Step 3.

B. Establish communication with the ECM. Result: The “Coolant Level Sensor” parameter is not
programmed correctly.
C. Verify that the “Coolant Level Sensor” parameter is programmed
to “Installed” . Repair: Program the “Coolant Level Sensor” parame-
ter to “Installed” .
D. Remove electrical power from the ECM.
Verify that the repair eliminates the problem.

If the problem is not resolved, proceed to Test Step 3.

158 UENR4349-03
Circuit Tests

Illustration 52 g02090761
Terminal locations at the harness connector for the
coolant level sensor
(Terminal A) Sensor supply
(Terminal B) Sensor return
(Terminal C) Sensor signal

Table 113
Troubleshooting Test Steps Values Results

3. Check the Supply Voltage at the Sensor Connector 8.0 ± 0.5 VDC Result: The voltage measurement is 8.0 ± 0.5 VDC.

A. Disconnect the coolant level sensor at the sensor connector. The supply voltage is reaching the sensor. Proceed to
Test Step 4.
B. Restore electrical power to the ECM.
Result: The voltage measurement is not 8.0 ± 0.5
C. Measure the voltage between terminals A (sensor supply) and B VDC.
(sensor return) at the harness connector for the coolant level sensor.
Repair: The sensor supply voltage is not reaching the
D. Remove electrical power from the ECM. sensor. There is a problem in the circuit for the sensor
supply. Repair the wiring between the sensor and the
ECM.

If the problem is not resolved, proceed to Test Step 4.

4. Short the Signal Wire to Ground and Monitor the Status for ±5 VDC Result: The status changes from “LOW” to “OK” when
“ Coolant Level”” the jumper wire is installed. The ECM and the wiring
harness to the coolant level sensor are OK.
A. Fabricate a jumper wire that is long enough to create a short cir-
cuit between two terminals at the coolant level sensor harness con- Repair: Replace the coolant level sensor. Verify that
nector. Crimp connector pins to each end of the jumper wire. the repair eliminates the problem.

B. Install the jumper wire between terminals B (sensor return) and C Result: The status does not change from “LOW” to
(sensor signal) on the harness side of the connector for the coolant “OK” when the jumper wire is installed.
level sensor.
Repair: The problem is between the ECM and the
C. Restore electrical power to the ECM. sensor connector. Repair the wiring.

D. Monitor the status of “Coolant Level” on Cat ET while the jumper Verify that the repair eliminated the problem.
wire is installed. Wait at least 30 seconds for activation of the status
indicator.

E. Remove the jumper wire. Connect the harness connector for the
coolant level sensor.
UENR4349-03 159
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07035316

Data Link - Test

SMCS Code: 1900-038
Use this procedure if a fault is suspected in the CAN
data link. This procedure also covers the following
diagnostic codes:
Table 114
Diagnostic Trouble Codes for the CAN Data Link

J1939 Code and Description Notes

639-9 Another controller has incorrectly stopped transmitting a J1939 speed
J1939 Network #1 : Abnormal Update Rate request (TSC1) or another controller has incorrectly started transmitting
a J1939 speed request.
The ECM will log the diagnostic code.
The engine will not start.

639-14 Communication has not been lost to one or more devices on the data-
J1939 Network #1 : Special Instruction link, however the affected Electronic Control Module (ECM) is missing
expected parameters. If no programming issues exist, there is likely a
problem with the data link wiring, power, or ground circuits.

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 in
order to transmit the data correctly. 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 circuit. If this resistance is not present, then
the data will be intermittent or 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.
160 UENR4349-03
Circuit Tests

Illustration 53 g06203933
Typical example of the schematic for the CAN data link

Table 115
Troubleshooting Test Steps Values Results

1. Check for Codes Codes Result: An associated code is active.

A. Connect Cat ® Electronic Technician (ET) to the service tool Repair: Troubleshoot any associated codes before continu-
connector. ing with this test.

B. Look for active codes that are associated with the system Result: An associated diagnostic trouble code is not active
for the diagnostic code. or logged.

Proceed to Test Step 2.

2. Use the “ System Communication Status”” to Determine Component Result: A -9 code is active. Refer to the above -9 detected
the Communication Issue Identified problems for additional information.

A. In Cat ET, click the “Diagnostics” tab on the tool bar. Proceed to Test Step 5.

B. Select the “System Communication Status” option from the Result: A -14 code is active. Refer to the above -14 detected
drop-down list. problems for additional information.

Proceed to Test Step 3.

(continued)
UENR4349-03 161
Circuit Tests

(Table 115, contd)

Troubleshooting Test Steps Values Results

3. Check for Incorrect Configuration Parameters Parameters Result: The parameters are correct.

A. Connect Cat ET. Proceed to Test Step 4.

B. Use Cat ET to verify that the correct parameters are being Result: The parameters are not correct.
used.
Repair: Input the correct parameters. Refer to Troubleshoot-
ing, “Configuration Parameters” for additional information.

If the problem is not resolved, proceed to Test Step 4.

4. Ensure that the latest Flash File Software is Installed in Flash File Result: The latest flash file is installed.
the ECM
Proceed to Test Step 9.
A. Connect Cat ET.
Result: The latest flash file is not installed.
B. Use Cat ET to verify that the correct flash file is being used.
Repair: Perform the following procedure:

1. Download the latest flash file from SIS web.

2. Install the software into the ECM.

Refer to Troubleshooting, “ECM Software - Install” for addi-

tional information.

Proceed to Test Step 9.

162 UENR4349-03
Circuit Tests

Illustration 54 g03846524
Device 1 present
(1) Column 1
UENR4349-03 163
Circuit Tests

Illustration 55 g03846007
Device 1 and Device 2 present
(1) Column 1 (3) Device 2 is the affected ECM/device that problem.
(2) Multiple Device 1 and Device 2 can be cannot be recognized by Device 1.
displayed Device 2 is the ECM/device with the
164 UENR4349-03
Circuit Tests

Table 116
Troubleshooting Test Steps Values Results

5. Use the System Communication Status to Determine Component Result: Device 1 and Device 2 are both present.
the Cause Identified
Record the devices identified as Device 1 and Device 2 in
A. Determine if both Device 1 and Device 2 are present in the column 1. Refer to Illustration 55 .
“ECM's” column (1) within the “System Communication Sta-
tus” screen. Refer to Illustration 55 . Proceed to Test Step 6.

Result: Only Device 1 is present.

Record the device identified as Device 1 in column 1. Refer

to Illustration 54 .

Proceed to Test Step 8.

6. Check the Resistance of the Data link 60+/-10 Ohms Result: The resistance is less than 50 Ohms.

A. Turn the breaker to the OFF position. Repair: There are more than 2 terminating resistors installed
in the wiring harness or a short circuit has been detected.
B. Measure the resistance of the data link between the follow- Repair or replace damaged components.
ing Device 2 wiring harness connector terminals:
Proceed to Test Step 9.
- +Data link and -Data link
Result: The resistance is 120 ±10 Ohms.

Repair: There is a problem with a terminating resistor.

Check the resistance on each terminating resistor. Replace
the failed terminating resistor.

Proceed to Test Step 9.

Result: The resistance is greater than 130 Ohms.

Repair: There is a problem with both terminating resistors or

an open circuit has been detected.

Determine the cause of the problem. Repair or replace dam-

aged components.

Proceed to Test Step 9.

Result: The resistance is 60 ±10 Ohms. The terminating re-

sistors are OK.

Proceed to Test Step 7.

(continued)
UENR4349-03 165
Circuit Tests

(Table 116, contd)

Troubleshooting Test Steps Values Results

7. Check the Power and Ground to Device 2 Battery Voltage Result: The voltage is not equal to battery voltage.

A. Turn the breaker to the ON position. Repair: There is an open or short in the wiring circuit. Repair
or replace the wiring circuit. Refer to the schematic for wiring
B. Measure the voltage between the following Device 2 wiring information.
harness connector terminals:
Proceed to Test Step 9.
- +Battery and -Battery
Result: The voltage is equal to battery voltage.

Repair: Replace the component identified as Device 2.

Proceed to Test Step 9.

8. Check the Resistance of the Data Link 60+/-10 Ohms Result: The resistance is less than 50 Ohms.

A. Turn the breaker to the OFF position. Repair: There are more than 2 terminating resistors installed
in the wiring harness or a short circuit has been detected.
B. Measure the resistance of the data link between the follow- Repair or replace damaged components.
ing Device 1 wiring harness connector terminals:
Proceed to Test Step 9.
- +Data link and -Data link
Result: The resistance is 60 ±10 Ohms. The terminating re-
sistors are OK.

Repair: Check the power, ground, and keyswitch (if applica-

ble) supply to each module on the affected data link. Refer
to the appropriate wiring diagram. Repair the power or
ground supply to the modules.

Note: The breaker must be in the ON position when

checking the power supply.

Proceed to Test Step 9.

Result: The resistance is 120 ±10 Ohms.

Repair: There is a problem with a terminating resistor.

Check the resistance on each terminating resistor. Replace
the failed terminating resistor.

Proceed to Test Step 9.

Result: The resistance is greater than 130 Ohms.

Repair: There is a problem with the wiring harness between

ECM 1 and the splice point into the data link wiring. Refer to
the appropriate wiring diagram.

Determine the cause of the problem. Repair or replace dam-

aged components.

Proceed to Test Step 10.

(continued)
166 UENR4349-03
Circuit Tests

(Table 116, contd)

9. Use the “ Systems Communication Status”” to Determine Component Result: The “Systems Communication Status” does not
the Communication Issue Identified show any communication issues.

A. In Cat ET, click the “Diagnostics” tab on the tool bar. Return to service.

B. Select the “System Communication Status” option from the

drop-down list.

C. Click the “Load from ECM” button to determine if any devi-

ces are not communicating.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046446

Electrical Power Supply - Test

SMCS Code: 1401-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the power to
the engines Electronic Control Module (ECM). Use
this procedure if any of the diagnostic codes in Table
117 are active or easily repeated.
Table 117
J1939 Code and Description Comments
168-3 The ECM detects voltage that is above the acceptable value.
Battery Potential / Power Input #1 : Voltage Above Normal

168-4 The ECM detects voltage that is below the acceptable value.
Battery Potential / Power Input #1 : Voltage Below Normal

The engine ECM requires the keyswitch to be in the

ON position in order to maintain communications with
Caterpillar Electronic Technician (ET).
UENR4349-03 167
Circuit Tests

Illustration 56 g02154189

Complete the procedure in the order in which the

steps are listed.
168 UENR4349-03
Circuit Tests

Table 118
Troubleshooting Test Steps Values Results

1. Determine the Diagnostic Code Diagnostic Code Result: A 168-3 diagnostic code is active.

A. Establish communication between the Cat ET and the Proceed to Test Step 2.
ECM. Refer to Troubleshooting, “Electronic Service Tools”,
if necessary. Result: A 168-4 diagnostic code is active.

B. Start the engine. Run the engine until the engine is at Proceed to Test Step 3
normal operating temperature.

C. Observe the “Active Diagnostic” screen on Cat ET. Wait

at least 30 seconds so that any codes may become active.

2. Check the Charging Circuit Charging Circuit Result: The charging system is OK.

A. Check the charging circuit. Refer to Special Instruction, Proceed to Test Step 3.
REHS0354, “Charging System Troubleshooting”.
Result: The charging system is not OK.

Repair: There is a problem with the charging system. Make

the necessary repairs. Refer to Special Instruction,
REHS0354, “Charging System Troubleshooting”.

If the problem is not resolved, proceed to Test Step 3.

3. Load Test the Battery Load Test Result: The battery voltage is low or the battery did not pass
the load test.
A. Load test the battery. Refer to Systems Operation and
Testing and Adjusting, “Battery - Test” Repair: Recharge or replace the faulty batteries. Verify that
the repair eliminates the problem.

Result: The batteries pass the load test. The measured volt-
age is between 11.5 VDC and 13.5 VDC for a 12 v system.
The measured voltage is between 23.0 VDC and 27.0 VDC
for a 24 v system.

Verify that the “System Operating Voltage Configuration” is

correctly configured in the Engine ECM configuration
parameters.

Check the wiring between the batteries and the ECM / NOx
sensor. Refer to the application-specific wiring schematic for
pin locations.
Check the connectors between the batteries and the ECM /
NOx sensor for moisture and/or corrosion.
Repair: Repair or replace the wiring and/or the connectors.
Verify that the repair eliminates the problem.

Verify that the repair eliminates the problem.

UENR4349-03 169
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046873

Fuel Injection Pump - Test

SMCS Code: 1251-038
The high-pressure fuel pump contains two
“pressurizing assemblies” . Each assembly contains
a solenoid. The Engine Electronic Control Module
(ECM) sends 105 v pulses to each solenoid. The
pulses are sent at the proper time and for the correct
duration for a given engine load and speed.
The ECM monitors the current flow through the circuit
for each solenoid. If the current flow is too high or too
low, the ECM activates one of the following
diagnostic codes:
Table 119
Diagnostic Trouble Codes

J1939 Code and Description Comments

1347-5 The ECM detects signal voltage that is not in the acceptable range.
Engine Fuel Pump Pressurizing Assembly #1 : Current Below Normal The code is logged.

1347-6 The ECM detects signal voltage that is not in the acceptable range.
Engine Fuel Pump Pressurizing Assembly #1 : Current Above Normal The code is logged.

1348-5 The ECM detects signal voltage that is not in the acceptable range.
Engine Fuel Pump Pressurizing Assembly #2 : Current Below Normal The code is logged.

1348-6 The ECM detects signal voltage that is not in the acceptable range.
Engine Fuel Pump Pressurizing Assembly #2 : Current Above Normal The code is logged.

Note: The automatic cylinder cutout test is disabled

while any of these codes are active.
Automatic Configuration of the Solenoid Drivers
The connectors for the solenoids are
interchangeable. The ECM determines the connector
that is connected to each solenoid during each
engine start cycle. For this reason, either pump
solenoid can be driven by either ECM driver.
170 UENR4349-03
Circuit Tests

Illustration 57 g03816750

Illustration 58 g03816975
Typical left side view
(1) Solenoid 1 (3) High-Pressure Fuel Pump (5) P2
(2) Solenoid 2 (4) ECM
UENR4349-03 171
Circuit Tests

Illustration 59 g01959046
Harness connectors for the solenoids
Complete the procedure in the order in which the
steps are listed.
Table 120
Troubleshooting Test Steps Values Results

1. Determine the Diagnostic Code Diagnostic Trouble Result: There is an active or there is a logged -5
Codes code
A. Establish communication between Caterpillar ® Electronic Techni-
cian (Cat ET) and the applicable ECM. Refer to Troubleshooting, Proceed to Test Step 2.
“Electronic Service Tools”, if necessary.
Result: There is an active or there is a logged -6
B. Download the “Warranty Report” from the engine ECM before code.
performing any troubleshooting or clearing diagnostic trouble codes.
Proceed to Test Step 3.
C. Look for an active or logged -5 code or -6 code.
172 UENR4349-03
Circuit Tests

Illustration 60 g03343300

Table 121
Troubleshooting Test Steps Values Results

2. Check the Wiring for an Open Circuit Short Circuit Result: The test results indicate “Not OK (*Open)”
for one or both solenoids.
A. Turn the keyswitch to the OFF position.
There is an open circuit in the wiring between a sol-
B. Verify that the harness connector is free of debris, free of corro- enoid and the ECM connector. Check both solenoid
sion, and securely connected. wiring circuits. There may be a problem with a
connector.
C. Disconnect both solenoids from the harness.
Repair: Repair the connectors and/or the wiring.
D. Connect a jumper wire between terminals 1 and 2 of the harness Replace parts, if necessary. Verify that the original
connector for each coil. Each coil is replaced with a short circuit. problem is resolved.

E.Turn the keyswitch to the ON position. Do not start the engine. Perform the “Fuel Rail Pump Solenoid Test” again
to verify that the problem is resolved.
F. Connect to Cat ET. Select the Diagnostics tab and perform the
“Fuel Rail Pump Solenoid Test” . Result: The test results indicate “Not OK (*Short)”
for both solenoids.

The ECM detected the jumper wires. There is a

problem with a solenoid.

Repair: Replace the pump.

Perform the “Fuel Rail Pump Solenoid Test” again

to verify that the problem is resolved.
UENR4349-03 173
Circuit Tests

Illustration 61 g03343302

Table 122
Troubleshooting Test Steps Values Results

3. Check the Wiring for a Short Circuit Short Circuit Result: The test results indicate “Not OK (*Short)” .

A. Verify that the harness connector is free of debris, free of corro- There is a short circuit in the wiring. There may be a
sion, and securely connected. problem with a connector.

B. Connect to Cat ET, Select the Diagnostics tab, and perform the Repair: Repair the wiring. Replace parts, if
“Fuel Rail Pump Solenoid Test” necessary.

C. Record the driver which has the “Not OK (*Short)” result. Reconnect both solenoids and all wiring.

D. Remove the driver return wire from the ECM connector that has Perform the “Fuel Rail Pump Solenoid Test” again.
the “Not OK (*Short)” result.
The test results will indicate “OK” if the short circuit
E. Disconnect the solenoid from the driver circuit that has the “Not is corrected.
OK (*Short)” result.
Result: The test results indicate “Not OK (*Open)”
F. Install a jumper wire between pins 1 and 2 on the solenoid for the suspect driver wiring circuit. The ECM de-
connector. tected the open circuit. There is a problem with the
solenoid.
G. Connect to Cat ET. Select the Diagnostics tab and perform the
“Fuel Rail Pump Solenoid Test” . Repair: Replace the pump.

Perform the “Fuel Rail Pump Solenoid Test” again

to verify that the problem is resolved.
174 UENR4349-03
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07044658

Fuel Level - Test

SMCS Code: 1250-038; 1439-038
The fuel level sensor is a component that is installed
by the customer. The sensor is a passive sensor. The
sensor does not require an operating voltage from
the Electronic Control Module (ECM).
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the fuel level
sensor or if any one of the diagnostic codes in Table
123 is active or easily repeated.
Table 123
Diagnostic Codes Table

Code and Description Conditions which Generate this Code System Response
96-3 The voltage on the signal wire for the fuel level
Fuel Level Sensor voltage above normal sensor is above normal.
The code is logged.
96-4 The voltage on the signal wire for the fuel level
Fuel Level Sensor voltage below normal sensor is below normal.

When the fuel tank is full, the fuel level sensor has a
resistance of 33 Ohms. When the fuel tank is empty,
the fuel level sensor has a resistance of 240 Ohms.
The resistance from the fuel level sensor varies
between these values as the fuel level varies.
The variable resistance of the sensor affects the pull-
up voltage that is created by the ECM. When the
resistance of the sensor is low, the pull-up voltage is
low. When the resistance of the sensor is high, the
pull-up voltage is high. Refer to Table 124 .
Table 124
Relationship Between the Resistance of the Sensor
and the Voltage on the Signal Wire
Fuel Level Resistance Approximate Voltage on the
Signal Wire

Full 33 Ohms 0.15 VDC

Empty 240 Ohms 1.8 VDC

The most likely electrical problem with the circuit for

the fuel level sensor is a problem in the wiring
harness. The next likely cause is a problem with the
fuel level sensor. The least likely cause is a problem
with the ECM.
UENR4349-03 175
Circuit Tests

Table 125
Troubleshooting Test Steps Expected Results Results

1. Inspect the Electrical Connectors and the All connectors, pins, and sockets are coupled Result: The connectors and the wiring are
Wiring and/or inserted and the harness and wiring are OK.
free of corrosion, of abrasion and of pinch
A. Remove the electrical power from the ECM. points. Proceed to Test Step 2.

B. Thoroughly inspect connectors (1) and (2). Result: There is a problem in the connectors
Refer to Troubleshooting, “Electrical Connec- and/or the wiring.
tors-Inspect” for details.
Repair the connectors and/or the wiring. Re-
C. Perform a 45 N (10 lb) pull test on each of place parts, if necessary. Verify that the repair
the wires that are associated with the fuel level eliminates the problem.
sensor.

D. Check the allen head screw on each of the

ECM connectors for the proper torque. Refer
to Troubleshooting, “Electrical Connectors - In-
spect” for the correct torque values.

E. Check the harness and the wiring for abra-

sion and for pinch points from the fuel level
sensor to the ECM.

2. Check the Resistance of the Sensor at The resistance measurement of the sensor is Result: The resistance measurement is be-
the Harness Connector between 33 and 240 Ohms. tween 33 and 240 Ohms. Connect the harness
connectors that are for the fuel level sensor.
A. Disconnect the fuel sensor at the harness The resistance of the sensor is OK.
connectors.
Proceed to Test Step 3.
B. Measure the resistance of the sensor be-
tween terminal 1 (fuel level) and terminal 2
(sensor return) at the harness connector. Re-
cord the measurement.

