RENR5089-23

March 2012

Troubleshooting
C7 and C9 Engines for Excavators

SAFETY.CAT.COM
 i03991620

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5089-23 3
Table of Contents

Table of Contents Low Power/Poor or No Response to Throttle .......

Mechanical Noise (Knock) in Engine ....................
51
53
Noise Coming from Cylinder ................................. 53
Poor Acceleration or Response ............................ 54
Troubleshooting Section Poor Acceleration or Response ............................ 55
Electronic Troubleshooting
Troubleshooting with a Diagnostic Code
System Overview .................................................... 5
Diagnostic Codes .................................................. 58
Electronic Service Tools .......................................... 6
CID 0001 FMI 05 Cylinder #1 Injector open
Replacing the ECM ............................................... 10
circuit ................................................................... 59
Self-Diagnostics .................................................... 12
CID 0001 FMI 06 Cylinder #1 Injector short ......... 59
Sensors and Electrical Connectors ....................... 13
CID 0002 FMI 05 Cylinder #2 Injector open
Sensors and Electrical Connectors ....................... 16
circuit ................................................................... 59
Engine Wiring Information .................................... 17
CID 0002 FMI 06 Cylinder #2 Injector short ......... 60
CID 0003 FMI 05 Cylinder #3 Injector open
Programming Parameters
circuit ................................................................... 60
Programming Parameters ..................................... 19
CID 0003 FMI 06 Cylinder #3 Injector short ......... 60
Test ECM Mode .................................................... 19
CID 0004 FMI 05 Cylinder #4 Injector open
Factory Passwords ............................................... 20
circuit ................................................................... 61
Flash Programming .............................................. 20
CID 0004 FMI 05 Cylinder #4 Injector open
Injector Trim File ................................................... 21
circuit ................................................................... 61
Service Information Report ................................... 21
CID 0004 FMI 06 Cylinder #4 Injector short ......... 61
CID 0005 FMI 05 Cylinder #5 Injector open
System Configuration Parameters
circuit ................................................................... 61
System Configuration Parameters ........................ 23
CID 0005 FMI 06 Cylinder #5 Injector short ......... 62
CID 0006 FMI 05 Cylinder #6 Injector open
Troubleshooting without a Diagnostic Code
circuit ................................................................... 62
Alternator (Charging Problem and/or Noisy
CID 0006 FMI 06 Cylinder #6 Injector short ......... 62
Operation) ........................................................... 26
CID 0041 FMI 03 8 Volt DC Supply short to +batt .. 63
Battery .................................................................. 26
CID 0041 FMI 04 8 Volt DC Supply short to
Can Not Reach Top Engine RPM ......................... 26
ground ................................................................. 63
Coolant in Engine Oil ............................................ 28
CID 0042 FMI 05 Injector Actuation Valve open
Coolant Temperature Is Too High ......................... 28
circuit ................................................................... 63
ECM Will Not Accept Factory Passwords ............. 30
CID 0042 FMI 06 Injector Actuation Valve short to
ECM Will Not Communicate with Other Systems or
ground ................................................................. 63
Display Modules .................................................. 30
CID 0091 FMI 08 Throttle Position signal
ECM Will Not Communicate with Other Systems or
abnormal ............................................................. 64
Display Modules .................................................. 31
CID 0094 FMI 03 Fuel Pressure open/short to
Electronic Service Tool Will Not Communicate with
+batt .................................................................... 64
ECM .................................................................... 31
CID 0094 FMI 04 Fuel Pressure short to ground .. 64
Engine Cranks but Will Not Start .......................... 32
CID 0100 FMI 03 Engine Oil Pressure open/short to
Engine Has Early Wear ........................................ 34
+batt .................................................................... 65
Engine Misfires, Runs Rough or Is Unstable ........ 34
CID 0100 FMI 04 Engine Oil Pressure short to
Engine Oil in Cooling System ............................... 35
ground ................................................................. 65
Engine Oil in Exhaust System .............................. 36
CID 0110 FMI 03 Engine Coolant Temperature
Engine Oil Temperature Is Too High ..................... 36
open/short to +batt .............................................. 65
Engine Oil Temperature Is Too High ..................... 37
CID 0110 FMI 04 Engine Coolant Temperature short
Engine Stalls at Low RPM .................................... 37
to ground ............................................................. 65
Engine Vibration ................................................... 38
CID 0164 FMI 03 Injector Actuation Pressure voltage
Engine Will Not Crank ........................................... 39
high ..................................................................... 66
Excessive Black Smoke ........................................ 40
CID 0164 FMI 04 Injector Actuation Pressure voltage
Excessive Engine Oil Consumption ...................... 41
low ....................................................................... 66
Excessive Fuel Consumption ............................... 41
CID 0168 FMI 00 System Voltage High ................ 66
Excessive Valve Lash ........................................... 42
CID 0168 FMI 01 System Voltage Low ................. 67
Excessive White Smoke ....................................... 42
CID 0168 FMI 02 System Voltage intermittent/
Exhaust Temperature Is Too High ......................... 43
erratic .................................................................. 67
Fuel in Cooling System ......................................... 44
CID 0168 FMI 02 System Voltage intermittent/
Fuel Dilution of Engine Oil .................................... 44
erratic .................................................................. 67
Intermittent Engine Shutdown ............................... 45
CID 0172 FMI 03 Intake Manifold Air Temp open/short
Intermittent Low Power or Power Cutout .............. 46
to +batt ................................................................ 67
Intermittent Low Power or Power Cutout .............. 47
CID 0172 FMI 03 Intake Manifold Air Temp open/short
Low Engine Oil Pressure ...................................... 48
to +batt ................................................................ 68
Low Power/Poor or No Response to Throttle ....... 49
4 RENR5089-23
Table of Contents

CID 0172 FMI 04 Intake Manifold Air Temp short to E539 High Intake Manifold Air Temperature ......... 90
ground ................................................................. 68
CID 0172 FMI 04 Intake Manifold Air Temp short to Diagnostic Functional Tests
ground ................................................................. 68 5 Volt Engine Pressure Sensor Supply Circuit -
CID 0174 FMI 03 Fuel Temperature open/short to Test ..................................................................... 91
+batt .................................................................... 69 5 Volt Engine Pressure Sensor Supply Circuit -
CID 0174 FMI 04 Fuel Temperature short to Test ..................................................................... 97
ground ................................................................. 69 Air Inlet Heater Circuit - Test ............................... 103
CID 0190 FMI 08 Engine Speed signal abnormal .. 69 Air Inlet Heater Circuit - Test ................................ 110
CID 0253 FMI 02 Personality Module mismatch .. 69 Cat Data Link Circuit - Test .................................. 115
CID 0261 FMI 13 Engine Timing Calibration Cat Data Link Circuit - Test .................................. 118
required ............................................................... 70 Digital Sensor Supply Circuit - Test .................... 121
CID 0262 FMI 03 5 Volt Sensor DC Power Supply Digital Sensor Supply Circuit - Test .................... 125
short to +batt ....................................................... 70 Electrical Connectors - Inspect ........................... 129
CID 0262 FMI 04 5 Volt Sensor DC Power Supply Electrical Power Supply Circuit - Test ................. 134
short to ground .................................................... 70 Electrical Power Supply Circuit - Test ................. 138
CID 0268 FMI 02 Check Programmable Engine Pressure Sensor Open or Short Circuit -
Parameters ......................................................... 71 Test ................................................................... 142
CID 0274 FMI 03 Atmospheric Pressure open/short Engine Pressure Sensor Open or Short Circuit -
to +batt ................................................................ 71 Test ................................................................... 149
CID 0274 FMI 04 Atmospheric Pressure short to Engine Speed/Timing Sensor Circuit - Test ........ 157
ground ................................................................. 71 Engine Temperature Sensor Open or Short Circuit -
CID 0274 FMI 04 Atmospheric Pressure short to Test ................................................................... 161
ground ................................................................. 72 Engine Temperature Sensor Open or Short Circuit -
CID 0286 FMI 05 EMS Oil Lamp open/short to Test ................................................................... 166
ground ................................................................. 72 Ether Injection System - Test .............................. 171
CID 0286 FMI 06 EMS Oil Lamp short to +batt .... 72 Ether Injection System - Test .............................. 177
CID 0342 FMI 08 Secondary Engine Speed signal Fuel Filter Differential Pressure Switch Circuit -
abnormal ............................................................. 72 Test ................................................................... 180
CID 0617 FMI 05 Air Inlet Heater Relay open/current Injection Actuation Pressure - Test ..................... 183
below normal ....................................................... 73 Injection Actuation Pressure Control Valve Circuit -
CID 0617 FMI 06 Air Inlet Heater Relay Test ................................................................... 193
grounded/current above norm ............................. 73 Injector Solenoid Circuit - Test ............................ 197
CID 1639 FMI 02 Machine Security System Injector Solenoid Circuit - Test ............................ 206
incorrect .............................................................. 73 Low Engine Oil Pressure Lamp Circuit - Test ..... 213
CID 1639 FMI 09 Machine Security System Module Throttle Switch Circuit - Test ............................... 214
not communicating on link .................................. 74 Throttle Switch Circuit - Test ............................... 218
CID 1785 FMI 03 Intake Manifold Pressure Sensor User Defined Shutdown Input Circuit - Test ........ 221
voltage high ......................................................... 74
CID 1785 FMI 04 Intake Manifold Pressure Sensor Calibration Procedures
voltage low .......................................................... 74 Engine Speed/Timing Sensor - Calibrate ............ 225
CID 1785 FMI 10 Intake Manifold Pressure Signal
abnormal rate of change ..................................... 74 Index Section
CID 2417 FMI 05 Ether Injection Control Solenoid
current low .......................................................... 75 Index ................................................................... 229
CID 2417 FMI 06 Ether Injection Control Solenoid
current high ......................................................... 75

Troubleshooting with an Event Code

Event Codes ........................................................ 76
Event Codes ........................................................ 79
E096 High Fuel Pressure ...................................... 82
E096 High Fuel Pressure ...................................... 82
E162 High Boost Pressure ................................... 82
E198 Low Fuel Pressure ...................................... 83
E198 Low Fuel Pressure ...................................... 83
E265 User Defined Shutdown .............................. 85
E360 Low Engine Oil Pressure ............................. 85
E360 Low Engine Oil Pressure ............................. 86
E361 High Engine Coolant Temperature .............. 87
E362 Engine Overspeed ....................................... 88
E362 Engine Overspeed ....................................... 89
E390 Fuel Filter Restriction .................................. 89
RENR5089-23 5
Troubleshooting Section

Troubleshooting Section Fuel Injection

The ECM controls the amount of fuel that is
injected by varying the signals to the injectors. The
Electronic Troubleshooting injectors will pump fuel only if the injector solenoid is
energized. The ECM sends a high voltage signal to
the solenoid. This high voltage signal energizes the
i02439954 solenoid. By controlling the timing and the duration of
the high voltage signal, the ECM can control injection
System Overview timing and the amount of fuel that is injected.
SMCS Code: 1900 The ECM limits engine power during cold mode
operation and the ECM modifies injection timing
System Operation during cold mode operation. Cold mode operation
provides the following benefits:
The engine utilizes a Hydraulic Electronic Unit
Injector (HEUI) fuel system. A solenoid on each • Increased cold weather starting capability
injector meters the amount of fuel that is delivered
by the injector. An axial piston pump that is referred • Reduced warm-up time
to as the unit injector hydraulic pump pressurizes
oil in order to activate the injector. An Electronic • Reduced white smoke
Control Module (ECM) sends a signal to the injection
actuation pressure control valve in order to control Cold mode is activated whenever the engine coolant
injection pressure. Another electrical signal is sent to temperature falls below 18 °C (64 °F). Cold mode
each injector solenoid in order to inject fuel. remains active until the engine coolant temperature
rises above 20 °C (68 °F) or until the engine has
Electronic Controls been running for 14 minutes.

The electronic system for the engine consists of the The flash file inside the ECM sets certain limits on
ECM, the wiring harness, the engine sensors, the the amount of fuel that can be injected. The “FRC
switches, the injection actuation pressure control Fuel Limit” is used to control the air/fuel ratio for
valve, the unit injector hydraulic pump, the HEUI control of emissions. The “FRC Fuel Limit” is a limit
injectors and the interface for a particular application. that is based on the turbocharger outlet pressure.
The ECM is the computer. The flash file is the A higher turbocharger outlet pressure indicates that
software for the computer. The flash file contains there is more air in the cylinder. When the ECM
the operating maps. The operating maps define the senses a higher turbocharger outlet pressure, the
following characteristics of the engine: ECM increases the “FRC Fuel Limit”. When the ECM
increases the “FRC Fuel Limit”, the ECM allows
more fuel into the cylinder. The “FRC Fuel Limit” is
• Horsepower programmed into the flash file at the factory. The
“FRC Fuel Limit” cannot be changed.
• Torque curves
The ECM determines the timing and the amount The “Rated Fuel Limit” is a limit that is based on the
of fuel that is delivered to the cylinders. This power rating of the engine and on the engine speed.
determination is based on the actual conditions and The “Rated Fuel Limit” is similar to the rack stops
the desired conditions at any given time. and the torque spring on a mechanically governed
engine. The “Rated Fuel Limit” provides the power
The ECM compares the desired engine speed to curves and the torque curves for a specific engine
the actual engine speed. The actual engine speed is family and for a specific engine rating. The “Rated
determined via a signal from the engine speed/timing Fuel Limit” is programmed into the flash file at the
sensor. If the desired engine speed is greater than factory. The “Rated Fuel Limit” cannot be changed.
the actual engine speed, the ECM injects more fuel
in order to increase the actual engine speed. Once the ECM determines the amount of fuel that
is required, the ECM must determine the timing
of the fuel injection. The ECM determines the top
center position of each cylinder from the engine
speed/timing sensor's signal. The ECM calculates
when fuel injection should occur relative to the top
center position. The ECM also provides the signal
to the injector at the desired time. The ECM adjusts
timing for optimum engine performance, optimum
fuel economy, and optimum control of white smoke.
6 RENR5089-23
Troubleshooting Section

Injection Actuation Pressure Control Table 1

System Service Tools

The injection actuation pressure control valve Part

Description
Number
(IAPCV) that is internal to the unit injector hydraulic
pump is a precision displacement control actuator. N/A 4 mm Allen Wrench
This actuator changes the pump outlet flow that
151-6320 Wire Removal Tool (14-GA TO 18-GA,
is based on the control current that is supplied by
RED)
the ECM. The variable displacement unit injector
hydraulic pump pressurizes only the amount of high 1U-5804 Crimp Tool (12−AWG TO 18−AWG)
pressure oil that is needed by the injectors.
6V-2197 Transducer

Starting Aids 7X-1171 Transducer Adapter

7X-1695 Cable As
The following devices (if equipped) are used in order
to improve the starting of the engine in cold weather 146-4080 Digital Multimeter Gp (RS232)
conditions. 7X-1710 Multimeter Probes
326-4904 Adapter Cable As (3-PIN BREAKOUT)
• Air inlet heater
7X-1715 Adapter Cable As (40-PIN BREAKOUT)
• Ether injection 134-5195 Harness (40-PIN)
(For ADEM 2 ECM (two 40-pin connectors))
The ECM controls the air inlet heater. The ether
208-0059 Adapter Cable As (70-PIN BREAKOUT)
injection system can be controlled by the ECM or by
(For ADEM 3 ECM (two 70-pin connectors)
the operator. and for ADEM 4 ECM (one 70-pin
connector and one 120-pin connector))
Programmable Parameters 257-8718 Adapter Cable As (120-PIN BREAKOUT)
(For ADEM 4 ECM (one 70-pin connector
Certain parameters that affect the engine operation and one 120-pin connector))
may be changed with electronic service tools.
The parameters are stored in the ECM, and the N/A Torque Wrench (capable of applying
1.5 N·m (13.3 lb in))
parameters are protected from unauthorized changes
by passwords. Repair Kits for Connectors
362-3555 Connector Repair Kit (AMPSEAL)
Passwords 175-3700 Connector Repair Kit (DEUTSCH DT)
Several system configuration parameters and Bypass Harnesses for the ECM
most logged events are protected by passwords.
Refer to programming parameters Troubleshooting, 129-2018 Power Cable
(Stand alone cable for ADEM 2 ECM)
“Customer Passwords” and refer to programming
parameters Troubleshooting, “Factory Passwords”. 217-0113 Wiring Harness (ECM BYPASS)
(The bypass harness connects to the
battery. The bypass harness is used with
i04405209 the following harnesses for different types
of electronic control modules.)
Electronic Service Tools
328-2292 Harness (ENGINE ECM BYPASS)
SMCS Code: 0785 (For ADEM 3 ECM and ADEM 4 ECM)
277-4734 Harness (ENGINE ECM BYPASS)
Service Tools (For A4:E2 ECM (Two 64-pin connectors))

Most of the tools that are listed in Table 1 are required Two short jumper wires may be needed to check the
to enable a service technician to perform the test continuity of some wiring harness circuits by shorting
procedures in this manual. Some of the devices may two adjacent terminals together in a connector. A
be specific to the type of Electronic Control Module long extension wire may also be needed to check the
(ECM) that is being used. continuity of some wiring harness circuits.

Optional Service Tools

Table 2 lists the optional service tools that may be
needed during testing or repair.
RENR5089-23 7
Troubleshooting Section

Table 2 Once you have downloaded Cat ET onto your

Optional Service Tools
PC, you will need a license from your Caterpillar
dealer in order to use the software. Various licenses
Part Number Description are available for different users with different
198-4240 Digital Pressure Indicator requirements. Consult your Caterpillar dealer.
or or
1U-5470 Engine Pressure Group Note: For more information regarding the use of Cat
ET and PC requirements, refer to the documentation
4C-4075 Crimp Tool (4−AWG TO 10−AWG) that accompanies your Cat ET software.
4C-4911(1) Battery Load Tester
5P-7277 Voltage Tester
Connecting Cat ET
6V-9130(2) Temperature Adapter (MULTIMETER) Connecting the Communication Adapter
8T-5319 Connector Tool Group
Table 4 lists the standard hardware that is required in
349-4199 AC/DC Current Probe order to connect Cat ET.
348-5430 Multi-Tool Gp
Note: The 275-5120 Communication Adapter
(1) Refer to Special Instructions, SEHS9249, “Use of 4C-4911 Gp was canceled and replaced by the 317-7484
Battery Load Tester for 6, 8, and 12 v Lead Acid Batteries” and Communication Adapter Gp. However, the 275-5120
Special Instructions, SEHS7633, “Battery Test Procedure”.
(2) Refer to Special Instructions, SEHS8382, “Use of the 6V-9130 Communication Adapter Gp can still be used.
Temperature Adapter Group”.
Table 4
Standard Hardware for Connecting with Cat ET
Caterpillar Electronic Technician
(ET) Part Number Description

N/A Personal Computer (PC)

Cat ET can be used by the technician to help perform
the following procedures: Communication Adapter
317-7484
Gp
• Diagnostic testing Components of the 317-7484 Communication
Adapter Gp
• Calibrations
Communication Adapter
317-7485
• Flash programming (3)
370-4617 Cable As (USB)
• Configuration of the ECM
327-8981 Cable As (DATA LINK)
• Print various reports Tool Operating Manual & Software CD ROM,
NETG5057, “Communication Adapter 3”
Cat ET can display the following information:

• Status parameters Follow the instructions for the communication

adapter. Use the following procedure in order to
• Event codes connect Cat ET and the communication adapter to
a PC.
• Diagnostic codes
1. Remove the electrical power from the ECM.
• ECM settings
• Engine configuration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.

Table 3
Software, JEBD3003, “CATERPILLAR
ELECTRONIC TECHNICIAN”
8 RENR5089-23
Troubleshooting Section

• Cat ET displays a message that indicates that

the firmware in the communications adapter is
old.

Dual Data Link Communications (If Equipped)

When the connection of the communication adapter

is complete, observe the communication adapter
and Cat ET. Certain applications require that dual
data link communications be established in order to
perform various test procedures. These tests will be
listed in the “Diagnostic Tests” menu, some tests may
not be available (grayed out). If there are diagnostic
tests that are unavailable in Cat ET, ensure that your
service tool is communicating in dual data link mode.

Use the following indicators to confirm that Cat ET is

communicating on dual data links:

• “J1939” indicator is flashing

Illustration 1
g02051513 • “Cat Data Link” indicator is flashing
(1) PC
(2) 353-5083 Cable As (USB) • Cat ET is not displaying “Service tool support is
(3) 317-7485 Communication Adapter (3) limited”
(4) 327-8981 Cable As (DATA LINK)
Refer to Troubleshooting, “Electronic Service Tool
2. Connect cables (2) and (4) to communication Does Not Communicate” if the “J1939” indicator
adapter (3). and the “Cat Data Link” indicator are not flashing.
Both indicators will be flashing during dual data link
Note: The communication adapter will power up communications with the ECM.
when the adapter is connected to a PC or to an ECM
that is powered up. Communicating with the Wireless Communication
Adapter (If Equipped)
3. Connect cable (2) to the USB port of the PC.
Table 6 lists the optional hardware that is needed
4. Connect cable (4) to a service tool connector. in order to connect Cat ET by using a wireless
connection.
5. Restore electrical power to the ECM. Verify that
the “POWER” indicator on the communication Note: Some applications cannot use a wireless
adapter is illuminated. Make sure that the PC is connection. Also, a dual data link cannot be used
powered up. with a wireless connection.

6. Establish communication between Cat ET and the Table 5

ECM. If Cat ET indicates that there is more than Optional Hardware for the Use of Cat ET
one ECM, select the engine ECM.
Part Number Description
7. If Cat ET and the communication adapter
do not communicate with the ECM, refer to N/A Personal Computer (PC)
Troubleshooting, “Electronic Service Tool Will Not
Communicate with ECM”.

Refer to Troubleshooting, “Electronic Service Tool

Does Not Communicate” if any of the following
conditions exist:

• Cat ET displays a message that refers to a

communication problem.

• Cat ET displays “Error #142 The interface

hardware is not responding”.
RENR5089-23 9
Troubleshooting Section

Note: Some applications cannot use a wireless

connection. Also, a dual data link cannot be used
with a wireless connection.

Although changes can be made to the internal

settings of the W-CA3 wirelessly. Caterpillar
recommends that the radio is connected to a PC
via 317-7496 Computer Cable As (USB)Cable
Assembly (8) and 317-7510 Radio Cable Assembly
(9).

Table 6
Optional Hardware for the Use of Cat ET
Part Number Description

N/A Personal Computer (PC)

g02342942
Illustration 2
(1) Personal computer (PC)
(5) 261-4867 Card (PCMCIA)
(6) 239-9955 Communication Radio Gp
(7) 259-3183 Data Link Cable As

Note: Items (5), (6), and (7) are part of the 261-3363
Wireless Communication Adapter Gp.

Note: The 261-3363 Wireless Communication

Adapter Gp was canceled and replaced by the
349-1206 Radio Kit. However, the 261-3363 Illustration 3
g02151132

Wireless Communication Adapter Gp can still be (8) 317-7496 Computer Cable As (USB)
used. (9) 317-7510 Radio Cable AssemblyC

Use the following procedure in order to connect the

wireless communication adapter for use with Cat ET.

1. Remove the electrical power from the ECM.

2. Ensure that the computer has been correctly

configured for the 261-4867 Card. Verify that
the PC card is installed in the computer PCMCIA
expansion slot.

3. Connect cable (9) between communication radio

(8) and the service tool connector.

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

g02596964
and the communication radio do not communicate Illustration 4
with the ECM, refer to Troubleshooting, “Electronic (9) 317-7510 Radio Cable Assembly
Service Tool Will Not Communicate with ECM”. (10) W-CA3

Communicating with the 349-1206 Wireless Note: Items (8), (9), and (10) are part of the
Communication Adapter (If Equipped) 349-1206 Radio Kit.

Table 6 lists the optional hardware that is needed Use the following procedure in order to connect the
in 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.
10 RENR5089-23
Troubleshooting Section

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”.

PL1000E Communication ECM (If

Equipped)

g01163897
Illustration 5

The PL1000E is an ECM that provides the customer i02881454

with the ability to integrate Caterpillar engines
into specific applications. The PL1000E enables Replacing the ECM
communication from a J1939 data link to a device
that utilizes a MODBUS communication protocol. SMCS Code: 1901-510
A PC with Cat ET installed can be connected
to the PL1000E through the RS232 serial port NOTICE
of the PC. The PL1000E contains an embedded Care must be taken to ensure that fluids are contained
communications adapter that will allow Cat ET to during performance of inspection, maintenance, test-
communicate with the engine over the J1939 data ing, adjusting and repair of the product. Be prepared to
link. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Refer to System Operation/Troubleshooting/Test and nent containing fluids.
Adjust, RENR8091, “PL1000E Communication ECM”
for additional information. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
RENR5089-23 11
Troubleshooting Section

Note: If the “Copy Configuration” process fails and

NOTICE the parameters were not obtained in Step 1, the
Keep all parts clean from contaminants. parameters must be obtained elsewhere. Some
parameters are stamped on the engine information
Contaminants may cause rapid wear and shortened plate, but most parameters must be obtained from
component life. the factory.

3. Remove the ECM from the engine.

The Electronic Control Module (ECM) contains no
moving parts. Replacement of the ECM can be a. Remove the electrical power from the ECM.
costly. Replacement can also be a time consuming
task. Use these procedures to ensure that the ECM b. Disconnect the J1/P1 and J2/P2 ECM
is the cause of the problem. connectors.
Note: Ensure that the ECM is receiving power and
NOTICE
that the ECM is properly wired to the negative battery
Use a suitable container to catch any fuel that might
circuit before you attempt to replace the ECM. Refer
spill. Clean up any spilled fuel immediately.
to the diagnostic functional test Troubleshooting,
“Electrical Power Supply Circuit - Test”.
NOTICE
Some application software supports the use of a new Do not allow dirt to enter the fuel system. Thoroughly
ECM as a test ECM. A new ECM can be temporarily clean the area around a fuel system component that
placed into a “Test ECM Mode”. This ECM can will be disconnected. Fit a suitable cover over discon-
then be used to replace a suspect ECM in order nected fuel system component.
to determine if the suspect ECM is faulty. Refer to
programming parameters Troubleshooting, “Test
ECM Mode”. c. Remove the fuel lines (if equipped) from the
ECM.
NOTICE
If the flash file and engine application are not matched, d. Remove the mounting bolts from the ECM.
engine damage may result.
e. Disconnect the ECM ground strap from the
engine.
Perform the following procedure in order to replace
the ECM: 4. Install the replacement ECM.

1. Print the parameters from the “Configuration” a. If the old mounting hardware is in good repair,
screen on Caterpillar Electronic Technician you can use the old mounting hardware to
(ET). If a printer is unavailable, record all of the install the replacement ECM.
parameters. Record any logged diagnostic codes
and logged event codes for your records. Record b. Reconnect the fuel lines (if equipped).
the injector serial numbers from the “Calibrations”
screen under the “Service” menu on Cat ET. c. Ensure that the ECM mounting hardware is
installed correctly. The fuel lines must not put
Note: The injector serial numbers are necessary for tension on the ECM. The rubber grommets
obtaining the correct injector trim files. The ECM are used to protect the ECM from excessive
uses the injector trim files in order to compensate for vibration. The ECM must be able to drift in
manufacturing variations between individual injectors. the rubber grommets. If the ECM cannot be
If you replace any of the unit injectors, you must moved slightly in the grommets, check that the
reprogram the injector trim files for the new injectors. fuel lines (if equipped) are not pulling the ECM
Also, if you replace the ECM, the injector trim files against one side of the grommets.
must be installed into the new ECM. A successful
“Copy Configuration” process will accomplish this d. Connect the ECM ground strap.
task. For more instruction, refer to programming
parameters Troubleshooting, “Injector Trim File”. e. Connect the J1/P1 and J2/P2 ECM connectors.
Tighten the allen head screw on each of the
2. Use the “Copy Configuration/ECM Replacement” ECM connectors to the proper torque. Refer to
feature that is found under the “Service” menu on the diagnostic functional test Troubleshooting,
Cat ET. Select “Load from ECM” in order to copy “Electrical Connectors - Inspect” for the correct
the configuration from the suspect ECM. torque value.
12 RENR5089-23
Troubleshooting Section

5. Program the flash file into the ECM. Refer to i02378227

programming parameters Troubleshooting, “Flash
Programming”. Self-Diagnostics
6. If the replacement ECM was used previously for SMCS Code: 1901
a different application, use Cat ET to match the
engine application and the flash file. The Electronic Control Module (ECM) has the ability
to detect problems with the electronic system and
7. Configure the ECM. with engine operation. When a problem is detected, a
code is generated. An alarm may also be generated.
a. If the “Load from ECM” process from Step There are two types of codes:
2 was successful, return to the “Copy
Configuration/ECM Replacement” screen on • Diagnostic
Cat ET and select “Program ECM”.
• Event
After using the “Program ECM” feature, be sure
to cycle the power to the ECM. Wait at least Diagnostic Code – When a problem with the
15 seconds after turning the keyswitch to the electronic system is detected, the ECM generates a
OFF position. diagnostic code. This indicates the specific problem
with the circuitry.
Note: Some control modules have a power off delay.
The 15 seconds will be sufficient to cover this delay. Diagnostic codes can have two different states:

b. If the “Program ECM” process was successful, • Active

proceed to Step 9.
• Logged
c. If the “Program ECM” process was
unsuccessful, manually program the ECM Active Code
parameters into the replacement ECM. The
parameters must match the parameters from An active diagnostic code indicates that an active
Step 1. problem has been detected. Active codes require
immediate attention. Always service active codes
Note: If the “Copy Configuration” process fails and prior to servicing logged codes.
the parameters were not obtained in Step 1, the
parameters must be obtained elsewhere. Some Logged Code
parameters are stamped on the engine information
plate, but most parameters must be obtained from Every generated code is stored in the permanent
the factory. memory of the ECM. The codes are logged.

d. If necessary, program the engine monitoring Logged codes may not indicate that a repair is
system. needed. The problem may have been temporary. The
problem may have been resolved since the logging
8. Program the injector trim files. Refer to of the code. If the system is powered, it is possible
programming parameters Troubleshooting, to generate an active diagnostic code whenever a
“Injector Trim File”. component is disconnected. When the component is
reconnected, the code is no longer active. Logged
9. Check for an active diagnostic code for timing codes may be useful to help troubleshoot intermittent
calibration. problems. Logged codes can also be used to review
the performance of the engine and of the electronic
If the diagnostic code is active, calibrate the system.
injection timing. Refer to calibration procedures
Troubleshooting, “Engine Speed/Timing Sensor - Event Code
Calibrate”.
An event code is generated by the detection of an
10. Check for diagnostic codes and for event codes. abnormal engine operating condition. For example,
an event code will be generated if the oil pressure is
too low. In this case, the event code indicates the
symptom of a problem.
RENR5089-23 13
Troubleshooting Section

i02472671

Sensors and Electrical

Connectors
SMCS Code: 1439; 7553-WW

g01233214
Illustration 6
Components for the engine's control system
14 RENR5089-23
Troubleshooting Section

Component Location

g01199980
Illustration 7
Typical component locations for C9 engines
(1) Engine coolant temperature sensor (6) Intake manifold air temperature sensor (12) Engine oil pressure sensor
(2) Fuel pressure sensor (7) J300/P300 Injector valve cover connector (13) J2/P2 ECM connector
(3) J500/P500 Injection actuation pressure (8) Atmospheric pressure sensor (14) ECM
control valve (internal to the pump) (9) Fuel temperature sensor (15) J1/P1 ECM connector
(4) Injection actuation pressure (IAP) sensor (10) Primary engine speed/timing sensor
(5) Intake manifold (boost) pressure sensor (11) Secondary engine speed/timing sensor
RENR5089-23 15
Troubleshooting Section

g01199982
Illustration 8
Typical component locations for C7 engines
(1) Fuel pressure sensor (6) Intake manifold air temperature sensor (12) Engine oil pressure sensor
(2) J500/P500 Injection actuation pressure (7) Atmospheric pressure sensor (13) J2/P2 ECM connector
control valve (internal to the pump) (8) Intake manifold (boost) pressure sensor (14) ECM
(3) Injection actuation pressure (IAP) sensor (9) Fuel temperature sensor (15) J1/P1 ECM connector
(4) Engine coolant temperature sensor (10) Primary engine speed/timing sensor
(5) J300/P300 Injector valve cover connector (11) Secondary engine speed/timing sensor
16 RENR5089-23
Troubleshooting Section

i02434650

Sensors and Electrical

Connectors
SMCS Code: 1439; 7553-WW

g01221751
Illustration 9
Components for the engine's control system
RENR5089-23 17
Troubleshooting Section

Component Location

g01221809
Illustration 10
Component locations for C9 engines
(1) Engine coolant temperature sensor (6) Intake manifold air temperature sensor (11) Engine oil pressure sensor
(2) Fuel pressure sensor (7) J300/P300 Injector valve cover entry (12) J2/P2 ECM connector
(3) J500/P500 Injection actuation pressure connector (13) ECM
control valve (internal to the pump) (8) Atmospheric pressure sensor (14) J1/P1 ECM connector
(4) Injection actuation pressure (IAP) sensor (9) Primary engine speed/timing sensor
(5) Intake manifold (boost) pressure sensor (10) Secondary engine speed/timing sensor

i02433503 Table 7

Engine Wiring Information Color Codes for the Harness Wire

Color Code Color Color Code Color
SMCS Code: 1408
BK Black GN Green
The wiring schematics are revised periodically. BR Brown BU Blue
The wiring schematics will change as updates are
made to the engine's harness. For the most current RD Red PU Purple
information, always check the revision number of the OR Orange GY Gray
schematic. Use the schematic with the latest revision
number. YL Yellow WH White
PK Pink
Harness Wire Identification
For example, a wire identification of A701-GY on the
Caterpillar identifies all wires with eleven solid colors. schematic would signify a gray wire with the circuit
The circuit number is stamped on the wire at a 25 mm number A701. A701-GY identifies the power circuit
(1 inch) spacing. Table 7 lists the wire colors and the for the No. 1 Injector solenoid.
color codes.
18 RENR5089-23
Troubleshooting Section

Another wire identification on the schematic is the 2. Disconnect the negative battery cable from the
size of the wire. The size of the wire will follow the battery. If a battery disconnect switch is installed,
wire color. Wire size or gauge is referred to as AWG open the switch.
(American Wire Gauge). AWG is a description of the
diameter of the wire.

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

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

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

AWG.

Conversion of AWG Numbers to Metric

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

Table 8
Metric Equivalents for AWG Numbers
AWG Diameter AWG Diameter
Number (mm) Number (mm) Illustration 11
g01143634

20 0.8 14 1.6 Service welding guide (typical diagram)

18 1.0 12 2.0
3. Connect the welding ground cable as close
16 1.3 4 3.2 as possible to the area that will be welded.
Components which may be damaged by welding
include bearings, hydraulic components, and
Welding on Applications that are electrical/electronic components.
Equipped with an Electronic Control
Module (ECM) 4. Protect the wiring harness from welding debris
and spatter.
Proper welding procedures are necessary in order
to avoid damage to the engine's electronic control 5. Weld the materials by using standard welding
module, sensors, and associated components. methods.
Remove the component that requires welding. When
welding on an application that is equipped with an
ECM and removal of the component is not possible,
the following procedure must be followed. This
procedure provides the minimum amount of risk to
the electronic components.

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

Clamp the ground cable from the welder to the com-

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

1. Stop the engine. Remove the electrical power

from the ECM.
RENR5089-23 19
Troubleshooting Section

Programming Parameters Note: If a newer software version is available for the

engine, install the newest software on the suspect
ECM. If the new software does not fix the problem,
i03312021 continue with this procedure.
Programming Parameters 2. Use the “Copy Configuration/ECM Replacement”
feature on Cat ET to copy the configuration
SMCS Code: 1901 parameters from the suspect ECM to your personal
computer (PC). If the “Copy Configuration/ECM
The electronic service tool can be used to view Replacement” feature cannot be used, record
certain parameters that can affect the operation of the the programmed values into the “Parameters
engine. The electronic service tool can also be used Worksheet” in system configuration parameters
to change certain parameters. The parameters are Troubleshooting, “System Configuration
stored in the Electronic Control Module (ECM). Some Parameters”. Record the injector serial numbers
of the parameters are protected from unauthorized from the “Calibrations” screen under the “Service”
changes by passwords. Parameters that can be menu on Cat ET.
changed have a tattletale number. The tattletale
number shows if a parameter has been changed. Note: Some applications use injectors that have trim
codes or injector trim files that are associated with
i04598766
the injectors. If injector trim codes are necessary,
the injector trim codes are printed on the injector. If
Test ECM Mode injector trim files are necessary, the injector serial
numbers are necessary for obtaining the correct
SMCS Code: 1901 injector trim files from Cat ET. The injector trim file is a
number that is specific to each unit injector. The ECM
“Test ECM Mode” is a feature on Caterpillar Electronic uses this number to compensate for manufacturing
Technician (ET) that is used to troubleshoot an variations between individual injectors. If you replace
engine that may have a problem with the Electronic any of the unit injectors, you must program the
Control Module (ECM). injector trim files for the new injectors. Also, if you
replace the ECM, you must program all of the injector
If an application supports this feature, Cat ET will trim files into the new ECM.
allow a new ECM to be used temporarily as a test
ECM. If an application does not support this feature, 3. Disconnect the suspect ECM. Temporarily connect
refer to Troubleshooting, “ECM - Replace”. the new ECM to the engine. Do not mount the
new ECM on the engine.
When the “Test ECM Mode” is activated, an internal
timer sets a 24 hour clock. This clock will count 4. Program the correct flash file into the new ECM.
down only while the ECM is powered. If the new
ECM fixes the problem, the engine can be released Note: The “Test ECM Mode” must be activated
while the “Test ECM Mode” is still active. After the before the engine serial number is programmed
ECM has counted down the 24 hour period, the ECM into the new ECM. “Test ECM Mode” can only be
will exit the “Test ECM Mode”. The parameters, the activated if the engine serial number has not already
accumulated hours, and the engine serial number been programmed during normal operation of the
will be permanently programmed into the new ECM. ECM. A new ECM can never be used as a test ECM
The new ECM can no longer be used for another after the engine serial number is programmed.
engine or for a test ECM.
5. Start the “Test ECM Mode” on Cat ET. Access the
Note: When the“Test ECM Mode” is activated, the feature through the “Service” menu. Cat ET will
“Personality Module Code” is 0. After the ECM has display the status of the “Test ECM Mode” and the
counted down the 24 hour period, the “Personality hours that are remaining for the “Test ECM Mode”.
Module Code” will be dependent on the application.
Note: If the “Copy Configuration/ECM Replacement”
If the new ECM does not resolve the problem, and feature cannot be used, program the values from the
24 hours has not expired, the ECM can be used as “Parameters Worksheet”.
a new ECM. Anytime prior to the 24 hour limit of the
“Test ECM Mode”, a new engine serial number and 6. Use the “Copy Configuration/ECM Replacement”
new parameters can be reprogrammed. feature on Cat ET to program the correct
parameters into the new ECM.
1. Search for the latest flash file for the engine.
7. Program the engine serial number into the new
ECM.
20 RENR5089-23
Troubleshooting Section

If the problem is resolved with the new ECM, i02445203

remove the original ECM and permanently install
the new ECM. Flash Programming
If the new ECM does not fix the problem, the SMCS Code: 1901-591
original ECM is not the problem. Remove the new
ECM before the 24 hour timer expires. Reconnect Flash Programming – This is a method of
the original ECM. programming or updating the flash file in an
Electronic Control Module (ECM).

i02433393 The Caterpillar Electronic Technician (ET) can be

utilized to program a new flash file into the ECM. The
Factory Passwords programming is accomplished by transferring the
data from a PC to the ECM.
SMCS Code: 0785

NOTICE Flash Programming a Flash File

Operating the engine with a flash file not designed for
that engine will damage the engine. Be sure the flash 1. Obtain the part number for the new flash file.
file is correct for your engine.
Note: If you do not have the flash file's part number,
use the “Flash File Search” tool on the Service
Note: Factory passwords are provided only to Technician Workbench (STW). Alternatively, use the
Caterpillar dealers. “Flash Software Files” feature on SIS Web.