3. Check the Resistance of the Sensor The resistance measurement of the sensor Result: The resistance measurement is be-
Through the Harness through the harness is between 33 and 240 tween 33 and 240 Ohms.
Ohms.
A. Remove the wire from terminal location The resistance of the sensor is OK and the
J1:33 for the fuel level sensor from the ECM vessel's wiring is OK. The resistance of the
connector in order to isolate the circuit. sensor and the resistance through the wiring
harness is OK. There appears to be a problem
B. Install a 7X-1709 Multimeter Probe with the ECM. Replace the ECM. Refer to
(BLACK) into terminal location J2:11 (sensor Troubleshooting, “ECM - Replace” for details.
return) at the ECM connector.
Result: The resistance measurement of the
NOTE: Ensure that the multimeter probe is in sensor through the harness is not between 33
good repair. A bent probe may contact other and 240 Ohms.
terminals inside the connector.
The resistance of the sensor at the sensor
C. Measure the resistance between the loose connector is within specifications. The resist-
wire and the multimeter probe at the ECM con- ance of the sensor through the harness is not
nector. Record the measurement. within specifications. There is a problem in the
wiring harness that is between the ECM con-
NOTE: Be sure to wiggle the harness during nector and the sensor connector. There may
the measurement in order to reveal an intermit- be a problem with a connector. Repair the wir-
tent electrical condition in the harness. ing, when possible. Replace parts, if neces-
sary. Verify that the problem is resolved.

Complete the procedure in the order in which the The procedure corrected the issue. - STOP
steps are listed.
176 UENR4349-03
Circuit Tests

Result: This procedure did not correct the issue.

Contact your Cat dealer Technical Communicator
(TC). For further assistance, your TC can confer with
the Dealer Solutions Network (DSN).

i07037522

Fuel Priming Pump - Test

SMCS Code: 1258-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the fuel pump
relay or if one of the diagnostic codes in Table 126 is
active or easily repeated.
Table 126
Diagnostic Codes Table
Code and Description Conditions which Generate This Code System Response

The engine Electronic Control Module (ECM) detects an open

931-5 circuit at the fuel pump relay for 60 seconds.
Engine Fuel Supply Pump Actuator : The ECM detects an open to battery voltage for the fuel pump The code is logged.
Current Below Normal relay.
The fuel priming pump is activated.

931-6
The ECM detects a short circuit.
Engine Fuel Supply Pump Actuator : The code is logged.
The fuel priming pump is NOT activated.
Current Above Normal

The ECM is able to energize the fuel pump relay. The

fuel pump relay controls battery power to the fuel
priming pump. The circuit that is for battery power
uses a 10 amp fuse for circuit protection. This circuit
also provides battery power to the power module that
is for the fuel control valve controller.
UENR4349-03 177
Circuit Tests

Illustration 62 g06204419
178 UENR4349-03
Circuit Tests

Table 127
Troubleshooting Test Steps Values Results

1. Inspect the Electrical Connectors and the Wiring Connectors and/ Results: The connectors and the wiring appear to be
or wiring OK.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 2.
B. Inspect the condition of relay . Remove the components from the
panel and check for good connections. Thoroughly inspect connec- Results: The connectors and/or the wiring are NOT
tors. Refer to Troubleshooting, “Electrical Connectors - Inspect”. OK.

C. Check the torque of the allen head screws for each of the ECM Repair: Repair the connectors and/or the wiring. Re-
connectors. Refer to Troubleshooting, “Electrical Connectors - In- place parts, if necessary.
spect” for the correct torque values.
If the problem is not resolved, proceed to Test Step 2.
D. Check the harness and the wiring for abrasion and for pinch
points from the connectors for the electric fuel priming pump to the
ECM.

2. Check for Active Diagnostic Codes Active Code Results: No diagnostic codes are active, but the fuel
priming pump is not activating.
A. Connect Cat ®Electronic Technician (Cat ET) to the service tool
connector. Proceed to Test Step 6.

B. Restore power to the ECM. Results: A -6 diagnostic code is active at this time.

C. Turn the keyswitch to the ON position. Repair:

D. Select diagnostic tests from Cat ET. Proceed to Test Step 3.

E. Select the “Override Parameters” screen on Cat ET. Results: A -5 diagnostic code is active at this time.

F. Activate the override for the fuel pump relay. Proceed to Test Step 4.

G. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 30 seconds in order for the diagnostic codes to

become active.

H. Deactivate the override for the fuel pump relay.

I. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 70 seconds in order for the diagnostic codes to

become active.

(continued)
UENR4349-03 179
Circuit Tests

(Table 127, contd)

Troubleshooting Test Steps Values Results

3. Create an Open at the Connector for the Fuel Pump Relay Fuel pump relay Results: A -5 diagnostic code became active after dis-
connecting the connector for the fuel priming pump.
A. Remove power from the ECM.
Repair: Install a new fuel pump relay. Verify that there
B. Turn the keyswitch to the OFF position. are no active diagnostic codes for the fuel pump relay.
Clear any logged diagnostic codes.
C. Disconnect the connector from the fuel pump relay.
Results: A -6 diagnostic code remains active. There is
D. Restore power to the ECM. a short between the connector for the fuel pump relay
and the ECM.
E. Turn the keyswitch to the ON position.
Proceed to Test Step 5.
F. Select diagnostic tests from Cat ET.

G. Select the “Override Parameters” screen on Cat ET.

H. Activate the override for the fuel pump relay.

I. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 30 seconds in order for the diagnostic codes to

become active.

J. Deactivate the override for the fuel pump relay.

K. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 70 seconds in order for the diagnostic codes to

become active.

4. Create a Short at the Connector for the Fuel Pump Relay Fuel pump relay Results: A 931–6 diagnostic code is active with the
jumper installed.
A. Remove power from the ECM.
Repair: Install a new fuel pump relay. Verify that there
B. Turn the keyswitch to the OFF position. are no active diagnostic codes for the fuel pump relay.
Clear any logged diagnostic codes.
C. Disconnect the connector for the fuel pump relay. Install a jumper
wire between the terminals at the connector for the fuel pump relay. Results: The -5 diagnostic code remains active with
Refer to Illustration 62 for the schematic of the circuit. the jumper in place. Verify that the wire at terminal 85
of the connector that is in the fuse panel for the fuel
D. Restore power to the ECM. pump relay has continuity to engine ground. If the
ground circuit is OK, the open circuit is between the
E. Turn the keyswitch to the ON position. ECM and the connector for the fuel pump relay.

F. Select diagnostic tests from Cat ET. Proceed to Test Step 6.

G. Select the “Override Parameters” screen on Cat ET.

H. Activate the override for the fuel pump relay.

I. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 30 seconds in order for the diagnostic code to be-
come active.

(continued)
180 UENR4349-03
Circuit Tests

(Table 127, contd)

Troubleshooting Test Steps Values Results
J. Deactivate the override for the fuel pump relay.

K. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 70 seconds in order for the diagnostic code to be-
come active.

5. Check the Operation of the ECM by Creating an Open at the ECM Results: A 931–5 code is active with the fuel pump re-
ECM Connector lay power wire disconnected.

A. Remove power from the ECM. Repair: Repair the connectors or wiring and/or replace
the connectors or wiring.
B. Turn the keyswitch to the OFF position.
Results: The -5 diagnostic code is not active when
a. Remove the wire from terminal location P1–11 at the ECM con- Fuel Pump relay (+) is open. The -6 diagnostic code re-
nector for the fuel priming pump. mains active when the fuel pump relay (+) wire is open.
The ECM is NOT OK.
b. Restore power to the ECM.
Repair: Perform the following procedure:
c. Turn the keyswitch to the ON position.
1. Temporarily connect a test ECM.
d. Select diagnostic tests from Cat ET.
Refer to Troubleshooting, “ECM - Replace”.
e. Select the “Override Parameters” screen on Cat ET.
2. Recheck the circuit in order to ensure that the origi-
f. Activate the override for the fuel pump relay. nal problem has been resolved.

g. Monitor the active diagnostic code screen on Cat ET. Check and If the problem is resolved with the test ECM, install the
record any active diagnostic codes. suspect ECM. If the problem returns with the suspect
ECM, replace the ECM.
Note: Wait at least 30 seconds in order for the diagnostic code to be-
come active. Verify that the problem is resolved.

h. Deactivate the override for the fuel pump relay. If the problem is not resolved with the test ECM, install
the original ECM. There is a problem in the wiring.
i. Monitor the active diagnostic code screen on Cat ET. Check and
record any active diagnostic codes.

Note: Wait at least 70 seconds in order for the diagnostic code to be-
come active.

C. Remove power from the ECM. Restore all wiring to the original
configuration.

(continued)
UENR4349-03 181
Circuit Tests

(Table 127, contd)

Troubleshooting Test Steps Values Results
6. Check the Operation of the ECM by Creating a Short Circuit at
the ECM Connector: ECM Results: A 931–6 diagnostic code is active with the
jumper installed. The problem is in the wiring between
A. Remove power from the ECM. the ECM and the connector for the fuel pump relay.

B. Turn the keyswitch to the OFF position. Repair: Repair the connectors or wiring and/or replace
the connectors or wiring.
a. Connect the jumper wire that is in terminal location P1-11 to a
good source of engine ground. Results: The -6 diagnostic code is not active when the
jumper wire is grounded. The ECM is NOT OK.
b. Restore power to the ECM.
Repair: Perform the following procedure:
c. Turn the keyswitch to the ON position.
1. Temporarily connect a test ECM.
d. Activate the override for the fuel pump relay.
Refer to Troubleshooting, “ECM - Replace”.
e. Monitor the active diagnostic code screen on CAT ET. Check and
record any active diagnostic codes. 2. Recheck the circuit in order to ensure that the origi-
nal problem has been resolved.
Note: Wait at least 30 seconds in order for the diagnostic code to be-
come active. If the problem is resolved with the test ECM, install the
suspect ECM. If the problem returns with the suspect
f. Deactivate the override for the fuel pump relay. ECM, replace the ECM.

g. Monitor the active diagnostic code screen on Cat ET. Check and Verify that the problem is resolved.
record any active diagnostic codes.
If the problem is not resolved with the test ECM, install
Note: Wait at least 70 seconds in order for the diagnostic code to be- the original ECM. There is a problem in the wiring.
come active.

C. Remove power from the ECM. Restore all wiring to the original
configuration.

7. Check the Voltage at the Connector for the Fuel Priming 24 ± 3 VDC Results: The voltage is OK.
Pump
Repair: The circuit for the fuel priming pump is operat-
A. Turn the keyswitch to the ON position. ing correctly up to the connector for the fuel priming
pump. Verify that the fuel priming pump is operating
B. Select diagnostic tests from Cat ET. correctly by testing the fuel priming pump.

C. Select the “Override Parameters” screen on Cat ET. Results: The voltage is NOT OK.

D. Activate the override for the fuel pump relay. Verify that the ground circuit at terminal 85 of the con-
nector that is in the fuse panel has continuity to engine
E. Measure the voltage between terminal 1 and terminal 2 at the con- ground.
nector for the fuel priming pump. Refer to Illustration 62 for the sche-
matic of the circuit. If the ground circuit is OK, proceed to Test Step 8.

F. Deactivate the override for the fuel pump relay.

8. Check the Normally Open Contacts at the Fuel Pump Relay 24 ± 3 VDC Results: The voltage is OK.

A. Remove power from the ECM. Repair: Repair the wire between the connector for the
fuel pump relay and the fuel priming pump.
B. Turn the keyswitch to the OFF position.
Results: The voltage is NOT OK.
C. Disconnect the connector for the fuel pump relay.

(continued)
182 UENR4349-03
Circuit Tests

(Table 127, contd)

Troubleshooting Test Steps Values Results
D. Remove the wire from terminal 85 of the connector at the relay. Repair: Verify that battery voltage is present on termi-
nal 30 at the connector for the fuel pump relay. Verify
E. Reconnect the connector for the fuel pump relay. that the fuse for the engine control is not tripped. If volt-
age is present on terminal 30, replace the fuel pump
F. Restore power to the ECM. relay.

G. Turn the keyswitch to the ON position.

H. Select diagnostic tests from Cat ET.

I. Select the “Override Parameters” screen on Cat ET.

J. Activate the override for the fuel pump relay.

K. Measure the voltage between terminal 85 on the connector for the

fuel pump relay and engine ground.

L. Deactivate the override for the fuel pump relay.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07046880

Injector Solenoid - Test

SMCS Code: 1290-038-JV
This procedure covers the following diagnostic
trouble codes.
Note: Refer to Troubleshooting, “Cat ET Service
Features” for information about service features.
Table 128
Diagnostic Trouble Codes

J1939 Code and Description Comments

The code is logged.

The engine Electronic Control Module (ECM) receives a signal from
651-2
the injector solenoid that is invalid. Or, the ECM receives a signal from
Engine Injector Cylinder #01 : Erratic, Intermittent, or Incorrect
the injector solenoid that cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

The code is logged.

651-5 The ECM detects an open circuit.
Engine Injector Cylinder #01 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

(continued)
UENR4349-03 183
Circuit Tests

(Table 128, contd)

Diagnostic Trouble Codes

J1939 Code and Description Comments

The code is logged.
The ECM detects a short circuit. The ECM will disable the solenoid
651-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #01 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

651-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #01 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

The code is logged.

The engine ECM receives a signal from the injector solenoid that is in-
652-2
valid. Or, the ECM receives a signal from the injector solenoid that
Engine Injector Cylinder #02 : Erratic, Intermittent, or Incorrect
cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

The code is logged.

652-5 The ECM detects an open circuit.
Engine Injector Cylinder #02 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid
652-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #02 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

652-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #02 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

The code is logged.

The engine ECM receives a signal from the injector solenoid that is in-
653-2
valid. Or, the ECM receives a signal from the injector solenoid that
Engine Injector Cylinder #03 : Erratic, Intermittent, or Incorrect
cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

The code is logged.

653-5 The ECM detects an open circuit.
Engine Injector Cylinder #03 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid
653-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #03 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

653-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #03 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

The code is logged.

The engine ECM receives a signal from the injector solenoid that is in-
654-2
valid. Or, the ECM receives a signal from the injector solenoid that
Engine Injector Cylinder #04 : Erratic, Intermittent, or Incorrect
cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

(continued)
184 UENR4349-03
Circuit Tests

(Table 128, contd)

Diagnostic Trouble Codes

J1939 Code and Description Comments

The code is logged.
654-5 The ECM detects an open circuit.
Engine Injector Cylinder #04 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid
654-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #04 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

654-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #04 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

The code is logged.

The engine ECM receives a signal from the injector solenoid that is in-
655-2
valid. Or, the ECM receives a signal from the injector solenoid that
Engine Injector Cylinder #05 : Erratic, Intermittent, or Incorrect
cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

The code is logged.

655-5 The ECM detects an open circuit.
Engine Injector Cylinder #05 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid
655-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #05 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

655-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #05 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

The code is logged.

The engine ECM receives a signal from the injector solenoid that is in-
656-2
valid. Or, the ECM receives a signal from the injector solenoid that
Engine Injector Cylinder #06 : Erratic, Intermittent, or Incorrect
cannot be accurately interpreted.
The ECM continues to energize the injector solenoid.

The code is logged.

656-5 The ECM detects an open circuit.
Engine Injector Cylinder #06 : Current Below Normal The ECM continues the attempt to energize the solenoid circuit until
the circuit is repaired.

The code is logged.

The ECM detects a short circuit. The ECM will disable the solenoid
656-6
circuit in order to prevent damage to the circuit.
Engine Injector Cylinder #06 : Current Above Normal
The ECM disables this solenoid circuit. The ECM will periodically at-
tempt to energize the solenoid circuit until the circuit is repaired.

The code is logged.

656-7 The ECM has determined that the mechanical wear for the injector is
Engine Injector Cylinder #06 : Not Responding Properly out of specifications.
The ECM continues to energize the injector solenoid.

Background Information
UENR4349-03 185
Circuit Tests

Perform this procedure when the engine is at normal

operating temperature. Pay careful attention to the
condition of the wiring and the connectors as you
perform this procedure. The wiring and/or the
connectors may have problems that only occur
during vibration.
Each injector for the common rail fuel system
contains a solenoid. The ECM sends 105 V pulses to
each injector solenoid. The pulses are sent at the
proper time and at the correct duration for a given
engine load and speed.
Cooling of the Injector Solenoids
Each injector solenoid is cooled by a stream of fuel.
Trim Files
When an injector is replaced, program the new
injector code into the ECM. Refer to Troubleshooting,
“Injector Trim File - Install” for information that is
related to trim files. If the ECM is replaced, all of the
injector codes must be programmed into the new
ECM. Refer to Troubleshooting, “ECM - Configure”
for information that is related to the configuration of a
new ECM.
Diagnostic Tests on the Caterpillar ® Electronic
Technician (Cat ET)
Cat ET includes the following test that aids in
troubleshooting injector solenoids:
Injector Solenoid Test – This test identifies an open
circuit or a short circuit in the circuits for the injector
solenoids. The test is performed while the engine is
not running. The “Injector Solenoid Test” briefly
activates each solenoid. A good solenoid will create
an audible click when the solenoid is activated. Cat
ET indicates the status of the solenoid as “OK” ,
“Open” , or “Short” .
Fuel System Verification Test – This test evaluates
the health of each injector. This test will determine if
an injector needs to be replaced. When the test is
performed, Cat ET indicates the status of each
injector as “Success” or “Failed” . Perform the test
immediately after replacing an injector. Also, perform
this test if a -2 code or a -7 code is active.

Note: The “Fuel System Verification Test” must be

performed when the engine is running and the
coolant temperature is above 65° C (149° F).
Note: Refer to the following schematic. Two injector
solenoids share a common supply wire. For this
reason, an open circuit or a short circuit in a supply
wire could cause diagnostic codes for two cylinders.
186 UENR4349-03
Circuit Tests

Illustration 63 g03405343
Schematic for the injector solenoids on C9.3 engines

Electrical shock hazard. The injector for the com- Contact with high pressure fuel may cause fluid
mon rail fuel system uses 90-120 volts. penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
UENR4349-03 187
Circuit Tests

NOTICE
Ensure that all adjustments and repairs that are
carried out to the fuel system are performed by
authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system,
refer to Operation and Maintenance Manual,
“General Hazard Information and High-Pressure
Fuel Lines” for safety information.
Refer to Systems Operation, “Cleanliness of Fuel
System Components” for detailed information on
the standards of cleanliness that must be ob-
served during ALL work on the fuel system.

Complete the procedure in the order in which the

steps are listed.
188 UENR4349-03
Circuit Tests

Table 129
Troubleshooting Test Steps Values Results

1. Determine the Diagnostic Code Diagnostic Result: A logged -5 code or a logged -6 code is present.
Code
A. Establish communication between Cat ET and the engine ECM. Proceed to Test Step 3.
Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
Result: An active -5 code is present.
B. Download the “Warranty Report” from the engine ECM before
performing any troubleshooting or clearing diagnostic trouble Proceed to Test Step 4.
codes.
Result: An active -6 code is present.
C. Determine the diagnostic trouble code that relates to an injector.
Proceed to Test Step 5.

Result: A -2 code or a -7 code is present.

Proceed to Test Step 2.

2. Perform the “ Fuel System Verification Test”” Fuel System Result: The injector passes the test.
Note: Do not clear the diagnostic trouble code. Verification Test
Result: The injector does not pass the test.
A. Perform the Fuel System Verification Test. Cat ET will clear the
code when the test begins. Perform the following steps:

If the injector passes the test, the injector is okay. STOP. 1. Replace the injector.

If the injector fails the test, the injector is not okay. 2. Flash program the injector trim file into the ECM. Refer
to Troubleshooting, “Injector Trim File - Install”, if
necessary.

3. Perform the “Fuel System Verification Test” . This test

will clear the active diagnostic code for the new injector.

4. If the problem has been corrected, return the unit to

service.

5. Troubleshoot any active codes.

If a -5 injector code is present, proceed to Test Step 4.

If a -6 injector code is present, proceed to Test Step 5

(continued)
UENR4349-03 189
Circuit Tests

(Table 129, contd)

Troubleshooting Test Steps Values Results

3. Check the Integrity of the External Engine Harness Fuel System Result: The external engine harness is OK. A logged
Verification Test code does not become active.
A. Inspect the injector wiring harness between the ECM and the
valve cover. Look for these problems: Proceed to Test Step 6.
· Improper routing of the wire harness
Result: A problem with the external engine harness has
· Missing clamps or other hardware been identified.

· Loose connectors or damaged connectors Repair: Stop the engine. Repair the wiring problem. Re-
place parts, if necessary. Start the engine. Verify that the
· Damage that is caused by excessive heat problem is resolved.

· Damage that is caused by chafing

B. Slowly wiggle the external wiring harness and the connectors.

Pay particular attention to the wiring near each connector. Look for
a logged code to become active as you wiggle the wiring.

4. Check the External Engine Harness for an Open Circuit Fuel System Result: “Short” is displayed for the cylinder with the
Verification Test jumper wire.
A. Turn the keyswitch to the OFF position. A strong electrical shock
hazard is present if the keyswitch is not turned off. The external engine harness is OK. Remove the jumper
wire. Connect the harness connectors. Proceed to Test
B. Disconnect the harness connectors for the affected cylinder at Step 6.
the cylinder head.
Result: “Open” is displayed for the cylinder with the
C. Fabricate a jumper wire to short circuit the different terminal loca- jumper wire. The ECM did not detect the jumper wire.
tions at the connector for the injector harness at the valve cover. There is an open circuit in the external engine harness.
Crimp connector pins on both ends of the jumper wire.
Repair: Repair the problem with the harness. Replace
D. Connect the jumper wire between terminal locations 1 (supply) parts, if necessary. Start the engine. Verify that the prob-
and 3 (return). This connection will effectively create a short circuit lem is resolved.
for the cylinder.

E. Turn the keyswitch to the ON position.

F. Perform the “Injector Solenoid Test” at least two times.

G. Monitor the screens on Cat ET.

H. Repeat this test for each suspect circuit. Stop the “Injector Sole-
noid Test” before handling the jumper wire. Restore the wiring to
the original configuration.

(continued)
190 UENR4349-03
Circuit Tests

(Table 129, contd)

Troubleshooting Test Steps Values Results

5. Check the External Engine Harness for a Short Circuit Short Circuit Result: All cylinders indicate “Open” . The external en-
gine harness does not have 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. Proceed to Test Step 6.

B. Disconnect the connector at the valve cover. Result: One or more cylinders indicate “Short” . Note the
cylinders that indicate “Short” .
C. Turn the keyswitch to the ON position.
Repair: Repair the problem with the harness. Replace
D. Perform the “Injector Solenoid Test” at least two times. parts, if necessary. Start the engine. Verify that the prob-
lem is resolved.
E. Turn the keyswitch to the ON position.

F. Perform the “Injector Solenoid Test” at least two times.

G. Monitor the screens on Cat ET.

6. Check the Injector Harness Under the Valve Cover for an Open or Short Result: “Short” is displayed for the cylinder with the
Open Circuit or for a Short Circuit Circuit jumper wire and “Open” when the jumper wire is re-
moved. The harness wiring is OK.
A. Turn the keyswitch to the OFF position. A strong electrical shock
hazard is present if the keyswitch is not turned off. Perform the following procedure:

B. Remove the valve cover in order to gain access to the suspect 1. Replace the suspect injector.
injector.
2. Program the injector trim file into the ECM. Refer to
C. Disconnect the harness connector from the suspect injector. Troubleshooting, “Injector Trim File - Install”, if
necessary.
D. Thoroughly clean the terminals on the injector solenoid and on
the harness connector. 3. Perform the “Fuel System Verification Test” . This test
will clear the active diagnostic code for the new injector.
E. Use a jumper wire to short circuit pin 1 (supply) and pin 3 (return)
for the suspect injector. This connection will effectively replace the 4. Return the unit to service.
injector solenoid with a short circuit.
Result: “Short” is not displayed for the cylinder with the
F. Turn the keyswitch to the ON position. jumper wire and “Open” is not displayed when the jump-
er wire is removed. There is a problem with the injector
G. Perform the “Injector Solenoid Test” at least two times. harness under the valve cover. There may be a problem
Note: The injector solenoid that shares the supply wire of the injec- with a connector.
tor that is short circuited may indicate a false test result. Disregard
this test result. Repair: Repair the problem with the harness. Replace
parts, if necessary. Start the engine. Verify that the prob-
H. Turn the keyswitch to the OFF position. lem is resolved.

I. Remove the jumper wire from the injector connector. Removing

the jumper will effectively replace the injector solenoid with an open
circuit.

J. Turn the keyswitch to the ON position.

K. Perform the “Injector Solenoid Test” at least two times.

L. Monitor the screens on Cat ET.

M. Turn the keyswitch to the OFF position.

UENR4349-03 191
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07035389

Relay - Test
(Start Relay)
SMCS Code: 4493-038
This procedure covers the following diagnostic
codes:
Table 130
Diagnostic Trouble Codes for the Start Relay

J1939 Code and Description Comments

677-5 The Electronic Control Module (ECM) detects a low current condition
Starter Motor Relay : Current Below Normal (open circuit) in the start relay control circuit.

677-6 The Electronic Control Module (ECM) detects a high current condition
Starter Motor Relay : Current Above Normal (short circuit) in the start relay control circuit.

Follow the troubleshooting procedure in order to identify the root cause of the fault.

Table 131
Component Electrical Checkout

Engine Starter Motor Relay Attempt to start the engine. Once the ECM attempts to energize the relay, the code will become active.
Refer to the machine-specific schematic for the "Engine Starter Motor Relay" wiring circuit.

During the following procedure, refer to the electrical

schematic for the application.
Complete the procedure in the order in which the
steps are listed.
192 UENR4349-03
Circuit Tests

Table 132
Troubleshooting Test Steps Values Results

1. Inspect Electrical Connectors and Wiring Loose connection Result: There is a fault in a connector or the wiring.
or damaged wire
A. Check that the fuses are not blown. Repair: Repair any faulty connectors or replace the wiring
harness. Ensure that all of the seals are properly in place
B. Inspect the terminals on the start relay. Refer to Trouble- and ensure that the connectors are correctly coupled.
shooting, “Electrical Connector - Inspect” for details.
Replace any blown fuses.
C. Perform a 45 N (10 lb) pull test on each of the wires in the
ECM connector that are associated with the start relay. Use the electronic service tool to clear all logged diagnostic
codes and verify that the repair eliminates the fault.
D. Check the screw for the ECM connector for the correct tor-
que of 6 N·m (53 lb in). Result: All connectors, pins, and sockets are correctly
coupled and/or inserted. The harness is free of corrosion,
E. Check the harness for abrasion and pinch points from the abrasion, and pinch points. The fuses are not blown.
start relay back to the ECM.
Proceed to Test Step 2.

2. Check for Active Diagnostic Codes Diagnostic codes Result: Diagnostic code 677-5 is active or recently logged.

A. Connect the electronic service tool to the diagnostic Proceed to Test Step 3.
connector.
Result: Diagnostic code 677-6 is active or recently logged.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine. Proceed to Test Step 4.

C. Use the electronic service tool to check for active diagnos-

tic codes.

(continued)
UENR4349-03 193
Circuit Tests

(Table 132, contd)

Troubleshooting Test Steps Values Results

3. Create a Short Circuit at the Relay Connector Diagnostic code Result: A 677-6 diagnostic code is active with the jumper
installed.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement start relay.
B. Remove the start relay.
Use the electronic service tool to clear all logged diagnostic
C. Fabricate a jumper wire. Install the jumper wire between codes and verify that the repair eliminates the fault.
terminal 1 and terminal 2 on the harness connector for the
start relay. Result: The 677-5 diagnostic code is still active.

D. Turn the keyswitch to the ON position. Repair: There is an open circuit for the starter motor relay
in the wiring harness. Repair or replace the wiring harness.
E. Perform the appropriate electrical checkout. Refer to Table
131 .

F. Use the electronic service tool to check for active diagnostic

codes. Wait at least 30 seconds for activation of the diagnostic
codes.

G. Turn the keyswitch to the OFF position and remove the

jumper wire.

4. Create an Open Circuit at the Relay Diagnostic codes Result: A 677-5 diagnostic code is active with the relay
disconnected.
A. Turn the keyswitch to the OFF position.
Repair: Install a replacement start relay.
B. Disconnect the start relay.
Use the electronic service tool to clear all logged diagnostic
C. Turn the keyswitch to the ON position. codes and verify that the repair eliminates the fault.

D. Perform the appropriate electrical checkout. Refer to Table Result: The 677-6 diagnostic code is still active with the re-
131 . lay disconnected.

E. Use the electronic service tool to check for active diagnos- Repair: There is a short circuit to ground or short circuit to a
tic codes. Wait at least 30 seconds for activation of the diag- power source in the harness. Repair or replace the wiring
nostic codes. harness.

If the procedure did not correct the issue, contact During each key on event of at least 2 seconds, the
your Cat dealer Technical Communicator (TC). For Electronic Control Module (ECM) evaluates the
further assistance, your TC can confer with the signal voltage from each pressure sensor. The ECM
Dealer Solutions Network (DSN). compares each signal voltage to a reference voltage.
The reference voltage that is used depends on the
i07046893
sensor.
If a signal voltage is close to the reference voltage,
Sensor Calibration Required - the ECM will internally adjust the signal voltage. The
internal adjustment causes the pressure value for the
Test sensor to be correct. This process is called automatic
sensor calibration.
SMCS Code: 1439-038
If a signal voltage is not close to the reference
During normal operation, each pressure sensor voltage, the ECM will not internally adjust the signal
outputs a signal voltage that accurately represents voltage. The ECM will set a fault code that indicates
the pressure that is sensed by the sensor. However, there is a problem with the signal voltage.
certain circuit conditions can cause a signal voltage
to become inaccurate. Table 133 indicates the maximum error that is
permitted for each sensor, and the reference for that
sensor. Refer to the troubleshooting procedure to
determine the root cause of the incorrect signal
voltage.
194 UENR4349-03
Circuit Tests

Table 133
Diagnostic Trouble Codes

J1939 Code and Description Comments

During key on, the signal voltage from the crankcase air pressure
101-13 sensor indicated a crankcase air pressure greater than +/- 1.5 kPa
Crankcase Air Pressure Sensor : Out of Calibration (0.2 psi).
There is not a reference sensor for this sensor
During key on, the signal voltage from the Intake Manifold pressure
3563-13 sensor indicated an Intake Manifold pressure greater than +/- 18 kPa
Engine Intake Manifold #1 Absolute Pressure : Calibration Required (3 psi) from the Atmospheric Pressure sensor.
Reference sensor : Atmospheric Pressure Sensor

Complete the procedure in the order in which the

steps are listed.
Table 134
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Diagnostic Result: There is an active or there is a logged -13 code.
Trouble
The engine coolant temperature must be greater than 0° C (32° F) Codes Proceed to Test Step 2.
before beginning this procedure.

A. Establish communication between Caterpillar ® Electronic Tech-

nician (Cat ET) and the Electronic Control Module (ECM) . Refer to
Troubleshooting, “Electronic Service Tools”, if necessary.

B. Download the “Warranty Report” from the engine ECM before

performing any troubleshooting or clearing diagnostic trouble
codes.

C. Wait at least 30 seconds in order for the diagnostic codes to be-

come active.

Look for an active -13 code or for a logged -13 code.

2. Check for Debris Debris Result: The sensor measurement port is not blocked by
debris.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 3.
B. Check the suspect sensor for debris.
Result: A -13 code is not present, return the unit to service.
C. If applicable, check the reference sensor for debris.
Result: A -13 code is present, replace the suspect sensor.
D. Check the sensor measurement port for blockage by debris. Verify that the problem is resolved.

E. If debris is found, clear the debris from the measurement port Result: If more than one -13 code is present and the codes
and replace the suspect sensor. have a reference sensor, replace the reference sensor. Verify
that the problem is resolved.
F. Turn the keyswitch to the ON position.

G. Check for -13 codes. Wait at least 30 seconds in order for the di-
agnostic codes to become active.

(continued)
UENR4349-03 195
Circuit Tests

(Table 134, contd)

Troubleshooting Test Steps Values Results

3. Inspect the Suspect Sensor Connector Moisture Result: The suspect sensor connector does not have mois-
ture and/or corrosion.
A. Turn the keyswitch to the OFF position.
Proceed to Test Step 5.
Inspect the suspect sensor connector for moisture and/or
corrosion. Result: The suspect sensor connector has moisture and/or
corrosion.

Proceed to Test Step 4.

4. Remove any moisture and/or corrosion Moisture Result: A -13 code is not present, return the unit to service.

A. Disconnect the suspect sensor connector. Result: A -13 code is present, replace the suspect sensor.
Verify that the problem is resolved.
B. Remove any moisture and/or corrosion from the outside of the
connector. Check for moisture and corrosion inside the connector. Result: If only a 289-13 code is present, replace the refer-
Verify that the seals for the wires are sealing correctly. Refer to ence sensor. Verify that the problem is resolved.
Troubleshooting, “Electrical Connectors - Inspect”, if necessary.
Result: If only a 460-13 or 5580 -13 code is present, replace
C. If necessary, repair the connector or replace the connector. the reference sensor. Verify that the problem is resolved.

D. Reconnect the connector. Verify that the connection is secure. Result: If more than one -13 code is present and the codes
have a reference sensor, replace the reference sensor. Verify
E. Turn the keyswitch to the ON position. that the problem is resolved.

F. Monitor the diagnostic codes on Cat ET. Check for -13 codes.
Wait at least 30 seconds in order for the diagnostic codes to be-
come active.

5. Check for Moisture and/or Corrosion in the Circuit Moisture Result: A -13 code is not present, return the unit to service.

A. Check all of the connectors in the circuit for moisture and/or Result: A -13 code is present, replace the suspect sensor.
corrosion. Verify that the problem is resolved.

B. Check for corrosion inside the connector. Verify that the seals Result: If only a 460-13 or 5580 -13 code is present, replace
for the wires are sealing correctly. Refer to Troubleshooting, “Elec- the reference sensor. Verify that the problem is resolved.
trical Connectors - Inspect”, if necessary.
Result: If more than one -13 code is present and the codes
C. If necessary, repair the connector or replace the connector. have a reference sensor, replace the reference sensor. Verify
that the problem is resolved.
D. Reconnect the connector. Verify that the connection is secure.

E. Turn the keyswitch to the ON position.

F. Monitor the diagnostic codes on Cat ET. Check for -13 codes.
Wait at least 30 seconds in order for the diagnostic codes to be-
come active.
196 UENR4349-03
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07157660

Sensor Signal (Analog, Active)

- Test
SMCS Code: 1439-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the sensors.
Also use this procedure if any one of the diagnostic
codes in Table 135 is active or easily repeated.
Table 135
Diagnostic Trouble Codes

J1939 Code Description Comments

The Electronic Control Module (ECM) detects signal voltage that is not in
100-3 the acceptable range.
Engine Oil Pressure Sensor : Voltage Above Normal The code is logged.
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
100-4
The code is logged.
Engine Oil Pressure Sensor : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
101-3
The code is logged.
Crankcase Air Pressure Sensor : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
101-4
The code is logged.
Crankcase Air Pressure Sensor : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
109–3
The code is logged.
Engine Coolant Pressure : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
109–4
The code is logged.
Engine Coolant Pressure : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
157-3
The code is logged.
Fuel Rail Pressure Sensor : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
157-4
The code is logged.
Fuel Rail Pressure Sensor : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

411-3 The ECM detects signal voltage that is not in the acceptable range.
Engine Exhaust Gas Recirculation Differential Pressure Sensor : The code is logged.
Voltage Above Normal The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
1208–3
The code is logged.
Engine Pre-Filter Oil Pressure : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

(continued)
UENR4349-03 197
Circuit Tests

(Table 135, contd)

Diagnostic Trouble Codes

J1939 Code Description Comments

The ECM detects signal voltage that is not in the acceptable range.
1208-4
The code is logged.
Engine Pre-filter Oil Pressure : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
1381-3
The code is logged.
Engine Fuel Supply Pump Inlet Pressure : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
1381-4
The code is logged.
Engine Fuel Supply Pump Inlet Pressure : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
1387–3
The code is logged.
Auxiliary Pressure #1 : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
1387–4
The code is logged.
Auxiliary Pressure #1 : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
2435-3
The code is logged.
Seawater Pump Outlet Pressure : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
2435-4
The code is logged.
Seawater Pump Outlet Pressure : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
3563-3
The code is logged.
Intake Manifold Pressure Sensor : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
5578-3
The code is logged.
Fuel Pressure Sensor - Before Fuel Filter : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
5578-4
The code is logged.
Fuel Pressure Sensor - Before Fuel Filter : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
5580-3
The code is logged.
Fuel Pressure Sensor - After Fuel Filter : Voltage Above Normal
The value of the parameter is set to a gauge pressure.

The ECM detects signal voltage that is not in the acceptable range.
5580-4
The code is logged.
Fuel Pressure Sensor - After Fuel Filter : Voltage Below Normal
The value of the parameter is set to a gauge pressure.

The supply voltage is routed to terminal 1 of each Wiggle Test – The Wiggle Test allows you to monitor
sensor connector. The sensor return is routed to the status of the signals from the sensors.
terminal 2 of each sensor connector. The sensor
signal is routed to terminal 3 of each sensor
connector. The ECM provides short circuit protection For additional information regarding the Wiggle Test,
for the internal power supply. A short circuit to the refer to the documentation that accompanies the Cat
battery will not damage the internal power supply. ET software.

Diagnostics on the Caterpillar Electronic

Technician (ET)
198 UENR4349-03
Circuit Tests

Illustration 64 g06204546
Schematic for 5 Volt Sensors
UENR4349-03 199
Circuit Tests

Illustration 65 g06204559
Schematic for 8 Volts Sensors

Note: The diagram above is a simplified schematic of

the electrical circuit. The schematic is electrically
correct. However, not all the possible harness
connectors are shown. Refer to the latest revision of
the Electrical Schematic for the complete schematic.
Locations of the sensors and the sensor connectors

Illustration 66 g03830913

(1) Fuel rail pressure sensor

200 UENR4349-03
Circuit Tests

Illustration 67 g03771536

(2) Intake manifold pressure sensor

Illustration 68 g03771581

(6) Crankcase pressure sensor

UENR4349-03 201
Circuit Tests

Illustration 69 g03830922
(3) Crankcase Pressure Sensor
(4) Oil Pressure Sensor
202 UENR4349-03
Circuit Tests

Illustration 70 g03830941

(5) Fuel Pressure Outlet Sensor (6) Fuel Temperature Sensor (7) Fuel Pressure Inlet Sensor

Complete the procedure in the order in which the

steps are listed.
UENR4349-03 203
Circuit Tests

Table 136
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Codes Diagnostic Result: A -3 diagnostic code is active.

Code
A. Establish communication between Cat ® Electronic Technician Proceed to Test Step 2.
(Cat ET) and the ECM . Refer to Troubleshooting, “Electronic Service
Tools”, if necessary. Result: A -4 diagnostic code is active.

B. Turn the keyswitch to the ON position. Proceed to Test Step 3.

C. Look for a -3, or -4 active or logged codes:

2. Create a Short at the Sensor Connector Short Created Result: A -4 diagnostic code became active after creat-
ing the short at the sensor connector.
A. Use a jumper wire in order to create a short between terminal 3
(signal) and terminal 2 (sensor return) at the sensor connector. Repair: The wiring is OK. Replace the sensor.

B. Turn the keyswitch to the ON position. Verify that the problem is resolved.

C. Monitor the diagnostic codes on Cat ET. Check for an active -4 di- Result: A -4 diagnostic code does not become active
agnostic code for the suspect sensor. for the suspect sensor.

D. Turn the keyswitch to the OFF position. Proceed to Test Step 4.

3. Create an Open at the Suspect Sensor Connector Create an Result: A -3 diagnostic code became active after dis-
Open connecting the sensor.
A. Turn the keyswitch to the OFF position.
Repair: The wiring is OK. Replace the sensor.
B. Disconnect the sensor connector of the suspect sensor with the
active -4 diagnostic code. Verify that the problem is resolved.

C. Turn the keyswitch to the ON position. Result: A -3 diagnostic code did not became active
after disconnecting the sensor.
D. Monitor the diagnostic codes on Cat ET. Check for an active -3 di-
agnostic code for the suspect sensor. Proceed to Test Step 4.

E. Turn the keyswitch to the OFF position.

(continued)
204 UENR4349-03
Circuit Tests

(Table 136, contd)

Troubleshooting Test Steps Values Results

4. Check the 5 VDC Supply Voltage at the Sensor Connector Test Passed Result: The supply voltage is approximately 5.0 ± 0.2
VDC
A. Turn the keyswitch to the ON position.
Connect the sensor and then proceed to Test Step 5
B. Measure the voltage between pin 1 and pin 2 at the suspect
sensor. Result: The supply voltage is not approximately 5.0 ±
0.2 VDC.

Repair: There is a short in the harness to the battery.

Repair the wiring or replace the harness

Verify that the problem is resolved.

5. Perform the Wiggle Test Test Passed Result: The wiring failed the Wiggle Test.

Carefully following this procedure is the best way to identify the root Repair: There is a problem with the wiring. Repair the
cause of an intermittent problem. wiring or replace the wiring.