Factory passwords are required to perform each of Note: You must have the engine serial number in
the following functions: order to search for the flash file's part number.

• Program a new Electronic Control Module (ECM). 2. Connect Cat ET to the service tool connector.

When an ECM is replaced, the system configuration 3. Restore the electrical power to the ECM. Do not
parameters must be programmed into the new start the engine.
ECM. A new ECM will allow these parameters to
be programmed once without factory passwords. 4. Select “WinFlash” from the “Utilities” menu on Cat
After the initial programming, some parameters are ET.
protected by factory passwords.
Note: If “WinFlash” will not communicate with the
• Clear event codes. ECM, refer to troubleshooting without a diagnostic
code Troubleshooting, “Electronic Service Tool Will
Most event codes require the use of factory Not Communicate with ECM”.
passwords to clear the code once the code has
been logged. Clear these codes only when you are 5. Program the flash file into the ECM.
certain that the problem has been corrected.
a. Select the engine ECM under the “Detected
• Unlock parameters. ECMs”.

Factory passwords are required in order to b. Press the “Browse” button in order to select
unlock certain system configuration parameters. the part number of the flash file that will be
Refer to Troubleshooting, “System Configuration programmed into the ECM.
Parameters”.
c. When the correct flash file is selected, press
Since factory passwords contain alphabetic the “Open” button.
characters, the Caterpillar Electronic Technician (ET)
must be used to perform these functions. In order to d. Verify that the “File Values” match the
obtain factory passwords, proceed as if you already application. If the “File Values” do not match
have the password. If factory passwords are needed, the application, search for the correct flash file.
Cat ET will request the factory passwords and Cat ET
will display the information that is required to obtain e. When the correct flash file is selected, press
the passwords. For the worksheet that is used for the “Begin Flash” button.
acquiring factory passwords, refer to programming
parameters Troubleshooting, “Factory Passwords f. Cat ET will indicate when flash programming
Worksheet”. has been successfully completed.

6. Start the engine and check for proper operation.

RENR5089-23 21
Troubleshooting Section

7. Access the “Configuration” screen under the 4. Download the injector trim file to the PC. Repeat
“Service” menu in order to determine the this procedure for each injector, as required.
parameters that require programming. Look under
the “Tattletale” column. All of the parameters 5. Connect Cat ET to the service tool connector. Refer
should have a tattletale of 1 or more. If a parameter to electronic troubleshooting Troubleshooting,
has a tattletale of 0, program that parameter. “Electronic Service Tools”.

“WinFlash” Error Messages 6. Restore the electrical power to the ECM.

If you receive any error messages during flash 7. Select the following menu options on Cat ET:
programming, click on the “Cancel” button in order
to stop the process. Access the information about • Service
the “ECM Summary” under the “Information” menu.
Make sure that you are programming the correct • Calibrations
flash file for your engine.
• Injector Trim Calibration
i02431150 8. Select the appropriate cylinder.
Injector Trim File 9. Click on the “Change” button.
SMCS Code: 1290 10. Select the appropriate injector trim file from the
PC.
The Caterpillar Electronic Technician (ET) is used to
load the injector trim files into the Electronic Control 11. Click on the “Open” button.
Module (ECM).
12. If you are prompted by Cat ET enter the injector
The injector trim files must be loaded into the ECM if confirmation code into the field.
any of the following conditions occur:
13. Click on the “OK” button.
• An injector is replaced.
The injector trim file is loaded into the ECM.
• The ECM is replaced.
14. Repeat the procedure for each cylinder, as
• A 253-02 diagnostic code is active (if applicable). required.
• A 268-02 diagnostic code is active (if applicable).
i02278907
• Injectors are exchanged between cylinders.
Service Information Report
Exchanging Injectors
SMCS Code: 0336
Exchanging injectors can help determine if a
combustion problem is in the injector or in the After verifying the correct repair has been performed
cylinder. If two injectors that are currently installed on the engine, it is critical to provide brief, detailed
in the engine are exchanged between cylinders, information. This information helps Caterpillar better
the injector trim files can also be exchanged. Press serve you and the customer.
the “Exchange” button at the bottom of the “Injector
Trim Calibration” screen on Cat ET. Select the two Recommendations
injectors that will be exchanged and press the “OK”
button. The tattletale for the injectors that were Customer's Complaint
exchanged will increase by one.
Obtain as much information from the customer
Note: The injector serial number and the injector as possible. Investigate any written information
confirmation code are located on the injector. that is available and document any information
that is gathered from the customer. The following
1. Record the injector serial number and the injector information is of particular importance:
confirmation code for each injector.

2. Click on “Service Software Files” in SIS Web. • Indicate if the diagnostic lamp was flashing.

3. Enter the serial number for the injector in the • Indicate if the warning lamp was flashing, or if the
lamp was on continuously.
search field.
22 RENR5089-23
Troubleshooting Section

• Indicate the symptoms of engine operation that are

present.

Be as specific as possible.

Cause of Failure
Comments on the cause of failure should include
the number of diagnostic codes that were logged.
Comments should also indicate if the code was an
active code. Indicate the source of the problem. Also
indicate the method that was used to discover the
problem. Examples of the methods that were used to
discover the problem could be one of the following
methods:

• A specific procedure in the manual was followed.

• A visual inspection indicated that wire abrasion on
the engine harness existed.

• An engine dynamometer test indicated that the

power was below the specification at 1700 rpm
due to the loss of the no. 4 injector and an engine
dynamometer test indicated that the power was
below the specification at all engine speeds above
1700 rpm due to the loss of the no. 4 injector.

Be as specific as possible.

Repair Procedure
Comments on the repair procedure should include
the following types of information:

• The wiring harness was repaired.

• The Full Load Setting (FLS) was changed per the
factory's instructions.

Be as specific as possible.
RENR5089-23 23
Troubleshooting Section

System Configuration Note: When you are requesting factory passwords,

always use the engine serial number that is
Parameters programmed in the ECM.

i02402915
“FLS” (Full Load Setting)

System Configuration “FLS” is a number that represents the adjustment to

the fuel system that was made at the factory in order
Parameters to fine tune the fuel system. The correct value for
this parameter is stamped on the engine information
SMCS Code: 1901 plate. Factory passwords are required in order to
change this parameter.
System configuration parameters are parameters
that affect the emissions and the power of the engine.
Default values for the parameters are programmed
“FTS” (Full Torque Setting)
at the factory. The values for certain configuration
“FTS” is similar to “FLS”. Factory passwords are
parameters are stamped on the engine information
required in order to change this parameter.
plate.

Some values may be changed by the customer in “Ether Control”

order to suit the needs of the specific application.
The values are programmed with the Caterpillar The “Ether Control” parameter allows the operation
Electronic Technician (ET). of this feature to be enabled or disabled.

If the parameters that are protected with the factory “Security System Immobilizer”
passwords are changed, the Caterpillar warranty
may be voided. The “Engine Security System Status” will inform
the user if the system has been installed and if the
Some parameters must be programmed if the system has been enabled. If the ECM does not detect
Electronic Control Module (ECM) is replaced and/or the security system, the status will be “Unavailable”.
you reprogram the engine rating. It is not necessary Once the ECM detects the security system on the
to reprogram these parameters if a new flash file is data link, the parameter is changed to “Enabled”.
flash programmed into the ECM. The user can disable this parameter with factory
passwords.
The system configuration parameters are listed in
Table 9.

Parameter Descriptions
“Product ID”
The “Product ID” parameter allows the customer to
enter a description into the ECM in order to identify
the machine. A maximum of 8 characters can be
entered in the field.

“Equipment ID”
“Equipment ID” allows the customer to enter a
description into the Electronic Control Module (ECM)
in order to identify the machine. A maximum of
17 characters may be entered in the field. This
parameter is only for reference by the customer. This
parameter is not required.

“Engine Serial Number”

Program the “Engine Serial Number” to match the
engine serial number that is stamped on the engine
information plate. If the ECM is replaced, the engine
serial number from the engine information plate must
be programmed into the new ECM.
24 RENR5089-23
Troubleshooting Section

System Configuration Parameters

Table 9

System Configuration Parameters

Required
Parameter Available Range or Options Default
Password
ECM Identification Parameters
“Product ID” 8 alphanumeric character “NOT PROGRAMMED” None
“Equipment ID” 17 alphanumeric characters “NOT PROGRAMMED” None
“Engine Serial Number” 0XX00000 or XXX00000 0XX00000 None
“ECM Serial Number” “Read Only” (1)

“ECM Part Number” “Read Only” (1)

“Software Gp Part Number” Software Dependent Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

“Software Gp Release Date” Software Dependent Read Only (1)

“FLS” (Full Load Setting) - 128 to 127 0 Factory

“FTS” (Full Torque Setting) -128 to 127 0 Factory
“Ether Control” “Enable” or “Disable” “Disable” None
“Security System Immobilizer” “Enable” or “Disable” “Enabled” Factory
“Total Tattletale” Read Only (1)

(1) The parameter can only be viewed. No changes are allowed.

(1) The parameter can only be viewed. No changes are allowed.

Parameters Worksheet
Note: A mistake in recording this information will
result in incorrect passwords.
RENR5089-23 25
Troubleshooting Section

Table 10
Engine Parameters
ECM Identification Parameters
“Product ID”

“Equipment ID”

“Engine Serial Number”

“ECM Serial Number”

“Software Gp Part Number”

“Software Gp Release
Date”
“FLS”

“FTS”

“Ether Control”

“Security System
Immobilizer”
“Total Tattletale”

Injector Codes

Injector Code (1)

Injector Code (2)

Injector Code (3)

Injector Code (4)

Injector Code (5)

Injector Code (6)

Note: Compare the FLS and the FTS from the

ECM with the values that are listed on the engine
information plate. Only change the FLS and the FTS
because of a mechanical change in the engine. The
use of the wrong parameters could cause damage to
the engine. The use of the wrong parameters may
also void the Caterpillar warranty.
26 RENR5089-23
Troubleshooting Section

Troubleshooting without a Charging Circuit

Diagnostic Code Inspect the battery cables, wiring, and connections in
the charging circuit. Clean all connections and tighten
all connections. Replace any faulty parts.
i02476459

Alternator Alternator or Regulator

(Charging Problem and/or Verify that the alternator or the regulator is operating
Noisy Operation) correctly. Refer to Special Instruction, REHS0354,
“Charging System Troubleshooting” for the proper
SMCS Code: 1405-035 testing procedures. Repair the alternator or replace
the alternator, as needed.

Probable Causes
i02475244

• Alternator drive belts Battery

• Alternator drive pulley SMCS Code: 1401-035
• Alternator bearings Refer to Special Instruction, SEHS7633, “Battery
Test Procedure” for the proper testing procedures.
• Charging circuit
• Regulator Probable Causes
• Alternator • Worn battery

Recommended Actions • Switched battery circuit

Alternator Drive Belts Recommended Actions

1. Inspect the condition of the alternator drive belts. Worn Battery
If the alternator drive belts are worn or damaged,
replace the belts. Refer to Disassembly and 1. Verify that the battery is no longer able to hold a
Assembly. charge.

2. Check the belt tension. Refer to the engine's 2. Replace the battery.
Specifications manual.
Switched Battery Circuit
3. If the engine is equipped with an automatic belt
tensioner, check the automatic belt tensioner. If 1. Verify that a switched battery circuit drained the
necessary, replace the automatic belt tensioner. battery by being left in the ON position.
Note: Excessive belt tension can result in damage to 2. Charge the battery.
the alternator.
3. Verify that the battery is able to maintain a charge.
Alternator Drive Pulley
i02471007
Check the condition of the alternator drive pulley.
Look for deep grooves that have been worn into the
pulley by the belt. If there is excessive wear, replace
Can Not Reach Top Engine
the pulley. Check that the nut for the pulley has not RPM
become loose. If necessary, tighten the nut.
SMCS Code: 1915-035
Note: Make sure that the alignment is correct.
Note: If this problem occurs only under load,
Alternator Bearings refer to troubleshooting without a diagnostic code
Troubleshooting, “Low Power/Poor or No Response
Check the alternator bearings for signs of wear. to Throttle”.
Repair the alternator or replace the alternator, as
needed.
RENR5089-23 27
Troubleshooting Section

Probable Causes Table 11

“Fuel Position” = “Rated Fuel Limit”
• Active engine derate
and
• Cold mode “Fuel Position” < “FRC Fuel Limit”

• Throttle signal
If “Fuel Position” equals “Rated Fuel Limit” and
• Intake manifold (boost) pressure sensor “Fuel Position” is less than “FRC Fuel Limit”, the
electronics are operating correctly. Otherwise,
• Atmospheric pressure sensor proceed with the next Step.

• Fuel supply 2. Monitor the status of “Intake Manifold (Boost)

Pressure” and “Atmospheric Pressure” for normal
• Air inlet and exhaust system operation on Cat ET. When the engine is not
running, the correct “Intake Manifold (Boost)
• Accessory equipment Pressure” is 0 kPa (0 psi).

3. Verify that the intake manifold (boost) pressure

Recommended Actions sensor is operating properly.

Active Engine Derate Fuel Supply

Connect Caterpillar Electronic Technician (ET) and 1. Check the fuel lines for the following problems:
check for an active derate event. A derate status flag restrictions, collapsed lines, and pinched lines. If
will appear on Cat ET if an active engine derate is problems are found with the fuel lines, repair the
occurring. In order to view active events, go to the lines and/or replace the lines.
“Events” menu under “Diagnostics”.
2. Check the fuel tank for foreign objects which may
Cold Mode block the fuel supply.

Use Cat ET to verify that the engine has exited

NOTICE
cold mode. A status flag will appear if the engine is
Do not crank the engine continuously for more than
operating in cold mode. This may limit engine speed.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Throttle Signal
Monitor the status for “Throttle Position” on Cat ET. 3. Prime the fuel system if any of the following
Verify that the status for “Throttle Position” is stable procedures have been performed:
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic functional test for • Replacement of the fuel filters
your application:
• Service on the low pressure fuel supply circuit
• Troubleshooting, “Throttle Position Sensor Circuit -
Test” • Replacement of unit injectors
• Troubleshooting, “Throttle Switch Circuit - Test” Note: A sight glass in the low pressure supply line
is helpful in diagnosing air in the fuel. Refer to the
• Troubleshooting, “Speed Control - Test” Systems Operation/Testing and Adjusting.

Intake Manifold (Boost) Pressure Sensor 4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
or Atmospheric Pressure Sensor Maintenance Manual.
1. Monitor the status of “Fuel Position”, “Rated Fuel 5. Check the fuel pressure during engine cranking.
Limit”, and “FRC Fuel Limit” on Cat ET while Check the fuel pressure after the fuel filter. Refer
the engine is operating under full load. These to the Systems Operation/Testing and Adjusting.
parameters should reflect the information below. If the fuel pressure is low, replace the fuel filters.
If the fuel pressure is still low, check the following
items: fuel transfer pump, fuel transfer pump
coupling, and fuel pressure regulating valve.
28 RENR5089-23
Troubleshooting Section

Air Inlet and Exhaust System 2. Check the cylinder liner projection. Refer to the
Systems Operation/Testing and Adjusting manual.
1. Replace plugged air filters and/or clean the filters.
Leaks in the air inlet manifold system can lower 3. Install a new cylinder head gasket and new water
Inlet manifold pressure. seals in the spacer plate. Refer to the Disassembly
and Assembly manual.
2. Check the exhaust system for restrictions and/or
for leaks. Cylinder Head
Accessory Equipment Check for cracks in the cylinder head. If a crack
is found, repair the cylinder head and/or replace
Check all accessory equipment for problems that the cylinder head. Refer to the Disassembly and
may create excessive load on the engine. Repair Assembly manual.
any damaged components or replace any damaged
components. Cylinder Liner

i04024629
Check for cracked cylinder liners. Replace any
cracked cylinder liners. Refer to the Disassembly and
Coolant in Engine Oil Assembly manual.

SMCS Code: 1348-035; 1395-035 Cylinder Block

Probable Causes Inspect the cylinder block for cracks. If a crack is

found, repair the cylinder block or replace the cylinder
• Engine oil cooler core block.

• Water-cooled turbocharger i02422808

• Cylinder head gasket Coolant Temperature Is Too

• Cylinder head High
SMCS Code: 1395-035
• Cylinder liner
• Cylinder block Probable Causes
Recommended Actions • Low coolant level

Engine Oil Cooler Core • Air in coolant

1. Check for leaks in the oil cooler core. If a leak is

• Water pump
found, install a new oil cooler core. Refer to the
Disassembly and Assembly manual.
• Environmental conditions

2. Drain the crankcase and refill the crankcase with

• Shunt line restriction
clean engine oil. Install new engine oil filters.
Refer to the Operation and Maintenance Manual.
• Radiator or heat exchanger
• Water temperature regulator
Water-Cooled Turbocharger
• Coolant temperature sensor
If the engine is equipped with a water-cooled
turbocharger, inspect the turbocharger for cracks. If • Engine coolant flow
the turbocharger is cracked, replace the turbocharger.
Refer to the engine Disassembly and Assembly. • Exhaust restriction
Cylinder Head Gasket • Excessive load
1. Remove the cylinder head. Refer to the • Combustion gas in the coolant
Disassembly and Assembly manual.
RENR5089-23 29
Troubleshooting Section

Recommended Repairs Determine the cause of the high air temperature.

Make corrections, when possible.
Low Coolant Level
Refer to Systems Operation/Testing and Adjusting.

Shunt Line Restriction

Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap, If the cooling system is equipped with a shunt line,
stop the engine and wait until the cooling system check for a restriction in the line. A restricted shunt
components are cool. Loosen the cooling system line can cause cavitation in the water pump. Remove
pressure cap slowly in order to relieve the pres- the restriction or replace the shunt line.
sure.
Radiator or Heat Exchanger
Note: Low coolant level can be the result of Measure the coolant temperature at the inlet to the
overheating rather than the cause. engine.
Check the coolant level. Radiator
Run the engine to operating temperature. If the engine is equipped with a radiator, check the
fins of the radiator for obstructions. Check the fan
Inspect the cooling system for leaks. Check for the for proper operation.
presence of coolant in the engine oil. This would
indicate an internal coolant leak. If the radiator fins are obstructed, clean the fins. If the
fan does not operate properly, make the necessary
Determine whether the leak occurs before the engine repairs.
overheats.
Heat Exchanger
Add coolant, if necessary. If leaking is found, make
the necessary repairs. If the engine is equipped with a heat exchanger,
check for sufficient flow and temperature of the
Air in Coolant cooling water through the heat exchanger. If the
flow of cooling water through the heat exchanger is
Air can enter the cooling system if the pressure cap insufficient, determine the location of the obstruction.
is not operating properly. Check the operation of the
pressure cap. Replace the pressure cap, if necessary. Water Temperature Regulator
If the coolant has been changed recently, ensure that Check the water temperature regulators for proper
the air has been purged from the cooling system. operation. Refer to Systems Operation/Testing and
Refer to Systems Operation/Testing and Adjusting. Adjusting.
The supply pressure to the water pump must be Replace the water temperature regulators, if
sufficient in order to prevent cavitation. Measure the necessary.
supply pressure at the inlet to the water pump.
Coolant Temperature Sensor
Water Pump
Compare the reading for the coolant temperature
The engine will overheat if the water pump is not from the Caterpillar Electronic Technician (ET) to
operating properly. Measure the coolant pressure the reading for the coolant temperature from a
at the outlet of the water pump. Make sure that the mechanical gauge. The temperature should rise
water pump is in good condition. steadily as the engine is warmed. Ensure that
the temperature is reasonable. Refer to Systems
Environmental Conditions Operation/Testing and Adjusting.

Determine if the ambient air temperature is within the If the reading on Cat ET for the coolant temperature
design specifications for the cooling system. is not reasonable, troubleshoot the circuit and the
coolant temperature sensor. Refer to the diagnostic
Ensure that the engine's exhaust does not heat the functional test Troubleshooting, “Engine Temperature
radiator or the heat exchanger. Sensor Open or Short Circuit - Test”.

Check for high inlet air temperature.

30 RENR5089-23
Troubleshooting Section

Engine Coolant Flow Recommended Actions

Insufficient coolant through the engine can be 1. Verify that the correct passwords were entered.
identified by checking the coolant temperature at Check every character in each password. Remove
various points in the cooling system. the electrical power from the engine for 30
seconds and then retry.
During normal operation, measure temperatures at
several different points in the cooling system. This 2. Verify that Cat ET is displaying the “Enter Factory
will help to identify possible locations of restrictions. Passwords” dialog box.

If a buildup of deposit in the cooling system is 3. Use Cat ET to verify that the following information
suspected, clean the cooling system. has been entered correctly:

If the flow of coolant through the engine is not • Engine serial number
sufficient, determine the cause of the obstruction.
Make necessary repairs. • Serial number for the electronic control module

Exhaust Restriction • Serial number for Cat ET

Check the back pressure of the exhaust system. • Total tattletale
Refer to the engine's Technical Marketing Information.
• Reason code
If the back pressure exceeds the specifications for
the engine, determine the cause of the excessive For additional information, refer to Troubleshooting,
back pressure. Make the necessary repairs. “Factory Passwords”.

Excessive Load i02471377

Make sure that the load is not excessive. Reduce the ECM Will Not Communicate
load. If necessary, disengage the driven equipment
and test the engine for high coolant temperature.
with Other Systems or Display
Modules
Combustion Gas in the Coolant
SMCS Code: 1901-035
Check the cooling system for combustion gas. This
can be identified by small air bubbles in the coolant Probable Causes
during engine operation. Identify the source of the
combustion gas. Make the necessary repairs. • Electronic Control Module (ECM)

i02826488
• Electrical connectors
ECM Will Not Accept Factory • Cat Data Link
Passwords Recommended Actions
SMCS Code: 1901-035
1. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. If the ECM does not
Probable Causes communicate with Cat ET, refer to troubleshooting
without a diagnostic code Troubleshooting,
One of the following items may not be recorded “Electronic Service Tool Will Not Communicate
correctly on the Caterpillar Electronic Technician with ECM”.
(ET):
2. Ensure that the following items are correctly
• Passwords installed and undamaged. Refer to the diagnostic
functional test Troubleshooting, “Electrical
• Serial numbers Connectors - Inspect”.

• Total tattletale • ECM connector J1/P1

• Reason code • Machine connector
• Wiring to display modules
RENR5089-23 31
Troubleshooting Section

• Wiring to other control modules • Communication adapter and/or cables

3. Troubleshoot the Cat Data Link for possible • Electrical power supply to the service tool
problems. Refer to the diagnostic functional test connector
Troubleshooting, “Cat Data Link Circuit - Test”.
• Caterpillar Electronic Technician (ET) and related
hardware
i02480112

ECM Will Not Communicate • Electrical power supply to the Electronic Control
Module (ECM)
with Other Systems or Display
Modules • Flash file

SMCS Code: 1901-035 • Cat Data Link

Probable Causes Recommended Actions

Start the engine. If the engine starts, but the ECM
• Wiring and/or electrical connectors will not communicate with Cat ET, continue with
this procedure. If the engine will not start, refer
• Cat Data Link to the troubleshooting without a diagnostic code
procedure Troubleshooting, “Engine Cranks but Will
• CAN data link (if equipped) Not Start”. If the engine will not crank, refer to the
troubleshooting without a diagnostic code procedure
• Electronic Control Module (ECM) Troubleshooting, “Engine Will Not Crank”.

Recommended Actions Configuration for the Communications

1. Check for correct installation of the connectors for Adapter
the Electronic Control Module (ECM) J1/P1, J2/P2
and J3/P3. Refer to the diagnostic functional test 1. Access “Preferences” under the “Utilities” menu
Troubleshooting, “Electrical Connectors - Inspect”. on Cat ET.

2. Connect the electronic service tool to the 2. Verify that the correct “Communications Interface
service tool connector. If the ECM does not Device” is selected.
communicate with the electronic service tool,
refer to troubleshooting without a diagnostic code 3. Verify that the correct port is selected for use by
Troubleshooting, “Electronic Service Tool Will Not the communication adapter.
Communicate with ECM”.
Note: The most commonly used port is “COM 1”.
3. Troubleshoot the Cat Data Link for possible
problems. Refer to the diagnostic functional test 4. Check for any hardware that is utilizing the
Troubleshooting, “Cat Data Link Circuit - Test”. same port as the communications adapter. If any
devices are configured to use the same port, exit
4. Troubleshoot the CAN data link (if equipped) or close the software programs for that device.
for possible problems. Refer to the diagnostic
functional test Troubleshooting, “CAN Data Link Electrical Connectors
Circuit - Test”.
Check for correct installation of the J1/P1 and
J2/P2 ECM connectors and of the service tool
i02429900 connector. Refer to the diagnostic functional test
Electronic Service Tool Will Troubleshooting, “Electrical Connectors - Inspect”.

Not Communicate with ECM Communication Adapter and/or Cables

SMCS Code: 0785-035; 1901-035 1. If you are using a “Communication Adapter II”,
ensure that the firmware and driver files for the
Probable Causes communication adapter are the most current files
that are available. If the firmware and driver files
• Configuration for the communications adapter do not match, the communication adapter will not
communicate with Cat ET.
• Electrical connectors
32 RENR5089-23
Troubleshooting Section

2. Disconnect the communication adapter and the i04523833

cables from the service tool connector. Reconnect
the communication adapter to the service tool Engine Cranks but Will Not
connector. Start
3. Verify that the correct cable is being used between SMCS Code: 1000-035
the communication adapter and the service tool
connector. Refer to electronic troubleshooting
Troubleshooting, “Electronic Service Tools”. Probable Causes

Electrical Power Supply to the Service • Diagnostic codes

Tool Connector • Event codes
Verify that battery voltage is present between • Flash file
terminals A and B of the service tool connector. If the
communication adapter is not receiving power, the • Power supply for the Electronic Control Module
display on the communication adapter will be blank. (ECM)

Cat ET and Related Hardware • Starting circuit

In order to eliminate Cat ET and the related hardware • Starting aids (if applicable)
as the problem, connect Cat ET to a different engine.
If the same problem occurs on a different engine, • Engine shutdown switches (if applicable)
check Cat ET and the related hardware in order to
determine the cause of the problem. • Crank without inject (if applicable)

Electrical Power Supply to the Electronic • Air shutoff system (if applicable)
Control Module (ECM) • Engine speed/timing
Check power to the ECM. Refer to the diagnostic
functional test Troubleshooting, “Electrical Power
• Fuel supply
Supply Circuit - Test”.
• Unit injectors
Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
• Combustion

Flash File Recommended Actions

Ensure that the correct flash file is properly installed Diagnostic Codes, Event Codes, and
in the ECM. ECM Power Supply
Note: A new ECM is not programmed to any specific Certain diagnostic codes and/or event codes may
engine until a flash file has been installed. The engine prevent the engine from starting. Connect the
will not start and the engine will not communicate Caterpillar Electronic Technician (ET) and check for
with Cat ET until the flash file has been downloaded. active codes and/or for logged codes. Troubleshoot
Refer to programming parameters Troubleshooting, any codes that are present before continuing with
“Flash Programming”. this procedure.

Cat Data Link Note: If Cat ET will not communicate with the ECM,
the problem is most likely with the electrical power
Troubleshoot the Cat Data Link for possible supply to the ECM. Refer to the diagnostic functional
problems. Refer to the diagnostic functional test test Troubleshooting, “Electrical Power Supply Circuit
Troubleshooting, “Cat Data Link Circuit - Test”. - Test”.

Starting Circuit
Test the operation of the starting motor and
associated circuit components. Refer to the Systems
Operation/Testing and Adjusting manual.
RENR5089-23 33
Troubleshooting Section

Flash File Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
Verify that the correct flash file has been flashed abnormal. This message will be replaced with an
into the ECM. Refer to programming parameters engine speed once the ECM is able to calculate a
Troubleshooting, “Flash Programming”. speed from the signal.

Starting Aids 2. Ensure that the timing reference gear is installed

correctly. The engine will not start if the gear was
Air Inlet Heater (if applicable) installed backward. Check for proper orientation
between the crankshaft and camshaft drive gears.
Make sure that the air inlet heater is programmed to Correct the orientation and/or replace the drive
the On position. Refer to the diagnostic functional gear, if necessary. Refer to the Disassembly and
test Troubleshooting, “Air Inlet Heater Circuit - Test”. Assembly manual.

Ether Injection System (if applicable) Fuel Supply

Ensure that the ether injection system is programmed 1. Visually check the fuel level. Do not rely on the fuel
to “On”. Refer to the diagnostic functional test gauge only. If necessary, add fuel. If the engine
Troubleshooting, “Ether Injection System - Test”. has been run out of fuel, it will be necessary to
prime the fuel system. Refer to the Operation and
Engine Shutdown Switches (If Maintenance Manual.
Applicable) 2. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
The engine shutdown switches should be in the
problems are found with the fuel lines, repair the
OFF position. Use Cat ET to verify the status of the
lines and/or replace the lines.
shutdown switches. When a shutdown occurs, the
engine control must be in the OFF/RESET mode for
3. Check the fuel tank for foreign objects which may
at least 15 seconds before restarting the engine.
block the fuel supply.
Note: If Cat ET will not communicate with the ECM,
the problem is most likely with the electrical power NOTICE
supply to the ECM. Refer to the diagnostic functional Do not crank the engine continuously for more than
test Troubleshooting, “Electrical Power Supply Circuit 30 seconds. Allow the starting motor to cool for two
- Test”. minutes before cranking the engine again.

Crank Without Inject (If Applicable) 4. Prime the low-pressure fuel supply system if any
of the following procedures have been performed:
Ensure the crank without inject circuit is not active.
• Replacement of the fuel filters
Air Shutoff System (If Applicable)
• Service on the low-pressure fuel supply circuit
Check the air shutoff mechanism. If an engine
overspeed has occurred, the keyswitch must be • Replacement of unit injectors
cycled. There may be a manual reset for the air
shutoff mechanism that is on the engine. Note: A sight glass in the low-pressure supply line is
helpful in diagnosing air in the fuel. Refer to Testing
Engine Speed/Timing and Adjusting.

5. Check fuel quality. Cold weather adversely

NOTICE affects the characteristics of the fuel. Refer to the
Do not crank the engine continuously for more than Operation and Maintenance Manual.
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. 6. Check the fuel pressure after the fuel filter while
the engine is being cranked. Refer to Testing and
1. Crank the engine and observe the engine speed Adjusting for the correct pressure values. If the
on the Cat ET status screen. If Cat ET indicates fuel pressure is low, replace the fuel filters. If
zero rpm, refer to the diagnostic functional test the fuel pressure is still low, check the following
Troubleshooting, “Engine Speed/Timing Sensor items: fuel transfer pump, fuel transfer pump
Circuit - Test”. coupling, and fuel pressure regulating valve. Refer
to Testing and Adjusting.
34 RENR5089-23
Troubleshooting Section

Unit Injectors Contaminated Engine Oil

Perform the “Injector Solenoid Test” on Cat ET in Drain the crankcase and refill the crankcase with
order to determine if all of the injector solenoids are clean engine oil. Install new engine oil filters. Refer to
being energized by the ECM. the engine's Operation and Maintenance Manual.

Perform the cylinder cutout test on Cat ET in order to If the oil filter bypass valve is open, the oil will not be
check the performance of each cylinder. Refer to the filtered. Check the oil filter bypass valve for a weak
diagnostic functional test Troubleshooting, “Injector spring or for a broken spring. If the spring is broken,
Solenoid Circuit - Test”. replace the spring. Refer to the engine's Disassembly
and Assembly manual. Make sure that the oil bypass
Verify that the injection system is delivering the valve is operating correctly.
correct pressure. Refer to the diagnostic functional
test Troubleshooting, “Injection Actuation Pressure - Low Oil Pressure
Test”.
When some components of the engine show bearing
Note: Refer to the procedure in Special Instruction, wear in a short time, the cause can be a restriction in
REHS3819, "Procedure for Troubleshooting and a passage for engine oil.
Cleaning the Oil Rail System for the Hydraulic
Electronic Unit Injector". Verify that the repair An indicator for the engine oil pressure may indicate
eliminates the problem. sufficient pressure, but a component is worn due
to a lack of lubrication. In such a case, look at the
Combustion passage for the engine oil supply to the component.

Check for combustion problems. Leaks in Air Intake System

i03506600
A leak in the air intake system may allow unfiltered
air into the engine. Inspect the air intake system for
Engine Has Early Wear streaks which may indicate a leakage of unfiltered air.
Inspect all of the gaskets and the connections. Repair
SMCS Code: 1000-035 any leaks. Refer to Systems Operation, Testing and
Adjusting for more information.
Probable Causes Inspect the air filter. Replace the air filter, if necessary.

Engine Oil Inspect the Fuel Filters for Contamination

• Incorrect maintenance intervals 1. Remove the fuel filters. Inspect the fuel filters for
contamination. Install new fuel filters. Refer to the
• Contaminated engine oil Operation and Maintenance Manual. Determine
the cause of the contamination.
• Low oil pressure
2. Contaminants in the fuel such as hydrogen sulfide
Contaminated Air and sulfur can lead to the formation of acids in the
crankcase. Obtain a fuel analysis.
• Leaks in air intake system
i04523835
Contaminated Fuel
Engine Misfires, Runs Rough
• Inspect the fuel filters for contamination.
or Is Unstable
Recommended Actions SMCS Code: 1000-035

Incorrect Maintenance Intervals Note: If the symptom is intermittent and the symptom
cannot be repeated, refer to troubleshooting without
Use engine oil that is recommended and change the a diagnostic code Troubleshooting, “Intermittent Low
engine oil at the interval that is recommended by the Power or Power Cutout”. If the symptom is consistent
engine's Operation and Maintenance Manual. and the symptom can be repeated, continue with this
procedure.
RENR5089-23 35
Troubleshooting Section

Probable Causes Air Inlet and Exhaust System

• Diagnostic codes 1. Check for an air filter restriction. Clean plugged air
filters or replace plugged air filters. Refer to the
• Electrical connectors Operation and Maintenance Manual.

• Fuel supply 2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems
• Air inlet and exhaust system Operation/Testing and Adjusting.

• Throttle signal Throttle Signal

• Cold mode Use Cat ET to view the status for the throttle position
on the status screen. Operate the throttle from the
• Injection actuation pressure low idle position to the high idle position. The status
should be 0 percent at low idle and the status should
• Unit injectors be 100 percent at high idle.

Recommended Actions Cold Mode

Note: If the symptom only occurs under certain Use Cat ET to verify that the engine has exited cold
operating conditions (high idle, full load, engine mode. Cold mode operation may cause the engine to
operating temperature, etc.), test the engine under run rough and engine power may be limited.
those conditions. Troubleshooting the symptom
under other conditions can give misleading results. Injection Actuation Pressure
Diagnostic Codes Note: Refer to the procedure in Special Instruction,
REHS3819, "Procedure for Troubleshooting and
Check for active diagnostic codes on the Caterpillar Cleaning the Oil Rail System for the Hydraulic
Electronic Technician (ET). Troubleshoot any Electronic Unit Injector". Verify that the repair
active diagnostic codes before continuing with this eliminates the problem.
procedure.
Unit Injectors
Electrical Connectors
Note: Refer to procedure in Special Instruction,
Check the condition of the connectors at the REHS3819, "Procedure for Troubleshooting and
Electronic Control Module (ECM). Check for the Cleaning the Oil Rail System for the Hydraulic
correct installation of the J2/P2 and J1/P1 ECM Electronic Unit Injector". Verify that the repair
connectors. Check the J300/P300 injector solenoid eliminates the problem.
harness connector. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect”. i02549498

Engine Oil in Cooling System

Fuel Supply
SMCS Code: 1348-035; 1350-035
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the Probable Causes
lines and/or replace the lines.
• Engine oil cooler core
2. Check the fuel tank for debris which may block
the fuel supply. • Cylinder head gasket

3. Check for air in the low-pressure fuel supply • Water pump

circuit. Refer to Systems Operation/Testing and
Adjusting. If air is present in the low-pressure fuel
supply circuit, prime the fuel system. Refer to
Systems Operation/Testing and Adjusting.
36 RENR5089-23
Troubleshooting Section

Recommended Actions Worn Valve Guides

Engine Oil Cooler Core Inspect the valve guides for wear. Refer to the
Specification manual for the maximum permissible
1. Inspect the engine oil cooler core for leaks. If a wear of the valve guides. If necessary, recondition
leak is found, replace the oil cooler core. Refer to the cylinder head.
Disassembly and Assembly.
Worn Piston Rings
2. Drain the crankcase and refill the crankcase with
clean engine oil. Install new engine oil filters. Piston rings that have excessive wear can cause
Refer to Operation and Maintenance Manual. too much pressure in the crankcase. The additional
pressure in the crankcase will cause more than
Cylinder Head Gasket the normal amount of crankcase blowby from the
crankcase breather. Use the 8T-2700 Blowby/Air
1. Remove the cylinder head. Refer to Disassembly Flow Indicator to check the amount of crankcase
and Assembly. blowby. The test procedure is in Special Instruction,
SEHS8712. Inspect piston rings and install new
2. Check the cylinder liner projection. Refer to parts, as required.
Systems Operation/Testing and Adjusting.
Scored Cylinder Walls or Worn Cylinder
3. Install a new cylinder head gasket and new water Walls
seals in the spacer plate. Refer to Disassembly
and Assembly. Inspect the cylinder liners for damage. Hone the
cylinder liners in order to remove the scoring. If
Water Pump necessary, install new liners.