A. Turn the keyswitch to the ON position. Verify that the problem is resolved.

B. Use CAT ET to run the “Wiggle Test” . Result: The wiring passed the Wiggle Test.

C. Slowly wiggle the wiring and the connectors between the P2 con- The problem may be intermittent. Inspect the wiring.
nector and the sensor. Pay particular attention to the wiring near Refer to Troubleshooting, “Electrical Connectors -
each connector. Be sure to wiggle all of the wiring. Inspect”.
As you wiggle the wiring look for these problems.
If the wiring looks OK perform the following procedure.
1. Loose connectors or damaged connectors
1. Turn the keyswitch to the OFF position.
2. Moisture on the connectors or the wiring
2. Disconnect the connectors. Carefully inspect the ter-
3. Damaged that is caused by excessive heat minals for proper installation. Make sure that each ter-
minal is clean and dry.
4. Damage that is caused by chafing
3. Insert a pin into each socket. Verify that each socket
5. Improper routing of wiring grips the pin firmly. Repair any problems.

6. Damaged insulation 4. Connect all connectors.

5. Verify that the problem is resolved.

6. Return the unit to service.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i06926360

Sensor Signal (Analog,

Passive) - Test
SMCS Code: 1439-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with a sensor. Use
this procedure if any one of the diagnostic codes in
Table 137 is active or easily repeated.
UENR4349-03 205
Circuit Tests

Table 137
Diagnostic Codes Table

J1939 Code and Description Comments

105-3 The Electronic Control Module (ECM) detects the following condi-
Engine Intake Manifold #1 Temperature : Voltage Above Normal tions: The signal voltage from the intake manifold air temperature
sensor is greater than 4.95 VDC for more than 8 seconds. Engine
coolant temperature is above −10 °C (15.0 °F). The ECM will use the
default value of 70 °C (158 °F) for the intake manifold air tempera-
ture. "Voltage High" will be displayed next to the status for "Intake
Manifold Air Temperature" on the electronic service tool. The engine
may show the following symptoms: Poor stability, Poor cold running,
Poor acceleration under load, White smoke

105-4 The ECM detects the following conditions: The signal voltage from
Engine Intake Manifold #1 Temperature : Voltage Below Normal the intake manifold air temperature sensor is less than 0.2 VDC for
more than 8 seconds. The ECM will use the default value of 70°C
(158°F) for the intake manifold air temperature. "Voltage Low" will be
displayed next to the status for "Intake Manifold Air Temperature" on
the electronic service tool. The engine may show the following symp-
toms: Poor stability Poor cold running, Poor acceleration under load,
White smoke.
110-3 The code is logged if the engine has been running for more than 7 mi-
Engine Coolant Temperature Sensor : Voltage Above Normal nutes and an open circuit has been detected.

110-4 The code is logged. The ECM detects voltage that is not in the ac-
Engine Coolant Temperature Sensor : Voltage Below Normal ceptable range.

172-3 The code is logged.

Air Inlet Temperature Sensor : Voltage Above Normal The ECM detects voltage that is not in the acceptable range.

172-4 The code is logged.

Air Inlet Temperature Sensor : Voltage Below Normal The ECM detects voltage that is not in the acceptable range.

174-3 The code is logged. The ECM will flag the fuel temperature as invalid
Fuel Temperature Sensor : Voltage Above Normal data and the fuel temperature is set to a default value of 40 °C
(104 °F).
174-4
Fuel Temperature Sensor : Voltage Below Normal

175-3 The code is logged. The ECM detects voltage that is not in the ac-
Engine Oil Temperature Sensor:Voltage Above Normal ceptable range.

175-4 The code is logged. The ECM detects voltage that is not in the ac-
Engine Oil Temperature Sensor:Voltage Below Normal ceptable range.

441–3 The ECM detects the following conditions:

Auxiliary Temperature #1 : Voltage Above Normal The signal voltage from the hydraulic oil temperature sensor is great-
er than 4.975 VDC for more than 8 seconds.
441–4 The ECM detects the following conditions:
Auxiliary Temperature #1 : Voltage Below Normal The signal voltage from the hydraulic oil temperature sensor is less
than 0.2 VDC for more than 8 seconds.

System Overview For additional information regarding the Wiggle Test,

refer to the documentation that accompanies the Cat
The sensor signal for the passive sensor is routed ET software.
from the ECM to terminal 1 of each sensor connector.
The sensor return for the passive sensors is routed to
the ECM from terminal 2 of each sensor connector.
Diagnostics on the Caterpillar Electronic
Technician (ET)
Wiggle Test – The Wiggle Test allows you to monitor
the status of the signals from the sensors.
206 UENR4349-03
Circuit Tests

Illustration 71 g01155187
Terminal locations at the connector for the passive
analog sensors
(Terminal 1) Sensor signal
(Terminal 2) Analog sensor return

Illustration 72 g06206642

Complete the procedure in the order in which the

steps are listed.
UENR4349-03 207
Circuit Tests

Table 138
Troubleshooting Test Steps Values Results

1. Check for Diagnostic Trouble Codes Codes Result: A -3 diagnostic code is active.

A. Connect to Caterpillar ® Electronic Technician (Cat ET). Proceed to Test Step 2.

B. Turn the keyswitch to the ON position. Result: A -4 diagnostic code is active.

C. Access the “Active Diagnostic Code” screen on Cat ET. Proceed to Test Step 3.

Wait at least 30 seconds in order for the diagnostic codes Result: For a diagnostic code that is logged but not cur-
to become active. rently active, Proceed to Test Step 4.

D. Look for these active codes or logged codes:

1. -3

2. -4

2. Create a Short at the Sensor Connector Short Circuit Result: The -3 diagnostic code remains active for the sus-
Recognized pect sensor.
A. Turn the keyswitch to the OFF position.
Repair: There is an open in the harness. Repair the wiring
B. Disconnect the suspect sensor. or replace the harness.

C. Install the jumper wire between terminal 1 (sensor signal) Verify that the problem is resolved.
and terminal 2 (sensor return) at the sensor connector.
Result: A -4 diagnostic code became active after creating
D. Turn the keyswitch to the ON position. the short at the sensor connector.

E. Monitor the diagnostic codes on Cat ET. Check for an active Repair: The wiring is OK. Replace the sensor.
-4 diagnostic code for the suspect sensor.
Verify that the problem is resolved.
Wait at least 30 seconds in order for the diagnostic codes
to become active.

F. Turn the keyswitch to the OFF position.

(continued)
208 UENR4349-03
Circuit Tests

(Table 138, contd)

3. Create an Open at the Suspect Sensor Connector Open Circuit Result: The -4 diagnostic code remains active for the sus-
Recognized pect sensor.
A. Turn the keyswitch to the OFF position.
Repair: There is an open in the harness. Repair the wiring
B. Disconnect the sensor connector of the suspect sensor with or replace the harness.
the active -4 diagnostic code.
Verify that the problem is resolved.
C. Turn the keyswitch to the ON position.
Result: A -3 diagnostic code became active after discon-
D. Monitor the diagnostic codes on Cat ET. Check for an active necting the sensor.
-3 diagnostic code for the suspect sensor.
Repair: The wiring is OK. Replace the sensor.
· For a 110-3 code, start the engine and let the engine idle
for 7 minutes. The engine must be running for at least 7 Verify that the problem is resolved.
minutes in order for the diagnostic to run.

E. Turn the keyswitch to the OFF position.

Wiggle test
4. Perform the Wiggle Test Result: The wiring failed the Wiggle Test.

Carefully following this procedure is the best way to identify Repair: There is a problem with the wiring. Repair the wiring
the root cause of an intermittent problem. or replace the wiring.

A. Turn the keyswitch to the ON position. Verify that the problem is resolved.

B. Use Cat ET to run the “Wiggle Test” . Result: The wiring passed the Wiggle Test.

C. Slowly wiggle the wiring and the connectors between the Repair: The problem may be intermittent. Inspect the wiring.
P2 connector and the sensor. Slowly wiggle the wiring and the Refer to Troubleshooting, “Electrical Connectors - Inspect”.
connectors between the P1 connector and the sensor. Pay
particular attention to the wiring near each connector. Be sure If the wiring looks OK perform the following procedure.
to wiggle all of the wiring.
1. Turn the keyswitch to the OFF position.
D. As you wiggle the wiring look for these problems.
2. Disconnect the connectors. Carefully inspect the terminals
1. Loose connectors or damaged connectors for proper installation. Make sure that each terminal is clean
and dry.
2. Moisture on the connectors or the wiring
3. Insert a pin into each socket. Verify that each socket grips
3. Damage that is caused by excessive heat the pin firmly. Repair any problems.

4. Damage that is caused by chafing 4. Connect all connectors.

5. Improper routing of wiring 5. Verify that the problem is resolved.

6. Damaged insulation 6. Return the unit to service.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the Deal
Solutions Network (DSN).
i07035477

Sensor Signal (PWM) - Test

SMCS Code: 1439-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the sensor or if
any one of the diagnostic codes in Table 139 is active
or easily repeated.
UENR4349-03 209
Circuit Tests

Table 139
Diagnostic Codes Table

Conditions which Generate

Code and Description this Code System Response Label on Sensor
173–3 Engine Exhaust Gas Tem- The Electronic Control Module The code is logged. “FRONT LEFT EXHAUST TC”
perature : Voltage Above Norma (ECM) detects a signal voltage that The ECM flags the exhaust tem- Located in the exhaust manifold
is above normal. perature as invalid data. below the turbocharger
173-4 Engine Exhaust Gas Tem- The Electronic Control Module
perature : Voltage Below Normal (ECM) detects a signal voltage that
is below normal.
173-8 Engine Exhaust Gas Tem- The Electronic Control Module
perature : Abnormal Frequency (ECM) detects a sensor frequency
pulse width or period that is greater than 600 Hz or less
than 400 Hz.
The ECM detects a duty cycle that
is greater than 88 percent or a duty
cycle that is less than 22 percent.

System Operation
A Pulse Width Modulated Sensor (PWM) provides a
signal to the Electronic Control Module (ECM) from
the exhaust temperature sensor. The sensor receives
a 8.0 ± 0.4 VDC regulated voltage from the ECM.
The sensor generates a PWM signal that is in a
specific range of duty cycle that is sent to the ECM.
This range is directly related to the temperature that
is sampled by the temperature probe. When the
temperature of the sensor probe is 50 °C (122 °F)
the duty cycle output of the sensor is 22 percent.
When the temperature of the sensor probe is 850 °C
(1550 °F) the duty cycle output of the sensor is 88
percent. As the temperature of the probe fluctuates
between the minimum and the maximum
temperatures, the duty cycle fluctuates on a scale
that is directly related to the temperature of the
temperature probe.
The ECM performs an automatic calibration of this
sensor whenever the ECM is powered and the
engine has been off for at least five seconds.
The ECM provides short circuit protection for the
internal power supply. A short circuit to the battery
will not damage the internal power supply of the
ECM.
210 UENR4349-03
Circuit Tests

Illustration 73 g06204112
Schematic of the sensor circuit for the PWM sensors

Test Step 1. Inspect the Electrical

Connectors and the Wiring

Illustration 74 g06204117
(1) Exhaust Temperature Sensor Connection

Illustration 75 g01406077
Location of the ECM connector that is for the exhaust
temperature sensors
(3) J2/P2 ECM connectors

1. Thoroughly inspect connectors (1),(2) and (3).

Refer to Troubleshooting, “Electrical Connectors -
Inspect” for details that are related to inspection of
the electrical connectors.
UENR4349-03 211
Circuit Tests

Illustration 78 g01159881
Terminal locations at the connectors for the exhaust
temperature sensor
(Terminal A) Digital sensor supply
(Terminal B) Digital return
(Terminal C) Exhaust temperature

Illustration 76 g06204128
2. Perform a 45 N (10 lb) pull test on each of the
ECM Side wires in the ECM connector and the customer
(4) P2-14 Exhaust Temperature Sensor Return/Ground connector that are associated with the circuit.
(5) P2-29 Exhaust Temperature Sensor Supply
(6) P2-73 Exhaust Temperature Sensor Signal 3. Check the allen head screw on each ECM
connector for the proper torque. refer to
Troubleshooting, “Electrical Connectors - Inspect”
for the correct torque values.
4. Check the harness and the wiring for abrasion and
for pinch points.

Expected Result:
All connectors, pins, and sockets are coupled and/or
inserted, and the harness and wiring are free of
corrosion, of abrasion and of pinch points.

Results:
• OK - The connectors and wiring appear to be OK.
Proceed to Test Step 2.
• Not OK - The connectors and/or wiring are not
OK.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring.
Illustration 77 g06204137 STOP
Terminal locations at the P2 ECM connector that are
for the exhaust temperature sensor
Test Step 2. Check the Supply Voltage at
(P2-29) Exhaust Temperature Sensor Supply
(P2-73) Exhaust Temperature Sensor Signal the Sensor
(P2-14) Exhaust Temperature Sensor Return/Ground
A. Disconnect the exhaust temperature sensor at the
harness connector.
B. Restore electrical power to the ECM. Turn the
keyswitch to the ON position.
212 UENR4349-03
Circuit Tests

C. Measure the voltage across terminal A (digital Note: When the temperature of the sensor probe is
sensor supply) and terminal B (digital return) on the 50 °C (122 °F) the duty cycle output of the sensor is
harness side of the connector. 22 percent. When the temperature of the sensor
probe is 850 °C (1550 °F) the duty cycle output of
D. Remove electrical power from the ECM. Turn the
the sensor is 88 percent.
keyswitch to the OFF position.
E. Restore the wiring to the original configuration. • OK - The frequency and the duty cycle are within
specifications. The sensor is producing a valid
Expected Result: signal. Proceed to Test Step 4.

The supply voltage measures 8.0 ± 0.4 VDC at the • Not OK - The frequency and the duty cycle are
sensor connector. not within specifications.
• Repair - The sensor is not producing a valid
Results: signal. Replace the exhaust temperature sensor.
Verify that the repair eliminates the problem.
• OK - The correct supply voltage is measured at
the sensor connector. The sensor is receiving the • STOP
correct supply voltage. Proceed to Test Step 3.

• Not OK - The voltage is not correct at the sensor Test Step 4. Check the Signal
connector. Frequency and the Duty Cycle at
Repair: There is a problem in the circuit for the digital the ECM
sensor supply that is between the ECM and the
A. Remove the signal wire of the suspect sensor from
exhaust temperature sensor. Repair the circuit. Refer
the P2–73 ECM connector in order to isolate the
to Troubleshooting, “Digital Sensor Supply Circuit - circuit.
Test” for details that are related to troubleshooting a
problem with the circuit. B. Restore electrical power to the ECM. Turn the
keyswitch to the ON position.
STOP
C. Install a 7X-1709 Multimeter Probe (BLACK) into
Test Step 3. Check the Signal Frequency terminal location P2-14 (digital return) at the ECM
connector.
and the Duty Cycle at the Sensor
Note: Ensure that the multimeter probe is in good
A. Disconnect the sensor connector from the exhaust repair. A bent probe may contact other terminals
temperature sensor. inside the connector.
B. Remove the signal wire from terminal C of the D. Measure the duty cycle and the frequency
harness side of the connector for the exhaust between the loose wire and the multimeter probe at
the ECM connector.
temperature sensor.
E. Remove electrical power from the ECM. Turn the
C. Install a 7X-6370 Adapter Cable As (3-PIN keyswitch to the OFF position.
BREAKOUT) at the sensor connector.
D. Connect the sensor to the breakout harness.
Expected Result:
The frequency is between 400 and 600 Hz. The duty
E. Restore electrical power to the ECM. Turn the cycle is between 22 and 88 percent.
keyswitch to the ON position.
Note: When the temperature of the sensor probe is
F. Measure the frequency and the duty cycle between
50 °C (122 °F) the duty cycle output of the sensor is
terminal B (digital return) and terminal C (exhaust
temperature) at the 7X-6370 Adapter Cable As (3- 22 percent. When the temperature of the sensor
PIN BREAKOUT). probe is 850 °C (1550 °F) the duty cycle output of
the sensor is 88 percent.
G. Remove electrical power from the ECM. Turn the
keyswitch to the OFF position. • OK - The frequency and the duty cycle are within
specifications.
H. Remove the breakout harness. Restore the wiring
to the original configuration. • Repair: A valid signal appears at the ECM, but
the ECM is not detecting the signal properly. There
Expected Result: is a problem with the ECM. Replace the ECM.
Refer to Troubleshooting, “ECM - Replace” for
The frequency is between 400 and 600 Hz. The duty details.
cycle is between 22 and 88 percent.
UENR4349-03 213
Circuit Tests

• STOP
• Not Ok The frequency and the duty cycle are not
within specifications.
• Repair: There is not a valid signal at the ECM
connector. Repair the signal wire in the harness
that is between the ECM connector and the
harness connector for the suspect exhaust
temperature sensor. Verify that the repair
eliminates the problem.
• STOP

i07037592

Sensor Supply - Test

SMCS Code: 1439-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with a sensor
supply. Use this procedure if any one of the
diagnostic codes in Table 140 is active or easily
repeated.
Note: Some of the following codes may not be
applicable for certain applications.

Table 140
Diagnostic Codes Table
J1939 Code and Description Comments

678-3
The code is logged.
8 VDC Supply : Voltage Above Normal

678-4
The code is logged.
8 VDC Supply : Voltage Below Normal

3509-3 The code is logged.

5 Volt Sensor DC Power Supply : Voltage Above Normal All sensors are set to default values.

3509-4 The code is logged.

5 Volt Sensor DC Power Supply : Voltage Below Normal All sensors are set to default values.

3510-3 The code is logged.

5 v Sensor DC Power Supply #2 : Voltage Above Normal Engine power may be derated.

3510-4 The code is logged.

5 v Sensor DC Power Supply #2 : Voltage Below Normal Engine power may be derated.

3563-21 The code is logged.

Intake Manifold Pressure Sensor : Data Drifted Low The 5 VDC supply to the sensor has been lost.

5578-21 The code is logged.

Fuel Pressure Sensor - Before Fuel Filter : Data Drifted Low The 5 VDC supply to the sensor has been lost.

5580-21 The code is logged.

Fuel Pressure Sensor - After Fuel Filter : Data Drifted Low The 5 VDC supply to the sensor has been lost.

System Operation
The Electronic Control Module (ECM) supplies a
regulated voltage of 5.0 ± 0.2 VDC to the sensors.
214 UENR4349-03
Circuit Tests

The supply voltage for the sensors is routed from the

ECM to terminal 1 of each sensor connector. The
sensor return for the sensors is routed from the ECM
to terminal 2 of each sensor connector. The ECM
provides short circuit protection for the internal power
supply. A short circuit to the battery will not damage
the internal power supply.
The ECM supplies a regulated voltage of 8.0 ± 0.4
VDC to the digital sensor.
Note: The sensors are not protected from
overvoltage. A short from the supply line to the
+Battery may damage the sensors. If any of the
diagnostic codes are active, a sensor may have been
damaged. Repair the sensor supply and check for
any active sensor diagnostic codes in order to
determine if a sensor has been damaged.

Illustration 79 g01240891
Sensor connector
(1) 5 V or 8 V sensor supply
(2) Sensor return
(3) Signal

Table 141
Sensor Supply Sensor Supply ECM Location

Sensor Supply #1 Sensors on A4:E4 engine ECM J2 connector

Sensor Supply #2 Sensors on A4:E4 engine ECM J1 connector

UENR4349-03 215
Circuit Tests

Illustration 80 g06204614
Schematic for 5 Volt Sensors
216 UENR4349-03
Circuit Tests

Illustration 81 g06204620
Schematic for 8 Volts Sensors

Note: The diagram above is a simplified schematic of

the ECM - relay circuit. The schematic is electrically
correct. However, not all of the possible sensors or
harness connectors are shown. Refer to the latest
revision of the Electrical Schematic for the complete
schematic for your application.
Complete the procedure in the order in which the
steps are listed.
Table 142
Troubleshooting Test Steps Values Results

1. Determine the Code Diagnostic Result: A -3 or -4 code is present.

Codes
A. Connect Cat ® ET to the service tool connector. Refer to Trou- Note which ECM is reporting the active sensor supply code.
bleshooting, “Electronic Service Tools”, if necessary.
Proceed to Test Step 2.
B. Turn the keyswitch to the ON position.
Result: A -21 code is present.
C. Determine if a diagnostic trouble code is present.
Proceed to Test Step 3.

(continued)
UENR4349-03 217
Circuit Tests

(Table 142, contd)

2. Check for a Failed Sensor Failed Result: The suspect sensor supply active code changes to
A. Connect to Cat ET. Sensor logged when a sensor is unplugged.

B. Turn the keyswitch to the ON position. Repair: Replace the failed sensor.

C. Disconnect a sensor on the suspect sensor supply circuit. Verify that the repair resolved the problem.

D. Monitor Cat ET while the sensor is disconnected to see if the ac- Result: The suspect sensor supply active code remains ac-
tive code changes to logged. tive after all sensors on the sensor supply circuit have been
checked.
E. Connect the suspect sensor to the wiring harness
Repair: A failed wiring harness has been detected. Repair
F. Repeat steps C through E for each sensor on the suspect sensor or replace the wiring harness.
supply.
Verify that the repair resolved the problem.