Check the weep hole in the water pump for blockage.

i02421677
Check the water pump seals.
Engine Oil Temperature Is Too
i02234636 High
Engine Oil in Exhaust System SMCS Code: 1348-035-TA
SMCS Code: 1050-035; 1348-035
Probable Causes
Probable Causes
• Engine oil level
• Failed turbocharger seals
• Engine oil cooler bypass valve
• Worn valve guide seals or faulty valve guide seals
• Engine oil cooler core
• Worn valve guides
• Engine coolant temperature
• Worn piston rings
Recommended Actions
• Scored cylinder liners or worn cylinder liners
Engine Oil Level
Recommended Actions
Use the engine oil dipstick to check for the correct oil
Failed Turbocharger Seals level. If necessary, add engine oil to the crankcase.

Check the inlet manifold and the exhaust manifold for

oil. If oil is present, replace the turbocharger.

Worn Valve Guide Seals or Faulty Valve

Guide Seals
Inspect the valve guide seals for wear and for
damage. Replace the valve guide seals, if necessary.
RENR5089-23 37
Troubleshooting Section

Engine Oil Cooler Bypass Valve Engine Oil Temperature Reading

Inspect the components of the engine oil cooler Compare the engine oil temperature reading from
bypass valve for damage. Clean the engine oil the Caterpillar Electronic Technician (ET) to the
cooler bypass valve and clean the bore for the temperature from a 6V-9130 Temperature Adapter.
valve. Ensure that the bypass valve is not stuck Verify that the readings are reasonably close.
in the open position. Replace the components of
the bypass valve, if necessary. Refer to Systems Engine Oil Cooler Bypass Valve
Operation/Testing and Adjusting for information that
is related to troubleshooting an increased engine oil Clean the engine oil cooler bypass valve and inspect
temperature. the engine oil cooler bypass valve. Clean the bore for
the valve. Ensure that the bypass valve is not stuck
Engine Oil Cooler Core in the open position. Replace the bypass valve, if
necessary. Refer to Disassembly and Assembly.
Check the engine oil cooler core for damage and for
plugging. Clean the engine oil cooler core or replace High Coolant Temperature
the engine oil cooler core, if necessary.
Check for a high coolant temperature. Resolve
Engine Coolant Temperature any problems with active event codes before
proceeding. If necessary, refer to troubleshooting
If a high coolant temperature condition is also without a diagnostic code Troubleshooting, “Coolant
occurring, refer to troubleshooting without a Temperature Is Too High”.
diagnostic code Troubleshooting, “Coolant
Temperature Is Too High”. Engine Oil Cooler

i02424562
Check for a damaged engine oil cooler or for
blockage in the engine oil cooler. Look for a restriction
Engine Oil Temperature Is Too in the passages for engine oil in the engine oil cooler.
Clean the engine oil cooler core or replace the engine
High oil cooler core.
SMCS Code: 1348-035-TA
i02455784

Probable Causes Engine Stalls at Low RPM

• Oil specifications SMCS Code: 1915-035

• Engine oil temperature reading

Probable Causes
• Engine oil cooler bypass valve
• Unit injectors
• High coolant temperature
• Fuel supply
• Engine oil cooler
• Air supply
Recommended Actions • Engine idle
Oil Specifications • Accessory equipment
Inspect the engine oil level. If necessary, add the Recommended Actions
correct engine oil. Check the condition of the engine
oil.
Unit Injectors
For information on oil specifications and/or
information on oil analysis, refer to the Operation and 1. Check for correct installation of the J1/P1 and
Maintenance manual . J2/P2 connectors for the Electronic Control
Module (ECM). Check for correct installation of the
J300/P300 connectors for the unit injectors. Refer
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
38 RENR5089-23
Troubleshooting Section

2. Perform the “Injector Solenoid Test” with the Engine Idle

Caterpillar Electronic Technician (ET) in order to
determine if all of the injector solenoids are being Check the parameter for the low engine idle (if
energized by the ECM. applicable). Refer to Troubleshooting, “System
Configuration Parameters”.
3. Perform the “Cylinder Cutout Test” with Cat ET
in order to identify any injectors that might be Accessory Equipment
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”. Check all accessory equipment for problems that
may create excessive load on the engine. Repair
Fuel Supply any damaged components or replace any damaged
components.
1. Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting.
i02419766

2. Check the fuel lines for the following problems:

restrictions, collapsed lines, and pinched lines. If
Engine Vibration
problems are found with the fuel lines, repair the SMCS Code: 1000-035
lines and/or replace the lines.

3. Check the fuel tank for foreign objects which may Probable Causes
block the fuel supply.
• Vibration damper
NOTICE
Do not crank the engine continuously for more than
• Engine supports
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
• Driven equipment
• Engine misfiring or running rough
4. Prime the fuel system if any of the following
procedures have been performed: Recommended Actions
• Replacement of the fuel filters Vibration Damper
• Service on the low pressure fuel supply circuit Check the vibration damper for damage. Install a
new vibration damper, if necessary. Inspect the
• Replacement of unit injectors mounting bolts for damage and/or for wear. Replace
any damaged bolts. Refer to the Disassembly and
Note: A sight glass in the low pressure supply line is
Assembly manual.
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting.
Engine Supports
5. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and Inspect the mounts and the brackets while you run
Maintenance Manual. the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten
6. Check the fuel pressure after the fuel filter all of the mounting bolts. Install new components, if
while the engine is being cranked. For the necessary.
correct pressure values, refer to the Systems
Operation/Testing and Adjusting manual. If the Driven Equipment
fuel pressure is low, replace the fuel filters. If the
fuel pressure is still low, check the following items: Check the alignment and the balance of the driven
fuel transfer pump, fuel transfer pump coupling, equipment.
and fuel pressure regulating valve.
Engine Misfiring or Running Rough
Air Supply
Refer to troubleshooting without a diagnostic code
Check for restrictions in the air inlet system. Refer to Troubleshooting, “Engine Misfires, Runs Rough or
Systems Operation/Testing and Adjusting. Is Unstable”.
RENR5089-23 39
Troubleshooting Section

i02445247 Battery Cables and/or Batteries

Engine Will Not Crank 1. Inspect the battery disconnect switch, bus bars,
battery posts, and battery cables for loose
SMCS Code: 1000-035 connections and corrosion. If the battery cables
are corroded, remove the battery cables and clean
Probable Causes the battery cables. Tighten any loose connections.

• Engine shutdown switches (if applicable) 2. Inspect the batteries.

• Circuit breakers a. Charge the batteries. Refer to Special

Instruction, SEHS7633, “Battery Test
• Battery cables Procedure”.

• Batteries b. Load test the batteries. Refer to Special

Instruction, SEHS9249, “Use of 4C-4911
• Starting circuit Battery Load Tester for 6, 8 and 12 Volt Lead
Acid Batteries”.
• Flywheel ring gear
Starting Circuit
• Driven equipment
Test the operation of the starting motor and
• Engine accessories associated circuit components. Refer to the Systems
Operation/Testing and Adjusting manual.
• Hydraulic cylinder lock
Driven Equipment and/or Engine
• Internal engine problem Accessories
Recommended Actions 1. Ensure free movement of the driveline.

Engine Shutdown Switches (If 2. Ensure that the timing pin was not left in the
Applicable) flywheel housing.

The engine shutdown switches should be in the OFF 3. Remove any engine accessories that may lock
position. Use Caterpillar Electronic Technician (ET) up the engine. Inspect the condition of the
to verify the status of the shutdown switches. When a accessories.
shutdown occurs, the engine control must be in the
OFF/RESET mode for at least 15 seconds before The following list illustrates examples of engine
restarting the engine. accessories that may lock up the engine:

Note: If Cat ET will not communicate with the • Fuel transfer pump
Electronic Control Module (ECM), the problem
is most likely with the electrical power supply to • Air compressor
the ECM. Refer to the diagnostic functional test
Troubleshooting, “Electrical Power Supply Circuit - • Engine oil pump
Test”.
Hydraulic Cylinder Lock
Circuit Breakers
Check for fluid in the cylinders (hydraulic cylinder
Check the state of each of the circuit breakers. Reset lock) by removing the individual unit injectors.
the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine Note: Be sure to drain the fuel from the cylinder head
the condition that caused the circuit breaker to trip. prior to removing the injectors. Fuel will flow from the
Make the necessary repairs. cylinder head into the cylinders when the unit injector
is removed.

Internal Engine Problem

1. Inspect the internal components for the following
conditions:

• Seizure
40 RENR5089-23
Troubleshooting Section

• Broken components Atmospheric Pressure Sensor

• Bent components 1. Remove the sensor.

2. Remove debris, moisture, or ice from the sensor.

i02432467

Excessive Black Smoke 3. Install the sensor.

SMCS Code: 1088-035 4. Check the Caterpillar Electronic Technician (ET)

for active diagnostic codes on the sensor. If no
active diagnostic code exists, the sensor may be
Probable Causes used. The correct reading for the atmospheric
pressure is between 50 kPa (7.25 psi) and
• Air inlet or exhaust system 100 kPa (14.5 psi).

• Engine speed/timing sensor Boost Pressure Sensor, “Fuel Position”,

• Atmospheric pressure sensor and/or “FRC Fuel Limit”

• Boost pressure sensor 1. Monitor the status of “Fuel Position” and “Rated
Fuel Limit” while the engine is operating under full
• “Fuel Position” and/or “FRC Fuel Limit” load. If “Fuel Position” equals “Rated Fuel Limit”
and “Fuel Position” is less than “FRC Fuel Limit”,
• Flash file the Electronic Control Module (ECM) is providing
the correct control. Otherwise, proceed to the next
• Fuel quality Step.

• Valve adjustment 2. Verify that there are no active diagnostic codes for
the boost pressure sensor.
Recommended Actions 3. Monitor the status of “Boost Pressure” and
“Atmospheric Pressure” on Cat ET. When the
Air Inlet or Exhaust System engine is not running, “Boost Pressure” should be
0 kPa (0 psi).
1. Check the air inlet system for restrictions and/or
for leaks. Note: A problem with the “FRC Fuel Limit” will only
cause black smoke during acceleration. A problem
a. Check for an air filter restriction. with the “FRC Fuel Limit” will not cause black smoke
during steady state operation.
b. Perform a visual inspection of the system for
restrictions and/or for leaks in the air inlet Flash File
piping .
Verify that the correct flash file is installed. Refer
2. Ensure that the turbocharger is in good repair. to Troubleshooting, “Flash Programming” for
information.
3. Check the exhaust system for restrictions.

4. Repair any leaks that were found. Remove

Fuel Quality
any restrictions that were found. Replace any
Cold weather adversely affects the characteristics of
damaged components that were found.
the fuel. Refer to Operation and Maintenance Manual
for information on improving the characteristics of the
Engine Speed/Timing fuel during cold weather operation.
1. Check the calibration of the engine speed/timing
sensor. Refer to Troubleshooting, “Engine
Valve Adjustment
Speed/Timing Sensor - Calibrate”.
Check the valve adjustment. Refer to Systems
Operation/Testing and Adjusting for information on
2. Verify that the crankshaft and the camshaft drive
valve adjustments.
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
RENR5089-23 41
Troubleshooting Section

i02410997 i02430014

Excessive Engine Oil Excessive Fuel Consumption

Consumption SMCS Code: 1250-035
SMCS Code: 1348-035
Probable Causes
Probable Causes • Engine operation
• Oil leaks • Fuel leaks
• Oil level • Fuel quality
• Turbocharger seal • Engine speed/timing
• Internal engine wear • Unit injectors
Recommended Actions • Air inlet and exhaust system

Oil Leaks • Accessory equipment

Check the engine compartment for oil leaks. Repair Recommended Actions
any oil leaks that are identified.
Engine Operation
Oil Level
Use the Caterpillar Electronic Technician (ET) to
Check the engine oil level. Too much oil in the engine check the “Current Totals” for excessive idle time
crankcase can cause the engine to consume oil. and/or for a high load factor which would be indicative
Remove excessive engine oil from the crankcase. of poor operating habits.
Ensure that the dipstick is properly calibrated Note: Engine operation may also be affected by
and/or that the dipstick is correct for the application. environmental conditions such as wind and snow.
Calibrate the dipstick and/or replace the dipstick.
Fuel Leaks
Turbocharger
Check the fuel pressure during engine cranking.
Check for turbocharger shaft seal leakage. Remove Check the fuel pressure after the fuel filter. Refer
the air inlet piping and the exhaust outlet piping from to Systems Operation/Testing and Adjusting for the
the turbocharger. Check the compressor wheel and correct pressure values. If the fuel pressure is low,
the turbine for evidence of an oil leak. If necessary, replace the fuel filters. If the fuel pressure is still low,
repair the turbocharger or replace the turbocharger. check the following items: fuel transfer pump, fuel
Refer to Systems Operation/Testing and Adjusting. transfer pump coupling, and fuel pressure regulating
valve.
Internal Engine Wear
Fuel Quality
Internal engine wear can cause excessive oil leakage
into the combustion area of the cylinders. Excessive Cold weather adversely affects the characteristics
wear on the following components may cause oil of the fuel. Refer to the Operation and Maintenance
consumption: Manual for information on improving the
characteristics of the fuel during cold weather
• Piston rings operation.

• Valve guides Engine Speed/Timing

Check for excessive crankcase blowby at the
Perform a speed/timing sensor calibration. Refer to
engine crankcase breather. Refer to Systems
the calibration procedure Troubleshooting, “Engine
Operation/Testing and Adjusting. Speed/Timing Sensor - Calibrate”.
42 RENR5089-23
Troubleshooting Section

Unit Injectors Valve Lash

1. Check for correct installation of the J1/P1 Adjust the engine valve lash. Refer to the engine's
and J2/P2 Electronic Control Module (ECM) Systems Operation/Testing and Adjusting manual.
connectors and the unit injector connectors. Refer
to the diagnostic functional test Troubleshooting, Valve Train Components
“Electrical Connectors - Inspect”.
1. Inspect the following components of the valve
2. Perform the “Injector Solenoid Test” on Cat ET in train:
order to determine if all of the injector solenoids
are being energized by the ECM. • Rocker arms
3. Perform the “Cylinder Cutout Test” on Cat ET • Pushrods
in order to identify any injectors that might be
misfiring. Refer to the diagnostic functional test • Valve lifters
Troubleshooting, “Injector Solenoid Circuit - Test”.
• Camshaft
Air Inlet and Exhaust System
• Valve stems
1. Inspect the air filter for a restriction. If the air filter
shows signs of being plugged, clean the air filter • Rocker shafts
or replace the air filter.
2. Check the components for the following conditions:
2. Check the air inlet and exhaust system for abnormal wear, excessive wear, straightness, and
restrictions and/or for leaks. Refer to Systems cleanliness. Replace parts, if necessary.
Operation/Testing and Adjusting.
Note: If you replace the camshaft, you must also
Accessory Equipment replace the valve lifters.

Check all accessory equipment for problems that 3. Adjust the engine valve lash. Refer to the engine's
may create excessive load on the engine. Repair Systems Operation/Testing and Adjusting manual.
any damaged components or replace any damaged
components. i03814032

i02424626
Excessive White Smoke
Excessive Valve Lash SMCS Code: 1088-035

SMCS Code: 1105-035 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
Probable Causes a problem.

• Lubrication
Probable Causes
• Valve lash
• Diagnostic codes
• Valve train components
• Cold mode
Recommended Actions • Starting aids (if applicable)
Lubrication • Water temperature regulators
1. Remove the valve mechanism covers. Refer to • Unit injectors
the engine's Disassembly and Assembly manual.
• Flash file
2. Check the lubrication in the valve compartment.
Ensure that there is adequate engine oil flow in • Fuel supply
the valve compartment. The passages for the
engine oil must be clean. • Component wear
• Cooling system
RENR5089-23 43
Troubleshooting Section

• Engine timing 2. Check for correct fuel pressure.

3. Check fuel quality. Low cetane fuel can create

Recommended Actions white smoke. Replace the fuel with a higher
cetane fuel. In temperatures below 0 °C (32 °F),
Diagnostic Codes check for solidified fuel (wax). Refer to Applied
Failure Analysis, SEBD0717, “Diesel Fuels And
Check for active diagnostic codes on the Caterpillar Your Engine”.
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure. 4. If necessary, replace the fuel with a higher cetane
fuel.
Cold Mode
Component Wear
Use Cat ET to verify that the engine has exited
cold mode. If the engine is operating in cold mode, Check the engine for the following problems:
an indicator will be displayed on the top of any of Excessive valve wear, piston wear, ring wear, liner
the status screens. Cold mode operation may slow wear, and reduced compression pressure.
throttle response.
Cooling System
Starting Aids
Check for a coolant leak. Check for coolant in the
Air Inlet Heater (if applicable) cylinder and for coolant in the exhaust system. Refer
to the Disassembly and Assembly manual.
Ensure that the air inlet heater is operating
correctly. Refer to the diagnostic functional test
Troubleshooting, “Air Inlet Heater Circuit - Test”.
Engine Timing
Check the calibration of the engine speed/timing
Ether Injection (if applicable)
sensors. Refer to Troubleshooting, “Engine
Ensure that the ether injection system is operating Speed/Timing Sensor - Calibrate”.
correctly. Refer to the diagnostic functional test
Verify that the crankshaft and camshaft drive
Troubleshooting, “Ether Injection System - Test”.
gears are properly oriented. Refer to the engine's
Disassembly and Assembly manual.
Water Temperature Regulators
1. Check the water temperature regulators for correct i02514091
operation. Refer to Testing and Adjusting.
Exhaust Temperature Is Too
2. If necessary, replace the water temperature High
regulators. Refer to Disassembly and Assembly.
SMCS Code: 1088-035-TA
Unit Injectors
Probable Causes
1. Use Cat ET in order to perform the cylinder
cutout test. Use similar conditions for the test
that were experienced during operation. Refer
• Diagnostic codes
to the diagnostic functional test Troubleshooting,
“Injector Solenoid Circuit - Test”.
• Electrical connectors

2. Cut out the individual cylinder for 30 to 60

• Air inlet and exhaust system
seconds. Verify that the smoke decreases.
Recommended Actions
Flash File
Diagnostic Codes
Verify that the correct flash file is installed. Refer to
programming parameters Troubleshooting, “Flash Connect the Caterpillar Electronic Technician (ET)
Programming”. and check for active diagnostic codes. Troubleshoot
any active diagnostic codes before continuing with
Fuel Supply this procedure.

1. Inspect the fuel system components.

44 RENR5089-23
Troubleshooting Section

Electrical Connectors
NOTICE
Check for correct installation of the J2/P2 Electronic Do not allow the pressure on the cooling system
Control Module (ECM) connector and of the to exceed 103 kPa (15 psi) during the test. Damage
J300/P300 connector that is for the injectors. Refer to the cooling system may result from applying
to the diagnostic functional test Troubleshooting, excessive pressure.
“Electrical Connectors - Inspect”.
3. Pressurize the cooling system in order to identify
Air Inlet and Exhaust System the injector sleeve that is leaking. Closely inspect
the sealing joint around the top of the injector
1. Check the air inlet manifold pressure. Check for
sleeve. Small amounts of coolant will be dripping
air inlet restrictions and/or leaks. Refer to Systems
from the injector sleeve that is leaking.
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”.
4. Remove the injector sleeve that is leaking.
Carefully inspect the sleeve for damage. If there
2. Check for leaks between the exhaust manifold and
are visible signs of damage to the injector sleeve,
the turbocharger. Check for exhaust restrictions.
replace the sleeve. Replace the O-ring seals
Refer to Systems Operation/Testing and Adjusting,
for the injector sleeve and reinstall the sleeve.
“Air Inlet and Exhaust System”.
Replace any damaged components.

i04807796 Note: Coolant may also be contaminating the fuel

system. After the engine is shut down, the retention
Fuel in Cooling System of pressure in the cooling system may cause the
transfer of coolant into the fuel system. Visually
SMCS Code: 1350-035 inspect the fuel tank for coolant. The contamination
of coolant in the fuel system may damage injectors
Probable Causes and other fuel system components. Ensure that all of
the fuel system components are in good repair prior
to returning the engine to service.
Injector Sleeve or Injector Sleeve Seal
• Leaking injector sleeve and/or damaged seal NOTICE
Do not crank the engine if a cylinder is full of fluid.
Catastrophic damage can occur to the engine.
Recommended Actions
Leaking injector sleeve and/or a damaged 5. Evacuate all cylinders of fluid before trying to start
the engine.
seal
1. Remove the valve mechanism covers. i02119587

2. Remove the fuel injectors from the cylinder head. Fuel Dilution of Engine Oil
Refer to the Disassembly and Assembly manual SMCS Code: 1348-035
for details.
Probable Causes
• Leaking seals on the case of the unit injector or on
Personal injury can result from hot coolant, steam the barrel of the unit injector
and alkali.
• Leaking seals on the fuel line adapter for the
At operating temperature, engine coolant is hot cylinder head
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or • Excessive leakage from the unit injector tip or
steam. Any contact can cause severe burns. breakage of the unit injector tip

Remove filler cap slowly to relieve pressure only • Cracked fuel supply manifold
when engine is stopped and radiator cap is cool
enough to touch with your bare hand. • Leaking seal on the fuel transfer pump
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
RENR5089-23 45
Troubleshooting Section

Recommended Actions Recommended Actions

Leaking Seals on the Case of the Unit Diagnostic Codes and/or Event Codes
Injector or on the Barrel of the Unit
Certain diagnostic codes and/or event codes may
Injector cause an engine shutdown. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
Look for signs of damage to the seals for the unit and for logged codes. Troubleshoot any codes that
injectors. Replace any seals that are leaking.
are present prior to continuing with this procedure.

Leaking Seals on the Fuel Line Adapter Electrical Connectors

for the Cylinder Head
1. Check for correct installation of the J1/P1 and
Look for signs of damage to the seals on the fuel line J2/P2 connectors for the Electronic Control Module
adapter for the cylinder head. Repair any leaking fuel (ECM). Also, thoroughly inspect the connectors
lines or components and/or replace any leaking fuel for the engine speed/timing sensors. Refer to
lines or components. the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
Excessive Leakage from the Unit Injector
Tip or Breakage of the Unit Injector Tip 2. Inspect the battery wires from the ECM to the
battery compartment. Refer to the Schematic for
Look for signs of damage to the unit injectors. If specific wiring information. Check the unit injector
necessary, repair the unit injectors or replace the unit connectors and associated wiring for damage, or
injectors. for intermittent problems. Inspect the wires and
connectors to all circuit protection for the engine.
Check the power and ground connections to
Cracked Fuel Supply Manifold the ECM. Check any engine shutdown switches
and associated wiring. Refer to the diagnostic
Look for signs of damage to the fuel supply manifold. functional test Troubleshooting, “Electrical Power
Supply Circuit - Test”.
Leaking Fuel Transfer Pump Seal
Air Inlet and Exhaust Restrictions
Ensure that the weep hole is not plugged. If
necessary, repair the fuel transfer pump or replace Check the air inlet system for the following problems:
the fuel transfer pump. restrictions, collapse, and pinched line. Repair the
lines and/or replace the lines.
i02881460
Check for an air filter restriction. Replace plugged air
Intermittent Engine Shutdown filters and/or clean filters. Repair any leaks.

SMCS Code: 1000-035 Circuit Breakers

Note: Use this procedure only if the engine shuts Check the state of each of the circuit breakers. Reset
down completely during operation. the circuit breakers if the circuit breakers are tripped.
Prior to returning the engine to service, determine
Probable Causes the condition that caused the circuit breaker to trip.
Make the necessary repairs.
• Diagnostic codes
Fuel Supply
• Event codes
1. Visually check the fuel level in the fuel tank. Do not
• Electrical connectors rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
• Air inlet and exhaust restrictions fuel, it will be necessary to prime the fuel system.
Refer to the Operation and Maintenance Manual.
• Circuit breakers
2. Check the fuel lines for the following problems:
• Fuel supply restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
46 RENR5089-23
Troubleshooting Section

3. Check the fuel tank for debris or foreign objects Recommended Actions
which may block the fuel supply.
Note: If the problem only occurs under certain
NOTICE conditions, test the engine under those conditions.
Do not crank the engine continuously for more than Examples of certain conditions are high engine
30 seconds. Allow the starting motor to cool for two idle, full load, or a specific operating temperature.
minutes before cranking the engine again. Troubleshooting the symptoms under other
conditions may give misleading results.

4. Prime the fuel system if any of the following Diagnostic Codes and Event Codes
procedures have been performed:
Certain diagnostic codes and/or event codes may
• Replacement of the fuel filters cause poor performance. Connect the Caterpillar
Electronic Technician (ET) and check for active codes
• Service on the low pressure fuel supply circuit and/or logged codes. Troubleshoot any codes that
are present before continuing with this procedure.
• Replacement of unit injectors
Note: Check the fuel system for air. Refer to the
Throttle Signal
Systems Operation/Testing and Adjusting manual.
Monitor the status for “Throttle Position” on Cat ET.
Verify that the status for “Throttle Position” is stable
5. Check fuel quality. Cold weather adversely
and that the engine is able to reach high idle speed.
affects the characteristics of the fuel. Refer to the
Refer to the appropriate diagnostic functional test for
Operation and Maintenance Manual.
your application:
6. Check the filtered fuel pressure while the
engine is being cranked. Refer to Systems • Troubleshooting, “Throttle Position Sensor Circuit -
Test”
Operation/Testing and Adjusting.

If the fuel pressure is low, replace the fuel filters. • Troubleshooting, “Throttle Switch Circuit - Test”
Clean the primary filter/water separator of debris.
Refer to the Operation and Maintenance Manual. • Troubleshooting, “Speed Control - Test”

If the fuel pressure is still low, check the operation ECM Power Supply
of the fuel pressure regulating valve. Also, check
for the proper operation of the fuel transfer pump. 1. Inspect the circuit between the ECM and the
Refer to Systems Operation/Testing and Adjusting. batteries for poor connections and damage.
Inspect the wiring, the connectors, and the power
relay. Refer to the Electrical System Schematic.
i02424639
2. Inspect the circuit between the ECM and the
Intermittent Low Power or keyswitch. Inspect the wires, the connectors, and
Power Cutout the keyswitch. Refer to the diagnostic functional
test Troubleshooting, “Electrical Power Supply
SMCS Code: 1000-035 Circuit - Test”.

Note: Use this procedure only if the engine does not Injection Actuation Pressure
shut down completely during operation.
Ensure that the injection actuation system is
Probable Causes operating properly. Refer to the diagnostic functional
test Troubleshooting, “Injection Actuation Pressure -
• Diagnostic codes Test”.

• Event codes Fuel Supply

• Throttle signal 1. Visually check the fuel level. Do not rely on the fuel
gauge only. If necessary, add fuel. If the engine
• Power supply to the Electronic Control Module has been run out of fuel, it will be necessary to
(ECM) prime the fuel system. Refer to the Operation and
Maintenance Manual.
• Injection actuation pressure
• Fuel supply
RENR5089-23 47
Troubleshooting Section

2. Check the fuel lines for the following problems: • Power supply to the Electronic Control Module
restrictions, collapsed lines, and pinched lines. If (ECM)
problems are found with the fuel lines, repair the
lines and/or replace the lines. • Injection actuation pressure
3. Check the fuel tank for foreign objects which may • Unit Injectors
block the fuel supply.
• Fuel supply
NOTICE
Do not crank the engine continuously for more than Recommended Actions
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again. Note: If the problem only occurs under certain
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
4. Prime the fuel system if any of the following idle, full load, or a specific operating temperature.
procedures have been performed: Troubleshooting the symptoms under other
conditions may give misleading results.
• Replacement of the fuel filters
• Service on the low pressure fuel supply circuit Diagnostic Codes and Event Codes

• Replacement of unit injectors Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar
Note: A sight glass in the low pressure supply line is Electronic Technician (ET) and check for active codes
helpful in diagnosing air in the fuel. Refer to Testing and/or logged codes. Troubleshoot any codes that
and Adjusting. are present before continuing with this procedure.

5. Check the fuel filters. Throttle Signal

6. Cold weather adversely affects the characteristics Monitor the status for “Throttle Position” on Cat ET.
of the fuel. Refer to the Operation and Verify that the status for “Throttle Position” is stable
Maintenance Manual. and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic functional test for
7. Check the fuel pressure during engine cranking. your application:
Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting. If the • Troubleshooting, “Throttle Position Sensor Circuit -
fuel pressure is low, replace the fuel filters. If the Test”
fuel pressure is still low, check the following items:
fuel transfer pump, fuel transfer pump coupling, • Troubleshooting, “Throttle Switch Circuit - Test”
and fuel pressure regulating valve.
• Troubleshooting, “Speed Control - Test”
i02445637
Decelerator Position Sensor (if
Intermittent Low Power or applicable)
Power Cutout Monitor the signal for the decelerator position sensor
SMCS Code: 1000-035 on Cat ET. Verify that the signal for the sensor is
stable at different set points between the low idle
Note: Use this procedure only if the engine does not position and the high idle position.
shut down completely during operation.
ECM Power Supply
Probable Causes 1. Inspect the circuit between the ECM and the
batteries for poor connections and damage.
• Diagnostic codes Inspect the wiring, the connectors, and the power
relay. Refer to the Electrical System Schematic.
• Event codes
2. Inspect the circuit between the ECM and the
• Throttle signal keyswitch. Inspect the wires, the connectors, and
the keyswitch. Refer to the diagnostic functional
• Decelerator position sensor (if applicable) test Troubleshooting, “Electrical Power Supply
Circuit - Test”.
48 RENR5089-23
Troubleshooting Section

Injection Actuation Pressure 6. Cold weather adversely affects the characteristics

of the fuel. Refer to the Operation and
Ensure that the injection actuation system is Maintenance Manual.
operating properly. Refer to the diagnostic functional
test Troubleshooting, “Injection Actuation Pressure - 7. Check the fuel pressure during engine cranking.
Test”. Check the fuel pressure after the fuel filter. Refer
to Systems Operation/Testing and Adjusting. If the
Unit Injectors fuel pressure is low, replace the fuel filters. If the
fuel pressure is still low, check the following items:
Perform the “Injector Solenoid Test” on Cat ET in fuel transfer pump, fuel transfer pump coupling,
order to determine if all of the injector solenoids are and fuel pressure regulating valve.
being energized by the ECM.
i02430113
Perform the cylinder cutout test on Cat ET in order to
check the performance of each cylinder. Refer to the Low Engine Oil Pressure
diagnostic functional test Troubleshooting, “Injector
Solenoids Circuit - Test”. SMCS Code: 1348-035-LP

Verify that the injection system is delivering the NOTICE

correct pressure. Refer to the diagnostic functional Do not operate engine with low oil pressure. Engine
test Troubleshooting, “Injection Actuation Pressure - damage will result. If measured engine oil pressure is
Test”. low, discontinue engine operation until the problem is
corrected.
Fuel Supply
1. Visually check the fuel level. Do not rely on the fuel Probable Causes
gauge only. If necessary, add fuel. If the engine
has been run out of fuel, it will be necessary to • Engine oil level
prime the fuel system. Refer to the Operation and
Maintenance Manual. • Engine oil filters and oil filter bypass valve
2. Check the fuel lines for the following problems: • Engine oil pump
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the • Engine oil cooler
lines and/or replace the lines.
• Fuel dilution
3. Check the fuel tank for foreign objects which may
block the fuel supply. • Engine wear

NOTICE Recommended Actions

Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Engine Oil Level
minutes before cranking the engine again.
Inspect the engine oil level. If engine oil is low add
4. Prime the fuel system if any of the following engine oil. Refer to the Operation and Maintenance
procedures have been performed: Manual.

• Replacement of the fuel filters Engine Oil Filters and Oil Filter Bypass
Valve
• Service on the low pressure fuel supply circuit
Check the service records of the engine for
• Replacement of unit injectors information that is related to the last oil change. If
necessary, perform an oil change on the engine and
Note: A sight glass in the low pressure supply line is replace the engine oil filters.
helpful in diagnosing air in the fuel. Refer to Testing
and Adjusting. Check the operation of oil filter bypass valve. Clean
the bypass valve and the housing. If necessary,
5. Check the fuel filters. install new parts.
RENR5089-23 49
Troubleshooting Section

Engine Oil Pump • Air inlet and exhaust system

Check for blockage of the inlet screen for the engine
oil pump. Check the components of the engine oil
Recommended Actions
pump for excessive wear. If necessary, repair the oil Note: If the problem only occurs under certain
pump or replace the oil pump.
conditions, test the engine under those conditions.
Examples of certain conditions are high engine
Oil Cooler speed, full load and engine operating temperature.
Troubleshooting the symptoms under other
Check the engine's oil cooler for plugging or conditions can give misleading results.
blockage. Clean the engine oil cooler core(s) and/or
install new engine oil cooler core(s).
Diagnostic Codes and Event Codes
Fuel Dilution Certain diagnostic codes and/or event codes may
cause poor performance. Connect the Caterpillar
Check for presence of fuel in lubricating oil. Refer Electronic Technician (ET) and check for active codes
to the troubleshooting without a diagnostic code and/or logged codes. Wait at least 30 seconds in
procedure Troubleshooting, “Fuel Dilution of Engine order for any codes to become active. Troubleshoot
Oil”. any codes that are present before continuing with
this procedure.
Engine Wear
Note: Although a sensor's signal may be in the
Inspect the camshaft and/or camshaft bearings operational range of the sensor, certain failure modes
for excessive wear. Inspect the crankshaft and/or of a sensor may produce an output signal that does
crankshaft bearings. Excessive wear to discrete not represent an accurate measurement. Use Cat ET
components may be an indication of a blocked oil to check that the pressures and the temperatures are
passage. Use an oil pressure gauge to check the fluctuating normally. Also check that the values are
oil pressure at the main oil gallery. This will help reasonable for the conditions that are present.
determine if the excessive wear is from low system
pressure or from passages that are blocked. Programmable Parameters
If the Electronic Control Module (ECM) has been
i02466495
replaced, compare the values on the engine
Low Power/Poor or No information plate to the following parameters from
Cat ET:
Response to Throttle
• FRC offset
SMCS Code: 1000-035
• Full Load Setting (FLS)
Probable Causes
• Full Torque Setting (FTS)
• Active engine derate
Determine the type of throttle that is used in the
• Diagnostic codes application. Program any parameters that may be
associated with the throttle. Program any parameters
• Event codes that may be associated with this troubleshooting
procedure.
• Programmable parameters
Note: If the parameters are not programmed
• Cold mode correctly, then the engine will have poor performance.

• Electrical connectors Cold Mode

• Throttle signal Verify that the engine has exited cold mode. If the
engine is operating in cold mode, an indicator will
• Circuit for electronic unit injectors be displayed on the top of any of the status screens
on the electronic service tool. Cold mode operation
• Injection actuation pressure may slow throttle response.

• Fuel supply
• Intake manifold (boost) pressure sensor
50 RENR5089-23
Troubleshooting Section

Electrical Connectors Fuel Supply

Check the associated wiring for damage, for 1. Visually check the fuel level in the fuel tank. Do not
abrasion, for corrosion or for incorrect attachment on rely on the fuel gauge only. If necessary, add fuel
the following connectors: Electronic Control Module to the fuel tank. If the engine has been run out of
(ECM) connectors and customer connector. Refer fuel, it will be necessary to prime the fuel system.
to the diagnostic functional test Troubleshooting, Refer to the Operation and Maintenance Manual.
“Electrical Connectors - Inspect”.
2. Check the fuel lines for the following problems:
Throttle Signal restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
Monitor the status for “Throttle Position” on Cat ET. lines and/or replace the lines.
Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed. 3. Check the fuel tank for debris or foreign objects
Refer to the appropriate diagnostic functional test for which may block the fuel supply.
your application:
NOTICE
• Troubleshooting, “Throttle Position Sensor Circuit - Do not crank the engine continuously for more than
Test” 30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
• Troubleshooting, “Throttle Switch Circuit - Test”
• Troubleshooting, “Speed Control - Test” 4. Prime the fuel system if any of the following
procedures have been performed:
Unit Injectors
• Replacement of the fuel filters
1. Use Cat ET to perform the injector solenoid test
in order to determine if all of the injector solenoids • Service on the low pressure fuel supply circuit
are being energized by the ECM.
• Replacement of unit injectors
2. Perform the cylinder cutout test on Cat ET in order
Note: A sight glass in the low pressure supply line is
to check the performance of each cylinder. Refer
helpful in diagnosing air in the fuel. Refer to Testing
to the diagnostic functional test Troubleshooting,
and Adjusting.
“Injector Solenoids Circuit - Test”.
5. Check fuel quality. Cold weather adversely
Injection Actuation Pressure affects the characteristics of the fuel. Refer to the
Operation and Maintenance Manual.
1. Check the engine oil level. Engine oil supplies the
injection actuation pressure circuit. The engine oil 6. Check the filtered fuel pressure while the engine
must be kept at the proper level for fuel injection. is being cranked. Refer to Testing and Adjusting.
If the fuel pressure is low, replace the fuel filters.
2. If service has recently been performed on the If the fuel pressure is still low, check the following
engine, air may be present in the injection items: fuel transfer pump, fuel transfer pump
actuation pressure circuit. Allow the engine to fully coupling, and fuel pressure regulating valve. Refer
warm up and operate the engine under load in to Testing and Adjusting.
order to purge the air from the injection actuation
pressure circuit.
Intake Manifold (Boost) Pressure Sensor
3. Check the injection actuation pressure. Refer to
1. With the engine at full load, monitor “Fuel Position”
the diagnostic functional test Troubleshooting,
and “Rated Fuel Limit” on the status screen. If
“Injection Actuation Pressure - Test”.
“Fuel Position” does not equal “Rated Fuel Limit”,
then check intake manifold (boost) pressure.
4. Check the operation of the injection actuation
pressure control valve. Refer to the diagnostic
2. Monitor intake manifold (boost) pressure and
functional test Troubleshooting, “Injection
atmospheric pressure for normal operation on the
Actuation Pressure Control Valve Circuit - Test”.
status screen.
RENR5089-23 51
Troubleshooting Section

Air Inlet and Exhaust System Diagnostic Codes and Event Codes
Check the air inlet and exhaust systems for Certain diagnostic codes and/or event codes may
restrictions and for leaks. Refer to the Operation cause poor performance. Connect the Caterpillar
and Maintenance Manual. Look for an indication of Electronic Technician (ET) and check for active codes
the warning lamp or restriction indicators that are and/or logged codes. Wait at least 30 seconds in
tripped if the filters are equipped with these devices. order for any codes to become active. Troubleshoot
These indicators are associated with plugged filters. any codes that are present before continuing with
Replace the plugged air filters or clean the plugged this procedure.
air filters per the guidelines of the Operation and
Maintenance Manual. Repair any leaks that are Note: Although a sensor's signal may be in the
found in the system. operational range of the sensor, certain failure modes
of a sensor may produce an output signal that does
not represent an accurate measurement. Use Cat ET
i02452810
to check that the pressures and the temperatures are
Low Power/Poor or No fluctuating normally. Also check that the values are
reasonable for the conditions that are present.
Response to Throttle
Programmable Parameters
SMCS Code: 1000-035
If the ECM has been replaced, compare the values
Probable Causes on the engine information plate to the following
parameters from Cat ET:
• Active engine derate
• FRC offset
• Diagnostic codes
• Full Load Setting (FLS)
• Event codes
• Full Torque Setting (FTS)
• Programmable parameters
Determine the type of throttle that is used in the
• Cold mode application. Program any parameters that may be
associated with the throttle. Program any parameters
• Electrical connectors that may be associated with this troubleshooting
procedure.
• Throttle signal
Note: If the parameters are not programmed
• Decelerator position sensor (if applicable) correctly, then the engine will have poor performance.