3. Check the Sensor Supply Diagnostic Result: A -4 code is activated on the suspect sensor supply.
Codes
A. Turn the keyswitch to the OFF position. Remove the sensor. Check the sensor passage for a block-
age or obstruction. Also, check for moisture frozen in the
B. Unplug the suspect sensor from the wiring harness. lines.

C. Place a jumper wire between pin 1 and pin 2 on the suspect Repair: If blockage is not found, replace the sensor.
sensor wiring harness connector.
Verify that the repair resolved the problem.
D. Connect to Cat ET.
Result: A -4 code is not activated on the suspect sensor
E. Turn the keyswitch to the ON position. supply.

F. Monitor the diagnostic codes using Cat ET. Repair: The problem is in the wiring from the ECM to the
sensor connector. Repair the wiring or replace the wiring.

Verify that the repair resolved the problem.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07038425

Speed Control - Test

SMCS Code: 7332-038-VF
Use this procedure to troubleshoot a problem with
the throttle position sensor. Also, use this procedure
if one of the following diagnostic codes is active or
easily repeated.
218 UENR4349-03
Circuit Tests

Table 143
J1939 Code and Description Comments
28-3 The Electronic Control Module (ECM) has detected that the analog "0–5
Accelerator Pedal Position 3 : Voltage Above Normal Volt" desired speed signal has exceeded the 4.5 volt trip point.
The setting for the upper diagnostic limit has been exceeded for .6
seconds.
The code is logged.

28-4 The ECM has detected that the analog "0–5 Volt" desired speed signal is
Accelerator Pedal Position 3 : Voltage Below Normal below the .5 volt trip point.
The setting for the lower diagnostic limit has been exceeded for .6
seconds.
The code is logged.

29-3 The ECM has detected that the "PWM" desired speed signal is above the
Accelerator Pedal Position 2 : Voltage Above Normal 95% diagnostic limit.
The alarm output is activated.
The code is logged.

29-4 The ECM has detected that the "PWM" desired speed signal is below the
Accelerator Pedal Position 2 : Voltage Below Normal 5% diagnostic limit.
The alarm output is activated
The code is logged.

29-8 The ECM has detected an erratic signal for the "PWM" desired speed
Accelerator Pedal Position 2 : Abnormal Frequency, Pulse Width, or signal.
Period The alarm output is activated.
The code is logged.

91-3 The ECM detects signal voltage that is not in the acceptable range.
Accelerator Pedal Position 1 : Voltage Above Normal The ECM flags the throttle position as invalid data and a default value is
used. The engine speed is limited to high idle.
The code is logged.

91-4 The ECM detects signal voltage that is not in the acceptable range.
Accelerator Pedal Position 1 : Voltage Below Normal The ECM flags the throttle position as invalid data and a default value is
used. The engine speed is limited to high idle.
The code is logged.

91-8 The PWM signal from the sensor to the ECM is not correct.
Accelerator Pedal Position 1 : Abnormal Frequency, Pulse Width, or The code is logged.
Period
974-5 The ECM detects signal voltage that is not in the acceptable range.
Remote Accelerator Pedal Position : Current Below Normal The ECM flags the throttle position as invalid data and a default value is
used. The engine speed is limited to high idle.
The code is logged.

974-6 The ECM detects signal voltage that is not in the acceptable range.
Remote Accelerator Pedal Position : Current Above Normal The ECM flags the throttle position as invalid data and a default value is
used. The engine speed is limited to high idle.
The code is logged.

For this troubleshooting procedure, the "Desired If using the CAN desired speed input, refer to
Speed Input" configuration parameter can be set to Troubleshooting, “Data Link - Test”.
"4 - 20 mA" input, "PWM" input, or "0-5 Volt"input.
The value of the current, frequency, or voltage
The engine ECM will only monitor the status of the corresponds to a range of desired engine speeds
input signal for the PWM and 0-5 Volt desired speed between minimum high idle and maximum high idle.
inputs. The "Minimum Engine High Idle Speed" and the
"Maximum Engine High Idle Speed" are set with the
The engine ECM does not supply the power and "Service/Configuration" screen of Cat ET. For more
ground for the PWM or 0-5 Volt speed control circuits. information, refer to Troubleshooting, “Configuration
Parameters”.
If an external speed control source device is used,
refer to that devices troubleshooting procedure.
UENR4349-03 219
Circuit Tests

When the idle/rated speed switch is in the Idle

position, a current value of 4.0 mA, 5% duty cycle, or
.5 Volts corresponds to the programmed "Minimum
Engine High Idle Speed". A current value of 20.0 mA,
95% duty cycle, or 4.5 Volts corresponds to
"Maximum Engine High Idle Speed". Desired speed
input values within this range will vary the desired
engine speed in a linear fashion between. The range
will vary between "Minimum Engine High Idle Speed"
and "Maximum Engine High Idle Speed".
The most likely causes of a diagnostic code for this
circuit are a poor connection or a problem in a wiring
harness. The next likely cause is a problem with a
component. The least likely cause is a problem with
the ECM.
220 UENR4349-03
Circuit Tests

Illustration 82 g06205151
UENR4349-03 221
Circuit Tests

Table 144
Troubleshooting Test Steps Values Results

1. Inspect the Electrical Connectors and the Wiring Connectors Result: The connectors and wiring appear to be OK.
and Wiring
A. Turn the main disconnect switch to the OFF position. Proceed to Test Step 2.

B. Thoroughly inspect the connectors. Refer to Troubleshooting, Result: There is a problem with the connectors and/or
Electrical Connectors - Inspect for additional information. wiring.

C. Perform a 45 N·m (33 lb ft) pull test on the connector wires. Repair: Repair or replace the connectors or wiring. Ensure
that all the seals are properly in place and ensure that the
D. Check the harness for abrasions and pinch points. connectors are coupled.

If the problem is not resolved, proceed to Test Step 2.

2. Check for Codes Codes Result: Any of the following codes are active or logged:

A. Connect Cat Electronic Technician (ET) to the service tool - 28-4

connector.
- 29-4
B. Determine if a code is active or logged.
- 91-4

- 91-8

Proceed to Test Step 3.

Result: Any of the following codes are active or logged: Re-

pair or replace the wiring harness.

- 28-3

- 29-3

- 91-3

- 974-6

Proceed to Test Step 7.

Result: A (974-5) code is active or logged.

Proceed to Test Step 9.

(continued)
222 UENR4349-03
Circuit Tests

(Table 144, contd)

Troubleshooting Test Steps Values Results

3. Check the Wiring for an Open Circuit Open Circuit Result: The resistance measured less than 10 ohms.

A. Ensure that the engine control is in the OFF/RESET position. Proceed to Test Step 4.
Ensure that the electrical power is removed from the engine ECM.
Result: The resistance measured more than 10 ohms.
B. Remove the signal wire at the Engine Interface Connector
(EIC), that carries the (PWM or Analog 0-5 Volt) desired speed in- Repair: An open circuit has been detected.
put signal to the engine ECM
Repair or replace the wiring harness.
Refer to Illustration 82 .

C. Perform one of the following:

- For the 29-4, 91-4, and 91-8 disconnect the P1 connector from
the ECM.
- For the 28-4 diagnostic disconnect the P2 connector from the
ECM.

D. Measure the resistance between the following terminals at the

removed ECM connector:

- For the 91-8 and 91-4 codes, ECM terminal P1-66 and terminal
10 on the EIC.
- For the 29-4 code, ECM terminal P1-68 and terminal 4 on the
EIC.
- For the 28-4 code, ECM terminal P2-41 and terminal 58 on the
EIC.

4. Check the Wiring for a Short Circuit to Engine Ground Short Circuit Result: The resistance measured more than 100k ohms.
The signal wire is not shorted to the engine ground.
A. Measure the resistance between the ground strap for the ECM
and the following terminals at the ECM connector. Proceed to Test Step 5.

- For the 91-4 and 91-8 codes, ECM terminal P1-66 and engine Result: The resistance measured less than 100k ohms.
ground. There is a short to engine ground on the signal wire.
- For the 29-4 code, ECM terminal P1-68 and engine ground.
- For the 28-4 code, ECM terminal P2-41 and engine ground. Repair: Repair or replace the wiring harness.

Refer to Illustration 82 .

(continued)
UENR4349-03 223
Circuit Tests

(Table 144, contd)

Troubleshooting Test Steps Values Results

5. Check the Wiring Harness for a Pin to Pin Short Circuit Short Circuit Result: One or more of the measurements were less than
100 K ohms between a connector terminals and any other
A. Turn the main disconnect switch to the OFF position. terminal in the ECM connector.

B. Disconnect the wiring harness form the ECM. Repair: There is a short circuit in the wiring harness.

C. Measure the resistance between the following ECM connector Repair or replace the wiring harness.
terminals:
Result: All measurements were greater than 100 K ohms
- For the 91-4 and 91-8 codes, ECM terminal P1-66 and all other between the affected signal wire pin and all other pins in the
pins in the ECM connector. ECM connector.
- For the 29-4 code, ECM terminal P1-68 and all other pins in the
ECM connector. Repair: The problem is located outside the Caterpillar sys-
- For the 28-4 code, ECM terminal P2-41 and all other pins in the tem wiring circuit. There is an open circuit or short to ground
ECM connector with the wiring or a problem with the speed control device
after the EIC.

Proceed to Test Step 6.

6. Check the Device that Provides the Desired Engine Speed Desired Result: The speed control device is not providing the correct
Signal Speed Signal desired speed input signal.

A. Measure the desired engine speed signal, according to the liter- Repair: Service the device that is providing the desired en-
ature that is provided by the OEM of the device. gine speed signal, according to the literature that is provided
by the OEM of the device.
B. Verify that the correct signal is being provided from the device
as close to the device as possible. Result: The speed control device is providing the correct de-
sired speed signal. The signal measure at the EIC is not
C. Verify that the correct signal is present at the correct EIC correct.
terminal.
Repair: There is an open circuit or short to ground with the
- For the 91-4 and 91-8 codes, EIC terminal 10. wiring in between the speed control device and the EIC.
- For the 29-4 code, EIC terminal 4.
- For the 28-4 code, EIC terminal 58. Refer to Customer system schematics or instruction for addi-
tional information.
Refer to Illustration 82 .
Verify that the repair eliminated the problem.

7. Check the Wiring for a Short Circuit to the +Battery or Short Circuit Result: The -3 or -6 code remains active after the signal wire
Ground is removed from the speed control device providing the de-
sired speed signal.
A. Remove the wires for the desired speed from the speed control
device. Proceed to Test Step 8.

B. Turn the battery disconnect switch to the ON position. Result: The -3 or -6 code is no longer active and has transi-
tioned to logged. A -4 or -5 code is now active.
C. Observe Cat ET for a diagnostic FMI state change.
Repair: Service the device that is providing the desired en-
gine speed signal, according to the literature that is provided
by the OEM of the device.

(continued)
224 UENR4349-03
Circuit Tests

(Table 144, contd)

Troubleshooting Test Steps Values Results

8. Check the Wiring for a Short Circuit to the +Battery or Short Circuit Result: The -3 or -6 code remains active with the signal wire
Ground removed from the EIC. There is a short to a positive voltage
for a -3 code or ground for a -6 code in between the engine
A. Turn the battery disconnect to the OFF position. ECM and the EIC.

B. Remove the wire for desired speed signal from the EIC. Repair: Repair or replace the wiring harness between the
ECM and the EIC.
C. Turn the battery disconnect to the ON position.
Result: The -3 or -6 code is no longer active with the signal
- For the 91-3 code, EIC terminal 10. wire removed from the EIC. There is a short to a positive
- For the 29-3 code, EIC terminal 4. voltage for a -3 code or ground for a -6 code in between the
- For the 974-6 code, EIC terminal 59. EIC and the speed control device.

Repair: Repair or replace the wiring harness between the

EIC and the speed control device.

9. Create a Short Circuit Short Circuit Result: The -5 code remains active after the short circuit
was created on the 4-20 mA (+) and (-) at the connector for
A. Turn the battery disconnect switch to the OFF position. the speed control device. An open circuit is present on the
wiring between the ECM and the speed control device.
B. Remove the connector for the desired speed from the speed
control device. Proceed to Test Step 10.

C. Insert a jumper wire into the terminals to create a short circuit Result: A -6 code is now active. The -5 code is no longer ac-
on the 4-20 mA (+) and (-). tive and has transitioned to logged.

D. Turn the battery disconnect switch to the ON position. Repair: Service the device that is providing the desired en-
gine speed signal, according to the literature that is provided
E. Observe Cat ET for a diagnostic FMI state change. by the OEM of the device.

10. Create a Short Circuit Short Circuit Result: The -5 code remains active after the short circuit
was created on the 4-20 mA (+) and (-) at the OEM side EIC
A. Turn the battery disconnect to the OFF position. connector. An open circuit is present on the wiring between
the Engine ECM and the EIC.
B. Remove the wires for the 4-20 mA desired speed from the
OEM side of the EIC. Repair: Repair or replace the wiring harness between the
Engine ECM and EIC.
C. Install a jumper wire into the OEM EIC terminals.
Result: A -6 code is now active after the short circuit was
D. Turn the battery disconnect switch to the ON position. created on the 4-20 mA (+) and (-) at the OEM side EIC con-
nector. An open circuit is present on the wiring between the
4-20 mA (+) EIC OEM side Terminal 59 EIC and the speed control device.
4-20 mA (-) EIC OEM side Terminal 60
UENR4349-03 225
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).

i07034967

Speed/Timing - Test
SMCS Code: 1912-038
Use this procedure to troubleshoot the electrical
system if a problem is suspected with the primary
engine speed/timing sensor. Also use this procedure
if a problem is suspected with the secondary engine
speed/timing sensor. Use this procedure to
troubleshoot the electrical system if a diagnostic code
in Table 145 is active or easily repeated.
Table 145
Diagnostic Trouble Codes
J1939 Code and Description Comments

The code is logged. The Electronic Control Module (ECM) can default to the
190-8 secondary engine speed/timing sensor. The default will occur if a valid signal
Engine Speed Sensor : Abnormal Frequency, Pulse Width, or is not received from the primary engine speed/timing sensor. The engine will
Period shutdown only if the signals from the primary engine speed/timing sensor
and the secondary engine speed/timing sensor are abnormal.

The code is logged. If a valid signal is not received from the secondary en-
723-8 gine speed/timing sensor, the ECM will default to the primary engine speed/
Secondary Engine Speed Sensor : Abnormal Frequency, Pulse timing sensor. The engine will shutdown only if the signals from the primary
Width, or Period engine speed/timing sensor and the secondary engine speed/timing sensor
are abnormal.

The engine uses two engine speed/timing sensors. After locating the No. 1 cylinder, the ECM triggers
Both sensors detect the reference for engine speed each injector in the correct firing order and at the
and timing from a unique pattern on the camshaft correct unit injector timing. The actual timing and
gear. The ECM uses the pattern of the pulses in duration of each injection is based on engine rpm
order to determine the position of the crankshaft. The and load. If the engine is running and the signal from
ECM measures the time between the pulses that are the primary engine speed/timing sensor is lost, a
created by the sensors as the gears rotate in order to slight change in engine performance will be noticed.
determine rpm. The change will be noticed when the ECM performs
the changeover to the secondary engine speed/
Under normal operation, the secondary engine timing sensor. Loss of the signal from the secondary
speed/timing sensor is used to determine timing for engine speed/timing sensor during engine operation
starting purposes. The secondary engine speed/ will not result in any noticeable change in engine
timing sensor is used to determine when the piston in performance. However, if the signal from the
the No. 1 cylinder is at the top of the compression secondary engine speed/timing sensor is not present
stroke. The primary engine speed/timing sensor is during start-up the following conditions may exist:
then used to determine engine speed and the signal
from the secondary camshaft sensor is ignored. • The engine may require a slightly longer amount
of time to start up.

• The engine may run rough for a few seconds until

the ECM determines the proper firing order by
using the primary engine speed/timing sensor
only.
226 UENR4349-03
Circuit Tests

The engine will start and the engine will run when
only one sensor signal is present from either of the
sensors. Loosing the signal from both of the sensors
during engine operation will result in the termination
of injection. The ECM will then shutdown the engine.
The loss of the signal from both of the sensors during
start-up will prevent the engine from starting.
Both sensors are magnetic sensors with an integral
connector. The two sensors are not interchangeable.
Do not switch the positions of the sensor. If the
sensors are replaced, a timing calibration is not
necessary for the engine.

Illustration 83 g03683458
Schematic for the engine speed/timing sensors

Complete the procedure in the order in which the

steps are listed.
UENR4349-03 227
Circuit Tests

Table 146
Troubleshooting Test Steps Values Results

1. Check the Engine Speed/Timing Circuit Circuit Check Result: The engine started.

A. Connect Caterpillar Electronic Technician (ET) to the service tool Proceed to Test Step 2.
connector. Refer to Troubleshooting, “Electronic Service Tools”, if
necessary. Result: The engine did not start.

B. Turn the keyswitch to the ON position. Proceed to Test Step 3.

C. Monitor the “Engine Starting” screen in Cat ET

D. Start the engine and run the engine. The problem may occur
when the engine is at any operating temperature. However, the prob-
lem is more likely to occur when the engine is at the normal operat-
ing temperature.

2. Check for Diagnostic Codes Diagnostic Result: There is an active diagnostic code or there is a
Codes timing pattern that is “Not Detected” .
A. While the engine is running monitor Cat ET for diagnostic codes.
Also monitor the “Engine Starting” screen for an engine speed/timing Proceed to Test Step 5.
that is “Not Detected” .
Result: There is not an active diagnostic code and there
B. Wait at least 30 seconds for activation of the diagnostic codes. is not a timing pattern that is “Not Detected” .
Look for these codes on Cat ET:
· 190-8 Repair: Download the “Warranty Report” from the engine
· 723-8 ECM. Troubleshoot any diagnostic codes that may be
present.
Return the unit to service.

3. Check the Battery Voltage Battery Result: The battery voltage is OK.
Voltage
A. Monitor the “Engine Starting” screen in Cat ET. Proceed to Test Step 4.

B. Monitor the battery voltage. Crank the engine for 5 seconds. Result: The battery voltage is not OK.

Repair: Refer to Troubleshooting, “Engine Cranks but

Does Not Start”.

4. Check the Engine Speed and the Engine Speed/Timing Status Speed/Timing Result: The sensors show an acceptable cranking
Status speed. The timing pattern shows “Detected” .
A. Monitor the “Engine Starting” screen in Cat ET.
Repair: Refer to Troubleshooting, “Engine Cranks but
B. Crank the engine for 5 seconds. While the engine is cranking, ver- Does Not Start”.
ify that the sensors show an acceptable cranking speed.
Result: A sensor does not show an acceptable cranking
C. While the engine is cranking check the status of the engine speed and/or the timing pattern shows “Not Detected” .
speed/timing.
Proceed to Test Step 5.
228 UENR4349-03
Circuit Tests

Illustration 84 g02227733
Typical left side engine view
(1) Crankshaft speed/timing sensor
UENR4349-03 229
Circuit Tests

Illustration 85 g02227753

(2) Camshaft speed/timing sensor

Table 147
Troubleshooting Test Steps Values Results

5. Inspect the Sensor Assembly Sensor Result: The sensor and the sensor assembly mounting
Inspection are OK.
A. Turn the keyswitch to the OFF position.
Do not reconnect the harness connector. Proceed to Test
B. Visually inspect the sensor and the sensor assembly without re- Step 6.
moving the sensor assembly from the engine. Flanges (2) must be
flush against the surface of the front timing gear housing (1) in order Result: The sensor and/or the sensor assembly has a
to ensure proper operation. mechanical problem or the harness has debris and/or
corrosion.
C. Inspect bracket (3). Verify that the bracket securely holds the
flanges of the sensors flush against the engine. Repair: Repair the sensor and/or the sensor assembly or
replace the sensor and/or the sensor assembly.
D. Verify that the bracket is not bent. If the bracket is bent or if an ob-
struction is preventing the sensor assembly from being installed cor- Repair: Replace the sensor and the sensor harness con-
rectly, the engine will not start. nector if there was debris and/or corrosion.

E. Disconnect the harness from the speed/timing sensors. Check Verify that the problem is resolved.
the harness for debris and for corrosion.

F. Perform a 45 N (10 lb) pull test on the harness wiring.

230 UENR4349-03
Circuit Tests

Illustration 86 g01218763
Terminal locations at the connector for the speed/
timing sensors
(1) Engine speed/timing signal (−)
(2) Engine speed/timing signal (+)

Table 148
Troubleshooting Test Steps Values Results

6. Use a Multimeter to Check the Harness Wiring Check Wir- Result: The voltage was OK for all the measurements.
ing Harness
A. Turn the keyswitch to the ON position. The harness and wiring are OK. Proceed to Test Step
7.
B. Perform the following procedure for each sensor.
Result: The voltage was not OK for at least one of the
1. Measure the voltage between terminal 1 and a good engine ground. measurements.
The voltage is 2.4 ± 0.2 VDC.
There is a problem in the harness wiring.
2. Measure the voltage between terminal 2 and a good engine ground. Repair: Repair the appropriate harness wiring or re-
The voltage is 2.4 ± 0.2 VDC. place the appropriate harness.
Verify that the problem is resolved.