• Circuit for electronic unit injectors Cold Mode

• Injection actuation pressure Verify that the engine has exited cold mode. If the
engine is operating in cold mode, an indicator will
• Fuel supply be displayed on the top of any of the status screens
on the electronic service tool. Cold mode operation
• Intake manifold (boost) pressure sensor may slow throttle response.

• Air inlet and exhaust system Electrical Connectors

Recommended Actions Check the associated wiring for damage, for
abrasion, for corrosion or for incorrect attachment on
Note: If the problem only occurs under certain the following connectors: Electronic Control Module
conditions, test the engine under those conditions. (ECM) connectors and customer connector. Refer
Examples of certain conditions are high engine to the diagnostic functional test Troubleshooting,
speed, full load and engine operating temperature. “Electrical Connectors - Inspect”.
Troubleshooting the symptoms under other
conditions can give misleading results.
52 RENR5089-23
Troubleshooting Section

Throttle Signal Fuel Supply

Monitor the status for “Throttle Position” on Cat ET. 1. Visually check the fuel level in the fuel tank. Do not
Verify that the status for “Throttle Position” is stable rely on the fuel gauge only. If necessary, add fuel
and that the engine is able to reach high idle speed. to the fuel tank. If the engine has been run out of
Refer to the appropriate diagnostic functional test for fuel, it will be necessary to prime the fuel system.
your application: Refer to the Operation and Maintenance Manual.

• Troubleshooting, “Throttle Position Sensor Circuit - 2. Check the fuel lines for the following problems:
Test” restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
• Troubleshooting, “Throttle Switch Circuit - Test” lines and/or replace the lines.

• Troubleshooting, “Speed Control - Test” 3. Check the fuel tank for debris or foreign objects
which may block the fuel supply.
Decelerator Position Sensor (if
applicable) NOTICE
Do not crank the engine continuously for more than
Monitor the signal for the decelerator position sensor 30 seconds. Allow the starting motor to cool for two
on Cat ET. Verify that the signal for the sensor is minutes before cranking the engine again.
stable at different set points between the low idle
position and the high idle position.
4. Prime the fuel system if any of the following
procedures have been performed:
Unit Injectors
• Replacement of the fuel filters
1. Use Cat ET to perform the injector solenoid test
in order to determine if all of the injector solenoids • Service on the low pressure fuel supply circuit
are being energized by the ECM.
• Replacement of unit injectors
2. Perform the cylinder cutout test on Cat ET in order
to check the performance of each cylinder. Refer Note: A sight glass in the low pressure supply line is
to the diagnostic functional test Troubleshooting, helpful in diagnosing air in the fuel. Refer to Testing
“Injector Solenoids Circuit - Test”. and Adjusting.

Injection Actuation Pressure 5. Check fuel quality. Cold weather adversely

affects the characteristics of the fuel. Refer to the
1. Check the engine oil level. Engine oil supplies the Operation and Maintenance Manual.
injection actuation pressure circuit. The engine oil
must be kept at the proper level for fuel injection. 6. Check the filtered fuel pressure while the engine
is being cranked. Refer to Testing and Adjusting.
2. If service has recently been performed on the If the fuel pressure is low, replace the fuel filters.
engine, air may be present in the injection If the fuel pressure is still low, check the following
actuation pressure circuit. Allow the engine to fully items: fuel transfer pump, fuel transfer pump
warm up and operate the engine under load in coupling, and fuel pressure regulating valve. Refer
order to purge the air from the injection actuation to Testing and Adjusting.
pressure circuit.
Intake Manifold (Boost) Pressure Sensor
3. Check the injection actuation pressure. Refer to
the diagnostic functional test Troubleshooting, 1. With the engine at full load, monitor “Fuel Position”
“Injection Actuation Pressure - Test”. and “Rated Fuel Limit” on the status screen. If
“Fuel Position” does not equal “Rated Fuel Limit”,
4. Check the operation of the injection actuation then check intake manifold (boost) pressure.
pressure control valve. Refer to the diagnostic
functional test Troubleshooting, “Injection 2. Monitor intake manifold (boost) pressure and
Actuation Pressure Control Valve Circuit - Test”. atmospheric pressure for normal operation on the
status screen.
RENR5089-23 53
Troubleshooting Section

Air Inlet and Exhaust System Crankshaft

Check the air inlet and exhaust systems for Inspect the crankshaft and the related components.
restrictions and for leaks. Refer to the Operation Inspect the connecting rod bearings and the bearing
and Maintenance Manual. Look for an indication of surfaces on the crankshaft. Make sure that the
the warning lamp or restriction indicators that are bearings are in the correct position. Look for worn
tripped if the filters are equipped with these devices. thrust plates and wear on the crankshaft. Check the
These indicators are associated with plugged filters. counterweight bolts. Replace any damaged parts.
Replace the plugged air filters or clean the plugged
air filters per the guidelines of the Operation and Piston
Maintenance Manual. Repair any leaks that are
found in the system. Inspect the condition of the pistons. Make sure that
the piston pins are correctly installed. Replace any
i02514294
damaged parts.

Mechanical Noise (Knock) in i02477338

Engine
Noise Coming from Cylinder
SMCS Code: 1000-035
SMCS Code: 1000-035
Probable Causes
Probable Causes
• Faulty accessory
• Diagnostic codes
• Cylinder head and related components
• Fuel quality
• Gear train
• Unit injectors
• Crankshaft and related components
• Valve lash
• Piston
• Cylinder head and related components
Recommended Repairs
Recommended Actions
Faulty Accessory
Diagnostic Codes
Isolate the source of the noise. Remove the suspect
engine accessories. Inspect the suspect engine Check for active diagnostic codes on the Caterpillar
accessories. Repair the engine accessories and/or Electronic Technician (ET). Troubleshoot any active
replace the engine accessories. codes before continuing with this procedure.

Cylinder Head and Related Components Fuel Quality

Inspect the components of the valve train for good Refer to Operation and Maintenance Manual for
condition. Check for signs of damage and/or wear information on the characteristics of the fuel.
to the valves, cylinder head gasket, springs, lifters,
pushrods, etc. Inspect the condition of the camshafts. Unit Injectors
If a camshaft is replaced, new valve lifters must be
installed. Replace any damaged parts. 1. Check the connectors at the Electronic Control
Module (ECM). Check for correct installation
Gear Train of the J1/P1 and J2/P2 ECM connectors. Also,
thoroughly inspect the unit injector wiring harness
Inspect the condition of the gear train. Replace any from the ECM to the J300/P300 valve cover entry
damaged parts. connector. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
Inspect the flywheel and the flywheel bolts.
2. Perform the “Injector Solenoid Test” on Cat ET in
Inspect the engine oil filters for nonferrous material. order to determine if all of the injector solenoids
Flaking of nonferrous material could indicate worn are being energized by the ECM.
gear train bearings.
54 RENR5089-23
Troubleshooting Section

3. Perform the “Cylinder Cutout Test” on Cat ET Diagnostic Codes, Event Codes and
in order to identify any injectors that may be Derates
misfiring. Refer to the diagnostic functional test
Troubleshooting, “Injector Solenoid Circuit - Test”. Certain diagnostic codes, event codes and/or derates
may cause poor performance. Connect the Caterpillar
Valve Lash Electronic Technician (ET) and check for active codes
and/or for logged codes. Troubleshoot any codes that
Check the engine valve lash settings. Inspect the are present before continuing with this procedure.
valve train for sufficient lubrication. Check damage to
valve train components which may cause excessive Cold Mode
valve lash. Repair any problems that are found.
Refer to troubleshooting without a diagnostic code Use Cat ET to verify that the engine has exited
Troubleshooting, “Excessive Valve Lash”. cold mode. Cold mode operation may slow throttle
response.
Cylinder Head and Related Components
Flash File
Check for signs of damage and/or wear to the valves,
cylinder head gasket, etc. Inspect the condition of Verify that the correct flash file is installed.
the camshafts.
Throttle Signal
i02520699
Monitor the status for “Throttle Position” on Cat ET.
Poor Acceleration or Response Verify that the status for “Throttle Position” is stable
and that the engine is able to reach high idle speed.
SMCS Code: 1000-035 Refer to the appropriate diagnostic test for your
application:
Probable Causes
• Troubleshooting, “Throttle Position Sensor Circuit -
• Diagnostic codes Test”

• Event codes • Troubleshooting, “Throttle Switch Circuit - Test”

• Cold mode • Troubleshooting, “Speed Control - Test”

• Flash file Electrical Connectors

• Throttle signal Check for correct installation of the J1/P1 and
J2/P2 Electronic Control Module (ECM) connectors
• Electrical connectors and the unit injector connectors. Refer to the
diagnostic functional test Troubleshooting, “Electrical
• Unit injectors Connectors - Inspect”.

• Intake manifold (boost) pressure sensor Unit Injectors

• Air inlet and exhaust system 1. Perform the “Injector Solenoid Test” on Cat ET in
order to determine if all of the injector solenoids
• Fuel supply are being energized by the ECM.

Recommended Actions 2. Perform the “Cylinder Cutout Test” on Cat ET

in order to identify any injectors that might be
Note: If the problem only occurs under certain misfiring. Refer to the diagnostic functional test
conditions, test the engine under those conditions. Troubleshooting, “Injector Solenoid Circuit - Test”.
Examples of certain conditions are high engine
speed, full load and engine operating temperature. Intake Manifold (Boost) Pressure Sensor
Troubleshooting the symptoms under other
conditions can give misleading results. 1. Monitor the status of “Fuel Position”, “Rated Fuel
Limit”, and “FRC Fuel Limit” on Cat ET while
the engine is operating under full load. These
parameters should reflect the information below.
RENR5089-23 55
Troubleshooting Section

Table 12 5. Check the fuel pressure after the fuel filter while
“Fuel Position” = “Rated Fuel Limit”
the engine is being cranked. Refer to Systems
Operation/Testing and Adjusting, “Fuel System”
and for the correct pressure values. If the fuel pressure
“Fuel Position” < “FRC Fuel Limit”
is low, replace the fuel filters. If the fuel pressure
is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling, and fuel
If “Fuel Position” equals “Rated Fuel Limit” and pressure regulating valve. Refer to Systems
“Fuel Position” is less than “FRC Fuel Limit”, the Operation/Testing and Adjusting.
electronics are operating correctly. Otherwise,
proceed with the next Step.
i02452881
2. Monitor the status of “Boost Pressure” and of
“Atmospheric Pressure” for normal operation
Poor Acceleration or Response
on Cat ET. When the engine is not running, the
SMCS Code: 1000-035
correct value for “Boost Pressure” is 0 kPa (0 psi).

Air Inlet and Exhaust System Probable Causes

1. Observe the check engine lamp. Check for an • Diagnostic codes and event codes
air filter restriction indicator. Clean plugged air
filters or replace plugged air filters. Refer to the • Cold mode operation and cold cylinder cutout
Operation and Maintenance Manual.
• Flash file
2. Check the air inlet and exhaust system for
restrictions and/or leaks. Refer to Systems • Throttle signal
Operation/Testing and Adjusting, “Air Inlet and
Exhaust System”. • Decelerator position sensor (if applicable)

Fuel Supply • Injection actuation pressure

1. Check the fuel lines for the following problems:

• Electrical connectors
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
• Unit injectors
lines and/or replace the lines.
• Intake manifold (boost) pressure sensor
2. Check the fuel tank for foreign objects which may
block the fuel supply.
• Air inlet and exhaust system

3. Prime the fuel system if any of the following

• Fuel supply
procedures have been performed:
Recommended Actions
• Replacement of the fuel filters
Note: If the problem only occurs under certain
• Service on the low pressure fuel supply circuit conditions, test the engine under those conditions.
Examples of certain conditions are high engine
• Replacement of unit injectors idle, full load, or a specific operating temperature.
Troubleshooting the symptoms under other
Note: A sight glass in the low pressure supply line is conditions may give misleading results.
helpful in diagnosing air in the fuel. Refer to Systems
Operation/Testing and Adjusting, “Air in Fuel - Test”. Diagnostic Codes and Event Codes
4. Cold weather adversely affects the characteristics Certain diagnostic codes and/or event codes may
of the fuel. Refer to the Operation and cause poor performance. Connect the Caterpillar
Maintenance Manual for information on improving Electronic Technician (ET) and check for active codes
the characteristics of the fuel during cold weather and/or logged codes. Troubleshoot any codes that
operation. are present before continuing with this procedure.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
56 RENR5089-23
Troubleshooting Section

Note: Although a sensor's signal may be in the 3. Check the injection actuation pressure. Refer to
operational range of the sensor, certain failure modes the diagnostic functional test Troubleshooting,
of a sensor may produce an output signal that does “Injection Actuation Pressure - Test”.
not represent an accurate measurement. Use Cat ET
to check that the pressures and the temperatures are 4. Check the operation of the injection actuation
fluctuating normally. Also check that the values are pressure control valve. Refer to the diagnostic
reasonable for the conditions that are present. functional test Troubleshooting, “Injection
Actuation Pressure Control Valve Circuit - Test”.
Cold Mode Operation and Cold Cylinder
Cutout Electrical Connectors

Use Cat ET to verify that the engine has exited Disconnect the J1/P1 and J2/P2 ECM connectors.
cold mode. Cold mode operation may cause a slow Inspect each connector for moisture and corrosion.
throttle response. Some engines use a feature such Also, inspect the harness and connectors for the unit
as the cold cylinder cutout in order to warm the injectors from the ECM to the valve cover. Refer
engine during cold mode. Again, ensure that the to the diagnostic functional test Troubleshooting,
engine has exited cold mode operation. “Electrical Connectors - Inspect”.

Flash File Unit Injectors

Verify that the latest flash file has been installed into 1. Use Cat ET to perform the injector solenoid test
the ECM. in order to determine if all of the injector solenoids
are being energized by the ECM.
Throttle Signal 2. Perform the cylinder cutout test on Cat ET in order
to check the performance of each cylinder. Refer
Monitor the status for “Throttle Position” on Cat ET. to the diagnostic functional test Troubleshooting,
Verify that the status for “Throttle Position” is stable
“Injector Solenoids Circuit - Test”.
and that the engine is able to reach high idle speed.
Refer to the appropriate diagnostic functional test for
your application: Intake Manifold (Boost) Pressure Sensor

• Troubleshooting, “Throttle Position Sensor Circuit - 1. Monitor the status of “Fuel Position”, “Rated Fuel
Test” Limit”, and “FRC Fuel Limit” on Cat ET while
the engine is operating under full load. These
• Troubleshooting, “Throttle Switch Circuit - Test” parameters should agree with the information
below.
• Troubleshooting, “Speed Control - Test” Table 13

Decelerator Position Sensor (if “Fuel Position” = “Rated Fuel Limit”

and
applicable) “Fuel Position” < “FRC Fuel Limit”

Monitor the signal for the decelerator position sensor

on Cat ET. Verify that the signal for the sensor is If “Fuel Position” equals “Rated Fuel Limit” and
stable at different set points between the low idle “Fuel Position” is less than “FRC Fuel Limit”, the
position and the high idle position. electronics are operating correctly. Otherwise,
proceed with the next Step.
Injection Actuation Pressure 2. Monitor the status of “Intake Manifold (Boost)
Pressure” and “Atmospheric Pressure” for normal
1. Check the engine oil level. Engine oil supplies the operation on Cat ET. When the engine is not
injection actuation pressure circuit. The engine oil running, “Intake Manifold (Boost) Pressure” should
must be kept at the proper level for fuel injection. be 0 kPa (0 psi).
2. If service has recently been performed on the
engine, air may be present in the injection Air Inlet and Exhaust System
actuation pressure circuit. Allow the engine to fully
warm up and operate the engine under load in 1. Check the air filter restriction indicator for a
order to purge the air from the injection actuation plugged filter. If necessary, service the engine.
pressure circuit. Refer to the Operation and Maintenance Manual.
RENR5089-23 57
Troubleshooting Section

2. Check the air inlet and exhaust system for

restrictions and/or leaks. Refer to Testing and
Adjusting.

Fuel Supply
1. Visually check the fuel level in the fuel tank. Do not
rely on the fuel gauge only. If necessary, add fuel
to the fuel tank. If the engine has been run out of
fuel, it will be necessary to prime the fuel system.
Refer to the Operation and Maintenance Manual.

2. Check the fuel lines for the following problems:

restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.

3. Check the fuel tank for debris or foreign objects

which may block the fuel supply.

NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.

4. Prime the fuel system if any of the following

procedures have been performed:

• Replacement of the fuel filters

• Service on the low pressure fuel supply circuit
• Replacement of unit injectors
Note: A sight glass in the low pressure supply line is
helpful in diagnosing air in the fuel. Refer to Testing
and Adjusting.

5. Check fuel quality. Cold weather adversely

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

6. Check the filtered fuel pressure while the engine

is being cranked. Refer to Testing and Adjusting
for the correct pressure values. If the fuel pressure
is low, replace the fuel filters. If the fuel pressure
is still low, check the following items: fuel transfer
pump, fuel transfer pump coupling, and fuel
pressure regulating valve. Refer to Testing and
Adjusting.
58 RENR5089-23
Troubleshooting Section

Troubleshooting with a
Diagnostic Code
i02281051

Diagnostic Codes
SMCS Code: 1900

Diagnostic Codes
Diagnostic codes alert the operator that a problem in
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to
the service technician. The Caterpillar Electronic
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic
codes may be viewed on a personal computer that
has Cat ET software. Diagnostic codes consist of
the component identifier (CID) and the failure mode
identifier (FMI).

Component Identifier (CID) – The CID is a number

with three or four digits. The CID indicates the
component that generated the code. For example,
the CID number 0001 identifies the fuel injector for
the number one cylinder.

Failure Mode Identifier (FMI) – The FMI is a two

digit code that indicates the type of failure.

Do not confuse diagnostic codes with event codes.

Event codes alert the operator that an abnormal Illustration 12
g01117578
operating condition such as low oil pressure or high
Output voltage from a typical analog temperature sensor
coolant temperature has been detected. Refer to
Troubleshooting, “Troubleshooting with an Event
Illustration 12 indicates the signal range for a typical
Code” for additional information on event codes.
analog sensor. Diagnostic codes will be generated if
the sensor's output signal is below 0.2 VDC or above
4.8 VDC.

Active Diagnostic Codes

An active diagnostic code represents a problem with
the electronic control system. Correct the problem
as soon as possible.

When the Electronic Control Module (ECM)

generates an active diagnostic code, the “Active
Alarm” indicator (“Engine Control Alarm Status” on
Cat ET) is activated in order 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.
RENR5089-23 59
Troubleshooting Section

Logged Diagnostic Codes Possible Performance Effect:

When the ECM generates a diagnostic code, the • Engine misfires

ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. Each ECM • Low power
will record the following information when a code is
generated: Troubleshooting:

• The hour of the first occurrence of the code Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
• The hour of the last occurrence of the code
Results:
• The number of occurrences of the code
• OK – STOP.
This information is a valuable indicator for
troubleshooting intermittent problems.
i02504233

A code is cleared from memory when one of the

following conditions occur:
CID 0001 FMI 06 Cylinder #1
Injector short
• The service technician manually clears the code.
SMCS Code: 1290-038
• The code does not recur for 100 hours.
Conditions Which Generate This Code:
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is The Electronic Control Module (ECM) is attempting to
cleared. operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that System Response:
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection The ECM will log the diagnostic code. The ECM will
or damaged wiring. The next likely cause is a continue to attempt to operate the injector after the
component failure. The least likely cause is the failure code has been logged.
of an electronic module. Diagnostic codes that are
logged repeatedly may indicate a problem that needs Possible Performance Effect:
special investigation.
• Engine misfires
Note: Always clear logged diagnostic codes after
investigating and correcting the problem which • Low power
generated the code.
Troubleshooting:
i02504219 Perform the following diagnostic procedure: “Injector
CID 0001 FMI 05 Cylinder #1 Solenoid Circuit - Test”

Injector open circuit Results:

SMCS Code: 1290-038 • OK – STOP.

Conditions Which Generate This Code:
i02504240

The Electronic Control Module (ECM) is attempting

to operate the injector. The ECM detects an open
CID 0002 FMI 05 Cylinder #2
circuit in the circuit for the injector. Injector open circuit
System Response: SMCS Code: 1290-038

The ECM will log the diagnostic code. The ECM will Conditions Which Generate This Code:
continue to attempt to operate the injector after the
code has been logged. The Electronic Control Module (ECM) is attempting
to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
60 RENR5089-23
Troubleshooting Section

System Response: i02504251

The ECM will log the diagnostic code. The ECM will CID 0003 FMI 05 Cylinder #3
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting
• Low power to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.

• OK – STOP. Possible Performance Effect:

i02504248 • Engine misfires

CID 0002 FMI 06 Cylinder #2 • Low power
Injector short Troubleshooting:
SMCS Code: 1290-038 Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit
in the circuit for the injector.
• OK – STOP.

System Response: i02504254

The ECM will log the diagnostic code. The ECM will CID 0003 FMI 06 Cylinder #3
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting to
• Low power operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.

• OK – STOP. Possible Performance Effect:

• Engine misfires
• Low power
RENR5089-23 61
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “Injector • The engine may misfire.
Solenoid Circuit - Test”
• The engine may experience low power.
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02504275

CID 0004 FMI 05 Cylinder #4 Results:

Injector open circuit • OK – STOP.

SMCS Code: 1290-038
i02504282

Conditions Which Generate This Code:

CID 0004 FMI 06 Cylinder #4
The Electronic Control Module (ECM) is attempting Injector short
to operate the injector. The ECM detects an open
circuit in the circuit for the injector. SMCS Code: 1290-038

System Response: Conditions Which Generate This Code:

The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting to
continue to attempt to operate the injector after the operate the injector. The ECM detects a short circuit
code has been logged. in the circuit for the injector.

Possible Performance Effect: System Response:

• Engine misfires The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
• Low power code has been logged.

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “Injector • Engine misfires

Solenoid Circuit - Test”
• Low power
Results:
Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
i02430368

CID 0004 FMI 05 Cylinder #4 Results:

Injector open circuit • OK – STOP.

SMCS Code: 1290-038
i02504291

Conditions Which Generate This Code:

CID 0005 FMI 05 Cylinder #5
The Electronic Control Module (ECM) is attempting Injector open circuit
to operate the injector. The ECM detects an open
circuit in the circuit for the injector. SMCS Code: 1290-038

System Response: Conditions Which Generate This Code:

The ECM will log the diagnostic code. The ECM will The Electronic Control Module (ECM) is attempting
continue to attempt to operate the injector after the to operate the injector. The ECM detects an open
code has been logged. circuit in the circuit for the injector.
62 RENR5089-23
Troubleshooting Section

System Response: i02504299

The ECM will log the diagnostic code. The ECM will CID 0006 FMI 05 Cylinder #6
continue to attempt to operate the injector after the Injector open circuit
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting
• Low power to operate the injector. The ECM detects an open
circuit in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.

• OK – STOP. Possible Performance Effect:

i02504292 • Engine misfires

CID 0005 FMI 06 Cylinder #5 • Low power
Injector short Troubleshooting:
SMCS Code: 1290-038 Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test”
Conditions Which Generate This Code:
Results:
The Electronic Control Module (ECM) is attempting to
operate the injector. The ECM detects a short circuit
in the circuit for the injector.
• OK – STOP.

System Response: i02504302

The ECM will log the diagnostic code. The ECM will CID 0006 FMI 06 Cylinder #6
continue to attempt to operate the injector after the Injector short
code has been logged.
SMCS Code: 1290-038
Possible Performance Effect:
Conditions Which Generate This Code:
• Engine misfires
The Electronic Control Module (ECM) is attempting to
• Low power operate the injector. The ECM detects a short circuit
in the circuit for the injector.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Injector
Solenoid Circuit - Test” The ECM will log the diagnostic code. The ECM will
continue to attempt to operate the injector after the
Results: code has been logged.

• OK – STOP. Possible Performance Effect:

• Engine misfires
• Low power
RENR5089-23 63
Troubleshooting Section

Troubleshooting: Troubleshooting:

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

Results: Results:

• OK – STOP. • OK – STOP.

i02419277 i02428618

CID 0041 FMI 03 8 Volt DC CID 0042 FMI 05 Injector

Supply short to +batt Actuation Valve open circuit
SMCS Code: 1439-038 SMCS Code: 1714-038

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

The voltage level of the 8 volt supply is above normal. The Electronic Control Module (ECM) detects an
open circuit in the circuit for the injection actuation
System Response: pressure control valve (IAPCV). The voltage is above
normal.
The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags all digital sensors System Response:
as invalid data and all digital sensors are set to the
respective default values. The ECM will trigger a snapshot and the ECM will
log the code.
Possible Performance Effect:
Possible Performance Effect:
• The engine may experience low power.
• The engine may misfire and/or shutdown
Troubleshooting:
• The engine may experience reduced speed (rpm)
Perform the following diagnostic procedure: “Digital and/or low power.
Sensor Supply Circuit - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “Injection
• OK – STOP. Actuation Pressure Control Valve Circuit - Test”

Results:
i02419278

CID 0041 FMI 04 8 Volt DC • OK – STOP.

Supply short to ground
i02428621

SMCS Code: 1439-038 CID 0042 FMI 06 Injector

Conditions Which Generate This Code: Actuation Valve short to
The voltage level of the 8 volt supply is below normal. ground
SMCS Code: 1714-038
System Response:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) logs the
diagnostic code. The ECM flags all digital sensors
as invalid data and all digital sensors are set to the The Electronic Control Module (ECM) detects
excessive current flow in the circuit for the injection
respective default values.
actuation pressure control valve (IAPCV).
Possible Performance Effect:

• The engine may experience low power.

64 RENR5089-23
Troubleshooting Section

System Response: i02424760

The ECM will trigger a snapshot and the ECM will CID 0094 FMI 03 Fuel Pressure
log the code. open/short to +batt
Possible Performance Effect: SMCS Code: 1439-038; 1718-038

• The engine may misfire and/or shutdown Conditions Which Generate This Code:

• The engine may experience reduced speed (rpm) The Electronic Control Module (ECM) reads signal
and/or low power. voltage that is above normal.
Troubleshooting: System Response:
Perform the following diagnostic procedure: “Injection The ECM will log the diagnostic code. The ECM flags
Actuation Pressure Control Valve Circuit - Test” fuel pressure as invalid data and a default value is
used.
Results:
Possible Performance Effect:
• OK – STOP.
• There are no performance effects.
i02507546
Troubleshooting:
CID 0091 FMI 08 Throttle
Perform the following diagnostic procedure: “Engine
Position signal abnormal Pressure Sensor Open or Short Circuit - Test”
SMCS Code: 1439-038; 1913-038 Results:
Conditions Which Generate This Code:
• OK – STOP.
The Electronic Control Module (ECM) detects a
signal for the throttle position that is not in the i02424763
operating range of the control.
CID 0094 FMI 04 Fuel Pressure
System Response: short to ground
The ECM will log the diagnostic code. The ECM SMCS Code: 1439-038; 1718-038
flags the throttle position as invalid data. The last
valid engine speed will be maintained as the desired Conditions Which Generate This Code:
engine speed until one of the following conditions
occur: The Electronic Control Module (ECM) reads signal
voltage that is below normal.
• The ECM receives an input from the throttle backup
switch for a different engine speed. System Response:

• The signal from the throttle switch becomes valid The ECM will log the diagnostic code. The ECM flags
and the signal from the throttle switch remains fuel pressure as invalid data and a default value is
valid. used.
Possible Performance Effect: Possible Performance Effect:
The throttle backup switch must be used to set • There are no performance effects.
engine speed.
Troubleshooting:
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Perform the following diagnostic procedure: “Throttle Pressure Sensor Open or Short Circuit - Test”
Switch Circuit - Test”
Results:
Results:
• OK – STOP.
• OK – STOP.
RENR5089-23 65
Troubleshooting Section

i02424766 i02427669

CID 0100 FMI 03 Engine Oil CID 0110 FMI 03 Engine

Pressure open/short to +batt Coolant Temperature
SMCS Code: 1439-038-OC; 1924-038 open/short to +batt
SMCS Code: 1439-038-CLT; 1906-038
Conditions Which Generate This Code:
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects signal
voltage that is above normal.
The signal voltage from the engine coolant
temperature sensor is above normal.
System Response:

The ECM will log the diagnostic code. The ECM flags System Response:
oil pressure as invalid data.
The Electronic Control Module (ECM) will log the
Possible Performance Effect: diagnostic code. The ECM flags coolant temperature
as invalid data and a default value is used. The
engine will not go into cold mode.
• There are no performance effects.
Possible Performance Effect:
Troubleshooting:

Perform the following diagnostic procedure: “Engine • The engine may misfire.
Pressure Sensor Open or Short Circuit - Test”
• The engine may experience reduced speed (rpm)
Results: and/or low power.

Troubleshooting:
• OK – STOP.
Perform the following diagnostic procedure: “Engine
i02424648 Temperature Sensor Open or Short Circuit - Test”

CID 0100 FMI 04 Engine Oil Results:

Pressure short to ground
• OK – STOP.
SMCS Code: 1439-038-OC; 1924-038
i02427678
Conditions Which Generate This Code:
CID 0110 FMI 04 Engine
The Electronic Control Module (ECM) detects a
signal voltage that is below normal.
Coolant Temperature short to
ground
System Response:
SMCS Code: 1439-038-CLT; 1906-038
The code is logged. The ECM flags oil pressure as
invalid data and a default value is used. Conditions Which Generate This Code:

Possible Performance Effect: The signal voltage from the engine coolant
temperature sensor is below normal.
• There are no performance effects.
System Response:
Troubleshooting:
The Electronic Control Module (ECM) will log the
Perform the following diagnostic procedure: “Engine diagnostic code. The ECM flags coolant temperature
Pressure Sensor Open or Short Circuit - Test” as invalid data and a default value is used. The
engine will not go into cold mode.
Results:
Possible Performance Effect:
• OK – STOP.
• The engine may misfire.
66 RENR5089-23
Troubleshooting Section

• The engine may experience reduced speed (rpm) System Response:

and/or low power.
The Electronic Control Module (ECM) will log the
Troubleshooting: diagnostic code. The ECM will flag injection actuation
pressure as invalid data and a default value will be
Perform the following diagnostic procedure: “Engine used. The ECM will set the current for the control
Temperature Sensor Open or Short Circuit - Test” valve to a fixed value.

Results: Possible Performance Effect:

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

i02427705
• The engine may experience poor idle quality.

CID 0164 FMI 03 Injector Troubleshooting:

Actuation Pressure voltage Perform the following diagnostic procedure: “Engine

high Pressure Sensor Open or Short Circuit - Test”

SMCS Code: 1439-038-UIN; 1925-038 Results:

Conditions Which Generate This Code: • OK – STOP.

The signal from the injection actuation pressure i02424772

sensor is above normal. Cold mode is not active.
CID 0168 FMI 00 System
System Response:
Voltage High
The Electronic Control Module (ECM) will log the
SMCS Code: 1401-038
diagnostic code. The ECM will flag injection actuation
pressure as invalid data and a default value is used. Conditions Which Generate This Code:
The ECM will set the current for the control valve to a
fixed value.
The Electronic Control Module (ECM) detects the
following condition:
Possible Performance Effect:
• For 12 volt systems, the ECM reads battery voltage
• The engine may experience low power. that is above 16 VDC.
• The engine may experience poor idle quality. • For 24 Volt systems, the ECM reads battery
voltage that is above 32 VDC.
Troubleshooting:
Note: Excessive voltage to the ECM may damage
Perform the following diagnostic procedure: “Engine the ECM.
Pressure Sensor Open or Short Circuit - Test”
System Response:
Results:
The ECM will log the diagnostic code.
• OK – STOP.
Possible Performance Effect:
i02427714
• There are no performance effects.
CID 0164 FMI 04 Injector
Actuation Pressure voltage Troubleshooting:

low Perform the following diagnostic procedure:

“Electrical Power Supply Circuit - Test”
SMCS Code: 1439-038-UIN; 1925-038
Results:
Conditions Which Generate This Code:
• OK – STOP.
The signal from the injection actuation pressure
sensor is below normal. Cold mode is not active.
RENR5089-23 67
Troubleshooting Section

i02415961 Results:
CID 0168 FMI 01 System • OK – STOP.
Voltage Low
i02508878
SMCS Code: 1401-038
CID 0168 FMI 02 System
Conditions Which Generate This Code:
Voltage intermittent/erratic
The Electronic Control Module (ECM) detects battery
voltage that is below 9 VDC on 12 volt systems or SMCS Code: 1401-038
below 18 VDC on 24 volt systems.
Conditions Which Generate This Code:
System Response:
While the engine is running the Electronic Control
The ECM will log the diagnostic code. The check Module (ECM) detects battery voltage that drops
engine lamp will illuminate while this diagnostic code below 6 VDC and returns above 9 VDC.
is active. The engine will be derated 100 percent.
System Response:
Possible Performance Effect:
The ECM will log the diagnostic code.
• The engine will be shutdown. Possible Performance Effect:
Troubleshooting:
• An engine misfire may occur.
Perform the following diagnostic procedure:
“Electrical Power Supply Circuit - Test” • An engine shutdown condition may occur.

Results: Troubleshooting:

Perform the following diagnostic procedure:

• OK – STOP. “Electrical Power Supply Circuit - Test”

i02458713 Results:
CID 0168 FMI 02 System • OK – STOP.
Voltage intermittent/erratic
i02434013
SMCS Code: 1401-038
CID 0172 FMI 03 Intake
Conditions Which Generate This Code:
Manifold Air Temp open/short
While the engine is running, the battery voltage drops to +batt
below 9 VDC intermittently, or the battery voltage
drops below 9 VDC three times in a seven second SMCS Code: 1439-038-AI; 1921-038
period.
Conditions Which Generate This Code:
System Response:
The Electronic Control Module (ECM) detects the
The Electronic Control Module (ECM) will log the following conditions:
diagnostic code.
• The signal voltage from the intake manifold air
Possible Performance Effect: temperature sensor is above normal.

• The engine may misfire and/or shutdown • Engine coolant temperature is above −10 °C
(14 °F).
Troubleshooting:
System Response:
Perform the following diagnostic procedure:
“Electrical Power Supply Circuit - Test” The ECM will log the diagnostic code. The check
engine lamp will illuminate while this diagnostic code
is active. The ECM will flag the engine oil pressure
as invalid data and a default value is used.
68 RENR5089-23
Troubleshooting Section

Possible Performance Effect: System Response:

• There are no performance effects. The Electronic Control Module (ECM) will log the
diagnostic code. The ECM will flag the intake
Troubleshooting: manifold air temperature as invalid data and a default
value is used.
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” Possible Performance Effect:

Results: • There are no performance effects.

• OK – STOP. Troubleshooting:

Perform the following diagnostic procedure: “Engine

i02440612
Temperature Sensor Open or Short Circuit - Test”
CID 0172 FMI 03 Intake Results:
Manifold Air Temp open/short
to +batt • OK – STOP.

SMCS Code: 1439-038-AI; 1921-038 i02424787

Conditions Which Generate This Code: CID 0172 FMI 04 Intake

The Electronic Control Module (ECM) detects a
Manifold Air Temp short to
signal voltage that is above normal or the intake ground
manifold air temperature is below −35 °C (−31 °F) .
SMCS Code: 1439-038-AI; 1921-038
System Response:
Conditions Which Generate This Code:
The code is logged. The ECM will flag the intake
manifold air temperature as invalid data and the The Electronic Control Module (ECM) detects a
intake manifold air temperature is set to a default signal voltage that is below normal.
value.
System Response:
Possible Performance Effect:
The code is logged. The ECM will flag the intake
• There are no performance effects. manifold air temperature as invalid data and the
intake manifold air temperature is set to a default
Troubleshooting: value.

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

Temperature Sensor Open or Short Circuit - Test”
• The engine may experience hard starting and/or
Results: rough running.

• OK – STOP. • The engine may smoke.

Troubleshooting:
i02430464

CID 0172 FMI 04 Intake Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test”
Manifold Air Temp short to
ground Results:

SMCS Code: 1439-038-AI; 1921-038 • OK – STOP.

Conditions Which Generate This Code:

The signal voltage from the intake manifold air

temperature sensor is below normal or the intake
manifold air temperature is above 140 °C (284 °F).
RENR5089-23 69
Troubleshooting Section

i02424795 Results:
CID 0174 FMI 03 Fuel • OK – STOP.
Temperature open/short to
+batt i02424806

SMCS Code: 1439-038; 1922-038

CID 0190 FMI 08 Engine Speed
signal abnormal
Conditions Which Generate This Code:
SMCS Code: 1439-038-VF; 1907-038
The Electronic Control Module (ECM) detects a
signal voltage from the sensor that is above normal. Conditions Which Generate This Code:

System Response: The Electronic Control Module (ECM) receives erratic

data from the engine speed/timing sensor.
The ECM will log the diagnostic code. The ECM flags
fuel temperature as invalid data and fuel temperature System Response:
is set to a default value.
The ECM will log the diagnostic code. The check
Possible Performance Effect: engine lamp will illuminate after a delay. The ECM
will default to the signal from the secondary engine
• There are no performance effects. speed/timing sensor.