7. Measure the Resistance of the Sensor Sensor Result: The resistance measurement for the sensor is
Resistance within the specification. There is no damage to the sen-
A. Turn the keyswitch to the OFF position. sor tip.

B. Disconnect the engine harness from the sensor. If the engine was running before removing the sensor,
reinstall the sensor.
C. Remove the sensor. Check the sensor tip for any damage. Use Cat ET to check for any active diagnostic codes.
Troubleshoot any active diagnostic codes.
D. For the primary engine speed/timing sensor, measure the resistance Return the unit to service.
between terminal 2 (Primary engine speed/timing +) to terminal 1 (Pri- If the engine was not running before removing the sen-
mary engine speed/timing −). sor, refer to Troubleshooting, “Engine Cranks but Does
Resistance: 75 Ohms to 230 Ohms Not Start”.

E. For the secondary engine speed/timing sensor, measure the resist- Result: The resistance measurement for the sensor is
ance between terminal 2 (secondary engine speed/timing +) to terminal within the specification. There is damage to the sensor
1 (secondary engine speed/timing −). tip.
Resistance: 600 Ohms to 1800 Ohms
Inspect the housing for a cause of the sensor damage.
Make any necessary repairs.
Repair: Replace the sensor assembly.
Verify that the problem is resolved.

Result: The resistance measurement for the sensor is

not within the specification.

Inspect the housing for a cause of the sensor damage.

Make any necessary repairs.
Repair: Replace the sensor assembly.
UENR4349-03 231
Circuit Tests

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).
232 UENR4349-03
Service

Service System Troubleshooting Settings Listed

in the Engine ECM Menu

Engine Emissions Operator Inducement

i06137749
Service Mode Override
Cat ET Service Features The override is used by service technicians to stop
the inducement counter and disable engine
SMCS Code: 0785; 1900 restrictions due to inducement in order to perform
troubleshooting. Once the override is activated,
Override Parameters navigation of other ET functions is possible.
The override parameters screen has multiple This override allows the service technician to disable
overrides. The parameters control various functions the inducement in order to troubleshoot problems.
on the engine. These functions and features allow Factory passwords are required to perform this
the technician to troubleshoot different engine override as the engine will be operating outside of the
systems. emissions window.

Caterpillar® Electronic Technician (Cat Injector Disable Override

ET) Location
This override will allow the user to disable the
injectors from activating when performing certain
1. Connect to Cat ET. troubleshooting procedures.
2. Select the appropriate Electronic Control Module
(ECM)
Active Diagnostic Codes
The purpose of this screen is to show all of the active
3. Select the Diagnostics tab. diagnostic codes.
4. Select the Diagnostic Tests tab.
Cat ET Location
5. Select the Override Parameter tab.
1. Connect to Cat ET.
Override Parameters Listed in the Engine
2. Select the appropriate Electronic Control Module
ECM Menu (ECM)

Engine Exhaust Manifold Bank #1 Flow 3. Select the Diagnostics tab.

Balance Valve Solenoid Override 4. Select the Active Diagnostic Codes tab.

The engine ECM will energize the exhaust balance Tab Functions At Bottom of Screen
valve solenoid to on or off. This override will be used
when troubleshooting the exhaust balance valve.
Reset
System Troubleshooting Settings
This tab will clear specific codes when highlighted.
The “System Troubleshooting Settings” screen will
allow overrides to be enabled.
Reset All
Cat ET Location This tab will reset all of the active codes.

1. Connect to Cat ET and select the appropriate Logged Diagnostic Codes

ECM.
The purpose of this screen is to show all of the
2. Select the Diagnostics tab. logged diagnostic codes.

3. Select the Diagnostic Tests tab. Cat ET Location

4. Select “System Troubleshooting Settings” .
1. Connect to Cat ET.
2. Select the appropriate Electronic Control Module
(ECM)
UENR4349-03 233
Service

3. Select the Diagnostics tab. Tab Functions At Bottom of Screen

4. Select the Logged Diagnostic Codes tab.
Clear
Tab Functions At Bottom of Screen This tab will clear specific codes when highlighted.

Clear Clear All

This tab will clear specific codes when highlighted. This tab will clear all logged diagnostic codes.

Clear All Diagnostic Tests

This tab will clear all logged diagnostic codes. Cat ET diagnostic tests are listed below.

Active Event Codes Cat ET Location

The purpose of this screen is to show all of the active
event codes. 1. Connect to Cat ET and select the appropriate
ECM.
Cat ET Location 2. Select the Diagnostics tab.

1. Connect to Cat ET. 3. Select the Diagnostic Tests tab.

2. Select the appropriate Electronic Control Module Diagnostic Tests Listed in the Engine
(ECM)
ECM Menu
3. Select the Diagnostics tab.
4. Select the Events tab. Injector Solenoid Test
5. Select the Active Events tab. The purpose of the injector solenoid test is to
diagnose injector wiring and injector solenoid
Tab Function At Bottom of Screen functionality.
This test identifies an open circuit or a short circuit in
Reset the circuit for the injector solenoids. The test
activates the injector solenoids one at a time while
This tab will clear specific codes when highlighted. the engine is not running. A good solenoid will create
an audible click when the solenoid is activated. Cat
Reset All ET indicates the status of the solenoid as “OK” ,
“Open” , or “Short” .
This tab will reset all of the active codes. Some of the
event codes will “latch” to active status. Repairing the Cylinder Cutout Test
system will not “unlatch” the event codes and the
event codes must be reset with Cat ET. The cylinder cutout test allows one cylinder or
multiple cylinders to be cut out. The cylinder cutout
Logged Event Codes test is useful when troubleshooting poor engine
performance or a suspected injector failure
The purpose of this screen is to show all of the
logged event codes. The cylinder cutout test disables the injector by not
providing the injector pulse to the solenoid. The
Cat ET Location cylinder cutout test can be performed on one injector
or multiple injectors at once.
1. Connect to Cat ET.
Wiggle Test
2. Select the appropriate Electronic Control Module
(ECM) The purpose of the Wiggle Test is to detect
3. Select the Diagnostics tab. intermittent electrical faults in electronic control
systems. The Wiggle Test function allows the user to
4. Select the Events tab. determine if there is an intermittent wiring problem.
The test will indicate (by changing the value reading)
5. Select the Logged Events tab. which parameter moved beyond a predetermined
range while wiggling the wiring harness, sensor, or
connector.
234 UENR4349-03
Service

This test requires that the engine is OFF and the key Note: Perform the Fuel System Verification Test after
switch is in the ON position (or ECM energized and 0 an injector is replaced. Also perform when a -2 or -7
engine speed). If the engine is started with the wiggle code is active.
test active, the wiggle test will abort.
The Wiggle Test will reduce all ECM requirements to Fuel System Functional Test
trip fault codes, making the diagnostics sensitive.
Under normal operation some fault codes need The Fuel System Functional Test contains four
multiple occurrences before the code will log. But separate tests that evaluate various aspects of the
during this test the fault codes will trip the first time. common rail fuel system. The test is a self-guided
test that will advance to the next test in the series if
The mechanic wiggles and shakes the wiring to see if the current test passes. If a test in series fails, the
codes go active. An audible alarm is also activated if test will abort.
the ECM sees any parameter change state
electrically. Once the test has ended, the ECM • The Fuel Pump Gear Installation Test evaluates if
returns to normal diagnostic state. the high-pressure fuel pump was installed
correctly.
Fuel Rail Pump Solenoid Test • The Low Rail Pressure Fuel Pump Flow Test
checks for leaks at low rail pressure. The test
The high-pressure fuel pump contains two momentarily cuts out pumping and injection and
assemblies for pressurizing fuel. Each assembly measures the resulting rail pressure drop. The test
contains a solenoid. This test checks each solenoid
to make sure that the solenoids are working properly. then calculates the fuel quantity leaving the rail
and compares to the expected results.
During the Fuel Rail Pump Solenoid Test, the ECM
pulses 105-volt to each solenoid. The pulses are sent • The Fuel Rail High Pressure Test checks for fuel
at the proper time and for the correct duration for a leaks at high rail pressure. The test momentarily
given engine load and speed. The ECM monitors the cuts out pumping and injection and measures the
current flow through the circuit for each solenoid. If resulting rail pressure drop. The test then
the current flow is too high or too low, the ECM calculates the fuel quantity leaving the rail and
activates one of the following diagnostic codes: compares to the expected results.
• 1347-5 Engine Fuel Pump Pressurizing Assembly • The High Rail Pressure Fuel Pump Flow Test
#1 : Current Below Normal assesses adequate fuel pump flow. The test
measures rail pressure response during a single
• 1347-6 Engine Fuel Pump Pressurizing Assembly pump event while fuel injection is disabled.
#1 : Current Above Normal
Possible Test Results
• 1348-5 Engine Fuel Pump Pressurizing Assembly
#2 : Current Below Normal • Fuel Pump Not Timed Correctly

• 1348-6 Engine Fuel Pump Pressurizing Assembly • Fuel Pump Flow Too Low
#2 : Current Above Normal
• Fuel Rail High Pressure Decay Too High
Fuel System Verification Test • Fuel Rail Low Pressure Decay Too High
The Fuel System Verification Test compensates for
wear of the internal components of each injector over Calibrations
a time. Internal component wear contributes to lower Cat ET calibrations are listed below.
volumes of fuel being delivered into the cylinder.
Injector wear also increases the amount of leakage
past each injector back to the fuel tank. This test Cat ET Location
evaluates the health of each injector.
1. Connect to Cat ET .
The engine ECM determines whether the injector is
delivering the correct volume of fuel into the cylinder. 2. Select the appropriate Electronic Control Module
Also the engine ECM determines if the injector is (ECM)
delivering a low volume of fuel into the cylinder based
on Valve Closing Time. Valve Closing Time is the 3. Select the Service tab.
difference between the time the engine ECM stops 4. Select the Calibrations tab.
sending current to the injector solenoid and when the
valve returns to the valve seat. When the test is
performed, Cat ET indicates the status of each
injector as “Success” or “Failed” .
UENR4349-03 235
Service

Calibrations Listed in the Engine ECM

Menu

Injector Trim Calibration

Injector trim files calibrate each injector. The injectors
are calibrated so the injectors will deliver a precise
amount of fuel at the exact time needed.
Caterpillar tests each injector to verify the accuracy
of the injector duration and timing. If the injectors do
not pass, the injectors are not used. If the injectors do
pass, trim files are created and the injectors are
installed. The trim file adjusts the duration and timing
of each injector, so the injectors all function the
same. When new injectors are installed, the Illustration 88 g02157717
technician records the serial numbers of each injector
and searches for the injectors in SIS Web. The trim Note: If the injectors fall outside of the main window,
files can be downloaded and stored on a pc. The the injectors are scrapped.
technician loads the trim file for each injector into the
ECM. Air Inlet Temperature Sensor Installation
In Illustration 87 you can see each injector that falls in Calibration
the box is a good injector that passed the tests.
1. Select Air Inlet Temperature Sensor Installation
Calibration and click Start.
2. Click Next and then click Accept.

Illustration 87 g02157706

In Illustration 88 you can see that the trim files have

been applied. The trim files correct the injectors back
to nominal so the injectors all inject the same amount
at the same time.
236 UENR4349-03
Service

Illustration 89 g03147678

3. Click Yes and the engine should be placed under a

relatively high load and high engine speed
operating condition. This load does not
necessarily have to be the highest possible load
the installation could see. If loading the engine is
not possible increase the engine speed to 1800
RPM.
4. Enter the ambient temperature from thermocouple
or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet
Temperature displayed in the window. Measure
the ambient temperature in the shade away from
hot air flow generated from the fan. Make sure to
use Celsius if Cat ET is set up in Celsius.
5. The engine should be placed under a relatively
high load and high engine speed for 2 minutes
then click Next. If loading the engine is not
possible, increase the engine speed to 1800 RPM
for 2 minutes then click Next.
UENR4349-03 237
Service

Illustration 90 g03147742

6. Click Yes and decrease the engine speed to low

idle (600 - 700 RPM) and remove any load from
the engine.
238 UENR4349-03
Service

Illustration 91 g03147748

7. Enter the ambient temperature from thermocouple

or hand held thermometer, then click OK. The
ambient temperature must be below the Air Inlet
Temperature displayed in the window. Measure
the ambient temperature in the shade away from
hot air flow generated from the fan. Make sure to
use Celsius if Cat ET is set up in Celsius.
8. Run the engine at low idle (600 - 700 RPM) and
remove any load from the engine for 2 minutes
and then click Next.
UENR4349-03 239
Service

Illustration 92 g03327553

9. The calibration value has been calibrated. Write

down the calibration so you can enter the
calibration value in the configuration parameters.
Next, click Accept.
240 UENR4349-03
Service

Illustration 93 g03147698

10. Calibration Successful, ignore “Conditions Not 1. Select the Dyno Mode tab.
Met” displayed in above window for Engine Intake
2. Select “Enable” to enable dyno mode.
Manifold Mass Flow Rate. Go to Configuration,
select System Settings and enter the calibrated 3. Return to the Service tab.
value into the Air Inlet Temperature Sensor
4. Select the Service Procedures tab.
Calibration. You will need Factory Passwords to
program this value.

Dyno Mode
Cat ET Location
1. Connect to Cat ET .
2. Select the appropriate Electronic Control Module
(ECM)
3. Select the Service tab.
4. Select the Dyno Mode tab.

Dyno Mode
Dyno Mode is used to run an engine on a dyno
without derates or diagnostic trouble codes tripping
from missing machine components. Normally, while
in chassis an ECM is looking for inputs from various
machine components, like the transmission ECM or
body ECM. If the ECM does not see the inputs, the
ECM assumes that something is wrong and sets a
diagnostic trouble code.
UENR4349-03 241
Service

Illustration 94 g06051935

5. Select the power train Protection Reset ( Available

on select models).
242 UENR4349-03
Service

Illustration 95 g03137155

6. Select “Reset Protection” .

The engine is installed on the dyno and the
technician selects Dyno mode. Dyno mode tells the
engine ECM that the engine is on a dyno and the
ECM ignores all the normal inputs from the machine.
Once in dyno mode, if the engine has multiple power
ratings the highest rating should be selected.
UENR4349-03 243
Service

Illustration 96 g03137154
244 UENR4349-03
Service

Illustration 97 g03137153

Service Procedures Clear All

Cat ET service procedures are listed below. This tab will clear the current histogram data for this
key cycle.
Cat ET Location
Show All Labels
1. Connect to Cat ET.
This labels all bars in the graph.
2. Select the appropriate Electronic Control Module
(ECM)
View Labels on Mouseover
3. Select the Service tab.
This labels each bar in the graph as the mouse
4. Select the Service Procedures tab. pointer is moved over the bar.

Histogram Screens
Tab Functions At Bottom of Screen

Histograms
This tab pulls up the histogram menu.

Clear
This tab is currently not available for Tier 4 engines.
UENR4349-03 245
Service

Screen Shots

Illustration 98 g03137091
The total amount of occurrences.
246 UENR4349-03
Service

Illustration 99 g03137090
The amount of engine hours operated at indicated inlet temperature.

Illustration 100 g03137088

The amount of engine hours operated at indicated coolant temperature.
UENR4349-03 247
Service

Illustration 101 g03137087

The amount of engine hours operated at indicated engine speed.

Illustration 102 g03137086

The amount of engine hours operated at indicated intake manifold air temperature.
248 UENR4349-03
Service

Illustration 103 g03137084

The amount of engine hours operated at indicated intake manifold pressure.
UENR4349-03 249
Service

Illustration 104 g03137081

This screen is used to illustrate load percentage at the current engine speed. This screen can be helpful in
understanding how the engine is being used. The screen can also be used for comparison between similar
machines and/or operators.
250 UENR4349-03
Service

Illustration 105 g03137080

This histogram is populated when the engine system has calculated a condition in which high exhaust
temperatures are present. A fault code will not be logged when the system calculates a high exhaust temperature
condition. But the high exhaust temperature will derate the engine in order to protect the engine system. This action
is normal under most circumstances and no additional troubleshooting is necessary. Refer to Troubleshooting,
“Exhaust Temperature is High” for additional information.
UENR4349-03 251
Service

Illustration 106 g03137079

There are certain engine conditions that put the engine in danger of turbocharger overspeed. The engines are
calibrated and certified up to a certain altitude and ambient temperature limit. If the engine is operated outside this
limit, the engine is more likely to experience turbocharger overspeed. In other words, the turbocharger has to work
harder to maintain the desired boost pressure. This action is normal under most circumstances and no additional
troubleshooting is necessary.

i06138373

Cat ET Service Error Identifiers

SMCS Code: 0785; 1900
Service Error ID's are displayed when the CAT ET
Service test has failed. The Service Error ID's are to
help explain why the service has test failed. There
could be cases when the service test error ID will
isolate the failed component. If applicable use the
appropriate troubleshooting procedure.
Table 149

Service Error Identifiers Description Troubleshooting

Only one service test may be active on a ma-
$0003 Another Service Test is Active
chine or engine at a time.

Another Service test from a different ECM is

$0004 Service Test Active by Another ECM active. Either wait until completed or abort the
test to proceed.

(continued)
252 UENR4349-03
Service

(Table 149, contd)

Service Error Identifiers Description Troubleshooting

There is a communication issue between the
ECM and ET. There is too much data commu-
$0005 Loss of Service Test Interlock nicating across the data link. Disconnect any
other data collecting tools like CANape, CAN-
cases, and Supercom2.

$0006 Service Test Aborted by Tool/Monitor Abort by user, Restart the test if desired

The throttle is depressed or faulty. If the appli-

$101A Incorrect Throttle Position
cation contains a rabbit/turtle, it maybe faulty.

Fuel System Functional Test

$111D Fuel Rail High Pressure Decay Too High

$111E Fuel Rail Low Pressure Decay Too High Refer to Troubleshooting, “Fuel Rail Pressure
is Low”. Refer to Test Step “Perform Fuel Sys-
$111F Fuel Pump Flow Too Low tem Functional Test” .
$1120 Fuel Pump Timing Incorrect

Do not allow engine RPM to fluctuate more

$1108 Excessive Engine RPM Change
than 100 RPM during test.

Coolant temperature must be greater than

$108C Coolant Temp Low
40° C (104° F)

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Fuel rate is too high for the test. Reduce load

$10CB Engine Load Too High
applied to the engine during the test.

Fuel System Verification Test

Fuel rate is too high for the test. Reduce load

$10CB Engine Load Too High
applied to the engine during the test.

Engine must be running during the test, start

$10D0 Engine Has Not Been Running Long Enough
the engine before starting the test.

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Injector Fuel Delivery Test

Fuel rate is too high for the test. Reduce load

$10CB Engine Load Too High
applied to the engine during the test.

Engine must be running during the test, start

$10D0 Engine Has Not Been Running Long Enough
the engine before starting the test.

Coolant temperature must be greater than

$108C Coolant Temp Low
65° C (149° F)

Resolve any active diagnostic codes. Refer to

$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

Check the service tool connection, do not

$0009 Service Test Aborted by ECM abort the test before the test is complete. Re-
peat the test, if necessary.

NOx Sensor Functional Test

(continued)
UENR4349-03 253
Service

(Table 149, contd)

Service Error Identifiers Description Troubleshooting

Resolve any active diagnostic codes. Refer to
$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

$10FC Engine Speed Too High Lower the engine speed to idle.

There was a change in the engine load while

the test was running. Make sure that the en-
$10F5 Excessive Change in Engine Load
gine load is constant while performing the
test.
The engine speed or load is above a thresh-
$1164 Engine Speed/Load Incorrect old, remove the load from the engine or re-
duce the engine speed to idle.

Coolant Diverter Valve Test

Resolve any active diagnostic codes. Refer to
$0002 Active Diagnostic Present
the appropriate troubleshooting procedure.

$0006 Aborted by User The user has aborted the test.

The ECM lost communication with the service

$0009 Test Aborted by ECM
tool.
The engine coolant temperature is too low to
$10A7 Coolant Temperature Too Low start the test. Allow the engine to reach oper-
ating temperature prior to performing the test.

i06138509 To obtain customer passwords, contact the owner of

the engine. If the owner has forgotten the customer
Customer Passwords passwords, factory passwords are used to create
temporary customer passwords. Temporary
SMCS Code: 0785; 1900 customer passwords can be used to change the
original customer passwords or any parameter that is
Customer passwords may be used to protect protected by a customer password. When Cat ET is
customer parameters from being changed. disconnected, you will be prompted to restore the
Caterpillar ® Electronic Technician (Cat ET) can be original customer passwords. If the original
used to change certain parameters. There are some passwords are not restored, the passwords will be
parameters that cannot be changed and there are changed to the temporary passwords.
some applications that do not allow any changes to
the programmable monitoring system. The i04772871
passwords are programmed into the Electronic
Control Module (ECM) with Cat ET. One password Factory Passwords
may be programmed or both passwords may be
programmed. If customer passwords are not SMCS Code: 0785; 1900
programmed, customer parameters may be changed
by anyone.
Note: Factory passwords are only available to
service technicians from an authorized Caterpillar
Dealership. Customers of Caterpillar do not have
access to the Caterpillar Factory Password System
(FPS).
Factory passwords are necessary to authorize
access to certain screens in Caterpillar Electronic
Technician (ET). Factory passwords are also used to
access specific configuration parameters in the
Electronic Control Module (ECM). If changes are
made that require factory passwords, the “Enter
Factory Passwords” dialog box will automatically be
displayed. A factory password must be obtained
before the change can be made.
254 UENR4349-03
Service

A hyperlink is available at the bottom of the dialog order to clear the code from ECM memory. For
box that will simplify the entry of ECM information into example, factory passwords must be obtained in
the FPS. In order to use this hyperlink, the Personal order to clear a code that is related to an engine
Computer (PC) that is running Cat ET must be overspeed condition. Clear these codes only when
connected to the Internet. When the hyperlink is you are certain that the problem has been corrected.
selected, the ECM information will automatically be
transferred to the entry screen on the Caterpillar
FPS. i04772885

If the PC that is running Cat ET is not connected to

the Internet, you may save the ECM information to a ECM Will Not Accept Factory
file. This file can be opened when the PC is Passwords
connected to the Internet and a hyperlink will be
displayed. When you select the hyperlink, the ECM SMCS Code: 0785; 1901
information will automatically be transferred to the
entry screen that is on the Caterpillar FPS.
Probable Causes
Factory passwords may be required to perform each
of the following functions in Cat ET: • Incorrect information for the password request

ECM Replacement – When an ECM is replaced, the • Incorrect passwords

system configuration parameters must be
programmed into the new ECM. The new ECM will Recommended Actions
allow specific parameters to be programmed once
without the use of factory passwords. There may be
parameters that require factory passwords on the Check the Information for the Password
ECM that is being replaced. Factory passwords may Request
be required in order to configure these parameters on
the new ECM. The information for the password request must be
Rerate Engine Power – Changing the interlock code obtained from the Engine Control Module (ECM) that
may be necessary. The interlock code is protected by is being programmed. Do not use information from an
factory passwords. old ECM in order to program factory passwords on a
replacement ECM.

Software Enabled Attachments – Your application Verify that the information used to request the
may have special features that can be enabled with password is identical to the information that is
Cat ET. This customized software is available to displayed on the Caterpillar Electronic Technician
provide enhanced operation for your application. (ET).
These features may also require the installation of
additional hardware on the application. A cost may Engine Serial Number – The engine serial number
be associated with these software enabled must be from the Cat ET screen rather than the
attachments. Factory passwords are necessary to engine information plate.
enable this software.
Reason Code – Use the reason code from the
factory password screen. Reason codes are
Customer passwords – Factory passwords are assigned for specific purposes and reason codes are
required in order to restore customer passwords and not interchangeable.
factory passwords are required in order to reset
customer passwords. Turn the key to the OFF position. Then, turn the
keyswitch to the ON position. Try to enter the
Set Configuration parameters – Factory passwords passwords again.
are required in order to modify specific configuration
parameters. Refer to Troubleshooting, “Configuration Incorrect Passwords
Parameters” for details that are related to the
parameters for your application. Verify that the correct passwords were entered.
Check each character in each password.
If factory passwords are needed in order to change a
parameter, Cat ET will prompt you for the password
when the change is attempted. Newer versions of
Cat ET display an icon of a padlock that is used to
indicate that a parameter requires a factory password
for modification.
Clear engine events and certain diagnostic codes
– Some engine events require factory passwords in
UENR4349-03 255
Service

If rechecking the passwords does not correct the

problem, change a customer parameter. Change the
parameter from the current value to another value
and then change the customer parameter back to the
original value. The sequence of events will change
the total tattletale. The new total tattletale will require
obtaining new factory passwords. Obtain new factory
passwords and enter the passwords.

i06926393

Electronic Service Tool Does

Not Communicate
SMCS Code: 0785; 1900
Use this procedure to solve communication problems
between the Caterpillar ® Electronic Technician (Cat
ET) and the applicable electronic control module
(ECM). Cat ET must communicate with the ECM on
the “Cat Data Link” and on the J1939 data link in
order to service the engine.
Indicators on the communication adapter indicate
that communication is occurring on a particular data
link. The “J1939 / DeviceNet” indicator indicates that
the communication adapter is communicating on the
J1939 data link. The “J1708” indicator indicates that
the communication adapter is communicating on the
“Cat Data Link” . Cat ET displays a message during
the connection if Cat ET cannot communicate on both
data links.
Refer to Special Instruction, REHS8170 for the
proper settings for Tier IV final engines.
The following conditions can cause a communication
problem:
• Incorrect communication adapter

• Incorrect version of Cat ET

• Incorrect firmware in the communication adapter

• Incorrect configuration of Cat ET

• A problem with electrical power to the
communication adapter

• A problem with electrical power to the engine ECM

• A problem with the wiring for a data link

• A problem with the electrical cables between the

PC and the vehicle
256 UENR4349-03
Service

Table 150
Troubleshooting Test Steps Values Results

1. Determine the Communications Problem Communication Result: Both indicators on the communication adapter are not
problem flashing.
A. Determine the communication problem.
If an indicator other than the “POWER” indicator is illumi- Proceed to Test Step 2.
nated when Cat ET is not communicating with an ECM,
disconnect and reconnect the communication adapter. Result: Cat ET indicates that the engine is serviced on both
links.

Proceed to Test Step 2.

Result:Cat ET displays a message that indicates the firmware

in the communication adapter does not support communica-
tion on both data links.

Proceed to Test Step 3.

Result: Cat ET displays an Error “#142 The interface hard-

ware is not responding” message.

Proceed to Test Step 3.

Result:Cat ET displays a message that indicates that Cat ET

cannot find an exact match for the software version in the
ECM.

Repair: Update Cat ET to the latest available version.

Result: The power indicator is not illuminated.

Proceed to Test Step 5.

2. Verify that the Correct Communication Adapter is Communication Result: An incorrect communication adapter is being used.
Being Used Adapter
Repair: Connect a correct communication adapter. Refer to
A. A 317-7484 Communication Adapter Gp must be Troubleshooting, “Electronic Service Tools”, if necessary.
used to with a 370-4617 Cable As (USB) and a
457-6114 Cable As (Datalink Cable CA3) to communi- Attempt to establish communication. Continue with this proce-
cate. The following communication adapters cannot be dure if the communication adapter does not communicate on
used because the communication adapters do not com- both data links.
municate over both data links:
Result: A correct communication adapter is being used. How-
1. Wireless communication adapter ever, the “Power” indicator is not illuminated.

2. 7X-1701 Communication Adapter As Proceed to Test Step 5.

B. Determine the communication adapter that is being Result: A correct communication adapter is being used. The
used. “Power” indicator is illuminated.

Proceed to Test Step 4.

(continued)
UENR4349-03 257
Service

(Table 150, contd)

Troubleshooting Test Steps Values Results

3. Check the Version of the Firmware for the Commu- Firmware Result: Cat ET communicates on both data links.
nication Adapter
The problem is resolved.
The version of the firmware for the communication adapt-
er must be “1.18.47” or higher. Result: Cat ET does not communicate on both data links.
Refer to Special Instruction, REHS8170 for instructions
on how to update the firmware in the Comm Adapter III. Proceed to Test Step 4.

A. Electronically disconnect Cat ET. Verify that the

“power” indicator on the communication adapter is
illuminated.

B. Click on the “Utilities” menu.

C. Click on the “Comm Adapter III Toolkit” menu.

D. Wait for the tool kit to open. Then, click the “Utilities”
menu.

E. Click “Reprogram CA3” .

F. Select the latest “.apf” file from the list.

G. Click “OK” . Then, click “Begin Flash” .

H. Wait for the “Flashes Completed Successfully” mes-

sage to appear.

I. Click “Toolkit” . Verify that the “Software Release Ver-

sion” is “1.18.47” or higher.

J. Attempt to connect Cat ET.

4. Verify That Cat ET is Configured Correctly Configured Correctly Result: Cat ET communicates on both data links.

Cat ET must be configured correctly in order to communi- The problem is resolved.

cate on both data links.
Result: Cat ET does not communicate on both data links. The
A. Click on the “Utilities” menu. “POWER” indicator is not illuminated.

B. Click on the “Preferences” menu. Proceed to Test Step 5.

C. Select the “Communications” tab. Result: Cat ET does not communicate on both data links. The
“POWER” indicator is illuminated.
D. Verify that “Caterpillar Comm Adapter III (RP120)” is
selected. Proceed to Test Step 6.

If “Caterpillar Comm Adapter III (RP120)” is not an option

for selection, the version of Cat ET is incorrect. Version
“2013B” or higher must be used.

Update the version of Cat ET. Then, perform this Test

Step again.

E. Verify that the port is correct.

F. Verify that the “Enable Dual Data Link Service” option

is checked.

(continued)
258 UENR4349-03
Service

(Table 150, contd)

Troubleshooting Test Steps Values Results

G. Click “OK” . Cat ET must reconnect in order for any

changes to be used.

H. Electronically disconnect Cat ET if changes are made

to any of the settings for communications. Electronically
connect Cat ET. Attempt to establish communication. Ob-
serve the indicators on the communication adapter.

A “limited support” warning should not be displayed. The

“J1939 / DeviceNet” indicators should be flashing. The in-
dicator indicates that Cat ET is communicating on both
data links.

Illustration 107 g02061279

Power terminals at the service tool connector
(Terminal A) +Battery
(Terminal B) −Battery
UENR4349-03 259
Service

Table 151
Troubleshooting Test Steps Values Results

5. Check the Electrical Power to the Communication Adapter Electrical Result: Battery voltage is not present at the service tool
Power connector.
A. Check for battery voltage at the service tool connector.
Repair: Inspect the vehicles wiring and fuses. Determine the
cause of the missing voltage. Make the necessary repairs.

Attempt to establish communication after the electrical

power is at the service tool connector.

Proceed to Test Step 6 if the service tool does not communi-

cate on both data links.

Result: Cat ET indicates that the engine is serviced on both

links.

Repair: Verify that the cable between the service tool con-
nector and the communication adapter is OK. Replace the
cable, if necessary.

Repair: Replace the communication adapter if the following

conditions are true:

1. There is power at the cables “DATA LINK” connector.

2. The communication adapters “POWER” indicator is not

illuminated.
260 UENR4349-03
Service

Illustration 108 g03822273

General information about the electrical power to the ECM
UENR4349-03 261
Service

Table 152
Troubleshooting Test Steps Values Results
Electrical
6. Check the Electrical Power to the ECM Power Result: Battery voltage is missing from a P1 terminal.

A. Verify that the keyswitch is ON. Repair: Inspect the vehicles wiring and fuses. Determine
the cause of the missing voltage. Make the necessary
B. Refer to Illustration 108 . Verify that battery voltage is present at repairs.
the terminals that are indicated in the Illustration. Be sure to con-
nect the voltmeter between the “UNSWITCHED +BATTERY” ter- Attempt to establish communication after the electrical
minals and the “-BATTERY” terminals. power is at all of the appropriate P1 terminals. Continue with
this procedure, if necessary.
C. Verify that battery voltage is present at P1-70.
Result: Battery voltage is present at all of the appropriate
P1 terminals.

Proceed to the Test Step 7

6. Try to Establish Communication With a Bypass Harness Harness Result: Cat ET communicates on both data links when the
bypass harness is used. There is a problem with the wiring.
A. Connect the communication adapter to the engine ECM with a
217-0113 Wiring Harness (ECM BYPASS) and a 328-2292 Repair: Repair the data link. Refer to Troubleshooting, “Da-
Harness (ELECTRONIC CONTROL MODULE). The harnesses ta Link - Test”.
support communication on both data links.

B. Attempt to establish communication.

If the procedure did not correct the issue, contact 3. Disconnect the suspect ECM. Temporarily connect
your Cat dealer Technical Communicator (TC). For the test ECM to the engine. Do not mount the test
further assistance, your TC can confer with the ECM on the engine.
Dealer Solutions Network (DSN).
4. Flash program the test ECM with the newest
i04772949 software that is available.
5. Start the “Test ECM Mode” on the electronic
Test ECM Mode service tool. Access the feature through the
SMCS Code: 1900 “Service” menu. The electronic service tool will
display the status of the test ECM and the hours
“Test ECM Mode” is a feature in the software that can that are remaining for the “Test ECM Mode” .
be used to help troubleshoot an engine that may
have a fault in the Electronic Control Module (ECM). Note: “Test ECM Mode” can only be activated if the
This feature allows a standard ECM to be used as a engine serial number has not already been
test ECM. This feature eliminates the need to stock a
test ECM. programmed during normal operation of the ECM. If
the engine serial number is programmed and the
1. Search for the latest flash file for the engine. ECM is not in “Test ECM Mode” , the ECM can never
be used as a test ECM.
Note: If a newer software version is available for the
engine, install the newest software on the suspect 6. Use the “Copy Configuration” feature on the
ECM. If the new software does not eliminate the fault, electronic service tool to program the test ECM.
continue with this procedure.
Note: If the “ECM Replacement” feature cannot be
2. Use the “Copy Configuration” feature on the used, program the test ECM with the values from the
electronic service tool to copy the parameters from “Parameters Worksheet” and the values from the
the suspect ECM. Configuration Parameters.

Note: If the “ECM Replacement” feature cannot be 7. Program the engine serial number into the test
used, record the programmed values into the ECM.
“Parameters Worksheet” . Also record the system
configuration parameters. Note: The “Test ECM Mode” must be activated
before the engine serial number is programmed into
the ECM.
262 UENR4349-03
Service

8. Verify that the test ECM eliminates the fault. Exchanging injectors can help determine if a
combustion problem is in the injector or in the
When the “Test ECM Mode” is activated, an internal cylinder. If two injectors that are currently installed in
timer sets a 24 hour clock. This clock will count down the engine are exchanged between cylinders, the
only while the ECM is powered and the keyswitch is injector trim files can also be exchanged. Press the
in the ON position. After the ECM has counted down “Exchange” button at the bottom of the “Injector Trim
the 24 hour period, the ECM will exit the “Test ECM Calibration” screen on Cat ET. Select the two
Mode” . The parameters and the engine serial injectors that have been exchanged and press the
number will be set. “OK” button. The tattletale for the injectors that were
If the test ECM eliminates the fault, the engine can be exchanged will increase by one.
released while the “Test ECM Mode” is still active. 1. Perform the following procedure to download an
Once an ECM has been activated in the “Test ECM injector trim file from SIS Web. Otherwise, use the
Mode” , the ECM will stay in the “Test ECM Mode” injector trim file from the CD-ROM that is
until the timer times out. Anytime prior to the “Test packaged with the injector.
ECM Mode” timing out, the “Test ECM Mode” can be
reset to 24 hours. Note: The injector serial number and the injector
confirmation code are located on the injector.
If the ECM is used as a test ECM for more than one
engine, reactivate the “Test ECM Mode” in order to
reset the parameters to default values. Then use the a. Record the injector serial number and the
“Copy Configuration” feature to program the injector confirmation code for each injector.
parameters into the test ECM or manually program
the parameters to the correct values. b. Click on Service Software Files in SIS Web.
Then select “Injector Trim Files” .
i04772988
c. Enter the serial number for the injector in the
Injector Trim File - Install search field.

SMCS Code: 1290-591; 7620-012 d. Download the injector trim file to the PC. Repeat
this procedure for each injector, as required.
The Caterpillar Electronic Technician (ET) is used to
load injector trim files into the Engine Control Module 2. Establish communication between Cat ET and the
(ECM). Injector trim files are available from these engine ECM. Refer to Troubleshooting, “Electronic
sources: Service Tools”, if necessary.
• A CD-ROM that is packaged with each new 3. Select the following menu options on Cat ET:
injector and each remanufactured injector
• Service
• SIS Web
• Calibrations
Replacing an Injector
• Injector Trim Calibration
An injector trim file must be loaded into the ECM if an
injector is replaced.
4. Select the appropriate cylinder.
Replacing the ECM 5. Click on the “Change” button.
The “Copy Configuration” utility on Cat ET copies the 6. Select the appropriate injector trim file from the PC
injector trim files between two engine control or the CD-ROM.
modules. If the “Copy Configuration” fails, load all of
the injector trim files manually into the new ECM. 7. Click on the “Open” button.
“Injector Trim” is displayed below a 268-2 or 630-2 8. Enter the injector confirmation code.
Programmed Parameter Fault : Erratic, Intermittent,
or Incorrect. The diagnostic code is displayed on Cat 9. Click on the “OK” button.
ET.
The injector trim file is loaded into the ECM.
Exchanging Injectors
UENR4349-03 263
Service

10. Repeat the procedure for each cylinder, as

required.

i07046901

ECM Software - Install

SMCS Code: 1901-591; 7620-012
Use this procedure to troubleshoot the electrical
system if the diagnostic code in Table 153 is active.
Table 153
Diagnostic Trouble Codes

J1939 Code and Description Comments

The flash file is for a different engine family or for a different engine
631-2 application.
Personality Module : Erratic, Intermittent, or Incorrect The engine will not start. Clearing this diagnostic code requires fac-
tory passwords. The personality module code must be reset to zero.

Flash programming is a method of programming or

updating the flash file in the engine Electronic Control
Module (ECM). Caterpillar Electronic Technician (ET)
is used to flash program a file into the memory of the
engine ECM.
Note: Customer versions of CAT ET do not have the
capability for flash programming. Consult your local
Cat Dealer for assistance.
If you do not have the flash file, use the “Flash File
Search” tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine.
Alternatively, use the “Service Software Files” feature
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write
down the name of the flash file for future reference.
264 UENR4349-03
Service

Table 154
Troubleshooting Test Steps Values Results

1. Programming a Flash File Programmed Result: The flash programming was successfully.
successfully
A. Establish communication between Cat ET and the Return the unit to service.
engine ECM.
Result: The flash programming was not successfully.
B. Select “WinFlash” from the “Utilities” menu on Cat
ET. Repair any active diagnostic or event codes. Proceed to Test
If “WinFlash” will not communicate with the ECM, refer Step 2.
to Troubleshooting, “Electronic Service Tool Does Not
Communicate”.

C. Program the flash file into the ECM.

D. Select the engine ECM under the “Detected ECMs” .

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

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

F. When the correct flash file is selected, press the

“Open” button.

G. Verify that the “File Values” match the application. If

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

H. When the correct flash file is selected, press the “Be-

gin Flash” button.

I. Cat ET will indicate when flash programming has

been successfully completed.

J. Start the engine and check for proper operation. Re-

pair any active diagnostic or event codes.

2. “ WinFlash”” Error Messages Error messages Result: There are no error messages.

A. If you receive any error messages during flash pro- Return the unit to service.
gramming, click on the “Cancel” button in order to stop
the process. Access the information about the “ECM
Summary” under the “Information” menu. Make sure
that you are flashing the correct file for your engine.

B. Record all error messages. The recorded error mes-

sages will be necessary if further assistance is needed.

Complete the procedure in the order in which the

steps are listed.
UENR4349-03 265
Service

If the procedure did not correct the issue, contact Note: The injector serial numbers and the injector
your Cat dealer Technical Communicator (TC). For confirmation code are necessary for obtaining the
further assistance, your TC can confer with the correct injector trim files. The injector serial number
Dealer Solutions Network (DSN). and the injector confirmation code are located on the
injector. The ECM uses the injector trim files in order
i06153359 to compensate for manufacturing variations between
individual injectors. If you replace any of the unit
ECM - Replace injectors, you must reprogram the injector trim files
for the new injectors. Also, if you replace the ECM,
SMCS Code: 1901-510 the injector trim files must be installed into the new
ECM. A successful “Copy Configuration” process will
accomplish this task. For more instruction, refer to
NOTICE
Care must be taken to ensure that fluids are con- Troubleshooting, “Injector Trim File - Install”.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 2. Use the “Copy Configuration/ECM Replacement”
Be prepared to collect the fluid with suitable contain- feature that is found under the “Service” menu on
ers before opening any compartment or disassem- Cat ET. Select “Load from ECM” in order to copy
bling any component containing fluids. the configuration from the suspect ECM.
Refer to Special Publication, NENG2500, “Dealer Note: If the “Copy Configuration” process fails and
Service Tool Catalog” for tools and supplies suitable the parameters were not obtained in Step 1, the
to collect and contain fluids on Cat ® products.
parameters must be obtained elsewhere. Some
Dispose of all fluids according to local regulations parameters are stamped on the engine information
and mandates. plate, but most parameters must be obtained from
the factory.