Troubleshooting: Possible Performance Effect:

Perform the following diagnostic procedure: “Engine • There are no performance effects.
Temperature Sensor Open or Short Circuit - Test”
Note: If the signals from both engine speed/timing
Results: sensors are lost, then the engine will shut down.

• OK – STOP. Troubleshooting:

Perform the following diagnostic procedure: “Engine

i02424798
Speed/Timing Sensor Circuit - Test”
CID 0174 FMI 04 Fuel
Results:
Temperature short to ground
• OK – STOP.
SMCS Code: 1439-038; 1922-038

Conditions Which Generate This Code: i02428636

The Electronic Control Module (ECM) detects signal

CID 0253 FMI 02 Personality
voltage that is below normal. Module mismatch
System Response: SMCS Code: 1902-038

The ECM will log the diagnostic code. The ECM flags Conditions Which Generate This Code:
fuel temperature as invalid data and a default value
is used. The flash file that is used for replacement is for
a different engine family or for a different engine
Possible Performance Effect: application.

• There are no performance effects. System Response:

Troubleshooting: Caterpillar Electronic Technician (ET) will not be able

to clear the code.
Perform the following diagnostic procedure: “Engine
Temperature Sensor Open or Short Circuit - Test” Possible Performance Effect:

• The fuel injection system is disabled and the

engine will not start.
70 RENR5089-23
Troubleshooting Section

Troubleshooting: Possible Performance Effect:

Check the Part Number of the Flash File • The engine may run rough and/or the engine may
emit white smoke in the exhaust.
A. Restore the electrical power to the Electronic
Control Module (ECM). Troubleshooting:

B. Verify that the part number for the flash file agrees Perform the following diagnostic procedure: “Engine
with the latest update that is available on Service Speed/Timing Sensor - Calibrate”
Technician Workbench (STW), or on SIS Web.
Results:
Expected Result:
• OK – STOP.
The correct flash file is installed in the ECM.
i02445665
Results:
CID 0262 FMI 03 5 Volt Sensor
• OK – The correct flash file is installed in the ECM.
DC Power Supply short to
Repair: The engine will not start until the 253-02
diagnostic code is cleared. Clearing this code
+batt
requires factory passwords.
SMCS Code: 1439-038
Acquire factory passwords. Clear the 253-02
Conditions Which Generate This Code:
diagnostic code. Return the engine to service.
The voltage level of the 5 volt supply is above normal.
STOP.
System Response:
• Not OK – The correct flash file is not installed in
the ECM.
The Electronic Control Module (ECM) will log the
diagnostic code. The ECM flags all 5 volt sensors
Repair: Flash program the ECM with the correct as invalid data and the respective default values are
flash file. Refer to programming parameters
used.
Troubleshooting, “Flash Programming”. Verify that
the problem is resolved. Possible Performance Effect:
STOP.
• The engine may experience low power.
i02445663 Troubleshooting:

CID 0261 FMI 13 Engine Timing Perform the following diagnostic procedure: “5 Volt
Calibration required Engine Pressure Sensor Supply Circuit - Test”

Results:
SMCS Code: 1439-038; 1912-038

Conditions Which Generate This Code: • OK – STOP.

The Electronic Control Module (ECM) detects an i02445677

incorrect engine timing.
CID 0262 FMI 04 5 Volt Sensor
Note: A timing calibration is required for a new
engine, replacing an ECM that fails to communicate
DC Power Supply short to
or following work on the front gear train, the camshaft, ground
or the crankshaft.
SMCS Code: 1439-038
System Response:
Conditions Which Generate This Code:
The check engine lamp will illuminate while this
diagnostic code is active. The ECM uses default The 5 volt sensor supply voltage drops below normal.
timing. Timing may be off as much as three degrees.
RENR5089-23 71
Troubleshooting Section

System Response: Results:

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

diagnostic code. The ECM flags all 5 volt sensors
as invalid data and the respective default values are
i02417898
used.

Possible Performance Effect:

CID 0274 FMI 03 Atmospheric
Pressure open/short to +batt
• The engine may experience low power.
SMCS Code: 1439-038-AI; 1923-038
Troubleshooting:
Conditions Which Generate This Code:
Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test” The Electronic Control Module (ECM) detects a
signal voltage that is above normal.
Results:
System Response:
• OK – STOP.
The code is logged. The ECM will use the default
value for atmospheric pressure.
i02445689

CID 0268 FMI 02 Check Possible Performance Effect:

Programmable Parameters • The engine power is derated.

SMCS Code: 1901-038 Troubleshooting:

Conditions Which Generate This Code: Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
The Electronic Control Module (ECM) detects one of
the following conditions: Results:

• At least one system configuration parameter is not • OK – STOP.

programmed.
i02473210
• At least one injector trim file is not programmed.
System Response:
CID 0274 FMI 04 Atmospheric
Pressure short to ground
The diagnostic code will only be active. The check
engine lamp will illuminate while this diagnostic code SMCS Code: 1439-038-AI; 1923-038
is active. Any unprogrammed parameters are set to
the default value. Conditions Which Generate This Code:

Possible Performance Effect: The signal voltage from the atmospheric pressure
sensor is below normal.
• The unprogrammed parameters determine the
action that is taken by the ECM. System Response:

Troubleshooting: The Electronic Control Module (ECM) will log

the diagnostic code. The ECM flags atmospheric
Program the missing parameter. pressure as invalid data and a default value is used.

If a system configuration parameter has not been Possible Performance Effect:

programmed, refer to Troubleshooting, “System
Configuration Parameters”. • The engine may experience low power.
If an injector trim file has not been programmed, Troubleshooting:
refer to programming parameters Troubleshooting,
“Injector Trim File”. Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
72 RENR5089-23
Troubleshooting Section

Results: Possible Performance Effect:

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

Troubleshooting:
i02416783

CID 0274 FMI 04 Atmospheric Perform the following diagnostic procedure: “Low
Engine Oil Pressure Lamp Circuit - Test”
Pressure short to ground
Results:
SMCS Code: 1439-038-AI; 1923-038
• OK – STOP.
Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects a i02473224

signal that is below normal. CID 0286 FMI 06 EMS Oil Lamp
System Response: short to +batt
The code is logged. The ECM will use the default SMCS Code: 7431-038
value for atmospheric pressure.
Conditions Which Generate This Code:
Possible Performance Effect:
The Electronic Control Module (ECM) detects the
• The engine power is derated. following conditions:

Troubleshooting: • The output driver for the engine monitoring

system's lamp is off.
Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test” • The battery voltage for the engine monitoring
system's lamp is above normal.
Results:
System Response:
• OK – STOP.
The lamp may not turn on. The ECM will log the
diagnostic code.
i02473223

CID 0286 FMI 05 EMS Oil Lamp Possible Performance Effect:

open/short to ground • The engine may experience low power.

SMCS Code: 7431-038 Troubleshooting:

Conditions Which Generate This Code: Perform the following diagnostic procedure: “Low
Engine Oil Pressure Lamp Circuit - Test”
The Electronic Control Module (ECM) detects the
following conditions: Results:

• The output driver for the engine monitoring • OK – STOP.

system's lamp is off.

• The battery voltage for the engine monitoring i02424825

system's lamp is above normal.

CID 0342 FMI 08 Secondary
System Response: Engine Speed signal abnormal
The ECM will log the diagnostic code. SMCS Code: 1439-038-VF; 1907-038

If the lamp is shorted to a voltage source, the lamp Conditions Which Generate This Code:
will be on continuously. If the circuit for the lamp is
open, the lamp will not turn on. The Electronic Control Module (ECM) detects the
signal from the secondary engine speed/timing
sensor has been lost.
RENR5089-23 73
Troubleshooting Section

System Response: i02473227

The ECM will log the diagnostic code. The ECM will CID 0617 FMI 06 Air Inlet Heater
default to the primary engine speed/timing sensor. Relay grounded/current above
Possible Performance Effect: norm
• The engine performance is not affected. SMCS Code: 4493-038

Note: If the signals from both engine speed/timing Conditions Which Generate This Code:
sensors are lost, the engine will shut down.
The Electronic Control Module (ECM) detects
Troubleshooting: excessive current while attempting to energize the
air inlet heater relay.
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor Circuit - Test” System Response:

Results: The ECM logs the diagnostic code. The air inlet
heater will be disabled.
• OK – STOP.
Possible Performance Effect:

i02424828 • The engine may experience hard starting and/or

the engine may emit excessive white smoke.
CID 0617 FMI 05 Air Inlet
Heater Relay open/current Troubleshooting:
below normal Perform the following diagnostic procedure: “Air Inlet
Heater Circuit - Test”
SMCS Code: 4493-038
Results:
Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects an

• OK – STOP.
open circuit while attempting to energize the air inlet
heater relay. i02418079

System Response: CID 1639 FMI 02 Machine

Security System incorrect
The ECM logs the diagnostic code. The air inlet
heater will be disabled or the air inlet heater will run SMCS Code: 7631-038
continuously.
Conditions Which Generate This Code:
Possible Performance Effect:
The serial number of the Machine Security System
• The engine may experience hard starting and/or (MSS) that is stored in the Electronic Control Module
the engine may emit excessive white smoke. (ECM) does not match the serial number of the MSS.
Troubleshooting: System Response:
Perform the following diagnostic procedure: “Air Inlet The code is logged.
Heater Circuit - Test”
Possible Performance Effect:
Results:
• The engine will not start.
• OK – STOP.
Troubleshooting:

Enter the correct serial number of the MSS.

Results:

• OK – STOP.
74 RENR5089-23
Troubleshooting Section

i02418084 Troubleshooting:
CID 1639 FMI 09 Machine Perform the following diagnostic procedure: “Engine
Security System Module not Pressure Sensor Open or Short Circuit - Test”

communicating on link Results:

SMCS Code: 7631-038 • OK – STOP.

Conditions Which Generate This Code:
i02445698
The Electronic Control Module (ECM) detects a loss
of communication with the Machine Security System CID 1785 FMI 04 Intake
(MSS). Manifold Pressure Sensor
System Response: voltage low
The code is logged. SMCS Code: 1439-038-IL

Possible Performance Effect: Conditions Which Generate This Code:

The signal voltage from the intake manifold (boost)

• The engine will not start. pressure sensor is below normal.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Cat
Data Link Circuit - Test” The ECM will log the diagnostic code. The ECM will
flag the engine intake manifold (boost) pressure as
Results: invalid data and a default value is used.

Possible Performance Effect:

• OK – STOP.
• The engine may experience low power.
i02481519
Troubleshooting:
CID 1785 FMI 03 Intake
Manifold Pressure Sensor Perform the following diagnostic procedure: “Engine
Pressure Sensor Open or Short Circuit - Test”
voltage high
Results:
SMCS Code: 1439-038-IL
• OK – STOP.
Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects the i02475274

following conditions:
CID 1785 FMI 10 Intake
• The signal voltage from the intake manifold (boost) Manifold Pressure Signal
pressure sensor is above normal.
abnormal rate of change
• For extremely low altitude conditions the engine SMCS Code: 1439-038-IL
speed is zero or the engine load is less than 50
percent with the engine retarder (if equipped) OFF.
Conditions Which Generate This Code:
System Response:
This diagnostic code is designed to detect the loss of
The ECM will log the diagnostic code. The ECM will the 5 volt supply at the sensor connector.
flag the engine intake manifold (boost) pressure as
invalid data and a default value is used. System Response:

Possible Performance Effect: The ECM will log the diagnostic code. The ECM will
flag the engine intake manifold (boost) pressure as
invalid data and a default value is used.
• The engine may experience low power.
RENR5089-23 75
Troubleshooting Section

Possible Performance Effect: Troubleshooting:

• Engine performance is adversely affected. Perform the following diagnostic procedure: “Ether
Injection System - Test”
Troubleshooting:
Results:
Perform the following diagnostic procedure: “5 Volt
Engine Pressure Sensor Supply Circuit - Test” • OK – STOP.
Results:

• OK – STOP.

i02418270

CID 2417 FMI 05 Ether Injection

Control Solenoid current low
SMCS Code: 5479-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects low

current in the circuit.

System Response:

The code is logged.

Possible Performance Effect:

• The engine may be difficult to start.

Troubleshooting:

Perform the following diagnostic procedure: “Ether

Injection System - Test”

Results:

• OK – STOP.

i02418652

CID 2417 FMI 06 Ether Injection

Control Solenoid current high
SMCS Code: 5479-038

Conditions Which Generate This Code:

The Electronic Control Module (ECM) detects

excessive current flow in the circuit.

System Response:

The code is logged.

Possible Performance Effect:

• The engine may be difficult to start.

76 RENR5089-23
Troubleshooting Section

Troubleshooting with an
Event Code
i04038378

Event Codes
SMCS Code: 1901

Event codes alert the operator that an abnormal

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

Active Event Codes

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

Active event codes are listed in ascending numerical

order. The code with the lowest number is listed first.

Illustration 13 is an example of the operating range of

a temperature sensor. Do not use the Illustration to
troubleshoot temperature sensors.

g01138880
Illustration 13
Example of the typical operating range of a temperature sensor
(1) This area represents the normal operating range of the
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC.
(2) In this area, the temperature above 107 °C (225 °F) is higher
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
(3) In these areas, the output voltage of the sensor is too high
or too low. The voltage is outside of the normal range. The
electronic problem will generate a diagnostic code. Refer to
Troubleshooting, “Troubleshooting with a Diagnostic Code”.

Events are represented in two formats. In the first

format, the “E” means that the code is an event code.
The “XXX” represents a numeric identifier for the
event code. The identifier is followed by a description
of the code. If a warning or derate or shutdown is
applicable, the numeric identifiers are different. Refer
to the following example:

• E004 Engine Overspeed Shutdown

In the second format, the “E” means that the code is
an event code. The “XXX-X” represents a numeric
identifier for the event code. The fourth “X” identifies
the event as a warning, derate, or a shutdown.A
description of the code follows. Refer to the following
example:
RENR5089-23 77
Troubleshooting Section

• E360-1 Low Oil Pressure Warning 1. Obtain the following information about the
complaint:
• E360-2 Low Oil Pressure Derate
• The event and the time of the event
• E360-3 Low Oil Pressure Shutdown
• Determine the conditions for the event. The
The definition for a warning, derate, and a shutdown conditions will include the engine rpm and the
are defined below: load.

Warning – This condition represents a serious • Determine if there are any systems that were
problem with engine operation. However, this installed by the dealer or by the customer that
condition does not require derate or a shutdown. could cause the event.

Derate – For this condition, the ECM reduces the • Determine whether any additional events
engine power in order to help prevent possible occurred.
engine damage.
2. Verify that the complaint is not due to normal
Shutdown – For this condition, the ECM shuts down engine operation. Verify that the complaint is not
the engine in order to help prevent possible engine due to error of the operator.
damage.
3. Narrow the probable cause. Consider the operator
information, the conditions of operation, and the
Logged Event Codes history of the engine.
Generated event codes are logged into the ECM
4. Perform a visual inspection. Inspect the following
permanent memory. The ECM has an internal
diagnostic clock. The ECM will record the following items:
information when an event code is generated:
• Fuel supply
• The hour of the first occurrence of the code
• Oil level
• The hour of the last occurrence of the code
• Oil supply
• The number of occurrences of the code
• Wiring
Logged events are listed in chronological order. The
most recent event code is listed first. • Connectors

This information can be helpful for troubleshooting Be sure to check the connectors. This check is
important for problems that are intermittent. Refer
intermittent problems. Logged codes can also be
to the diagnostic functional test Troubleshooting,
used to review the performance of the engine.
“Electrical Connectors - Inspect”.

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

• The code does not recur for 100 hours. Trip Points for the Monitoring
• A new code is logged and there are already ten System
codes in memory. In this case, the oldest code is
cleared. The monitoring system determines the level of action
that is taken by the ECM in response to a condition
• The service technician manually clears the code. that can damage the engine. When any of these
conditions occur, the appropriate event code will trip.
Always clear logged event codes after investigating
and correcting the problem which generated the
code.

Troubleshooting
For basic troubleshooting of the engine, perform the
following steps in order to diagnose a malfunction:
78 RENR5089-23
Troubleshooting Section

Each event has a trip point. The trip points for some
of the parameters may be adjustable with Caterpillar
Electronic Technician (ET). The trip point is a value
that is out of the normal operating range for a system
such as the engine cooling system. Once the trip
point has been exceeded, the ECM will generate an
event code once the trip delay expires. The delay
ensures that the condition is valid.

Table 14 contains the conditions that are monitored

and the default trip points for each condition. The
actual setting for each parameter can be viewed with
Cat ET.

Table 14
Trip Points for the Monitoring System
Delay Time in Seconds Trip Point
Condition Action Default
Min Max Default Min Max Default State
E096(1) High Fuel
Warning N/A N/A 8 N/A N/A 758 kPa (110 psi) On
Pressure
E162(2) Excessive Boost
Derate N/A N/A 8 N/A N/A 460 kPa (67 psi) On
Pressure
E198(1) Low Fuel
Warning N/A N/A 10 N/A N/A 400 kPa (58 psi) On
Pressure
E360(1) Low Engine Oil Maps are not
Warning N/A N/A 8 N/A N/A On (2)
Pressure programmable. (1)
E360(2) Low Engine Oil Maps are not
Derate N/A N/A 4 N/A N/A On (2)
Pressure programmable. (3)
E361(1) High Engine 85 °C 113 °C
Warning N/A N/A 10 113 °C (235°F) On (2)
Coolant Temperature (185°F) (235 °F)
E361(2) High Engine 86 °C 116 °C
Derate N/A N/A 10 116 °C (241°F) On (2)
Coolant Temperature (187 °F) (241°F)
E362(1) Engine
Warning N/A N/A 0.6 N/A N/A 2600 rpm On (2)
Overspeed
E362(2) Engine
Derate N/A N/A 0.6 N/A N/A 2800 rpm On (2)
Overspeed
E363(1) High Fuel
Warning 1 120 30 N/A N/A 90 °C (194°F) On (2)
Temperature
E363(2) High Fuel
Derate 1 120 10 N/A N/A 91 °C (196°F) On
Temperature
E390(1) Fuel Filter 3660 (1
Warning N/A N/A N/A N/A Open On
Resriction hour)
E390(2) Fuel Filter 14640 (4
Derate N/A N/A N/A N/A Open On
Resriction hours)
E539(1) High Engine Inlet
Warning N/A N/A 8 N/A N/A 75 °C (167 °F) On (2)
Air Temperature
E539(2) High Engine Inlet
Derate N/A N/A 8 N/A N/A 79 °C (174 °F) On (2)
Air Temperature
(1) Refer to Table 15 for trigger points.
(2) This event is permanently enabled. The event cannot be disabled.
(3) Refer to Table 16 for trigger points.
RENR5089-23 79
Troubleshooting Section

Table 15
Trip Points for Low Oil Pressure Warning
0 rpm 0 kPa (0 psi)
500 rpm 0 kPa (0 psi)
1600 rpm 154 kPa (22 psi)
2400 rpm 154 kPa (22 psi)

Table 16

Trip Points for Low Oil Pressure Derate

0 rpm 0 kPa (0 psi)
500 rpm 0 kPa (0 psi)
1600 rpm 104 kPa (15 psi)
2400 rpm 104 kPa (15 psi)

i02440730

Event Codes
SMCS Code: 1901

Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
When the event code is generated, this indicates that
an event has taken place.

Active of Event Codes

g01138880
An event code represents a problem with engine Illustration 14
operation. Correct the problem as soon as Example of the typical operating range of a temperature sensor
possible. (1) This area represents the normal operating range of the
parameter. The normal output voltage of the sensor is between
Event codes are listed in ascending numerical order. 0.2 VDC and 4.2 VDC.
The code with the lowest number is listed first. (2) In this area, the temperature above 107 °C (225 °F) is higher
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
Illustration 14 is an example of the operating range of (3) In these areas, the output voltage of the sensor is too high
a temperature sensor. Do not use the Illustration to or too low. The voltage is outside of the normal range. The
troubleshoot temperature sensors. electronic problem will generate a diagnostic code. Refer to
Troubleshooting, “Troubleshooting with a Diagnostic Code” for
additional information on diagnostic codes.

Events are represented in two formats. In the first

format, the “E” means that the code is an event
code. The “XXX” represents a numeric identifier for
the event code. This is followed by a description of
the code. If a warning, a derate, or a shutdown is
applicable, the numeric identifiers are different. Refer
to the following example:

• E004 Engine Overspeed Shutdown

In the second format, the “E” means that the code is
an event code. The “XXX-X” represents a numeric
identifier for the event code. The fourth “X” identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
80 RENR5089-23
Troubleshooting Section

• E360-1 Low Oil Pressure Warning Troubleshooting

• E360-2 Low Oil Pressure Derate For basic troubleshooting of the engine, perform the
following steps in order to diagnose a malfunction:
• E360-3 Low Oil Pressure Shutdown
1. Obtain the following information about the
The definition for a warning, a derate, and a shutdown complaint:
are defined below:
• The event and the time of the event
Warning – This condition represents a serious
problem with engine operation. However, this • Determine the conditions for the event. The
condition does not require a derate or a shutdown. conditions will include the engine rpm and the
load.
Derate – For this condition, the Electronic Control
Module (ECM) reduces the engine's power in order • Determine if there are any systems that were
to help prevent possible engine damage. installed by the dealer or by the customer that
could cause the event.
Shutdown – For this condition, the ECM shuts down
the engine in order to help prevent possible engine • Determine whether any additional events
damage. occurred.

Logged Event Codes 2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not
When the ECM generates an event code the ECM due to error of the operator.
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record 3. Narrow the probable cause. Consider the operator
the following information when an event code is information, the conditions of operation, and the
generated: history of the engine.

4. Perform a visual inspection. Inspect the following

• The hour of the first occurrence of the code items:
• The hour of the last occurrence of the code
• Fuel supply
• The number of occurrences of the code
• Oil level
Logged events are listed in chronological order. The
most recent event code is listed first. • Oil supply

This information can be helpful for troubleshooting • Wiring

intermittent problems. Logged codes can also be
used to review the performance of the engine. • Connectors
Be sure to check the connectors. This is very
Clearing Event Codes important for problems that are intermittent.
Refer to troubleshooting with a diagnostic code
A code is cleared from memory when one of the Troubleshooting, “Electrical Connectors - Inspect”.
following conditions occur:
If these steps do not resolve the problem, identify
• The code does not recur for 100 hours. the procedures in this manual that best describe the
event. Check each probable cause according to the
• A new code is logged and there are already ten tests that are recommended.
codes in memory. In this case, the oldest code is
cleared.
Trip Points for the Monitoring
• The service technician manually clears the code. System
Always clear logged event codes after investigating The monitoring system determines the level of action
and correcting the problem which generated the that is taken by the ECM in response to a condition
code. that can damage the engine. When any of these
conditions occur, the appropriate event code will trip.
RENR5089-23 81
Troubleshooting Section

Table 17 contains the conditions that are monitored

and the default trip points for each condition. Each
condition has an associated parameter. The settings
for each parameter can be viewed with the Caterpillar
Electronic Technician (ET). The trip points for some
of the parameters may be adjustable with Cat ET.

Table 17
Trip Points for the Monitoring System
Time Delay in
Default Set Points
Parameter Action Seconds
Value
Range Default Range Default
758 kPa
E096-(1) High Fuel Pressure Warning On N/A 8 N/A
(110 psi)
E172-(1) High Air Filter
Warning On N/A 30 N/A 8 kPa (1 psi)
Restriction
E172-(2) High Air Filter
Derate On N/A 30 N/A 9 kPa (1 psi)
Restriction
E194-(2) High Exhaust Software
Derate On N/A N/A N/A
Temperature dependent
550 to 600 kPa
E198-(1) Low Fuel Pressure Warning On 5 to 10 10 550 kPa (80 psi)
(80 to 88 psi)
540 to 600 kPa
E198-(2) Low Fuel Pressure Derate Off 5 to 10 10 540 kPa (78 psi)
(78 to 88 psi)
E241-(2) Abnormal Engine
Derate Off N/A 45 N/A 1625 RPM
Fan System Operation
E360-(1) Low Engine Oil
Warning On N/A 4 Maps are not programmable. (1)
Pressure
E360-(3) Low Engine Oil
Derate On N/A 4 Maps are not programmable. (2)
Pressure
E361-(1) High Engine 85 to 113 °C
Warning On N/A 10 113 °C (235°F)
Coolant Temperature (185 to 235 °F)
E361-(2) High Engine 86 to 116 °C
Derate Off 1 to 120 10 116 °C (241 °F)
Coolant Temperature (187 to 241 °F)
E362-(1) Engine Overspeed Warning On N/A 0.6 N/A 2600 RPM
E362-(2) Engine Overspeed Derate On N/A 0.6 N/A 2800 RPM
E539-(1) High Intake Manifold
Warning On N/A 8 N/A 90 °C (194°F)
Air Temperature
E539-(2) High Intake Manifold
Derate On N/A 8 N/A 110 °C (230 °F)
Air Temperature
(1) Refer to Table 18 for trigger points.
(2) Refer to Table 19 for trigger points.

Table 18 Table 19
Trip Points for Low Oil Pressure Warning Trip Points for Low Oil Pressure Shutdown
0 rpm 0 kPa (0 psi) 0 rpm 0 kPa (0 psi)
500 rpm 0 kPa (0 psi) 500 rpm 0 kPa (0 psi)
1600 rpm 154 kPa (22 psi) 1600 rpm 104 kPa (15 psi)
2400 rpm 154 kPa (22 psi) 2400 rpm 104 kPa (15 psi)
82 RENR5089-23
Troubleshooting Section

i02490670 Troubleshooting:
E096 High Fuel Pressure Check the Fuel System
SMCS Code: 1250-038-HQ Check the fuel system's components.
Conditions Which Generate This Code: Check the pressure of the fuel system.
The Electronic Control Module (ECM) detects a Expected Result:
problem with the engine's fuel pressure. Information
on default settings and ranges for this event code There is a problem with the fuel system.
can be found in Troubleshooting, “Event Codes”.
Results:
System Response:
• OK – There is a problem with the fuel system.
The event code will be logged.
Repair: Make the necessary repairs. Verify that
Possible Performance Effect: the repair eliminates the problem.
E096(1) STOP.

• There are no performance effects.

i02507604
Check the Fuel System
E162 High Boost Pressure
A. Verify that the check valve in the fuel manifold is
operating correctly. Check for damage or for dirt SMCS Code: 1052-038-HQ
in the check valve.
Conditions Which Generate This Code:
B. Check the return line from the check valve to the
fuel tank for damage or collapse. The Electronic Control Module (ECM) detects a
problem with the engine's boost pressure. Information
Results: on default settings and ranges for this event can be
found in Troubleshooting, “Event Codes”.
• OK – A problem was found in either the check System Response:
valve or in the return line to the fuel tank.

Repair: Replace all suspect parts. The event is logged.

STOP. Possible Performance Effect:

E162(1)
i02416641
• The engine may experience low power.
E096 High Fuel Pressure
E162(2)
SMCS Code: 1250-038-HQ
• Engine power will be derated.
Conditions Which Generate This Code:
Check for “ACTIVE” Diagnostic Codes.
The Electronic Control Module (ECM) detects a
high fuel pressure. Information on default settings A. Start the Caterpillar Electronic Technician (ET).
and ranges for these event codes can be found in
troubleshooting with an event code Troubleshooting, B. Restore the electrical power to the ECM. The
“Event Codes”. engine should be OFF.
System Response: C. Check for any active diagnostic codes or logged
diagnostic codes. Wait at least 30 seconds in
The ECM will log the code. order for the codes to become active.
Possible Performance Effect: Expected Result:

• Engine performance is not affected. No diagnostic codes are present.

RENR5089-23 83
Troubleshooting Section

Results: B. Verify that the pressure regulating valve in the fuel

manifold is operating correctly. Check for damage
• OK – No diagnostic codes are present. or for dirt in the valve assembly.

Repair: Check the “turbine nozzle ring” for C. Check the return line from the fuel filter base to
excessive carbon buildup. If necessary, clean the the fuel tank for damage or collapse.
“turbine nozzle ring”.
Expected Result:
Talk to the operator. Excessive engine load can
result in high boost pressure. There is a problem in the pressure relief valve, in the
pressure regulating valve, or in the return line to the
If an intermittent problem is suspected, refer to fuel tank.
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. Results:

STOP. • OK – A problem was found in the pressure relief

valve, in the pressure regulating valve, or in the
• Not OK – Diagnostic codes are present. return line to the fuel tank.

Repair: Repair the diagnostic codes that are Repair: Make the necessary repairs. Verify that
present. Refer to the appropriate topic in the the repair eliminates the problem.
“Troubleshooting With a Diagnostic Code” section
of this manual. Refer to Systems Operation/Testing and Adjusting.

Ensure that the repair eliminates the problem. STOP.

STOP. • Not OK – A mechanical problem has not been

found with the fuel system.
i03706907
Repair: If an electrical problem with the sensor
E198 Low Fuel Pressure circuit is suspected, refer to the diagnostic
functional test Troubleshooting, “Engine Pressure
SMCS Code: 1250-038-LP Sensor Open or Short Circuit - Test”.

Conditions Which Generate This Code: STOP.

The Electronic Control Module (ECM) detects a i03111502

problem with the engine's fuel pressure. Information
on default settings and ranges for this event code E198 Low Fuel Pressure
can be found in Troubleshooting, “Event Codes”.
SMCS Code: 1250-038-LP
System Response:
Conditions Which Generate This Code:
The ECM will log the event.
The Electronic Control Module (ECM) detects all of
Possible Performance Effect: the following conditions:

E198(1) • Engine speed is greater than zero rpm.

• There are no performance effects. • Engine speed is within 100 rpm of idle speed but
the engine speed is less than idle speed.
E198(2)
• Fuel pressure is less than 175 kPa (25 psi).
• The engine power is derated.
• Coolant temperature is greater than −5 °C (23 °F).
Check the Fuel System's Components
In a fuel system that is functioning properly, this
A. Inspect the pressure relief valve that is in the body code is usually generated after a fuel filter has
of fuel transfer pump. Check for damage to the been serviced. This code becomes active if the low
spring or to the valve assembly. pressure fuel system does not achieve the proper
pressure.
84 RENR5089-23
Troubleshooting Section

System Response: Test Step 3. Prime the Fuel System

The event code will be logged. A. Use the hand priming pump to prime the fuel
system.
Possible Performance Effect:
B. Connect the Caterpillar Electronic Technician (ET)
E198(1) to the data link connector.

• There are no performance effects. C. Crank the engine. Monitor the status for “Fuel
Pressure” during engine cranking.
E198(2)
Expected Result:
• The engine power will be derated.
“Fuel Pressure” is greater than 175 kPa (25 psi)
Test Step 1. Check the Fuel Level during engine cranking.

Check the fuel level. Results:

Expected Result: • OK – The fuel pressure exceeds 175 kPa (25 psi)
during engine cranking. Priming the fuel system
The fuel level is OK. resolved the problem.

Results: Repair: If the fuel filter was serviced immediately

prior to the activation of this diagnostic code, the
• OK – The fuel level is OK. Proceed to Test Step 2. fuel system was not properly primed before the
engine was cranked.
• Not OK – The fuel level is low.
Verify that the repair eliminates the problem.
Repair: Fill the fuel tanks with fuel.
If the fuel filter had not been serviced prior to
Verify that the repair eliminates the problem. the activation of this fault, air may be entering
the fuel system. Check the fuel system for air
STOP. prior to releasing the vehicle. Refer to Systems
Operation/Testing and Adjusting for information
Test Step 2. Verify Proper Sensor that is related to checking for air in the fuel system.
Installation If necessary, repair the low pressure fuel system.

A. Check the installation of the fuel pressure sensor. Verify that the repair eliminates the problem.

B. Check the wiring of the fuel pressure sensor. Refer STOP.

to the engine's Electrical Schematic. Ensure that
all of the wires and the connectors are properly • Not OK – The fuel pressure does not exceed
connected. 175 kPa (25 psi) during engine cranking. Proceed
to Test Step 4.
Expected Result:
Test Step 4. Verify the Operation of the
The sensor is properly installed and the wiring is Fuel Pressure Sensor
correct.
A. Turn the keyswitch to the OFF position.
Results:
B. Remove the fuel pressure sensor.
• OK – The sensor is properly installed and the
wiring is correct. Proceed to Test Step 3. C. Install a 1U-5470 Engine Pressure Group into the
low pressure fuel system with a Tee fitting in the
• Not OK – The sensor is not properly installed port for the fuel pressure sensor.
and/or the wiring is incorrect.
D. Connect the fuel pressure sensor to the Tee fitting.
Repair: Install the fuel pressure sensor properly.
Repair the wiring and/or the connectors. E. Monitor the status for “Fuel Pressure” on Cat ET.

Verify that the repair eliminates the problem. F. Crank the engine.

STOP.
RENR5089-23 85
Troubleshooting Section

G. Compare the pressure reading on the gauge to Talk to the Operator

the pressure reading on Cat ET.
Determine the reason for the activation of the user
Expected Result: defined shutdown.

The pressure readings are within 35 kPa (5.0 psi) Results:

of each other.
• OK – The operator activated the user defined
Results: shutdown switch. STOP.

• OK – The sensor is functioning properly. • Not OK – The operator did not activate the user
defined shutdown.
Repair: There is a mechanical problem with the
low pressure fuel system. Repair: If you suspect that there is a problem
with the user defined shutdown circuit, refer to the
Repair the low pressure fuel system. Refer to diagnostic functional test Troubleshooting, “User
the Systems Operation/Testing and Adjusting for Defined Shutdown Input Circuit - Test”.
information that is related to repairing the low
pressure fuel system. STOP.

Verify that the repair eliminates the problem.

i02548373

STOP. E360 Low Engine Oil Pressure

• Not OK – The sensor is not functioning properly. SMCS Code: 1348-038-LP
Repair: Temporarily install a new fuel pressure Conditions Which Generate This Code:
sensor.
The Electronic Control Module (ECM) detects a
If the new sensor repairs the problem, reinstall the problem with the engine's oil pressure. Information
suspect sensor. on default settings and ranges for these event codes
can be found in troubleshooting with an event code
If the problem returns, replace the sensor. Troubleshooting, “Event Codes”.
Verify that the repair eliminates the problem. System Response:
STOP. The event code will be logged.

i02432507 Possible Performance Effect:

E265 User Defined Shutdown 360(1)

SMCS Code: 1400-038 • There are no performance effects.

Conditions Which Generate This Code: 360(3)

The user defined shutdown switch has been • The engine may be derated or the engine may be
activated. shut down.

Note: Certain conditions must be met on some Note: For certain applications, the ECM may only
applications prior to the activation of the user derate the engine. The ECM will notify the operator
defined shutdown switch. These conditions may that the condition exists and that the engine must be
include setting the parking brake and/or placing the shutdown.
transmission in neutral.
Troubleshooting:
System Response:
There may be a problem with the engine's lubrication
The Electronic Control Module (ECM) will log the system.
event.

Possible Performance Effect:

• The engine will be shutdown.

86 RENR5089-23
Troubleshooting Section

Check the Engine's Lubrication System Results:

A. Check the engine oil level. If the oil level is below • OK – There is a problem in the engine's lubrication
the oil pump's supply tube, the oil pump will not system.
have the ability to supply enough lubrication to
the engine components. If the engine oil level is Repair: Repair the problem. Ensure that the repair
low, add engine oil in order to obtain the correct eliminates the problem.
engine oil level.
STOP.
B. Check the following problems that may occur to
the engine oil pump:
i02440858

a. Air leakage in the supply side of the oil pump

will also cause cavitation and loss of oil
E360 Low Engine Oil Pressure
pressure. Check the supply side of the oil pump SMCS Code: 1348-038-LP
and make necessary repairs.
Conditions Which Generate This Code:
b. Oil pump gears that have too much wear will
cause a reduction in oil pressure. Repair the The Electronic Control Module (ECM) detects a
engine oil pump. problem with the engine's oil pressure. Information
on default settings and ranges for this event can be
c. If the engine is equipped with a scavenge found in Troubleshooting, “Event Codes”.
pump, the scavenge pump may not be
supplying oil to the main engine oil pump. System Response:
C. The inlet screen of the oil suction tube for the The event code will be logged.
engine oil pump can have a restriction. This
restriction will cause cavitation and a loss of Possible Performance Effect:
engine oil pressure. Check the inlet screen on
the oil pickup tube and remove any material that E360-(2) (Derate)
may be restricting engine oil flow. Low engine oil
pressure may also be the result of the oil pickup
tube that is drawing in air. Check the joints of the
• The engine power will be derated.
oil pickup tube for cracks or a damaged O-ring E360-(3) (Shutdown)
seal.

D. If the engine oil bypass valves are held in the open

• The engine will be shutdown.
position, a reduction in the oil pressure can be the Note: Certain applications will only derate the engine
result. This may be due to debris in the engine power.
oil. If the engine oil bypass valves are stuck in
the open position, remove each engine oil bypass Troubleshooting:
valve and clean each bypass valve in order to
correct this problem. You must also clean each There may be a problem with the engine's lubrication
bypass valve bore. system.
E. Engine oil that is contaminated with fuel or coolant Check the Engine's Lubrication System
will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of A. Check the engine oil level. If the oil level is below
contamination. the oil pump's supply tube, the oil pump will not
have the ability to supply enough lubrication to
F. Excessive clearance at engine bearings will the engine components. If the engine oil level is
cause low engine oil pressure. Check the engine low, add engine oil in order to obtain the correct
components for excessive bearing clearance. engine oil level.
G. An oil line that is open, broken, or disconnected B. Check the following problems that may occur to
will cause low engine oil pressure. the engine oil pump:
Expected Result: a. Air leakage in the supply side of the oil pump
will also cause cavitation and loss of oil
An inspection of the engine's lubrication system pressure. Check the supply side of the oil pump
indicated a problem. and make necessary repairs.
RENR5089-23 87
Troubleshooting Section

b. Oil pump gears that have too much wear will i02566446
cause a reduction in oil pressure. Repair the
engine oil pump. E361 High Engine Coolant
Temperature
c. If the engine is equipped with a scavenge
pump, the scavenge pump may not be SMCS Code: 1395-038-TA
supplying oil to the main engine oil pump.
Conditions Which Generate This Code:
C. The inlet screen of the oil suction tube for the
engine oil pump can have a restriction. This The Electronic Control Module (ECM) detects a
restriction will cause cavitation and a loss of problem with the engine's cooling system. Information
engine oil pressure. Check the inlet screen on on default settings and ranges for this event can be
the oil pickup tube and remove any material that found in Troubleshooting, “Event Codes”.
may be restricting engine oil flow. Low engine oil
pressure may also be the result of the oil pickup System Response:
tube that is drawing in air. Check the joints of the
oil pickup tube for cracks or a damaged O-ring The event code will be logged.
seal.
Possible Performance Effect:
D. If the engine oil bypass valves are held in the open
position, a reduction in the oil pressure can be the E361(1)
result. This may be due to debris in the engine
oil. If the engine oil bypass valves are stuck in • There are no performance effects.
the open position, remove each engine oil bypass
valve and clean each bypass valve in order to E361(2)
correct this problem. You must also clean each
bypass valve bore. • The engine power will be derated.
E. Engine oil that is contaminated with fuel or coolant Troubleshooting:
will cause low engine oil pressure. High engine
oil level in the crankcase can be an indication of There may be a problem with the engine's cooling
contamination. system.
F. Excessive clearance at engine bearings will Check the Engine's Cooling System
cause low engine oil pressure. Check the engine
components for excessive bearing clearance.

G. An oil line that is open, broken, or disconnected

will cause low engine oil pressure. Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
Expected Result: stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
An inspection of the engine's lubrication system pressure cap slowly in order to relieve the pres-
indicated a problem. sure.

Results:
A. Verify that the cooling system is filled to the proper
level. If the coolant level is too low, air will get into
• OK – There is a problem in the engine's lubrication the cooling system. Air in the cooling system will
system.
cause a reduction in coolant flow.
Repair: Repair the problem. Ensure that the repair
B. Check the radiator or the heat exchanger for a
eliminates the problem.
restriction to coolant flow.
STOP.
a. Check for debris or damage between the fins
of the radiator core. Debris between the fins of
the radiator core restricts air flow through the
radiator core.

b. Check internally for debris, dirt, or deposits on

the radiator core. Debris, dirt, or deposits will
restrict the flow of coolant through the radiator.
88 RENR5089-23
Troubleshooting Section

C. Check the mixture of antifreeze and water. L. Check for a restriction in the exhaust system.
Make sure that the coolant mixture meets A restriction of the air that is coming out of the
recommendations. engine can cause high cylinder temperatures.

D. Check the water temperature regulator. A water M. Consider high ambient temperatures. When
temperature regulator that does not open, or a ambient temperatures are too high for the rating
water temperature regulator that only opens part of the cooling system, there is not enough of a
of the way can cause overheating. temperature difference between the ambient air
and coolant temperatures.
E. Check the water pump. A water pump with a
damaged impeller does not pump enough coolant. N. Consider high altitude operation. The cooling
Remove the water pump and check for damage capability of the cooling system is reduced at
to the impeller. higher altitudes. A pressurized cooling system that
is large enough to keep the coolant from boiling
F. If the cooling system for this application is must be used.
equipped with a fan, check the operation of the
fan. A fan that is not turning at the correct speed O. The engine may be running in the lug condition.
can cause improper air speed across the radiator When the load that is applied to the engine is
core. The lack of proper air flow across the too large, the engine will run in the lug condition.
radiator core can cause the coolant not to cool to When the engine is running in the lug condition,
the proper temperature differential. engine rpm does not increase with an increase of
fuel. This lower engine rpm causes a reduction in
G. Check for air in the cooling system. Air can enter coolant flow through the system.
the cooling system in different ways. The most
common causes of air in the cooling system are Expected Result:
the incorrect filling of the cooling system and
combustion gas leakage into the cooling system. A thorough inspection of the cooling system revealed
Combustion gas can get into the system through a problem.
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket. Results:

H. Check the cooling system hoses and clamps. • OK – There is a problem with the cooling system.
Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during Repair: Repair the problem. Ensure that the repair
operation. The soft areas of the hose can become eliminates the problem.
kinked or crushed during operation. These areas
of the hose can restrict the coolant flow. Hoses STOP.
become soft and/or get cracks after a period of
time. The inside of a hose can deteriorate, and the
i03706980
loose particles of the hose can restrict the coolant
flow. E362 Engine Overspeed
I. If the cooling system for this application is SMCS Code: 7410-038; 7427-038
equipped with an expansion tank, check the shunt
line for the expansion tank. The shunt line must be Conditions Which Generate This Code:
submerged in the expansion tank. A restriction of
the shunt line from the expansion tank to the inlet The Electronic Control Module (ECM) detects
of the jacket water pump will cause a reduction in an overspeed condition. Information on default
water pump efficiency. A reduction in water pump settings and ranges for this event can be found in
efficiency will result in low coolant flow. troubleshooting with an event code Troubleshooting,
“Event Codes”.
J. If the cooling system for this application
is equipped with an aftercooler, check the System Response:
aftercooler. A restriction of air flow through the air
to air aftercooler can cause overheating. Check The event code will be logged.
for debris or deposits which would prevent the free
flow of air through the aftercooler. Possible Performance Effect:
K. Check for a restriction in the air inlet system. A E362(1)
restriction of the air that is coming into the engine
can cause high cylinder temperatures. High
cylinder temperatures cause higher than normal
• There are no performance effects.
temperatures in the cooling system. E362(2)
RENR5089-23 89
Troubleshooting Section

• The engine power is derated. Results:

E362(3) • OK – STOP.
• The engine power is derated and/or the engine is i02507630
shut down.

Note: If the engine is not shutdown immediately

E390 Fuel Filter Restriction
perform a safe shutdown. SMCS Code: 1261-038
Troubleshooting: Conditions Which Generate This Code:
• The operator may be operating the machine The Electronic Control Module (ECM) detects an
incorrectly. Determine the events that caused the abnormal fuel filter differential pressure. Information
overspeed of the engine. Avoid sudden drops in on default settings and ranges for this event can
load from the engine. be found in troubleshooting with an event code
Troubleshooting, “Event Codes”.
• There may be a combustible atmosphere. Check
for hydrocarbons in the surrounding atmosphere. System Response:
Do not operate the engine in an environment with
hydrocarbons in the surrounding atmosphere. The event code will be logged.
Results: Possible Performance Effect:
• OK – STOP. E390(1)

i02440912 • There are no performance effects.

E362 Engine Overspeed E390(2)

SMCS Code: 7410-038; 7427-038 • The ECM will derate power.

Conditions Which Generate This Code: Troubleshooting:

The Electronic Control Module (ECM) detects The fuel filter element may need to be replaced.
an overspeed condition. Information on default
settings and ranges for this event can be found in Replace the Fuel Filter Element
troubleshooting with an event code Troubleshooting,
“Event Codes”. A. Replace the fuel filter element. Refer to the
Operation and Maintenance Manual.
System Response:
B. Restart the engine and check for an active event
The event code will be logged. code.

Possible Performance Effect: Expected Result:

E362-(3) (Shutdown) The event code is no longer active.

• The engine will be shut down. Results:

Note: Certain applications will only derate the engine. • OK – The event code is no longer active. STOP.
Troubleshooting: • Not OK – The event code is active.
• The operator may be operating the machine Repair: Perform the diagnostic functional test
incorrectly. Determine the events that caused the Troubleshooting, “Fuel Filter Differential Pressure
overspeed of the engine. Avoid sudden drops in Switch Circuit - Test”.
load from the engine.
STOP.
• There may be a combustible atmosphere. Check
for hydrocarbons in the surrounding atmosphere.
Do not operate the engine in an environment with
hydrocarbons in the surrounding atmosphere.
90 RENR5089-23
Troubleshooting Section

i02498485 When inlet air pressure is low, the turbocharger

works harder in order to achieve the desired
E539 High Intake Manifold Air inlet manifold pressure. This increases inlet air
Temperature temperature.

SMCS Code: 1050-038-TA a. Measure the inlet air pressure while the engine
is operating under load. For specific data, refer
Conditions Which Generate This Code: to the Technical Marketing Information for the
engine.
The Electronic Control Module (ECM) detects
a problem with the engine's intake manifold air b. Check for plugged air filters. Check for
temperature. Information on default settings and obstructions to the air inlet. A restriction of
ranges for this event can be found in troubleshooting the air that enters the engine can cause
with an event code Troubleshooting, “Event Codes”. high cylinder temperatures. High cylinder
temperatures cause higher than normal
System Response: temperatures in the cooling system.

The event code will be logged. c. Replace the air filters and/or remove the
obstruction from the air inlet.
Possible Performance Effect:
d. Consider high altitude operation. The cooling
E539(1) capability of the cooling system is reduced
at higher altitudes. A pressurized cooling
• There are no performance effects. system that has been designed for the higher
altitudes must be used. Ensure that the engine
E539(2) is configured for high altitude operation.

• The engine power will be derated. C. Check for Exhaust System Restriction

Troubleshooting: Check for a restriction in the exhaust system.

A restriction of the air that is coming out of the
Intake manifold air temperature can be high for the engine can cause high cylinder temperatures.
following reasons:
Expected Result:
• High ambient air temperature
A problem has been found in the inlet air system
• High inlet air restriction and/or high altitude and/or the related engine systems.

• Restriction in the exhaust system Results:

• Faulty inlet air temperature sensor and/or circuit • OK – A thorough inspection revealed a problem.

Perform the following Inspections Repair: Repair the problem.

A. Check for High Ambient Air Temperature STOP.

a. Determine if the ambient air temperature is • Not OK – A thorough inspection did not reveal a
within the design specifications for the inlet problem.
air system. When ambient temperatures
are too high for the rating of the inlet air Repair: Connect Caterpillar Electronic Technician
system, there is not enough of a temperature (ET) to the service tool connector. Check Cat ET
difference between the ambient air and inlet for active/logged diagnostic codes related for the
air temperatures. inlet air system. If an active/logged code is found,
refer to the appropriate troubleshooting procedure.
b. Determine the cause of the high inlet air
temperature. Correct the situation, when STOP.
possible.

B. Check for High Inlet Air Restriction and/or

High Altitude Operation
RENR5089-23 91
Troubleshooting Section

Diagnostic Functional
Tests
i02886465

5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1439-038

System Operation Description:

The Electronic Control Module (ECM) creates a

regulated voltage of 5.0 ± 0.2 VDC that is supplied
to terminal A of the harness connectors for these
sensors:

• Injection actuation pressure sensor

• Boost pressure sensor for the Intake manifold
• Atmospheric pressure sensor
• Fuel pressure sensor
• Engine oil pressure sensor
This procedure covers the following diagnostic codes:

• 262-03 5 Volt Sensor DC Power Supply short to

+batt

• 262-04 5 Volt Sensor DC Power Supply short to

ground

• 1785-10 Intake Manifold Pressure Signal abnormal

rate of change

A +5 V diagnostic code is probably caused by a

short circuit to ground or a short circuit to another
voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
a problem with the ECM.
92 RENR5089-23
Troubleshooting Section

g01436855
Illustration 15
Schematic for the 5 volt supply

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.
RENR5089-23 93
Troubleshooting Section

g01199199
Illustration 16
A typical left side view of the C9 engine
(1) Fuel pressure sensor (4) Atmospheric pressure sensor (8) J1/P1 connectors
(2) Injection actuation pressure sensor (5) Engine oil pressure sensor
(3) Boost pressure sensor for the intake (6) J2/P2 connectors
manifold (7) ECM
94 RENR5089-23
Troubleshooting Section

g01255900
Illustration 17
A typical left side view of the C7 engine
(9) Fuel pressure sensor (12) Boost pressure sensor for the intake (14) J2/P2 connectors
(10) Injection actuation pressure sensor manifold (15) ECM
(11) Atmospheric pressure sensor (13) Engine oil pressure sensor (16) J1/P1 connectors

B. Thoroughly inspect the ECM connectors.

Thoroughly inspect the connectors for each
pressure sensor. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect”.
RENR5089-23 95
Troubleshooting Section

g01123211
Illustration 19
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

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

wires that are associated with the pressure sensor
supply.

D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Illustration 18
g01223554 Connectors - Inspect”.
P2 terminals that are associated with the 5 volt supply for the
pressure sensors E. Check the harness and the wiring for abrasion
(P2-17) Return and for pinch points from each sensor back to the
(P2-54) Return ECM.
(P2-72) +5 VDC
(P2-80) +5 VDC Expected Result:

All of the connectors, pins and sockets are completely

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

Results:

• OK – The harness and connectors appear to be

OK. Proceed to Test Step 2.

• Not OK – The connectors and/or wiring are not

OK.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.

STOP.
96 RENR5089-23
Troubleshooting Section

Test Step 2. Check for Active Diagnostic B. Remove electrical power from the ECM.
Codes
Expected Result:
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector. The diagnostic code deactivates when a particular
sensor is disconnected.
B. Restore electrical power to the ECM.
Results:
C. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes. • OK – The diagnostic code deactivates when a
Look for the following diagnostic codes: particular sensor is disconnected.

• 03 Repair: Connect the suspect sensor. If the code

returns, replace the sensor. Connect all of the
• 04 connectors. Verify that the problem is resolved.

• 10 STOP.

Note: Wait at least 30 seconds in order for the • Not OK – The diagnostic code remains active
diagnostic codes to become active. after all of the sensors are disconnected. Leave
the sensors disconnected. The sensors are not
Expected Result: the cause of the diagnostic code. Proceed to Test
Step 4.
No diagnostic codes are active.
Test Step 4. Check the 5 Volt Supply
Results: Voltages at the ECM
• OK – No diagnostic code is active. A. Disconnect the J2/P2 ECM connector.

Repair: The problem is no longer present. If the B. Fabricate four jumper wires that are long enough
problem is intermittent, refer to the diagnostic to be used to measure the supply voltage at the
functional test Troubleshooting, “Electrical ECM connectors. Crimp connector sockets to one
Connectors - Inspect”. end of each jumper wire.

STOP. C. Remove the wires from the following terminal

locations and install a jumper wire into each of
• Not OK – One of the diagnostic codes that is listed these terminal locations:
above is active at this time. Proceed to Test Step 3.
• P2-72 (5 V sensor supply)
Test Step 3. Disconnect the 5 Volt
Sensors while you Monitor the Active • P2-17 (sensor return)
Diagnostic Codes
• P2-80 (5 V sensor supply)
A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 5 Volt sensor at the • P2-54 (sensor return)
sensor connector. Check for an active 03 code, an
active 04 code, or an active 10 code. D. Connect the J2/P2 ECM connector.

Note: Wait at least 30 seconds in order for the E. Restore electrical power to the engine ECM.
diagnostic codes to become active.
F. Measure the voltage between the jumper wire in
a. Disconnect the following sensors one at a time: P2-72 (5 V sensor supply) and the jumper wire in
P2-17 (sensor return).
• Injection actuation pressure sensor
G. Measure the voltage between the jumper wire in
• Boost pressure sensor for the intake manifold P2-80 (5 V sensor supply) and the jumper wire in
P2-54 (sensor return).
• Engine oil pressure sensor
H. Remove electrical power from the ECM.
• Fuel pressure sensor
Expected Result:
• Atmospheric pressure sensor
The voltage measurement is 5.0 ± 0.2 VDC.
RENR5089-23 97
Troubleshooting Section

Results: A +5 V diagnostic code is probably caused by a

short circuit to ground or a short circuit to another
• OK – The voltage measurement is 5.0 ± 0.2 VDC. voltage source in the harness. The next likely cause
The ECM is operating correctly. is a problem with a sensor. The least likely cause is
a problem with the ECM.
Repair: The supply wire is shorted to another wire
in the harness or the supply wire is shorted to
engine ground. Repair the supply wire.

STOP.

• Not OK – The voltage measurement is not 5.0 ±

0.2 VDC.

Repair: Replace the ECM. Refer to electronic

troubleshooting Troubleshooting, “Replacing the
ECM”.

STOP.

i02446273

5 Volt Engine Pressure Sensor

Supply Circuit - Test
SMCS Code: 1439-038

System Operation Description:

The Electronic Control Module (ECM) creates a

regulated voltage of 5.0 ± 0.2 VDC that is supplied
to terminal A of the harness connectors for these
sensors:

• Injection actuation pressure sensor

• Intake manifold (boost) pressure sensor
• Atmospheric pressure sensor
• Fuel pressure sensor
• Engine oil pressure sensor
• Turbocharger inlet pressure sensor
This procedure covers the following diagnostic codes:

• 262-03 5 Volt Sensor DC Power Supply short to

+batt

• 262-04 5 Volt Sensor DC Power Supply short to

ground

• 100-10 Engine Oil Pressure Sensor abnormal rate

of change

• 1785-10 Intake Manifold Pressure Signal abnormal

rate of change
98 RENR5089-23
Troubleshooting Section

g01222300
Illustration 20
Schematic for the 5 volt supply

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.
RENR5089-23 99
Troubleshooting Section

g01223541
Illustration 21
A typical right side view of the engine
(1) Fuel pressure sensor
(2) Turbocharger inlet pressure sensor

g01223554
Illustration 23
P2 terminals that are associated with the 5 volt supply for the
pressure sensors
(P2-17) Return
(P2-54) Return
(P2-72) +5 VDC
(P2-80) +5 VDC

g01223547
Illustration 22
A typical left side view of the engine
(3) Injection actuation pressure sensor
(4) Intake manifold (boost) pressure sensor
(5) Atmospheric pressure sensor
(6) J2/P2 connectors
(7) J1/P1 connectors
(8) Engine oil pressure sensor

B. Thoroughly inspect connectors (6) and (7).

Thoroughly inspect the connectors for each
pressure sensor. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect”.
100 RENR5089-23
Troubleshooting Section

g01123211
Illustration 25
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

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

wires that are associated with the pressure sensor
supply.

D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Illustration 24
g01123207 Connectors - Inspect”.
P1 terminals that are associated with the 5 volt supply for the
pressure sensors E. Check the harness and the wiring for abrasion
(P1-2) +5 VDC and for pinch points from each sensor back to the
(P1-3) Return ECM.

Expected Result:

All of the connectors, pins and sockets are completely

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

Results:

• OK – The harness and connectors appear to be

OK. Proceed to Test Step 2.

• Not OK – The connectors and/or wiring are not

OK.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.

STOP.
RENR5089-23 101
Troubleshooting Section

Test Step 2. Check for Active Diagnostic • Boost pressure sensor J200/P200
Codes
• Atmospheric pressure sensor J203/P203
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic • Fuel pressure sensor J209/P209
troubleshooting Troubleshooting, “Electronic
Service Tools”. • Engine oil pressure sensor J201/P201
B. Restore the electrical power to the ECM. • Turbocharger inlet pressure sensor J205/P205
C. Observe the “Active Diagnostic” screen on Cat ET. C. Restore the electrical power to the ECM.
Wait at least 30 seconds so that any codes may
become active. Look for these codes: Note: Be sure to wiggle the harness during the
following measurements in order to reveal an
• 262-03 intermittent condition.

• 262-04 D. Measure the voltage between terminals A and B

at each sensor connector on the engine harness.
• 100-10
Expected Result:
• 1785-10
Each voltage measurement is 5.0 ± 0.2 VDC.
Expected Result:
Results:
One of the above codes is active.
• OK – Each voltage measurement is 5.0 ± 0.2 VDC.
Results:
Repair: Connect all of the sensor connectors. Clear
• No active codes – None of the above codes are all diagnostic codes. Check for active diagnostic
active. codes. If the problem is intermittent, refer to
the diagnostic functional test Troubleshooting,
Repair: If any of the above codes are logged “Electrical Connectors - Inspect”.
and the engine is not running properly, refer to
Troubleshooting, “Troubleshooting Without a STOP.
Diagnostic Code”.
• Not OK – At least one voltage measurement is not
If the engine is running properly at this time, there 5.0 ± 0.2 VDC. There is a problem with the wiring
may be an intermittent problem in a harness or with the ECM. Proceed to Test Step 6.
that is causing the codes to be logged. Refer to
the diagnostic functional test Troubleshooting, Test Step 4. Check the Voltage on the +5
“Electrical Connectors - Inspect”. V Supply Wire for the Suspect Sensor
STOP. A. Remove the electrical power from the ECM.

• Active 03 code – An 03 diagnostic code is active. B. Disconnect the harness connectors for the suspect
Proceed to Test Step 3. sensor.

• Active 04 code – An 04 diagnostic code is active. C. Restore the electrical power to the ECM.
Proceed to Test Step 5.
Note: Be sure to wiggle the harness during the
• Active 10 code – A 10 diagnostic code is active. following measurement in order to reveal an
Proceed to Test Step 4. intermittent condition.

Test Step 3. Check the Voltage on the +5 D. Measure the voltage between terminals A and B
V Supply Wire on the harness connector for the suspect sensor.

A. Remove the electrical power from the ECM. Expected Result:

B. Disconnect the harness connectors for the The voltage measurement is 5.0 ± 0.2 VDC.
following sensors:

• Injection actuation pressure sensor J204/P204

102 RENR5089-23
Troubleshooting Section

Results: Test Step 6. Check the +5 V Supply Wire

for a Short to Engine Ground or a Short
• Yes – The voltage measurement is 5.0 ± 0.2 Circuit
VDC. The 5 volt supply is present at the harness
connector for the suspect sensor. However, there A. Remove the electrical power from the ECM.
is an active 10 diagnostic code.
B. Disconnect the P1 and P2 connectors.
Repair: Replace the suspect sensor.
C. Verify that all of the pressure sensors are
Verify that the problem is resolved. disconnected.

STOP. Note: Wiggle the harness during the following

measurements in order to reveal an intermittent
• No – The voltage measurement is not 5.0 ± 0.2 condition.
VDC. The 5 volt supply is not present at the
harness connector. There is a problem with the D. Measure the resistance between terminal P2-72
wiring or with the ECM. Proceed to Test Step 6. (+5 V Supply) and all of the other terminals on the
P2 connector.
Test Step 5. Disconnect the +5 V Pressure
Sensors and Check for Active Diagnostic E. Measure the resistance between terminal P2-72
Codes and the engine ground.

A. Disconnect the following sensors one at a time: F. Measure the resistance between terminal P2-80
(+5 V Supply) and all of the other terminals on the
• Injection actuation pressure sensor J204/P204 P2 connector.

• Intake manifold (boost) pressure sensor G. Measure the resistance between terminal P2-80
J200/P200 and the engine ground.

• Atmospheric pressure sensor J203/P203 H. Measure the resistance between terminal P1-2
(+5 V Supply) and all of the remaining terminals
• Fuel pressure sensor J209/P209 on the P1 connector.

• Engine oil pressure sensor J201/P201 I. Measure the resistance between terminal P1-2
and the engine ground.
• Turbocharger inlet pressure sensor J205/P205
Expected Result:
B. Wait for 30 seconds after you disconnect each
sensor. Look for the active 04 diagnostic code to Each resistance measurement indicates an open
deactivate. circuit.

Expected Result: Results:

The 04 diagnostic code deactivates when a particular • OK – Each resistance measurement indicates an
sensor is disconnected. open circuit. Proceed to Test Step 7.

Results: • Not OK – At least one of the resistance

measurements does not indicate an open circuit. A
• OK – The 04 diagnostic code deactivates when a +5 V supply wire has a problem. There may be a
particular sensor is disconnected. problem with a connector.

Repair: Connect the suspect sensor. If the code Repair: Repair the wire and/or the connector,
returns, replace the sensor. when possible. Replace parts, if necessary. Verify
that the problem is resolved.
Connect all of the connectors. Verify that the
problem is resolved. STOP.

STOP. Test Step 7. Check the +5 V Supply and

the Sensor Common for an Open Circuit
• Not OK – The 04 diagnostic code remains after
all of the sensors are disconnected. Leave the A. Install a wire jumper between terminals P2-72 (+5
sensors disconnected. Proceed to Test Step 6. V Supply) and P2-3 (Sensor Common).
RENR5089-23 103
Troubleshooting Section

B. Install a wire jumper between terminals P1-2 (+5 Results:

V Supply) and P1-3 (Sensor Common).
• OK – Both voltage measurements are 5.0 ± 0.2
Note: Wiggle the harness during the following VDC. The ECM is producing the correct voltage.
measurements in order to reveal any intermittent
short condition. Repair: Clear all diagnostic codes. Check
for active diagnostic codes. If the problem is
C. Measure the resistance between terminals A and intermittent, refer to the diagnostic functional test
B at the harness connector for each pressure Troubleshooting, “Electrical Connectors - Inspect”.
sensor.
STOP.
Expected Result:
• Not OK – At least one voltage measurement is not
Each resistance measurement is less than ten Ohms. 5.0 ± 0.2 VDC.

Results: Repair: Replace the ECM. Refer to electronic

troubleshooting Troubleshooting, “Replacing the
• OK – Each measurement is less than ten Ohms. ECM”.
Proceed to Test Step 8.
STOP.
• Not OK – At least one resistance measurement is
greater than ten Ohms. The +5 V supply wire or
i02907631
the return wire has excessive resistance. There
may be a problem in a connector. Air Inlet Heater Circuit - Test
Repair: Repair the wire and/or the connector, SMCS Code: 1090-038
when possible. Replace parts, if necessary. Verify
that the problem is resolved. System Operation Description:
STOP. Use this procedure to troubleshoot any suspect
problems with the air inlet heater circuit.
Test Step 8. Check the +5 V Supply at the
ECM This procedure covers the following diagnostic codes:
A. Remove terminal 72 (+5 V Supply) from the • 617-05 Air Inlet Heater Relay open/current below
P2 connector. Install a wire jumper with socket normal
terminals on both ends into P2-72.
• 617-06 Air Inlet Heater Relay grounded/current
B. Connect the J2/P2 connectors. above norm
C. Remove terminal 2 (+5 V Supply) from the P1 The air inlet heater improves the engine's ability to
connector. Install a wire jumper with socket start when the engine is cold. The air inlet heater also
terminals on both ends into P1-2. reduces white smoke when the engine is cold.
D. Connect the J1/P1 connectors. The Electronic Control Module (ECM) controls the
operation of the air inlet heater via the air inlet heater
E. Restore the electrical power to the ECM. relay.
F. Measure the voltage between the wire jumper in The operation of the air inlet heater is determined
P1-2 and the engine ground. by the following cycles:
G. Measure the voltage between the wire jumper in Power Up Cycle – The air inlet heater is turned on
P2-2 and the engine ground. for two seconds after the ECM is first powered up.
This will happen regardless of temperatures and
H. Remove the electrical power from the ECM. engine speed.
I. Restore both wires to the original configuration. Preheat Cycle – If the “SUM” of the coolant
temperature and the inlet manifold air temperature is
Expected Result: less than 25 °C (109 °F), then the heater will remain
on up to 30 seconds. If the engine speed is zero after
Both voltage measurements are 5.0 ± 0.2 VDC. 30 seconds, the heater is turned off regardless of the
temperature.
104 RENR5089-23
Troubleshooting Section

Crank Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
still less than 25 °C (109 °F), the air inlet heater will
remain on while the engine is being cranked.

Running Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
less than 35 °C (127 °F), then the air inlet heater will
remain on for seven minutes.

Postheat Cycle – The air inlet heater is cycled on

and off for an additional 13 minutes if the “SUM” of
the coolant temperature and the inlet manifold air
temperature is still less than 35 °C (127 °F). The air
inlet heater will turn on for ten seconds and the air
inlet heater will turn off for ten seconds.

Note: When you convert the “SUM” of two

temperatures that are in degrees Celsius,
the resulting value in degrees Fahrenheit will
be incorrect. The two temperatures must be
converted prior to the addition of the two values.

• Convert the reading for the coolant temperature

from degrees Celsius to degrees Fahrenheit.

• Convert the reading for the inlet manifold air

temperature from degrees Celsius to degrees
Fahrenheit.

• Add the two conversions together in order to arrive

at the correct conversion for the sum in degrees
Fahrenheit. Refer to the example that is in Table
20.

Table 20
Example
Reading °C °F
Coolant Temperature 15 °C 59 °F
Inlet Manifold Air Temperature 10 °C 50 °F
“SUM”(1) 25 °C 109 °F
(1) The sum cannot be directly converted. The direct conversion
of 25 °C is 77 °F.

g01234809
Illustration 26
Schematic for the air inlet heater
RENR5089-23 105
Troubleshooting Section

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.

g01208064
Illustration 27
Typical component locations for the air inlet heater
(1) Air inlet heater (3) Ground connector for the air inlet heater
(2) Air inlet heater relay (4) J2/P2 connectors

B. Thoroughly inspect the connector for the air inlet

heater and connector (4). Inspect the connections
on air inlet heater relay (2) and air inlet heater
(1). Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
106 RENR5089-23
Troubleshooting Section

Results:

• OK – The harness and the connectors appear to

be OK. Proceed to Test Step 2.

• Not OK – There is a problem with the connectors

and/or the wiring.

Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.

STOP.

Test Step 2. Check for Active Diagnostic

Codes
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic
Service Tools”.

B. Restore the electrical power to the ECM.

C. Observe the “Active Diagnostic” screen on Cat ET.

Wait at least 30 seconds so that any codes may
become active. Look for these codes:

• 617-05
• 617-06

Illustration 28
g01208070 Expected Result:
P2 terminals that are associated with the air inlet heater
One of the above codes is active.
(P2-5) Air inlet heater
(P2-79) Air inlet heater
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the connectors that are associated with • Active 05 code – A 05 diagnostic code is active.
Proceed to Test Step 3.
the circuit.

D. Check the torque of the allen head screws for the • Active 06 code – A 06 diagnostic code is active.
Proceed to Test Step 5.
ECM connectors. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque values. • No active codes – None of the above codes are
active. There may be a problem with the high
power circuit. Proceed to Test Step 6.
E. Check the harness and wiring for abrasion and
for pinch points from the air inlet heater back to
the ECM and from the air inlet heater back to the
battery.

Expected Result:

All connectors, pins and sockets are completely

coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points.
RENR5089-23 107
Troubleshooting Section

Test Step 3. Check for an Open Circuit B. Measure the resistance between terminal P2-5
to the Relay and terminal 1 on the connector for the air inlet
heater.

C. Measure the resistance between terminal P2-79

and terminal 2 on the connector for the air inlet
heater.

Expected Result:

Both of the resistance measurements are less than

ten Ohms.

Results:

• OK – Both of the resistance measurements are

less than ten Ohms.
g01118589
Illustration 29
Small terminals for the typical air inlet heater relay Repair: Perform the following repair:

A. Disconnect the wires from the small terminals of 1. Temporarily connect a spare ECM.
the air inlet heater relay.
2. Reconnect all connectors and wires.
B. Install a test lamp across the wires.
3. Recheck the system for active diagnostic codes.
C. Start the “Air Inlet Heater Override” on Cat ET and
observe the test lamp. 4. Repeat this test step.

Note: Do not leave the “Air Inlet Heater Override” 5. If the problem is resolved with the spare ECM,
ON. This prevents unnecessary cycling of the air inlet reconnect the suspect ECM.
heater and the battery from discharging. The “Air
Inlet Heater Override” has a one minute timer that 6. If the problem returns with the suspect ECM,
disables the test when the time expires. replace the ECM.

D. Stop the “Air Inlet Heater Override” and restore 7. Verify that the repair eliminates the problem.
electrical power to the ECM.
STOP.
Expected Result:
• Not OK – At least one of the resistance
The test lamp turned on while the override was active. measurements is more than ten Ohms. There is a
problem with the wiring between the ECM and the
Results: air inlet heater relay. There may be a problem with
a connector.
• OK – The test lamp turned on while the override
was active. The open circuit is in the relay. Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
Repair: Replace the air inlet heater relay. Clear that the problem is resolved.
any diagnostic codes. Verify that the problem is
resolved. STOP.

STOP.

• Not OK – The test lamp did not turn on while the

override was active. Proceed to Test Step 4.

Test Step 4. Check the Wiring Between

the ECM and the Relay
A. Disconnect the J2/P2 connectors.

Note: Be sure to wiggle the harness during the

following measurements in order to reveal an
intermittent condition.
108 RENR5089-23
Troubleshooting Section

Test Step 5. Check for a Short Circuit in Test Step 6. Check for Battery Voltage at
the Wiring to the Relay the Relay
A. Connect a test lamp between the +Battery side of
the air inlet heater relay and the engine ground.

Expected Result:

The test lamp turns ON.

Results:

• OK – The test lamp turns ON. Battery voltage is

reaching the relay. Proceed to Test Step 7.

• Not OK – The test lamp does not turn ON. Battery

voltage is not reaching the relay.
g01118589
Illustration 30
Small terminals for the typical air inlet heater relay Repair: There is an open circuit in the wiring
between the battery and the relay. There may be a
A. Disconnect the wires from the small terminals for problem with a connection.
the air inlet heater relay.
Repair the wire and/or the connection, when
B. Restore the electrical power to the ECM. possible. Replace parts, if necessary. Verify that
the problem is resolved.
C. Observe the “Active Diagnostic” screen on Cat ET.
Wait at least 30 seconds so that any codes may STOP.
become active.
Test Step 7. Check for Voltage Output at
D. Remove the electrical power from the ECM. the Relay
Expected Result: A. Connect a test lamp between the output terminal
of the air inlet heater relay and the engine ground.
The short circuit diagnostic code (06) changed to an
open circuit diagnostic code (05) when the wires to Note: Observe the test lamp. The test lamp should
the relay were disconnected. be off, since the relay is not energized. If the test
lamp is on, ensure that the test lamp is connected to
Results: the output side of the relay.

• OK – The short circuit diagnostic code (06) B. Restore the electrical power to the ECM.
changed to an open circuit diagnostic code (05)
when the wires to the relay were disconnected. C. Run the “Air Inlet Heater Override” on Cat ET and
The short circuit is in the relay. observe the test lamp.

Repair: Replace the relay. Clear the diagnostic Note: Do not leave the “Air Inlet Heater Override”
codes. ON. This prevents unnecessary cycling of the air inlet
heater and the battery from discharging. The “Air
Verify that the problem is resolved. Inlet Heater Override” has a one minute timer that
disables the test when the time expires.
STOP.
D. Stop the “Air Inlet Heater Override” and remove
• Not OK – The short circuit diagnostic code electrical power from the ECM.
(06) remained when the wires to the relay were
disconnected. There is a problem in the wiring Expected Result:
between the ECM and the relay. There may be a
problem with a connector. The test lamp turned on when the “Air Inlet Heater
Override” was enabled.
Repair: Repair the wire and/or the connector,
when possible. Replace parts, if necessary. Verify
that the problem is resolved.

STOP.
RENR5089-23 109
Troubleshooting Section

Results: Repair: Repair the wire and/or the connector,

when possible. Replace parts, if necessary. Verify
• OK – The test lamp turned on when the “Air Inlet that the problem is resolved.
Heater Override” was enabled. The air inlet heater
relay and the +Battery connection to the air inlet STOP.
heater relay are operating correctly. Proceed to
Test Step 8. Test Step 9. Measure the Current through
the Heater
• Not OK – The test lamp did not turn on when the
“Air Inlet Heater Override” was enabled.

Repair: Replace the relay.

Verify that the problem is resolved.

STOP.

Test Step 8. Check the Wiring Between

the Relay and the Heater and Between
the Heater and the Engine Block

g01235514
Illustration 32
Typical left side view
(3) Ground connector
(5) Wire
(6) Terminal

A. Connect a 155-5176 AC/DC Current Probe or an

equivalent inductive pickup clamp around wire (5)
between the relay and the air inlet heater.

B. Connect the current probe to a multimeter.

Illustration 31
g01235513 C. Restore the electrical power to the ECM.
Typical left side view
D. Run the “Air Inlet Heater Override” on Cat ET and
(3) Ground connector
(5) Wire
observe the current reading on the multimeter.

A. Measure the resistance of wire (5) that connects Note: Do not leave the “Air Inlet Heater Override”
the relay to the air inlet heater. On. Avoid unnecessary cycling of the air inlet heater
in order to prevent the battery from discharging. The
B. Measure the resistance of the ground strap that is “Air Inlet Heater Override” has a one minute timer in
connected between terminal (3) and the engine order to disable the test when the time expires.
block.
E. While the override is active, measure the voltage
Expected Result: between terminals (6) and (3).

Both of the resistance measurements are less than F. Stop the “Air Inlet Heater Override” and remove
ten Ohms. the electrical power from the ECM.

Results: Expected Result:

The current reading is between 84 and 104 Amperes.

• OK – Both of the resistance measurements are The voltage reading is approximately 22 VDC.
less than ten Ohms. Proceed to Test Step 9.
Note: If the voltage reading does not match the
• Not OK – At least one of the resistance specified value, you will need to adjust the current
measurements is more than ten Ohms. There is an
open circuit in the wiring. There may be a problem value accordingly. For slightly lower voltages, the
with a connector. current value will be slightly lower. For slightly higher
voltages, the current value will be slightly higher.
110 RENR5089-23
Troubleshooting Section

Results: Running Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
• OK – The readings are within the specified ranges. less than 35 °C (127 °F), then the air inlet heater will
remain on for seven minutes.
Repair: The readings are within the specified
ranges. The air inlet heater circuit appears to be Postheat Cycle – The air inlet heater is cycled on
operating correctly at this time. If an intermittent and off for an additional 13 minutes if the “SUM” of
problem is suspected, refer to diagnostic functional the coolant temperature and the inlet manifold air
tests Troubleshooting, “Electrical Connectors - temperature is still less than 35 °C (127 °F). The air
Inspect”. inlet heater will turn on for ten seconds and the air
inlet heater will turn off for ten seconds.
STOP.
Note: When you convert the “SUM” of two
• Not OK – The voltage reading and/or the current temperatures that are in degrees Celsius,
reading is not within the specified ranges. the resulting value in degrees Fahrenheit will
be incorrect. The two temperatures must be
Repair: Replace the air inlet heater. converted prior to the addition of the two values.

Verify that the problem is resolved. • Convert the reading for the coolant temperature
from degrees Celsius to degrees Fahrenheit.
STOP.
• Convert the reading for the inlet manifold air
temperature from degrees Celsius to degrees
i02450159
Fahrenheit.
Air Inlet Heater Circuit - Test
• Add the two conversions together in order to arrive
SMCS Code: 1090-038 at the correct conversion for the sum in degrees
Fahrenheit. Refer to the example that is in Table
System Operation Description: 21.

Table 21
Use this procedure to troubleshoot any suspect
problems with the air inlet heater circuit. Example
Reading °C °F
The air inlet heater improves the engine's ability to
start when the engine is cold. The air inlet heater also Coolant Temperature 15 °C 59 °F
reduces white smoke when the engine is cold. Inlet Manifold Air Temperature 10 °C 50 °F
The Electronic Control Module (ECM) controls the “SUM”(1) 25 °C 109 °F
operation of the air inlet heater via the air inlet heater (1) The sum cannot be directly converted. The direct conversion
relay. of 25 °C is 77 °F.

The operation of the air inlet heater is determined

by the following cycles:

Power Up Cycle – The air inlet heater is turned on

for two seconds after the ECM is first powered up.
This will happen regardless of temperatures and
engine speed.