NOTICE 3. Remove the ECM from the engine.

Keep all parts clean from contaminants.
a. Remove the electrical power from the ECM.
Contaminants may cause rapid wear and shortened
component life. b. Disconnect the J1/P1 and J2/P2 ECM
connectors.
The Electronic Control Module (ECM) contains no
moving parts. Replacement of the ECM can be NOTICE
costly. Replacement can also be a time consuming Use a suitable container to catch any fuel that might
task. Follow the troubleshooting procedures in this spill. Clean up any spilled fuel immediately.
manual in order to ensure that replacing the ECM will
correct the problem and that the ECM is the cause of
the problem.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
Note: Ensure that the ECM is receiving power and
clean the area around a fuel system component that
that the ECM is properly wired to the negative battery will be disconnected. Fit a suitable cover over discon-
circuit before you attempt to replace the ECM. Refer nected fuel system component.
to Troubleshooting, “Electrical Power Supply - Test”.

c. Remove the fuel lines (if equipped) from the

NOTICE
If the flash file and engine application are not ECM.
matched, engine damage may result.
d. Remove the mounting bolts from the ECM.

Perform the following procedure in order to replace e. Disconnect the ECM ground strap from the
the ECM: engine.
1. Print the parameters from the “Configuration” 4. Install the replacement ECM.
screen on Caterpillar Electronic Technician (ET). If
a printer is unavailable, record all of the a. If the old mounting hardware is in good repair,
parameters. Record any logged diagnostic codes you can use the old mounting hardware to install
and logged event codes for your records. Record the replacement ECM.
the injector serial numbers from the “Calibrations”
b. Reconnect the fuel lines (if equipped).
screen under the “Service” menu on Cat ET.
c. Ensure that the ECM mounting hardware is
installed correctly. The rubber grommets are
266 UENR4349-03
Service

used to protect the ECM from excessive 9. Check for an active diagnostic code for timing
vibration. The ECM must be able to drift in the calibration.
rubber grommets. If the installation is equipped
If the diagnostic code is active, calibrate the
with fuel lines, the fuel lines must not put tension injection timing. Refer to calibration procedures
on the ECM. If the ECM cannot be moved Troubleshooting, “Timing - Calibrate”.
slightly in the grommets, check that the fuel lines
are not pulling the ECM against one side of the 10. Check for diagnostic codes and for event codes.
grommets.
i07044583
d. Connect the ECM ground strap.
Timing - Calibrate
e. Connect the J1/P1 and J2/P2 ECM connectors.
Tighten the allen head screw on each of the SMCS Code: 1000-524; 1900-524; 1912-524
ECM connectors to the proper torque. Refer to
Use this procedure if the diagnostic code in Table
Troubleshooting, “Electrical Connectors - 155 is active.
Inspect” for the correct torque value.
5. Install the ECM software. Refer to
Troubleshooting, “ECM Software - Install”.
6. If the replacement ECM was used previously for a
different application, obtain factory passwords in
order to reset the interlock codes.
7. Configure the ECM.

a. If the “Load from ECM” process from Step 2 was

successful, return to the “Copy Configuration/
ECM Replacement” screen on Cat ET and
select “Program ECM” .
After using the “Program ECM” feature, be
sure to cycle the power to the ECM. Wait at
least 30 seconds after turning the keyswitch to
the OFF position.
Note: Some control modules have a power off
delay. The 30 seconds will be sufficient to cover
this delay.

b. If the “Program ECM” process was successful,

proceed to Step 7.d.

c. If the “Program ECM” process was

unsuccessful, manually program the ECM
parameters into the replacement ECM. The
parameters must match the parameters from
Step 1.

Note: If the “Copy Configuration” process fails and

the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
plate, but most parameters must be obtained from
the factory.

d. If necessary, program the engine monitoring

system.
8. If necessary, install the injector trim files. Refer to
Troubleshooting, “Injector Trim File - Install”.
UENR4349-03 267
Service

Table 155
Diagnostic Trouble Codes

J1939 Code and Description Comments

637-11
The wiring to the sensors has the wrong polarity.
Engine Timing Offset Fault

A timing calibration is required for a new engine, replacing an Electronic

637-13
Control Module (ECM) that fails to communicate or following work on the
Engine Timing Calibration : Calibration Required
front gear train, the camshaft, or the crankshaft.

If a 637-11 diagnostic code is active, verify that the

wiring is installed correctly to the engine speed/timing
sensors.
The ECM can calibrate the mechanical differences
between the Top Center (TC) of the flywheel and the
TC of the timing gear on the camshaft. A transducer
signals the TC of the flywheel to the ECM when a
notch on a counterweight passes by the transducer.
The engine speed/timing sensor signals the TC of the
timing gear to the ECM. Any offset between the TC of
the flywheel and the TC of the timing gear is stored
into the memory of the ECM.
Note: A timing calibration will not increase the
available engine power.
Table 156 lists the special tools that are required in
order to perform this procedure.
Table 156
Required Special Tools

Part Number Description

Illustration 109 g03822694
7X-1171 Transducer Adapter
(A) Timing mark
6V-2197 Transducer (B) Idler gear

7X-1695 Cable as

170-3519 Harness (1)

(1) This item is not required if the engine harness has a connector
for timing calibration.

Table 157
Troubleshooting Test Steps Values Results

A. If the engine is at TDC for cylinder 6, remove cam idler gear (B) Diagnostic code Result: After starting the engine the code is still
and rotate the crankshaft 360 degrees and repin the flywheel. present.

B. Install idler gear (B). Proceed to Test Step 2.

C. Check timing mark (A). Result: After starting the engine the code did not
return.
D. Rotate the engine by hand 360° to ensure that the engine rotates
freely. If the engine does not rotate freely, the engine is not timed Return the unit to service.
correctly. Remove the front housing and check all timing marks. Re-
fer to Testing and Adjusting, “Gear Group (Front) - Time” for the cor-
rect procedure.

E. Connect to Cat ET and clear the DTC.

F. Start the engine.

268 UENR4349-03
Service

Table 158
Crankshaft Rotation
Engine Model Number of Degrees Direction of Rotation
C9.3 85 Normal Rotation

Table 159
Location of the Timing Calibration Port

Engine Model Crankshaft Counterweight Engine Location

C9.3 3 Left Side

Table 160
Troubleshooting Test Steps Values Results

2. Install the Transducer Adapter Transducer Result: The transducer adapter was installed.
adapter
A. Remove the electrical power from the ECM. Proceed to Test Step 3.

B. Use the appropriate engine turning tool to put either the No. 1
piston or the No. 6 piston at the top center. Refer to the Systems
Operation/Testing and Adjusting.

C. Refer to Table 158 . After the top center position has been lo-
cated, rotate the crankshaft for the number of degrees that is appli-
cable to your engine model. Be sure to rotate the crankshaft in the
direction of rotation that is specified in the Table.

D. Refer to Table 159 . Locate the engines timing calibration port.

E. Remove the plug from the timing calibration port.

F. Thread the transducer adapter into the port

3. Install the Transducer Transducer Result: The transducer was installed.

If the crankshaft is not in the correct position when the trans- Proceed to Test Step 4.
ducer is installed, the transducer will be damaged when the en-
gine is started.

A. Apply clean engine oil to a 2D-6392 O-Ring Seal. Install the O-

ring seal on the end of the 6V-2197 Transducer.

B. Push the transducer through the transducer adapter until the

transducer contacts the crankshaft counterweight.

C. Withdraw the transducer 1.0 mm (0.04 inch) and hand tighten

the nut on the adapter sleeve in order to secure the transducer.
Move the O-ring seal against the adapter.
UENR4349-03 269
Service

Illustration 110 g03341373

Engine Control Module

Table 161
Terminal Locations for Connection of the 170-3519 Harness
ECM Type ADEM 4

Connector P2
Timing Calibration + 26
(White)
(Terminal 1) Location

Timing Calibration - 36
(Yellow)
(Terminal 2) Location
270 UENR4349-03
Service

Table 162
Troubleshooting Test Steps Values Results

4. Connect the 7X-1695 Cable as Wiring Result: The wiring is installed correctly.

A. If the engine harness is equipped with a connector for timing cali- Proceed to Test Step 5.
bration, connect the 7X-1695 Cable as to the connector for timing
calibration and to the transducer.

B. If the engine harness is not equipped with a connector for timing

calibration, or the connector is not easily accessible, a connector
can be installed. The connector can be installed on either ECM
connector.

C. Refer to Illustration 110 to determine the type of engine ECM. Al-

so, determine the ECM connector that is easily accessible.

D. Refer to Table 161 to determine the proper terminal locations for

the connector that is easily accessible.

E. Remove the sealing plugs from the appropriate terminals. Do not

discard the sealing plugs. The sealing plugs may be reinstalled
when the timing calibration is complete.

F. Install the WH(White)wire of the 170-3519 Harness into the ap-

propriate location.

G. Install the YL(Yellow)wire of the 170-3519 Harness into the ap-

propriate location. Disregard the pin-outs on the label of the
harness.

H. Ensure that each wire is installed into the correct location. The
timing calibration will not be successful if the wires are installed
incorrectly.

5. Check for Diagnostic Codes Diagnostic Result: There are active codes other than a 637-13 di-
codes agnostic code.
A. Connect Caterpillar Electronic Technician (ET) to the service tool
connector. Refer to Troubleshooting, “Electronic Service Tools”. Troubleshoot the active diagnostic other than the 637-
13 diagnostic codes.
B. Start the engine and run the engine until the engine is at the nor-
mal operating temperature. Result: There are no active codes other than a 637-13
diagnostic code.
C. Check for active diagnostic codes. Wait at least 30 seconds in or-
der for the codes to become active. Proceed to Test Step 6.

The engine must not have any active diagnostic codes during
the timing calibration except for a 637-13 diagnostic code.

6. Calibrate the Timing Timing Result: The timing calibration was successful.
calibration
A. After the engine has warmed up, access the “Timing Calibration” Return the unit to service.
screen on the Cat ET. Access the following display screens in order:
Result: The timing calibration was not successful.
· Service
The following conditions can cause the timing calibra-
· Calibrations tion to fail:

· Timing Calibration 1. The crankshaft and camshaft gears have been reas-
sembled incorrectly.

(continued)
UENR4349-03 271
Service

(Table 162, contd)

Troubleshooting Test Steps Values Results
B. Set the engine speed to 1100 ± 50 rpm. The engine speed must
be steady within this rpm range in order for the calibration to be 2. The timing calibration probe is not installed correctly.
successful.
3. The engine speed is not correct and the engine
C. To calibrate the timing, select “Continue” on Cat ET. Wait until speed is unstable. If the engine speed is unstable, refer
Cat ET indicates that the timing is calibrated. to Troubleshooting, “Engine Misfires, Runs Rough, or Is
Unstable”.
D. Perform the following procedure if Cat ET indicates that the tim-
ing is calibrated: 4. There is a problem with the transducer or with the ca-
bles. Obtain a new transducer and/or a new cable and
1. Set the engine speed to low idle. repeat the timing calibration.

2. Disconnect the 7X-1695 Cable as before you exit the “Timing 5. There is an active 190-8 code or an active 723-8
Calibration” screen. Otherwise, diagnostic codes may be activated. code. Troubleshoot the active codes before calibration.

3. Exit the “Timing Calibration” screen on Cat ET. Correct any of the above conditions and repeat the cali-
bration procedure.
4. Remove the electrical power from the ECM.

5. Remove the transducer and remove the transducer adapter.

6. Install the plug into the timing calibration port.

7. If you installed a 170-3519 Harness, you may remove the har-

ness or you may permanently install the harness for future use. If
you remove the harness, install the sealing plugs into the unused
cavities of the ECM connector. Otherwise, moisture and debris will
enter the connector.

8. If you permanently installed the harness, fasten the harness to

the existing engine wiring harness with cable ties. Also, install a
3E-3364 Receptacle and two 8T-8737 Seal Plugs on the P400
timing calibration probe connector in order to prevent moisture and
debris from entering the connector.

If the procedure did not correct the issue, contact

your Cat dealer Technical Communicator (TC). For
further assistance, your TC can confer with the
Dealer Solutions Network (DSN).
272 UENR4349-03
Index Section

Index
A D
Acceleration Is Poor or Throttle Response Is Data Link - Test ................................................. 159
Poor .................................................................33 Diagnostic Capabilities ........................................14
Probable Causes .............................................33 Diagnostic Codes.............................................14
Recommended Actions ....................................33 Diagnostic Trouble Codes....................................22
Alternator Problem (Charging Problem and/or Active Diagnostic Codes...................................32
Noisy Operation) ...............................................36 Diagnostic Codes.............................................31
Probable Causes .............................................36 Logged Diagnostic Codes.................................32
Recommended Actions ....................................36
E
B
ECM - Replace ................................................. 265
Battery Problem ..................................................37 ECM Software - Install ....................................... 263
Probable Causes .............................................37 ECM Will Not Accept Factory Passwords ............ 254
Recommended Actions ....................................38 Probable Causes ........................................... 254
Recommended Actions .................................. 254
Electrical Connectors ..........................................15
C Connectors for the Electronic Control Module
Cat ET Service Error Identifiers .......................... 251 (ECM) ...........................................................15
Cat ET Service Features.................................... 232 Injector Connectors..........................................16
Active Diagnostic Codes................................. 232 Sensor Connectors ..........................................17
Active Event Codes........................................ 233 Electrical Power Supply - Test ............................ 166
Calibrations ................................................... 234 Electronic Service Tool Does Not Communicate .. 255
Diagnostic Tests ............................................ 233 Electronic Service Tools.........................................5
Dyno Mode.................................................... 240 Cat ®Electronic Technician (Cat ET) ....................6
Histogram Screens ........................................ 244 Optional Service Tools........................................6
Logged Diagnostic Codes............................... 232 PL1000E Communication ECM (If Equipped).....10
Logged Event Codes...................................... 233 Service Tools.....................................................5
Override Parameters...................................... 232 Electronic System Overview.................................12
Service Procedures........................................ 244 Engine Cranks but Does Not Start ........................58
System Troubleshooting Settings .................... 232 Probable Causes .............................................59
Circuit Tests...................................................... 156 Recommended Actions ....................................60
Component Location ...........................................13 Engine Does Not Crank .......................................62
Configuration Parameters ....................................19 Engine Has Early Wear........................................64
Check Programmable Parameters (630-2).........21 Probable Causes .............................................64
Coolant Contains Fuel .........................................38 Recommended Actions ....................................64
Probable Causes .............................................38 Engine Has Mechanical Noise (Knock) .................66
Recommended Actions ....................................38 Probable Causes .............................................66
Coolant Contains Oil ...........................................39 Recommended Actions ....................................66
Probable Causes .............................................39 Engine Misfires, Runs Rough or Is Unstable..........70
Recommended Actions ....................................39 Probable Causes .............................................70
Coolant Level - Test........................................... 156 Recommended Actions ....................................70
Coolant Level Is Low ...........................................42 Engine Monitoring System ...................................13
Probable Causes .............................................42 Viewing or Changing the Settings of the Monitoring
Recommended Actions ....................................42 System..........................................................14
Coolant Pressure Is Low ......................................43 Engine Overcrank Occurrence .............................72
Coolant Temperature Is High................................45 Probable Causes .............................................73
Probable Causes .............................................46 Recommended Actions ....................................73
Recommended Actions ....................................46 Engine Overspeeds.............................................76
Coolant Temperature Is Low ................................48 Probable Causes .............................................77
Probable Causes .............................................49 Recommended Actions ....................................77
Recommended Actions ....................................50 Engine Stalls at Low RPM....................................77
Crankcase Fumes Disposal Tube Has Oil Probable Causes .............................................77
Draining............................................................51 Recommended Actions ....................................77
Probable Cause...............................................51 Engine Top Speed Is Not Obtained .......................79
Recommended Actions ....................................52 Probable Causes .............................................79
Crankcase Pressure Is High.................................53 Recommended Actions ....................................80
Probable Causes .............................................54 Engine Vibration Is Excessive ..............................82
Recommended Actions ....................................54 Probable Causes .............................................82
Customer Passwords ........................................ 253 Recommended Actions ....................................82
Cylinder Is Noisy .................................................56 Exhaust Has Excessive Black Smoke ...................83
Probable Causes .............................................56 Recommended Actions ....................................83
Recommended Actions ....................................56 Exhaust Has Excessive White Smoke...................85
UENR4349-03 273
Index Section

Probable Causes .............................................85 Oil Filter Differential Pressure Problem ............... 139
Recommended Actions ....................................85 Probable Causes ........................................... 140
Exhaust System Contains Coolant........................88 Recommended Actions .................................. 140
Probable Causes .............................................88 Oil Level Is Low................................................. 141
Recommended Actions ....................................88 Recommended Actions .................................. 141
Exhaust System Contains Oil ...............................89 Oil Pressure Is Low ........................................... 142
Probable Causes .............................................89 Probable Causes ........................................... 143
Recommended Actions ....................................89 Recommended Actions .................................. 144
Exhaust Temperature Is High ...............................91 Oil Temperature Is High ..................................... 146
Probable Causes .............................................91 Probable Causes ........................................... 147
Recommended Actions .................................. 147
F
P
Factory Passwords............................................ 253
Fuel Consumption Is Excessive............................94 Power Is Intermittently Low or Power Cutout Is
Probable Causes .............................................94 Intermittent...................................................... 148
Recommended Actions ....................................94 Probable Causes ........................................... 148
Fuel Filter Is Restricted ........................................96 Recommended Actions .................................. 148
Probable Causes .............................................97
Fuel Injection Pump - Test.................................. 169
Fuel Level - Test................................................ 174 R
Fuel Pressure Is High ..........................................98 Relay - Test (Start Relay) ................................... 191
Fuel Pressure Is Low ......................................... 102
Fuel Priming Pump - Test................................... 176
Fuel Rail Pressure Is Low .................................. 106 S
Troubleshooting Procedure............................. 107
Fuel Rail Pressure Is Low While Cranking ........... 111 Sea Water Pump Pressure Problem ................... 151
Fuel Rail Pressure Leakage Is High .................... 117 Probable Causes ........................................... 151
Fuel Temperature Is High................................... 122 Recommended Actions .................................. 151
Probable Causes ........................................... 122 Sensor Calibration Required - Test ..................... 193
Recommended Actions .................................. 122 Sensor Signal (Analog, Active) - Test .................. 196
Sensor Signal (Analog, Passive) - Test ............... 204
Sensor Signal (PWM) - Test ............................... 208
G Expected Result: ....................................211–212
Test Step 1. Inspect the Electrical Connectors and
General Information ..............................................4 the Wiring .................................................... 210
Application Interface ..........................................4 Test Step 4. Check the Signal Frequency and the
Electronic Control System ..................................4 Duty Cycle at the ECM.................................. 212
Fault Detection and Reporting.............................4 Sensor Supply - Test ......................................... 213
Important Safety Information...............................4 Service............................................................. 232
Overview...........................................................4 Service Information Report ..................................10
Troubleshooting.................................................4 Recommendations...........................................10
Speed Control - Test.......................................... 217
I Speed/Timing - Test .......................................... 225
Symptom Troubleshooting ...................................33
Important Safety Information ..................................2 System Overview ................................................12
Indicator Lamp Problem..................................... 127 Other ECM Functions for Performance ..............12
Probable Causes ........................................... 127 Passwords ......................................................13
Recommended Actions .................................. 127 Programmable Parameters...............................13
Injector Solenoid - Test ...................................... 182 System Operation ............................................12
Injector Trim File - Install .................................... 262
Inlet Air Is Restricted ......................................... 127
Intake Manifold Air Pressure Is Low .................... 128 T
Intake Manifold Air Temperature Is High.............. 131 Table of Contents ..................................................3
Introduction ..........................................................4 Test ECM Mode ................................................ 261
Timing - Calibrate .............................................. 266
O Troubleshooting Section ........................................4

Oil Consumption Is Excessive ............................ 133

Probable Causes ........................................... 133 V
Recommended Actions .................................. 133 Valve Lash Is Excessive .................................... 152
Oil Contains Coolant ......................................... 135 Probable Causes ........................................... 152
Probable Causes ........................................... 135 Recommended Actions .................................. 152
Recommended Actions .................................. 135 Valve Rotator or Spring Lock Is Free................... 154
Oil Contains Fuel .............................................. 138 Probable Cause............................................. 154
Probable Causes ........................................... 138 Recommended Actions .................................. 154
Recommended Actions .................................. 138
274 UENR4349-03
Index Section

W
Welding Precaution ...............................................5
UENR4349 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2018 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

276 January 2018