Preheat Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
less than 25 °C (109 °F), then the heater will remain
on up to 30 seconds. If the engine speed is zero after
30 seconds, the heater is turned off regardless of the
temperature.

Crank Cycle – If the “SUM” of the coolant

temperature and the inlet manifold air temperature is
still less than 25 °C (109 °F), the air inlet heater will
remain on while the engine is being cranked.
RENR5089-23 111
Troubleshooting Section

g01223271
Illustration 33
Schematic for the air inlet heater

Test Step 1. Inspect Electrical Connectors

And Wiring
A. Remove the electrical power from the ECM.

g01223199
Illustration 34
Typical left side engine view
(1) Air inlet heater relay
(2) Connector for the air inlet heater relay
(3) Air inlet heater
(4) J2/P2 ECM connectors

B. Thoroughly inspect all connections for components

(1) and (3). Also, thoroughly inspect connectors
(2) and (4). Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.

g01223205
Illustration 35
P2 terminal locations for the air inlet heater
(P2-5) Air inlet heater +Battery
(P2-79) Air inlet heater −Battery

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

wires in the ECM connector that are associated
with the air inlet heater.
112 RENR5089-23
Troubleshooting Section

D. Check the allen head screw at each ECM Expected Result:

connector for the proper torque. Refer to the
diagnostic functional test Troubleshooting, Result 1 The relay is active.
“Electrical Connectors - Inspect”.
Result 2 The relay is active but the air inlet heater is
E. Check the harness and wiring for abrasion and suspected of having a problem.
for pinch points from the air inlet heater back to
the ECM and from the air inlet heater back to the Result 3 The relay does not activate.
battery.
Results:
Expected Result:
• RESULT 1 – The lamp and the relay are
All connectors, pins and sockets are completely functioning normally. STOP.
coupled and/or inserted and the harness and wiring
are free of corrosion, of abrasion and of pinch points. • RESULT 2 – There may be a problem with the air
inlet heater. Proceed to Test Step 3.
Results:
• RESULT 3 – There is a problem with the relay
• OK – The harness and connectors appear to be circuit. Proceed to Test Step 4.
OK. Proceed to Test Step 2.
Test Step 3. Check the Voltage at the
• Not OK – A problem has been found with a Relay Contacts for the Air Inlet Heater
connector and/or wiring.

Repair: Repair the connectors or wiring and/or

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

STOP.

Test Step 2. Use the “Air Inlet Heater

Overide” to Check the Circuit
A. Restore the electrical power to the ECM.

B. Remove the electrical power from the ECM. g01223211

Illustration 36
Connections for the test lamp
The lamp for the air inlet heater should illuminate
for two seconds. The lamp for the air inlet heater A. Remove the electrical power from the ECM.
should shut off.
B. Disconnect the wire from the relay terminal of the
C. Connect the Caterpillar Electronic Technician (ET) air inlet heater to the air inlet heater.
to the service tool connector.
C. Fabricate two jumper wires with Deutsch sockets
D. Restore the electrical power to the ECM. on one end and Deutsch pins on the other end.
Strip a small amount of insulation from the middle
E. Go to the “Air Inlet Heater Override” in the of one jumper wire.
“Override Parameters” in the “Diagnostic Tests”
under the “Diagnostics” menu on Cat ET. D. Disconnect J501/P501 and insert the jumper wires
in the electrical connectors.
F. Start the test and listen for a click from the air inlet
heater relay. E. Connect a voltage test lamp from the disconnected
relay terminal to the jumper wire that is connected
Note: The air inlet heater relay is located on the front to J501 and P501 terminals.
left side of the engine.
F. Restore the electrical power to the ECM.
Note: Do not leave the “Air Inlet Heater Override”
ON. Avoid unnecessary cycling of the air inlet heater G. Go to the “Air Inlet Heater Override” on Cat ET.
in order to prevent the battery from discharging. The
“Air Inlet Heater Override” has a one minute timer in H. Start the test and watch the voltage test lamp.
order to disable the test when the time expires.
RENR5089-23 113
Troubleshooting Section

Note: Do not leave the “Air Inlet Heater Override” B. Disconnect the J501/P501 air inlet heater relay
On. Avoid unnecessary cycling of the air inlet heater connector.
in order to prevent the battery from discharging. The
“Air Inlet Heater Override” has a one minute timer in C. Connect a voltage test lamp to the two terminals
order to disable the test when the time expires. on the engine harness side of the P501 air inlet
heater relay connector.
Expected Result:
D. Restore the electrical power to the ECM.
The test lamp turned ON and the test lamp turned
OFF with the “Air Inlet Heater Override”. E. Go to the “Air Inlet Heater Override” on Cat ET.

Results: F. Start the test and watch the voltage test lamp.

• OK – The air inlet heater relay and the +Battery Note: Do not leave the “Air Inlet Heater Override”
connection to the air inlet heater relay are OK. On. Avoid unnecessary cycling of the air inlet heater
Leave the wire disconnected from the relay in order to prevent the battery from discharging. The
terminal. Proceed to Test Step 5. “Air Inlet Heater Override” has a one minute timer in
order to disable the test when the time expires.
• Not OK – The test lamp does not turn ON.
Reconnect the wire from the air inlet heater to the Expected Result:
terminal on the air inlet heater relay. Proceed to
Test Step 6. The test lamp turns ON and the test lamp turns OFF
with the “Air Inlet Heater Override”.
• NO – The test lamp turns ON. The test lamp
remains ON. Reconnect the wire from the air inlet Results:
heater to the terminal on the air inlet heater relay.
Proceed to Test Step 6. • OK – The ECM and the wiring to the P501
connector are OK.
Test Step 4. Check the Voltage at the Air
Inlet Heater Relay Repair: Replace the air inlet heater and rerun the
test. Verify that the repair eliminates the problem.

STOP.

• Not OK – The P501 connector is not receiving the

correct voltage. Proceed to Test Step 7.

Test Step 5. Check the Wiring for the Air

Inlet Heater
A. Remove the electrical power from the ECM.

B. Disconnect both wires from the air inlet heater.

C. Use a multimeter to measure the resistance

between the two ends of the wire that connects
the air inlet heater to the air inlet heater relay.

D. Measure the resistance from the engine ground

stud to the other end of the wire for the air inlet
heater that connects to the ground stud.
g01223213
Illustration 37
Expected Result:
Typical example of the locations for the components
(1) Air inlet heater lamp connector The measured resistance is less then 20 Ohms.
(2) J501/P501 Air inlet heater relay connector
(3) Contact side to the air inlet heater
(4) Contact side to the circuit protection Results:
(5) Air inlet heater relay
(6) Test lamp • OK – There is a problem with the air inlet heater.
(7) Air inlet heater relay connector

A. Remove the electrical power from the ECM.

114 RENR5089-23
Troubleshooting Section

Repair: Replace the air inlet heater. Verify that the Repair: Inspect the circuit protection for the air
problem is resolved. inlet heater and the air inlet heater wiring. Replace
the circuit breaker. Verify that the problem has
STOP. been resolved.

• Not OK – There is a problem with the wiring for STOP.

the air inlet heater.
Test Step 7. Check Battery Voltage to the
Repair: Repair the damaged wire. Verify that the Air Inlet Heater Relay
problem is resolved.
A. Remove the electrical power from the ECM.
STOP.
B. Disconnect the J501/P501 air inlet heater relay
Test Step 6. Check the Relay Contact at connector.
the +Battery Terminal Connection
C. Connect a voltage test lamp from P501-1 to the
engine ground stud.

D. Restore the electrical power to the ECM.

Expected Result:

The voltage test lamp comes on and the voltage test

lamp stays on when the engine control is in the ON
mode.

Results:

• OK – The air inlet heater relay is receiving +Battery

voltage. Proceed to Test Step 8.
g01223217
Illustration 38
Connections for the test lamp • Not OK – There appears to be a problem with the
wiring.
A. Remove the electrical power from the ECM.
Repair: Repair the wiring or replace the wiring
B. Connect one lead of a voltage test lamp to the from the negative battery to P501-1. Verify that the
terminal for the relay contact. problem is resolved.

C. Connect the other end of the voltage test lamp to STOP.

the engine ground stud.
Test Step 8. Check the ECM
D. Place the engine control in the ON mode.
A. Remove the electrical power from the ECM.
Expected Result:
B. Disconnect the J2/P2 ECM connector. Install a
The test lamp comes on when the engine control is in breakout T to the J2 ECM connector only.
the ON mode.
C. Connect a voltage test lamp from the +Battery
Results: terminal to the −Battery terminal. Refer to
Illustration 33.
• OK – There is a problem with the wiring between
the air inlet heater relay and the J501/P501 D. Restore the electrical power to the ECM.
connector.
E. Go to the “Air Inlet Heater Override” on Cat ET.
Repair: Repair the wiring or replace the wiring.
Verify that the problem has been resolved. F. Start the test and watch the voltage test lamp.

STOP. Note: Do not leave the “Air Inlet Heater Override”

On. Avoid unnecessary cycling of the air inlet heater
• Not OK – There may be a problem with the circuit in order to prevent the battery from discharging. The
protection. “Air Inlet Heater Override” has a one minute timer in
order to disable the test when the time expires.
RENR5089-23 115
Troubleshooting Section

Note: When the J2/P2 ECM connector is Send the vehicle to the OEM dealer for repair.
disconnected and the keyswitch is in the ON position, Verify that the problem has been resolved.
open circuit diagnostic codes will be active or logged
for all of the engine sensors. This is normal. STOP.

Expected Result:
i02473631

The test lamp turned ON and the test lamp turned

OFF with the “Air Inlet Heater Override”.
Cat Data Link Circuit - Test
SMCS Code: 1901-038
Results:
System Operation Description:
• OK – The ECM appears to be OK.
Note: This procedure checks for an open circuit
Repair: Repair the wiring between the P501 or for a short circuit in the Cat Data Link. If you
connector and the P2 ECM connector. Verify that are experiencing problems with communications
the problem has been resolved. between the Caterpillar Electronic Technician
(ET) and the Electronic Control Module (ECM),
STOP. refer to troubleshooting without a diagnostic code
Troubleshooting, “Electronic Service Tool Will
• Not OK – There may be a problem with the ECM. Not Communicate with ECM” before you use this
Proceed to Test Step 9. procedure.
Test Step 9. Test the Battery Voltage to The Cat Data Link is the standard data link that
the ECM is used by the ECM to communicate with Cat ET.
The ECM communicates with Cat ET in order to
A. Remove the electrical power from the ECM. share status information and diagnostic information.
Cat ET can also be used to configure the ECM
B. Install a breakout T between the J1 and P1 ECM parameters. This information will not be available if
connectors. communication fails between the ECM and Cat ET.
C. Place the engine control in the ON mode.

D. Measure the voltage between the +Battery

terminal of the breakout harness and the −Battery
terminal of the breakout harness.

E. Measure the voltage between the +Battery

terminal of the breakout harness and the −Battery
terminal of the breakout harness.

Expected Result:

The voltage is between 11.0 VDC and 13.5 VDC for a

12 volt system and the voltage is between 22.0 VDC
and 27.0 VDC for a 24 volt system when the engine g01233970
Illustration 39
control is in the ON mode. Schematic for the Cat Data Link

Results: Test Step 1. Inspect the Electrical

Connectors and the Wiring
• OK – The ECM is receiving the correct voltage,
but the lamp is not turning ON. A. Remove the electrical power from the ECM.
Repair: Replace the ECM. Verify that the problem
is resolved.

STOP.

• Not OK – The problem is in the wiring.

Repair: Repair the wiring or replace the wiring.
116 RENR5089-23
Troubleshooting Section

g01167488
Illustration 40
Typical engine view
(1) J1/P1 ECM connectors

g01202018
Illustration 42
P1 terminals that are associated with the Cat Data Link
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −

g01149983
Illustration 41
Typical engine view
(2) P61 customer connector
(3) P63 service tool connector

B. Thoroughly inspect connectors (1), (2), and

(3). Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
RENR5089-23 117
Troubleshooting Section

Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
original problem is resolved.

STOP.

Test Step 2. Check for a Short Circuit

A. Disconnect the J1 connector.

B. Disconnect Cat ET from the service tool connector.

C. Measure the resistance between the points that

are listed in Table 22. Be sure to wiggle the wires
in the harnesses as you make each resistance
measurement.

Table 22
Resistance Measurements for the Cat Data Link
Connector and Terminal
Terminal
P1-8 (Cat Data Link +) All of the other terminals on
the P1 connector
Ground stud
g01119122
Illustration 43 P1-9 (Cat Data Link -) All of the other terminals on
J61 and P61 terminals that are associated with the Cat Data Link the P1 connector
(6) Cat Data Link − Ground stud
(7) Cat Data Link +

C. Perform a 45 N (10 lb) pull test on each of the Expected Result:

wires that are associated with the Cat Data Link.
Each check of the resistance indicates an open
D. Check the allen head screw on each ECM circuit.
connector for the proper torque. Also, check the
allen head screw on the customer connector Results:
for the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical • OK – Each check of the resistance indicates an
Connectors - Inspect” for the correct torque open circuit. Proceed to Test Step 3.
values.
• Not OK – At least one check of the resistance
Expected Result: does not indicate an open circuit. There is a short
circuit in the harness or in a connector.
All connectors, pins, and sockets are completely
inserted and coupled. The harness and wiring are Repair: Repair the connectors and/or the wiring.
free of corrosion, of abrasion, and of pinch points. Replace parts, if necessary. Verify that the original
problem is resolved.
Results:
STOP.
• OK – The harness and the connectors appear to
be OK. Proceed to Test Step 2. Test Step 3. Check for an Open Circuit

• Not OK – The connectors and/or the wiring are A. Fabricate a jumper wire. Use the jumper wire in
not OK. order to create a short circuit between terminals
J63-D (Cat Data Link +) and J63-E (Cat Data Link
−).

B. Measure the resistance between P1-8 (Cat Data

Link +) and P1-9 (Cat Data Link −).
118 RENR5089-23
Troubleshooting Section

Expected Result: Note: This procedure checks for an open circuit

or for a short circuit in the Cat Data Link. If you
Each check of the resistance is less than ten Ohms. are experiencing problems with communications
between the Caterpillar Electronic Technician (ET)
Results: and the Electronic Control Module (ECM), refer
to the troubleshooting without a diagnostic code
• OK – Each check of the resistance is less than procedure Troubleshooting, “Electronic Service Tool
ten Ohms. Will Not Communicate with ECM” before you use this
procedure.
Repair: Perform the following procedure:
The Cat Data Link is the standard Data Link that
1. Connect the J1/P1 connectors. Connect Cat ET is used by the ECM to communicate with Cat ET.
to the service tool connector. The ECM communicates with Cat ET in order to
share status information and diagnostic information.
2. Check the Cat Data Link for proper operation. If Cat ET can also be used to configure the ECM
the Data Link does not operate correctly, there parameters. This information will not be available if
may be a problem with the ECM. communication fails between the ECM and Cat ET.

Temporarily install a new ECM. Check the Cat

Data Link again. If the new ECM solves the
problem, install the original ECM and verify that
the original problem returns. If the new ECM
operates correctly and the original ECM does
not operate correctly, replace the original ECM.
Verify that the problem is resolved.

STOP.

• Not OK – At least one check of the resistance is

greater than ten Ohms. There is an open circuit or
excessive resistance in the harness. There may be
a problem with a connector.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Verify that the original
problem is resolved.

STOP.

i02444803

Cat Data Link Circuit - Test

SMCS Code: 1901-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the Cat Data Link.

Use this procedure to troubleshoot the system when

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

• 296-09 Unable to communicate with Transmission

ECM

• 296-12 Transmission ECM Failed

• 1639-09 Machine Security System Module not
communicating on link
RENR5089-23 119
Troubleshooting Section

g01222915
Illustration 44
Schematic for the “Cat Data Link”

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.

g01167488
Illustration 45
Engine view (typical example)
(1) J1/P1 connectors

B. Thoroughly inspect connector (1). Refer to

the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.

g01104274
Illustration 46
P1 terminals that are associated with the “Cat Data Link”
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −
120 RENR5089-23
Troubleshooting Section

Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
original problem is resolved.

STOP.

Test Step 2. Check for a Short Circuit

A. Disconnect the P1 ECM connector.

B. Disconnect Cat ET from the service tool connector.

C. Disconnect any other control modules from the

“Cat Data Link”. Refer to Illustration 44.

D. Measure the resistance between the points that

are listed in Table 23. Be sure to wiggle the wires
in the harnesses as you make each resistance
measurement.

Table 23
Resistance Measurements for the Cat Data Link
Connector and Terminal
Terminal

g01222949 P1-8 (Cat Data Link +) All of the other terminals on

Illustration 47 the P1 connector
Terminals that are associated with the “Cat Data Link” on the
machine connector Ground stud
(P1-40) Cat Data Link + P1-9 (Cat Data Link -) All of the other terminals on
(P1-39) Cat Data Link − the P1 connector

C. Perform a 45 N (10 lb) pull test on each of the Ground stud

wires that are associated with the “Cat Data Link”.
Expected Result:
D. Check the allen head screw on each ECM
connector for the proper torque. Also, check the Each check of the resistance indicates an open
allen head screw on the customer connector circuit.
for the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical Results:
Connectors - Inspect”.
• OK – Each check of the resistance indicates an
Expected Result: open circuit. Proceed to Test Step 3.

All connectors, pins, and sockets are completely • Not OK – At least one check of the resistance
inserted and coupled. The harness and wiring are does not indicate an open circuit. There is a short
free of corrosion, of abrasion, and of pinch points. circuit in the harness or in a connector.

Results: Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Verify that the original
• OK – The harness and the connectors appear to problem is resolved.
be OK. Proceed to Test Step 2.
STOP.
• Not OK – The connectors and/or the wiring are
not OK. Test Step 3. Check for an Open Circuit
A. Fabricate a jumper wire. Use the jumper wire in
order to create a short circuit between terminals
D (Cat Data Link +) and terminal E (Cat Data Link
−) on the service tool connector.
RENR5089-23 121
Troubleshooting Section

B. Measure the resistance between P1-8 (Cat Data • 041-03 8 Volt DC Supply short to +batt
Link +) and P1-9 (Cat Data Link −).
• 041-04 8 Volt DC Supply short to ground
C. Measure the resistance between the terminals
at the connector for each control module that A +8 V diagnostic code is probably caused by a
was connected to the “Cat Data Link”. Refer to short circuit to ground or a short circuit to another
Illustration 44. voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
Expected Result: a problem with the ECM.

Each check of the resistance indicates a short circuit.

Results:

• OK – Each check of the resistance indicates a

short circuit.

Repair: Perform the following procedure:

1. Connect the J1/P1 connectors. Connect Cat ET

to the service tool connector.

2. Check the “Cat Data Link” for proper operation.

If the data link does not operate correctly, there
may be a problem with the ECM.

Temporarily install a new ECM. Check the “Cat

Data Link” again. If the new ECM solves the
problem, install the original ECM and verify that
the original problem returns. If the new ECM
operates correctly and the original ECM does
not operate correctly, replace the original ECM.
Verify that the problem is resolved.

STOP.

• Not OK – At least one check of the resistance

does not indicate a short circuit. There is an open
circuit or excessive resistance in the harness.
There may be a problem with a connector.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Verify that the original
problem is resolved.

STOP.

i02527314

Digital Sensor Supply Circuit

- Test
SMCS Code: 1439-038

System Operation Description:

The Electronic Control Module (ECM) supplies a

regulated voltage of 8.0 ± 0.4 VDC to the throttle
sensor.

This procedure covers the following diagnostic codes:

122 RENR5089-23
Troubleshooting Section

g01234104
Illustration 48
Schematic for the digital sensor supply

Test Step 1. Inspect the Electrical B. Thoroughly inspect connector(1). Inspect the
Connectors and the Wiring connectors for each digital sensor. Refer to
the diagnostic functional test Troubleshooting,
A. Remove the electrical power from the ECM. “Electrical Connectors - Inspect”.

g01234113 g01234119
Illustration 49 Illustration 50
Typical left side view P1 ECM connector
(1) J1/P1 ECM connectors (P1-4) +8 VDC
(P1-5) Return
(P1-66) Throttle position signal
RENR5089-23 123
Troubleshooting Section

C. Perform a 45 N (10 lb) pull test on each of the • Active 04 code – A 04 diagnostic code is active.
wires that are associated with the digital sensor Proceed to Test Step 4.
supply.
• No active codes – None of the above codes are
D. Check the torque of the allen head screws for active.
the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical Repair: If any of the above codes are logged
Connectors - Inspect”. and the engine is not running properly, refer to
Troubleshooting, “Troubleshooting Without a
E. Check the harness and wiring for abrasions and Diagnostic Code”.
for pinch points from the battery to the ECM.
If the engine is running properly at this time, there
Expected Result: may be an intermittent problem in a harness
that is causing the codes to be logged. Refer to
All of the connectors, pins, and sockets are the diagnostic functional test Troubleshooting,
completely coupled and/or inserted, and the harness “Electrical Connectors - Inspect”.
and wiring are free of corrosion, of abrasion or of
pinch points. STOP.

Results: Test Step 3. Check the Voltage on the +8

V Supply Wire
• OK – The connectors and the wiring are OK.
Proceed to Test Step 2. A. Remove the electrical power from the ECM.

• Not OK – There is a problem with a connector B. Disconnect the harness connector for the throttle
and/or the wiring. sensor.

Repair: Repair the connector and/or the wiring. C. Restore the electrical power to the ECM.
Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the D. Measure the voltage between terminals A and B
connectors are completely coupled. Verify that the at the harness connector for each sensor.
problem is resolved.
Expected Result:
STOP.
Each voltage measurement is 8.0 ± 0.4 VDC.
Test Step 2. Check for Active Diagnostic
Codes Results:

A. Connect the Caterpillar Electronic Technician (ET) • OK – Each voltage measurement is 8.0 ± 0.4 VDC.
to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic Repair: Connect the sensor connector. Clear all
Service Tools”. diagnostic codes. Check for active diagnostic
codes. If the problem is intermittent, refer to
B. Restore the electrical power to the ECM. the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
C. Observe the active diagnostic code screen on Cat
ET. Wait at least 30 seconds so that any codes STOP.
may become active. Look for these codes:
• Not OK – At least one voltage measurement is not
• 041-03 8 Volt DC Supply short to +batt 8.0 ± 0.4 VDC. There is a problem with the wiring
or with the ECM. Proceed to Test Step 5.
• 041-04 8 Volt DC Supply short to ground
Test Step 4. Disconnect the +8 V Digital
Expected Result: Sensors and Check for Active Diagnostic
Codes
One of the above diagnostic codes is active.
A. Disconnect the throttle sensor.
Results:
B. Wait for 30 seconds after you disconnect the
• Active 03 code – A 03 diagnostic code is active. sensor. Look for the active 04 diagnostic code in
Proceed to Test Step 3. order to deactivate.
124 RENR5089-23
Troubleshooting Section

Expected Result: Test Step 6. Check the +8 V Supply and

the Sensor Common for an Open Circuit
The 04 diagnostic code deactivates when the sensor
is disconnected. A. Install a jumper wire between terminals P1-4 (+8
V supply) and P1-5 (Return).
Results:
Note: Wiggle the harness during the following
• OK – The 04 diagnostic code deactivates when measurement in order to reveal any intermittent short
the sensor is disconnected. condition.

Repair: Connect the suspect sensor. If the B. Measure the resistance between terminals A and
diagnostic code returns, replace the sensor. B at the harness connector for each digital sensor.

Connect the connector. Verify that the problem is C. Remove the jumper wire.
resolved.
Expected Result:
STOP.
Each resistance measurement is less than ten Ohms.
• Not OK – The 04 diagnostic code remains after
the sensor is disconnected. Leave the sensor Results:
disconnected. Proceed to Test Step 5.
• OK – Each resistance measurement is less than
Test Step 5. Check the +8 V Supply Wire ten Ohms. Proceed to Test Step 7.
for a Short Circuit
• Not OK – At least one resistance measurement
A. Remove the electrical power from the ECM. is more than ten Ohms. A +8 V supply wire or a
return wire has excessive resistance. There may
B. Disconnect the J1/P1 and J2/P2connectors. be a problem with a connector.

C. Verify that the digital sensor is disconnected. Repair: Repair the wires and/or the connector,
when possible. Replace parts, if necessary. Verify
Note: Wiggle the harness during the following that the problem is resolved.
measurements in order to reveal an intermittent
condition. STOP.

D. Measure the resistance between P1-4 (+8 V Test Step 7. Check the +8 V Supply at the
supply) and the remaining terminals on the P1 ECM
and P2 connectors.
A. Remove terminal 4 from the P1 connector. Install
E. Measure the resistance between P1-4 (+8 VDC a jumper wire with socket terminals on both ends
supply) and the engine ground. into P1-4.

Expected Result: B. Remove terminal 5 from the P1 connector. Install

a jumper wire with socket terminals on both ends
Each check of the resistance indicates an open into P1-5.
circuit.
C. Connect the P1 connector.
Results:
D. Restore the electrical power to the ECM.
• OK – Each check of the resistance indicates an
open circuit. Proceed to Test Step 6. E. Measure the voltage between the jumper wires
in P1-4 and P1-5.
• Not OK – At least one check of the resistance
does not indicate an open circuit. A +8 V supply F. Remove the electrical power from the ECM.
wire has a problem. There may be a problem with
a connector. G. Restore all wiring to the original configuration.

Repair: Repair the wire and/or the connector, Expected Result:

when possible. Replace parts, if necessary. Verify
that the problem is resolved. The voltage measurement is 8.0 ± 0.4 VDC.

STOP.
RENR5089-23 125
Troubleshooting Section

Results:

• OK – The voltage measurement is 8.0 ± 0.4 VDC.

Repair: Clear all diagnostic codes. Check
for active diagnostic codes. If the problem is
intermittent, refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.

STOP.

• Not OK – The voltage measurement is not 8.0 ±

0.4 VDC.

Repair: Replace the ECM. Refer to electronic

troubleshooting Troubleshooting, “Replacing the
ECM”.

STOP.

i02443420

Digital Sensor Supply Circuit

- Test
SMCS Code: 1439-038

System Operation Description:

The Electronic Control Module (ECM) supplies a

regulated voltage of 8.0 ± 0.4 VDC to the throttle
sensor.

This procedure covers the following diagnostic codes:

• 041-03 8 Volt DC Supply short to +batt

• 041-04 8 Volt DC Supply short to ground
A +8 V diagnostic code is probably caused by a
short circuit to ground or a short circuit to another
voltage source in the harness. The next likely cause
is a problem with a sensor. The least likely cause is
a problem with the ECM.
126 RENR5089-23
Troubleshooting Section

g01220875
Illustration 51
Schematic for the digital sensor supply

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.

g01140657
Illustration 52
Typical left side view
(1) J1/P1 ECM connectors
RENR5089-23 127
Troubleshooting Section

B. Thoroughly inspect connector(1). Inspect the Results:

connectors for each digital sensor. Refer to
the diagnostic functional test Troubleshooting, • OK – The connectors and the wiring are OK.
“Electrical Connectors - Inspect”. Proceed to Test Step 2.

• Not OK – There is a problem with a connector

and/or the wiring.

Repair: Repair the connector and/or the wiring.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
problem is resolved.

STOP.

Test Step 2. Check for Active Diagnostic

Codes
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic
Service Tools”.

B. Restore the electrical power to the ECM.

C. Observe the active diagnostic code screen on Cat

ET. Wait at least 30 seconds so that any codes
may become active. Look for these codes:

• 041-03 8 Volt DC Supply short to +batt

• 041-04 8 Volt DC Supply short to ground
Expected Result:

One of the above diagnostic codes is active.

g01223008 Results:
Illustration 53
P1 ECM connector • Active 03 code – A 03 diagnostic code is active.
(P1-4) +8 VDC Proceed to Test Step 3.
(P1-5) Return
(P1-66) Throttle position sensor
(P!-32) Engine fan speed sensor • Active 04 code – A 04 diagnostic code is active.
Proceed to Test Step 4.
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the digital sensor • No active codes – None of the above codes are
supply. active.

D. Check the torque of the allen head screws for Repair: If any of the above codes are logged
the ECM connectors. Refer to the diagnostic and the engine is not running properly, refer to
functional test Troubleshooting, “Electrical Troubleshooting, “Troubleshooting Without a
Connectors - Inspect”. Diagnostic Code”.

E. Check the harness and wiring for abrasions and If the engine is running properly at this time, there
for pinch points from the battery to the ECM. may be an intermittent problem in a harness
that is causing the codes to be logged. Refer to
Expected Result: the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
All of the connectors, pins, and sockets are
completely coupled and/or inserted, and the harness STOP.
and wiring are free of corrosion, of abrasion or of
pinch points.
128 RENR5089-23
Troubleshooting Section

Test Step 3. Check the Voltage on the +8 • Not OK – The 04 diagnostic code remains after
V Supply Wire the sensor is disconnected. Leave the sensor
disconnected. Proceed to Test Step 5.
A. Remove the electrical power from the ECM.
Test Step 5. Check the +8 V Supply Wire
B. Disconnect the harness connector for the throttle for a Short Circuit
sensor.
A. Remove the electrical power from the ECM.
C. Restore the electrical power to the ECM.
B. Disconnect the J1/P1 and J2/P2 connectors.
D. Measure the voltage between terminals A and B
at the harness connector for each sensor. C. Verify that the digital sensor is disconnected.

Expected Result: Note: Wiggle the harness during the following

measurements in order to reveal an intermittent
Each voltage measurement is 8.0 ± 0.4 VDC. condition.

Results: D. Measure the resistance between P1-4 (+8 V

supply) and the remaining terminals on the P1
• OK – Each voltage measurement is 8.0 ± 0.4 VDC. and P2 connectors.

Repair: Connect the sensor connector. Clear all E. Measure the resistance between P1-4 (+8 VDC
diagnostic codes. Check for active diagnostic supply) and the engine ground.
codes. If the problem is intermittent, refer to
the diagnostic functional test Troubleshooting, Expected Result:
“Electrical Connectors - Inspect”.
Each check of the resistance indicates an open
STOP. circuit.

• Not OK – At least one voltage measurement is not Results:

8.0 ± 0.4 VDC. There is a problem with the wiring
or with the ECM. Proceed to Test Step 5. • OK – Each check of the resistance indicates an
open circuit. Proceed to Test Step 6.
Test Step 4. Disconnect the +8 V Digital
Sensors and Check for Active Diagnostic • Not OK – At least one check of the resistance
Codes does not indicate an open circuit. A +8 V supply
wire has a problem. There may be a problem with
A. Disconnect the +8 V digital sensors. a connector.

B. Wait for 30 seconds after you disconnect the Repair: Repair the wire and/or the connector,
sensor. Look for the active 04 diagnostic code in when possible. Replace parts, if necessary. Verify
order to deactivate. that the problem is resolved.

Expected Result: STOP.

The 04 diagnostic code deactivates when the sensor Test Step 6. Check the +8 V Supply and
is disconnected. the Sensor Common for an Open Circuit
Results: A. Install a jumper wire between terminals P1-4 (+8
V supply) and P1-5 (Return).
• OK – The 04 diagnostic code deactivates when
the sensor is disconnected. Note: Wiggle the harness during the following
measurement in order to reveal any intermittent short
Repair: Connect the suspect sensor. If the condition.
diagnostic code returns, replace the sensor.
B. Measure the resistance between terminals A and
Connect the connector. Verify that the problem is B at the harness connector for each digital sensor.
resolved.
C. Remove the jumper wire.
STOP.
Expected Result:

Each resistance measurement is less than ten Ohms.

RENR5089-23 129
Troubleshooting Section

Results: i02378207

• OK – Each resistance measurement is less than Electrical Connectors - Inspect

ten Ohms. Proceed to Test Step 7.
SMCS Code: 7553-040-WW
• Not OK – At least one resistance measurement
is more than ten Ohms. A +8 V supply wire or a System Operation Description:
return wire has excessive resistance. There may
be a problem with a connector. Most electrical problems are caused by poor
connections. The following procedure will assist in
Repair: Repair the wires and/or the connector, detecting problems with connectors and with wiring.
when possible. Replace parts, if necessary. Verify If a problem is found correct the condition and verify
that the problem is resolved. that the problem is resolved.

STOP. Intermittent electrical problems are sometimes

resolved by disconnecting and reconnecting
Test Step 7. Check the +8 V Supply at the connectors. It is very important to check for diagnostic
ECM codes immediately before disconnecting a connector.
Also check for diagnostic codes after reconnecting
A. Remove terminal 4 from the P1 connector. Install the connector. If the status of a diagnostic code is
a jumper wire with socket terminals on both ends changed due to disconnecting and reconnecting a
into P1-4. connector, there are several possible reasons. The
likely reasons are loose terminals, improperly crimped
B. Remove terminal 5 from the P1 connector. Install terminals, moisture, corrosion, and inadequate
a jumper wire with socket terminals on both ends mating of a connection.
into P1-5.
Follow these guidelines:
C. Connect the P1 connector.
• Always use a 1U-5804 Crimp Tool to service
D. Restore the electrical power to the ECM. Deutsch HD and DT connectors. Never solder the
terminals onto the wires. Refer to “SEHS9615,
E. Measure the voltage between the jumper wires Servicing Deutsch HD and DT Style Connectors”.
in P1-4 and P1-5.
• Always use a 147-6456 Wedge Removal Tool to
F. Remove the electrical power from the ECM. remove wedges from DT connectors. Never use a
screwdriver to pry a wedge from a connector.
G. Restore all wiring to the original configuration.
• Always use a breakout harness for a voltmeter
Expected Result: probe or a test light. Never break the insulation
of a wire in order to access to a circuit for
The voltage measurement is 8.0 ± 0.4 VDC. measurements.

Results: • If a wire is cut, always install a new terminal for

the repair.
• OK – The voltage measurement is 8.0 ± 0.4 VDC.
The ECM is OK.

Repair: Clear all diagnostic codes. Check The connection of any electrical equipment and
for active diagnostic codes. If the problem is the disconnection of any electrical equipment may
intermittent, refer to the diagnostic functional test cause an explosion hazard which may result in in-
Troubleshooting, “Electrical Connectors - Inspect”. jury or death. Do not connect any electrical equip-
ment or disconnect any electrical equipment in an
STOP. explosive atmosphere.

• Not OK – The voltage measurement is not 8.0 ±

0.4 VDC. The ECM is not producing the correct
voltage.

Repair: Replace the ECM. Refer to electronic

troubleshooting Troubleshooting, “Replacing the
ECM”.

STOP.
130 RENR5089-23
Troubleshooting Section

Test Step 1. Check Connectors for B. Ensure that the sealing plugs are in place. If
Moisture and Corrosion any of the plugs are missing, replace the plug.
Ensure that the plugs are inserted correctly into
the connector. Refer to Illustration 55.

g01131019
Illustration 56
Seal for a three-pin connector (typical example)

g01131211
Illustration 54
Leaky seal at the connector (typical example)

A. Inspect all wiring harnesses. Ensure that the

routing of the wiring harness allows the wires to
enter the face of each connector at a perpendicular
angle. Otherwise, the wire will deform the seal
bore. Refer to Illustration 54. This will create a
path for the entrance of moisture. Verify that the
seals for the wires are sealing correctly.

g01131165
Illustration 57
Seal for ECM connector (typical example)

C. Disconnect the suspect connector and inspect the

connector seal. Ensure that the seals are in good
condition. If necessary, replace the connector.

D. Thoroughly inspect the connectors for evidence

of moisture entry.

Note: It is normal to see some minor seal abrasion

on connector seals. Minor seal abrasion will not allow
Illustration 55
g01131276 the entry of moisture.
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
RENR5089-23 131
Troubleshooting Section

If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:

• Missing seals • Exposed insulation

• Improperly installed seals • Rubbing of a wire against the engine
• Nicks in exposed insulation • Rubbing of a wire against a sharp point
• Improperly mated connectors B. Check all of the wiring harness fasteners in order
to verify that the harness is properly secured. Also
Moisture can also travel to a connector through check all of the fasteners in order to verify that the
the inside of a wire. If moisture is found in a harness is not compressed. Pull back the harness
connector, thoroughly check the connector's sleeves in order to check for a flattened portion
harness for damage. Also check other connectors of wire. A fastener that has been overtightened
that share the harness for moisture. flattens the harness. This damages the wires that
are inside the harness.
Note: The ECM is a sealed unit. If moisture is found
in an ECM connector, the ECM is not the source of Expected Result:
the moisture. Do not replace the ECM.
The wires are free of abrasion, of nicks, and of cuts
Expected Result: and the harness is properly clamped.

The harness wiring, connectors, and seals are in Results:

good condition. There is no evidence of moisture in
the connectors. • OK – The harness is OK. Proceed to Test Step 3.
Results: • Not OK – There is damage to the harness.
• OK – The harness wiring, connectors, and seals Repair: Repair the wires or replace the wires,
are in good condition. Proceed to Test Step 2. as required. Verify that the repair eliminates the
problem.
• Not OK – A problem has been found with the
harness or the connectors. STOP.

Repair: Repair the connectors or the wiring, as Test Step 3. Inspect the Connector
required. Ensure that all of the seals are properly Terminals
in place. Ensure that the connectors have been
reattached. A. Visually inspect each terminal in the connector.
Verify that the terminals are not damaged.
If corrosion is evident on the pins, sockets or the Verify that the terminals are properly aligned in
connector, use only denatured alcohol to remove the connector and verify that the terminals are
the corrosion. Use a cotton swab or a soft brush properly located in the connector.
to remove the corrosion.
Expected Result:
If moisture was found in the connectors, run the
engine for several minutes and check again for The terminals are properly aligned and the terminals
moisture. If moisture reappears, the moisture is appear undamaged.
wicking into the connector. Even if the moisture
entry path is repaired, it may be necessary to Results:
replace the wires.
• OK – The terminals are OK. Proceed to Test Step
Verify that the repair eliminates the problem. 4.

STOP. • Not OK – The terminals of the connector are

damaged.
132 RENR5089-23
Troubleshooting Section

Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.

STOP.

Test Step 4. Perform a Pull Test on Each

Wire Terminal Connection

g01131604
Illustration 59
Diagram for testing pin retention (typical example)

A. Verify that the sockets provide good retention for

the pins. Insert a new pin into each socket one
at a time in order to check for a good grip on the
g01131435
pin by the socket.
Illustration 58
Receptacle lock wedge (typical example) Expected Result:

A. Ensure that the locking wedge for the connector The sockets provide good retention for the new pin.
is installed properly. Terminals cannot be retained
inside the connector if the locking wedge is not Results:
installed properly.
• OK – The terminals are OK. Proceed to Test Step
B. Perform the 45 N (10 lb) pull test on each wire. 6.
Each terminal and each connector should easily
withstand 45 N (10 lb) of tension and each wire • Not OK – Terminals are damaged.
should remain in the connector body. This test
checks whether the wire was properly crimped Repair: Use the 1U-5804 Crimp Tool to replace
in the terminal and whether the terminal was the damaged terminals. Verify that the repair
properly inserted into the connector. eliminates the problem.

Expected Result: STOP.

Each terminal and each connector easily withstands Test Step 6. Check the Locking
45 N (10 lb) of pull and each wire remains in the Mechanism of the Connectors
connector body.
A. Ensure that the connectors lock properly. After
Results: locking the connectors, ensure that the two halves
cannot be pulled apart.
• OK – All terminals pass the pull test. Proceed to
Test Step 5. B. Verify that the latch tab of the connector is
properly latched. Also verify that the latch tab of
• Not OK – A wire has been pulled from a terminal the connector returns to the locked position.
or a terminal has been pulled from the connector.
Expected Result:
Repair: Use the 1U-5804 Crimp Tool to replace
the terminal. Replace damaged connectors, as The connector will securely lock. The connector and
required. Verify that the repair eliminates the the locking mechanism are without cracks or breaks.
problem.
Results:
STOP.
• OK – The connectors are in good repair. Proceed
to Test Step 7.
RENR5089-23 133
Troubleshooting Section

• Not OK – The connector's locking mechanism is

damaged or missing.

Repair: Repair the connector or replace the

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

STOP.

Test Step 7. Check the Allen Head Screws

on the Connectors
Visually inspect the allen head screws for the ECM
connectors. Ensure that the threads on each allen
head screw are not damaged. g01132863
Illustration 62
A. Connect the ECM connectors. Allen head screw for the 40 pin ECM connector (typical example)

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

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

g01132827
Illustration 60
Allen head screw for the 120 pin ECM connector (typical example)

g01133047
a. Torque the allen head bolt for the 120 pin ECM Illustration 63
connector to 7.0 ± 0.5 N·m (60 ± 4 lb in). Allen head screw for the 40 pin customer connector and the 70 pin
customer connector (typical example)

B. Connect the customer connector.

Torque the allen head screw for the 40 pin

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

Expected Result:

The ECM connector is secure and the allen head

screws are properly torqued.

Results:

Illustration 61
g01132849
• OK – The ECM connectors and the customer
Allen head screw for the 70 pin ECM connector (typical example) connector is properly connected. Proceed to Test
Step 8.
b. Torque the allen head screw for the 70
pin ECM connector to 6.0 + 1.5 - 0.5 N·m • Not OK – The allen head screws for the ECM
(55 + 13 - 4 lb in). connector or the customer connector is damaged.
134 RENR5089-23
Troubleshooting Section

Repair: Repair the connector or replace the Use this test if there are intermittent engine
connector, as required. Verify that the repair shutdowns or if a difficulty in starting is not
eliminates the problem. accompanied by loss of electrical accessories.
Engine shutdowns that are accompanied by a loss of
STOP. other electrical accessories indicate a problem in the
keyswitch. This does not indicate a problem in the
Test Step 8. Perform the “Wiggle Test” on wiring at the engine's ECM. Verify that there are no
the Caterpillar Electronic Technician (ET) problems with the starting system or the charging
system before you use this test.
A. Select the “Wiggle Test” from the diagnostic tests
on Cat ET. The ECM receives battery voltage through the main
relay and the 15 Amp fuse for the engine control.
B. Choose the appropriate group of parameters to Switched battery voltage is supplied to the ECM at
monitor. P1-48, P1-52, and P1-53. The negative battery is
supplied to the ECM at P1-61, P1-63, and P1-65.
C. Press the “Start” button. Wiggle the wiring harness
in order to reproduce intermittent problems. The ECM receives the input from the keyswitch at
P1-70 when the keyswitch is in the ON position or in
If an intermittent problem exists, the status will be the START position. When the ECM detects battery
highlighted and an audible beep will be heard. voltage on P1-70, the ECM will electrical powerup.
When battery voltage is removed from P1-70, the
Expected Result: ECM will electrical powerdown.

No intermittent problems were indicated during the The engine ECM requires the keyswitch to be in the
“Wiggle Test”. ON position in order to maintain communications with
the Caterpillar Electronic Technician (ET).
Results:

• OK – No intermittent problems were found. The

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

• Not OK – At least one intermittent problem was

indicated.

Repair: Repair the harness or the connector. Verify

that the repair eliminates the problem.

STOP.

i02473780

Electrical Power Supply Circuit

- Test
SMCS Code: 1401-038

System Operation Description:

Use this test to troubleshoot any suspect problems

with power to the Electronic Control Module (ECM).

This procedure covers the following diagnostic codes:

• 168-00 “System Voltage High”

• 168-01 “System Voltage Low”
• 168-02 “System Voltage intermittent/erratic”
RENR5089-23 135
Troubleshooting Section

g01198705
Illustration 64
Typical schematic
136 RENR5089-23
Troubleshooting Section

E. Check the harness and the wiring for abrasion

and for pinch points.

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

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

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check the Battery Voltage at

the ECM
A. Disconnect the J1/P1 ECM connector.

B. Restore the electrical power to the ECM.

g01112632
Illustration 65
C. Measure the voltage between P1-48 (Switched
P1 ECM connections
Positive Battery) and P1-61 (Negative Battery).
(P1-48) +Battery
(P1-52) +Battery
(P1-53) +Battery
D. Measure the voltage between P1-52 (Switched
(P1-61) −Battery Positive Battery) and P1-63 (Negative Battery).
(P1-63) −Battery
(P1-65) −Battery E. Measure the voltage between P1-53 (Switched
(P1-70) Keyswitch
Positive Battery) and P1-65 (Negative Battery).
Test Step 1. Inspect Electrical Connectors F. Measure the voltage between P1-70 (Keyswitch)
and Wiring and P1-63 (Negative Battery).
A. Remove the electrical power from the ECM. G. Remove the electrical power from the ECM.
B. Thoroughly inspect the ECM connectors J1/P1 Expected Result:
and J2/P2. Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”. The voltage measures 24 ± 3.0 VDC.
C. Perform a 45 N (10 lb) pull test on each of the Results:
wires in the ECM connector that are associated
with the circuit.
• OK – The ECM is receiving the correct voltage.
D. Check the ECM connector (allen head screw) Repair: If an intermittent condition is
for the proper torque. Refer to the diagnostic suspected, refer to the diagnostic functional test
functional test Troubleshooting, “Electrical Troubleshooting, “Electrical Connectors - Inspect”.
Connectors - Inspect”.
STOP.
RENR5089-23 137
Troubleshooting Section

• Not OK – The voltage is not correct at the ECM. Results:

Proceed to Test Step 3.
• OK – Voltage is present on terminal B and terminal
• Not OK - Keyswitch – The voltage is not correct at R at the keyswitch. Proceed to Test Step 5.
the input for the keyswitch. Proceed to Test Step 4.
• Not OK – Voltage is not present on terminal B at
Test Step 3. Check the Batteries the keyswitch.

A. Measure the no-load battery voltage at the battery Repair: If voltage is not present on terminal B,
posts. repair the wire between the +Battery and the
keyswitch. Verify that the fuse for the keyswitch is
B. Load test the batteries. Use the 4C-4911 not blown. Verify that the problem is eliminated.
Battery Load Tester. Refer to Special Instruction,
SEHS9249, “Use of 4C-4911 Battery Load Tester STOP.
for 6, 8 and 12 Volt Lead Acid Batteries” and
Special Instruction, SEHS7633, “Battery Test • Not OK – Voltage is not present on terminal R at
Procedure”. the keyswitch.

Expected Result: Repair: If voltage is present on terminal B of the

keyswitch but not present on terminal R, replace
The batteries pass the load test. The measured the keyswitch. Return all wiring to the original
voltage is the minimum specification for a 12V or 24V configuration. Verify that the problem is eliminated.
system.
STOP.
Results:
Test Step 5. Check the Voltage from the
• OK – The batteries are OK. Proceed to Test Step Main Relay to the Fuse for the Engine
4. Control
• Not OK – The battery voltage is low or the battery A. Remove the electrical power from the ECM.
did not pass the load test.
B. Remove the wire 112-PU from the normally open
Repair: Recharge or replace the faulty batteries. terminal of the main relay.
Verify that the repair eliminates the problem.
C. Restore the electrical power to the ECM.
STOP.
D. Measure the voltage between the normally open
Test Step 4. Check the Voltage from the terminal of the main relay and engine ground.
Keyswitch
E. Remove the electrical power from the ECM.
A. Remove the electrical power from the ECM.
F. Reconnect all wires to the original configuration.
B. Remove the wire from terminal R of the keyswitch.
Expected Result:
C. Restore the electrical power to the ECM.
The voltage measures 24 ± 3.0 VDC.
D. Measure the voltage between terminal B of the
keyswitch and engine ground. Results:

E. Measure the voltage between terminal R of the • OK – The voltage measures 24 ± 3.0 VDC.
keyswitch and engine ground.
Repair: Verify that the 15 Amp fuse for the ECM is
F. Remove the electrical power from the ECM. not blown. Repair the wire between the main relay
and the fuse for the engine control or repair the
G. Reconnect all wires to the original configuration. wire between the fuse for the engine control and
the ECM connector P1.
Expected Result:
STOP.
Voltage is present on terminal B and terminal R at
the keyswitch. • Not OK – The voltage does not measure 24 ± 3.0
VDC. Proceed to Test Step 6.
138 RENR5089-23
Troubleshooting Section

Test Step 6. Check the Voltage at the i02444545

Main Relay
Electrical Power Supply Circuit
A. Remove the electrical power from the ECM. - Test
B. Remove the wire 308-YL from the coil of the main SMCS Code: 1401-038
relay.
System Operation Description:
C. Remove the wire 101-RD from the normally open
contact of the main relay. Use this test to troubleshoot any suspect problems
with power to the Electronic Control Module (ECM).
D. Restore the electrical power to the ECM.
This procedure covers the following diagnostic codes:
E. Measure the voltage between wire 308-YL and
engine ground. • 168-00 “System Voltage High”
F. Measure the voltage between wire 101-RD and • 168-01 “System Voltage Low”
engine ground.
• 168-02 “System Voltage intermittent/erratic”
G. Remove the electrical power from the ECM.
Use this test if there are intermittent engine
H. Reconnect all wires to the original configuration. shutdowns or if a difficulty in starting is not
accompanied by loss of electrical accessories.
Expected Result: Engine shutdowns that are accompanied by a loss of
other electrical accessories indicate a problem in the
The voltage measures 24 ± 3.0 VDC. keyswitch. This does not indicate a problem in the
wiring at the engine's ECM. Verify that there are no
Results: problems with the starting system or the charging
system before you use this test.
• OK – The voltage measures 24 ± 3.0 VDC on both
wires. Unswitched battery voltage is supplied to the ECM
at P1-48, P1-52, and P1-53. The negative battery
Repair: Verify that the wire 200-BK has continuity is supplied to the ECM at P1-61, P1-63, and P1-65.
to engine ground. If wire 200-BK is OK, replace The ECM receives the input from the keyswitch at
the main relay. Verify that the problem is no longer P1-70 when the keyswitch is in the ON position or in
present. the START position. When the ECM detects battery
voltage at this input, the ECM will power up. When
STOP. battery voltage is removed from this input, the ECM
will power down. The ECM continuously receives
• Not OK – The voltage does not measure 24 ± 3.0 battery voltage through the circuit breaker for the
VDC on wire 101-RD. engine ECM.
Repair: Repair the wire between the main relay The engine ECM requires the keyswitch to be in the
and the battery. ON position in order to maintain communications with
Caterpillar Electronic Technician (ET).
STOP.

• Not OK – The voltage does not measure 24 ± 3.0

VDC on wire 308-YL.

Repair: Repair the wire between the main relay

and terminal R of the keyswitch.

STOP.
RENR5089-23 139
Troubleshooting Section

g01222529
Illustration 66
Schematic for the electrical power supply circuit

Test Step 1. Inspect the Electrical B. Thoroughly inspect the J1/P1 ECM connectors.
Connectors and the Wiring Inspect all of the connectors that are in the
circuit. Refer to the diagnostic functional test
A. Remove electrical power from the engine ECM. Troubleshooting, “Electrical Connectors - Inspect”
for details.

g01183529
Illustration 67
J1/P1 ECM connectors (typical left side engine view)
140 RENR5089-23
Troubleshooting Section

Results:

• OK – The harness and wiring appear to be OK.

Proceed to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

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

STOP.

Test Step 2. Check the Battery Voltage at

the ECM
A. Remove electrical power from the engine ECM.

B. Disconnect the J1/P1 ECM connector.

C. Restore electrical power to the engine ECM.

D. Measure the voltage between P1-48 (Unswitched

+Battery) and P1-61 (−Battery).

E. Measure the voltage between P1-52 (Unswitched

+Battery) and P1-63 (−Battery).

F. Measure the voltage between P1-53 (Unswitched

+Battery) and P1-65 (−Battery).

Illustration 68
g01112632 G. Measure the voltage between P1-70 (Keyswitch)
and P1-63 (−Battery).
P1 connections for the electrical power supply circuit
(P1-48) +Battery Expected Result:
(P1-52) +Battery
(P1-53) +Battery
(P1-61) −Battery The measured voltage is between 22 VDC and 27
(P1-63) −Battery VDC.
(P1-65) −Battery
(P1-70) Keyswitch
Results:
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector that are associated
• OK – The ECM is receiving the correct voltage.
with the circuit. Repair: There may be an intermittent electrical
problem in a harness or in a connector. If an
D. Check the allen head screw for each of the intermittent condition is suspected, refer to
ECM connectors for the proper torque. Refer to the diagnostic functional test Troubleshooting,
Troubleshooting, “Electrical Connectors - Inspect” “Electrical Connectors - Inspect”.
for the correct torque values.
STOP.
E. Check the harness and the wiring for abrasion
and for pinch points.
• Unswitched power out of range – The voltage
is not correct for one of the unswitched battery
Expected Result: circuits at the ECM. Proceed to Test Step 3.
All connectors, pins, and sockets are completely
inserted and coupled. The harness and wiring are
• Keyswitch voltage out of range – The voltage is
not correct for the keyswitch circuit at the ECM.
free of corrosion, of abrasion, and of pinch points. Proceed to Test Step 4.
All connections and grounds are tight and free of
corrosion.
RENR5089-23 141
Troubleshooting Section

Test Step 3. Check the Batteries Expected Result:

A. Measure the no-load battery voltage at the battery Voltage is present on terminal B and terminal R at
posts. the keyswitch.

B. Load test the batteries. Use the 4C-4911 Results:

Battery Load Tester. Refer to Special Instruction,
SEHS9249, “Use of 4C-4911 Battery Load Tester • OK – Voltage is present on terminal B and terminal
for 6, 8 and 12 Volt Lead Acid Batteries” and R at the keyswitch. Proceed to Test Step 5.
Special Instruction, SEHS7633, “Battery Test
Procedure”. • Not OK – Voltage is not present on terminal B at
the keyswitch.
Expected Result:
Repair: If voltage is not present on terminal B,
The batteries pass the load test. The measured repair the circuit between the +Battery and the
voltage is the minimum specification for a 24V keyswitch. Check the circuit protection for the
system. circuit. Verify that the problem is eliminated.

Results: STOP.

• OK – The batteries pass the load test. • Not OK – Voltage is not present on terminal R at
the keyswitch.
Repair: The batteries are OK. There is an open
circuit or excessive resistance in the wiring or Repair: If voltage is present on terminal B of the
connections between the batteries and the ECM. keyswitch but not present on terminal R, replace
Verify that the 15 Amp circuit breaker for the ECM the keyswitch. Return all wiring to the original
is not tripped. Verify that the connection at the configuration. Verify that the problem is eliminated.
engine ground stud is clean and tight and that the
battery disconnect switch is functioning properly. STOP.
Repair the connectors or wiring and/or replace the
connectors or wiring between the battery and the Test Step 5. Check the Voltage from the
ECM connector J1/P1. Main Relay to the “ECM Switch Fuse”
STOP. A. Remove the wire 112-PU from the normally open
terminal of the main relay.
• Not OK – The battery voltage is low or the battery
did not pass the load test. B. Turn the keyswitch to the ON position.

Repair: Recharge or replace the faulty batteries. C. Measure the voltage between the normally open
Verify that the repair eliminates the problem. terminal of the main relay and engine ground.

STOP. D. Turn the keyswitch to the OFF position.

Test Step 4. Check the Voltage from the E. Reconnect all wires to the original configuration.
Keyswitch to the ECM
Expected Result:
A. Remove electrical power from the engine ECM.
The voltage measures 24 ± 3.0 VDC.
B. Remove the wire from the terminal R of the
keyswitch. Results:

C. Restore electrical power to the engine ECM. • OK – The voltage measures 24 ± 3.0 VDC.
D. Turn the keyswitch to the ON position. Repair: Verify that the “ECM Switch Fuse” is not
blown. Repair the wire between the main relay and
E. Measure the voltage on terminal B of the keyswitch the fuse for the engine control or repair the wire
to engine ground. between the fuse for the engine control and the
ECM connector P1.
F. Measure the voltage on terminal R of the
keyswitch to engine ground. STOP.

G. Remove electrical power from the engine ECM. • Not OK – The voltage does not measure 24 ± 3.0
VDC. Proceed to Test Step 6.
142 RENR5089-23
Troubleshooting Section

Test Step 6. Check the Voltage at the i02886496

Main Relay
Engine Pressure Sensor Open
A. Remove the wire 308-YL from the coil of the main or Short Circuit - Test
relay.
SMCS Code: 1439-038-PX
B. Remove the wire 101-RD from the normally open
contact of the main relay. System Operation Description:
C. Turn the keyswitch to the ON position. Use this procedure to troubleshoot any suspect
problems with the following sensors:
D. Measure the voltage between wire 308-YL and
engine ground. • Injection actuation pressure sensor
E. Measure the voltage between wire 101-RD and • Boost pressure sensor for the intake manifold
engine ground.
• Atmospheric pressure sensor
F. Reconnect all wires to the original configuration.
• Fuel pressure sensor
Expected Result:
• Engine oil pressure sensor
The voltage measures 24 ± 3.0 VDC.
This procedure covers the following diagnostic codes:
Results:
• 094-03 Fuel Pressure open/short to +batt
• OK – The voltage measures 24 ± 3.0 VDC on both
wires. • 094-04 Fuel Pressure short to ground
Repair: Verify that the wire 200-BK has continuity • 100-03 Engine Oil Pressure open/short to +batt
to engine ground. If wire 200-BK is OK, replace
the main relay. Verify that the problem is no longer • 100-04 Engine Oil Pressure short to ground
present.
• 164-03 Injector Actuation Pressure voltage high
STOP.
• 164-04 Injector Actuation Pressure voltage low
• Not OK – The voltage does not measure 24 ± 3.0
VDC on wire 101-RD. • 274-03 Atmospheric Pressure open/short to +batt
Repair: Verify that the main circuit breaker is not • 274-04 Atmospheric Pressure short to ground
tripped. Repair the wire between the main relay
and the main circuit breaker or repair the wire • 1785-03 Intake Manifold Pressure Sensor voltage
between the main circuit breaker and the battery. high
STOP. • 1785-04 Intake Manifold Pressure Sensor voltage
low
• Not OK – The voltage does not measure 24 ± 3.0
VDC on wire 308-YL. The troubleshooting procedures for the diagnostic
codes of each pressure sensor are identical. The
Repair: Repair the wire between the main relay Engine Control Module (ECM) sends a 5 volt supply
and terminal R of the keyswitch. to terminal A of each sensor. The sensor common
connection is connected to terminal B of each
STOP. sensor. The signal voltage from terminal C of each
sensor is sent to the appropriate terminal on an ECM
connector.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect an open in the
signal circuit. When the ECM detects the presence of
a voltage that is above a threshold on the signal wire,
the ECM will generate a 03 diagnostic code.
RENR5089-23 143
Troubleshooting Section

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the return
wire from the sensor connector to the ECM are good.

If the sensor is disconnected at the sensor connector,

the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connector

and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

g01436855
Illustration 69
Schematic for the engine pressure sensors

Test Step 1. Inspect the Electrical

Connectors and Wiring
A. Remove the electrical power from the ECM.
144 RENR5089-23
Troubleshooting Section

g01199199
Illustration 70
A typical left side view of the C9 engine
(1) Fuel pressure sensor (4) Atmospheric pressure sensor (8) J1/P1 connectors
(2) Injection actuation pressure sensor (5) Engine oil pressure sensor
(3) Boost pressure sensor for the intake (6) J2/P2 connectors
manifold (7) ECM
RENR5089-23 145
Troubleshooting Section

g01255900
Illustration 71
A typical left side view of the C7 engine
(9) Fuel pressure sensor (12) Boost pressure sensor for the intake (14) J2/P2 connectors
(10) Injection actuation pressure sensor manifold (15) ECM
(11) Atmospheric pressure sensor (13) Engine oil pressure sensor (16) J1/P1 connectors

B. Thoroughly inspect connectors (6) and (8).

Thoroughly inspect the connectors for each
engine pressure sensor. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
146 RENR5089-23
Troubleshooting Section

g01123211
Illustration 73
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

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

wires that are associated with the engine pressure
sensors.

D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Illustration 72
g01209367 Connectors - Inspect”.
P2 ECM connector
E. Check the harness and wiring for abrasions and
(P2-15) Boost pressure sensor for the intake manifold
(P2-17) Sensor return for pinch points from each sensor back to the
(P2-54) Sensor return ECM.
(P2-28) Engine oil pressure sensor
(P2-40) Fuel pressure sensor Expected Result:
(P2-57) Atmospheric pressure sensor
(P2-85) Injection actuation pressure sensor
(P2-72) +5 V Supply All connectors, pins, and sockets are completely
(P2-80) +5 V Supply coupled and/or inserted. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.

• Not OK – There is a problem in the wiring and/or

the connectors.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the problem is resolved.

STOP.
RENR5089-23 147
Troubleshooting Section

Test Step 2. Check the Voltage on the +5 Expected Result:

V Supply Wire
No diagnostic codes are active.
A. Remove the electrical power from the ECM.
Results:
B. Disconnect the harness connectors for the
following sensors: • OK – No diagnostic codes are active for the engine
pressure sensors.
• Injection actuation pressure sensor
Repair: If any of the above codes are logged
• Boost pressure sensor for the intake manifold and the engine is not running properly, refer
to troubleshooting without a diagnostic code
• Atmospheric pressure sensor Troubleshooting.

• Fuel pressure sensor If the engine is running properly at this time, there
may be an intermittent problem in a harness
• Engine oil pressure sensor that is causing the codes to be logged. Refer to
the diagnostic functional test Troubleshooting,
C. Restore the electrical power to the ECM. “Electrical Connectors - Inspect”.

D. Measure the voltage between terminals A (+5 STOP.

VDC) and B (Return) at each sensor connector
on the engine harness. • Active 04 code – An 04 diagnostic code is active.
Proceed to Test Step 4.
E. Remove the electrical power from the ECM.
• Active 03 code – An 03 diagnostic code is active.
F. Connect all of the sensors. Proceed to Test Step 5.

Expected Result: Test Step 4. Disconnect the Suspect

Sensor in Order to Create an Open Circuit
Each voltage measurement is 5.0 ± 0.2 VDC.
A. Remove the electrical power from the ECM.
Results:
B. Disconnect the sensor connector of the sensor
• OK – Each voltage measurement is 5.0 ± 0.2 with the 04 diagnostic code.
VDC. Proceed to Test Step 3.
C. Restore the electrical power to the ECM. Wait at
• Not OK – At least one voltage measurement is not least 30 seconds for activation of the diagnostic
5.0 ± 0.20 VDC. codes.

Repair: Refer to the diagnostic functional test D. Access the “Active Diagnostic Code” screen on
Troubleshooting, “5 Volt Engine Pressure Sensor Cat ET. Check for an active 03 diagnostic code for
Supply Circuit - Test”. the disconnected sensor.

STOP. E. Remove the electrical power from the ECM.

Test Step 3. Check for Active Diagnostic Expected Result:

Codes
A 03 diagnostic code is now active for the
A. Connect the Caterpillar Electronic Technician (ET) disconnected sensor.
to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic Results:
Service Tools”.
• OK – A 04 diagnostic code was active before you
B. Restore the electrical power to the ECM. disconnected the sensor. A 03 diagnostic code
became active after the sensor was disconnected.
C. Observe the “Active Diagnostic” screen on Cat ET. The harness and the ECM are OK. There may be
Wait at least 30 seconds so that any codes may a problem with the sensor.
become active. Look for an active diagnostic code
for an engine pressure sensor.

D. Determine if the problem is related to a 03

diagnostic code or a 04 diagnostic code.
148 RENR5089-23
Troubleshooting Section

Repair: Connect a new sensor to the harness, but Test Step 6. Create a Short at the Suspect
do not install the new sensor in the engine. Verify Sensor Connector
that there are no active diagnostic codes for the
sensor. If there are no active diagnostic codes for A. Remove the electrical power from the ECM.
the sensor, permanently install the new sensor.
Clear any logged diagnostic codes. B. Install a jumper wire with Deutsch sockets on
each end between terminals B (Sensor return)
STOP. and C (Signal) on the harness connector for the
suspect sensor.
• Not OK – A 04 diagnostic code was active before
you disconnected the sensor. The 04 diagnostic C. Restore the electrical power to the ECM.
code remained after the sensor was disconnected.
There is a problem with the harness or the ECM. Note: Monitor the “Active Diagnostic Codes” screen
Leave the sensor disconnected. Proceed to Test on the electronic service tool before installing the
Step 7. jumper wire and after installing the jumper wire.

Test Step 5. Check the Signal Wire for a D. Observe the “Active Diagnostic Codes” screen on
Short Circuit Cat ET. Wait at least 30 seconds so that any codes
may become active. Look for a 04 diagnostic code.
A. Remove the electrical power from the ECM.
E. Remove the jumper wire.
B. Disconnect the J2/P2 connector and disconnect
the J1/P1 connectors. F. Remove the electrical power from the ECM.

C. Disconnect the harness connector for the suspect Expected Result:

sensor.
A 04 diagnostic code was active when the jumper
D. Identify the terminal for the signal wire on the wire was installed. A 03 diagnostic code became
ECM connector that is appropriate for the suspect active when the jumper wire was removed.
sensor. Measure the resistance between the
appropriate terminal and the remaining terminals Results:
on both ECM connectors.
• OK – A 04 diagnostic code was active when the
E. Measure the resistance between the appropriate jumper wire was installed. A 03 diagnostic code
terminal and the engine ground. became active when the jumper wire was removed.
The engine harness and the ECM are OK.
F. Connect the J2/P2 connector and connect the
J1/P1 connectors. Connect the connectors for the Repair: Temporarily connect a new sensor to the
suspect sensor. harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
Expected Result: codes for the sensor. If there are no active
diagnostic codes for the new sensor, permanently
Each resistance measurement indicates an open install the new sensor. Clear any logged diagnostic
circuit. codes.

Results: Verify that the problem is resolved.

• OK – Each resistance measurement indicates an STOP.

open circuit. Proceed to Test Step 6.
• Not OK – A 04 diagnostic code was active when
• Not OK – At least one resistance measurement the jumper wire was installed. The 04 code
does not indicate an open circuit. There is a remained when the jumper wire was removed.
problem in the wiring for the sensor. There may be There is a problem with the harness or with the
a problem with a connector. ECM. Proceed to Test Step 7.

Repair: Repair the wiring and/or the connector. Test Step 7. Check the Operation of the
Replace parts, if necessary. ECM
Verify that the problem is resolved. A. Remove the electrical power from the ECM.

STOP. B. Check the operation of the ECM by creating an

open at the ECM:
RENR5089-23 149
Troubleshooting Section

a. Disconnect the appropriate ECM connector. Results:

b. Remove the signal wire for the suspect sensor • OK – The ECM is operating properly. There is a
from the ECM connector. problem in the wiring between the ECM and the
sensor connector.
c. Remove the return wire for the suspect sensor
from the ECM connector. Repair: If the code is active for more than one
sensor, the problem is most likely in the return wire
Note: Disconnecting the return wire from the ECM for the sensor. The problem may be in a connector.
will generate an open circuit diagnostic code for Repair the return wire and/or the connector.
all sensors that are connected to the return wire. Replace parts, if necessary.
Ignore the additional codes. Troubleshoot the original
diagnostic code and clear the codes when you are If the code is only active for one sensor, the
finished. problem is most likely in the signal wire for the
sensor. Repair the signal wire and/or the connector.
d. Connect the ECM connector. Replace parts, if necessary.

C. Restore the electrical power to the ECM. Verify that the problem is resolved.

D. Monitor the “Active Diagnostic Code” screen on STOP.

Cat ET. Wait at least 30 seconds so that any
codes may become active. • Not OK – One of the following conditions exists:
The 03 diagnostic code is not active when the
A 03 diagnostic code should be active for the signal wire is disconnected. The 04 diagnostic
suspect sensor. code is not active when the wire jumper is installed.

E. Remove the electrical power from the ECM. Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
F. Check the operation of the ECM by creating a ECM”. Verify that the problem is resolved.
short circuit at the ECM:
STOP.
a. Disconnect the appropriate ECM connector.
i02444550
b. Install a jumper wire between the two terminals
for the sensor's signal wire and the sensor's
return wire.
Engine Pressure Sensor Open
or Short Circuit - Test
c. Connect the ECM connector.
SMCS Code: 1439-038-PX
G. Restore the electrical power to the ECM.
System Operation Description:
H. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 30 seconds so that any Use this procedure to troubleshoot any suspect
codes may become active. problems with the following sensors:

A short circuit diagnostic code (04) should be • Injection actuation pressure sensor
active when the wire jumper is installed.
• Intake manifold (boost) pressure sensor
I. Remove the electrical power from the ECM.
• Atmospheric pressure sensor
J. Remove the jumper wire. Return the wiring to the
original configuration. • Fuel pressure sensor
Expected Result: • Engine oil pressure sensor
A 03 diagnostic code was active when the signal • Turbo inlet air pressure sensor
wire was removed from the ECM connector. A 04
diagnostic code became active when the signal wire This procedure covers the following diagnostic codes:
was connected to the return wire.
• 094-03 Fuel Pressure open/short to +batt
• 094-04 Fuel Pressure short to ground
150 RENR5089-23
Troubleshooting Section

• 100-03 Engine Oil Pressure open/short to +batt

• 100-04 Engine Oil Pressure short to ground
• 100-10 Engine Oil Pressure Sensor abnormal rate
of change

• 164-03 Injector Actuation Pressure voltage high

• 164-04 Injector Actuation Pressure voltage low
• 274-03 Atmospheric Pressure open/short to +batt
• 274-04 Atmospheric Pressure short to ground
• 1589-03 Turbo Inlet Air Pressure Sensor
open/short to +batt

• 1589-04 Turbo Inlet Air Pressure Sensor short to

ground

• 1785-03 Intake Manifold Pressure Sensor voltage

high

• 1785-04 Intake Manifold Pressure Sensor voltage

low

• 1785-10 Intake Manifold Pressure Signal abnormal

rate of change

The troubleshooting procedures for the diagnostic

codes of each pressure sensor are identical. The
Engine Control Module (ECM) sends a 5 volt supply
to terminal A of each sensor. The sensor common
connection is connected to terminal B of each
sensor. The signal voltage from terminal C of each
sensor is sent to the appropriate terminal on an ECM
connector.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect an open in the
signal circuit. When the ECM detects the presence of
a voltage that is above a threshold on the signal wire,
the ECM will generate a 03 diagnostic code.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the return
wire from the sensor connector to the ECM are good.

If the sensor is disconnected at the sensor connector,

the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connector

and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
RENR5089-23 151
Troubleshooting Section

g01222783
Illustration 74
Schematic for the engine pressure sensors

Test Step 1. Inspect the Electrical

Connectors and Wiring
A. Remove the electrical power from the ECM.
152 RENR5089-23
Troubleshooting Section

g01224255
Illustration 75
A typical right side view of the engine
(1) Fuel pressure sensor
(2) Turbo inlet air pressure sensor

g01217011
Illustration 77
P2 connector
(P2-15) Intake manifold (boost) pressure sensor
(P2-17) Sensor return
(P2-54) Sensor return
(P2-28) Engine oil pressure sensor
(P2-40) Fuel pressure sensor
(P2-57) Atmospheric pressure sensor
(P2-85) Injection actuation pressure sensor
(P2-72) +5 V Supply
(P2-80) +5 V Supply

g01223413
Illustration 76
A typical left side view of the engine
(3) Injection actuation pressure sensor
(4) Intake manifold (boost) pressure sensor
(5) Atmospheric pressure sensor
(6) J2/P2 connectors
(7) J1/P1 connectors
(8) Engine oil pressure sensor

B. Thoroughly inspect connectors (6) and (7).

Thoroughly inspect the connectors for each
engine pressure sensor. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.
RENR5089-23 153
Troubleshooting Section

g01123211
Illustration 79
Connectors for the sensors
(A) Supply
(B) Return
(C) Signal

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

wires that are associated with the engine pressure
sensors.

D. Check the torque of the allen head screws for

the ECM connectors. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Illustration 78
g01217015 Connectors - Inspect”.
P1 connector
E. Check the harness and wiring for abrasions and
(P1-2) +5 VDC
(P1-3) Return for pinch points from each sensor back to the
(P1-15) Turbo inlet air pressure sensor ECM.

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.

• Not OK – There is a problem in the wiring and/or

the connectors.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled.

Verify that the problem is resolved.

STOP.
154 RENR5089-23
Troubleshooting Section

Test Step 2. Check the Voltage on the +5 D. Determine if the problem is related to a 03
V Supply Wire diagnostic, a 04 code, or a 10 diagnostic code.

A. Remove the electrical power from the ECM. Expected Result:

B. Disconnect the harness connectors for the No diagnostic codes are active.
following sensors:
Results:
• Injection actuation pressure sensor
• OK – No diagnostic codes are active for the engine
• Intake manifold (boost) pressure sensor pressure sensors.

• Atmospheric pressure sensor Repair: If any of the above codes are logged
and the engine is not running properly, refer
• Fuel pressure sensor to troubleshooting without a diagnostic code
Troubleshooting.
• Engine oil pressure sensor
If the engine is running properly at this time, there
• Turbo inlet air pressure sensor may be an intermittent problem in a harness
that is causing the codes to be logged. Refer to
C. Restore the electrical power to the ECM. the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
D. Measure the voltage between terminals A (+5
VDC) and B (Return) at each sensor connector STOP.
on the engine harness.
• Active 04 code – An 04 diagnostic code is active.
E. Remove the electrical power from the ECM. Proceed to Test Step 4.

F. Connect all of the sensors. • Active 03 code – An 03 diagnostic code is active.

Proceed to Test Step 5.
Expected Result:
• Active 10 code – A 10 diagnostic code is active.
Each voltage measurement is 5.0 ± 0.2 VDC. Proceed to Test Step 6.

Results: Test Step 4. Disconnect the Suspect

Sensor in Order to Create an Open Circuit
• OK – Each voltage measurement is 5.0 ± 0.2
VDC. Proceed to Test Step 3. A. Remove the electrical power from the ECM.

• Not OK – At least one voltage measurement is not B. Disconnect the sensor connector of the sensor
5.0 ± 0.20 VDC. with the 04 diagnostic code.

Repair: Refer to the diagnostic functional test C. Restore the electrical power to the ECM. Wait at
Troubleshooting, “5 Volt Engine Pressure Sensor least 30 seconds for activation of the diagnostic
Supply Circuit - Test”. codes.

STOP. D. Access the “Active Diagnostic Code” screen on

Cat ET. Check for an active 03 diagnostic code for
Test Step 3. Check for Active Diagnostic the disconnected sensor.
Codes
E. Remove the electrical power from the ECM.
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic Expected Result:
troubleshooting Troubleshooting, “Electronic
Service Tools”. A 03 diagnostic code is now active for the
disconnected sensor.
B. Restore the electrical power to the ECM.

C. Observe the “Active Diagnostic” screen on Cat ET.

Wait at least 30 seconds so that any codes may
become active. Look for an active diagnostic code
for an engine pressure sensor.
RENR5089-23 155
Troubleshooting Section

Results: Test Step 6. Check the Signal Wire for a

Short Circuit
• OK – A 04 diagnostic code was active before you
disconnected the sensor. A 03 diagnostic code A. Remove the electrical power from the ECM.
became active after the sensor was disconnected.
The harness and the ECM are OK. There may be B. Disconnect the J2/P2 connector and disconnect
a problem with the sensor. the J1/P1 connector.

Repair: Temporarily connect a new sensor to the C. Disconnect the harness connector for the suspect
harness, but do not install the new sensor in the sensor.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active D. Identify the terminal for the signal wire on the
diagnostic codes for the sensor, permanently ECM connector that is appropriate for the suspect
install the new sensor. Clear any logged diagnostic sensor. Measure the resistance between the
codes. appropriate terminal and the remaining terminals
on both ECM connectors.
STOP.
E. Measure the resistance between the appropriate
• Not OK – A 04 diagnostic code was active before terminal and the engine ground.
you disconnected the sensor. The 04 diagnostic
code remained after the sensor was disconnected. F. Connect the J2/P2 connector and disconnect the
There is a problem with the harness or the ECM. J1/P1 connector. Connect the connectors for the
Leave the sensor disconnected. Proceed to Test suspect sensor.
Step 8.
Expected Result:
Test Step 5. Check the Pull-up Voltage at
the Sensor Connector Each resistance measurement indicates an open
circuit.
A. Restore the electrical power to the ECM.
Results:
B. Disconnect the suspect sensor.
• OK – Each resistance measurement indicates an
C. Measure the voltage between terminals C (Signal) open circuit. Proceed to Test Step 7.
and B (Sensor return) at the harness connector
for the sensor. • Not OK – At least one resistance measurement
does not indicate an open circuit. There is a
D. Remove the electrical power from the ECM. problem in the wiring for the sensor. There may be
a problem with a connector.
Expected Result:
Repair: Repair the wiring and/or the connector.
The voltage is 11 ± 2 VDC. Replace parts, if necessary.

Results: Verify that the problem is resolved.

• OK – The voltage is 11 ± 2 VDC. The signal wire STOP.

to the ECM from the sensor connector is OK.
Test Step 7. Create a Short at the Suspect
Repair: The open circuit is in the sensor or the Sensor Connector
wire between the sensor and the sensor connector.
Temporarily connect a new sensor to the engine A. Remove the electrical power from the ECM.
harness. Do not install the sensor in the engine.
Verify that no diagnostic codes are active for the B. Install a jumper wire with Deutsch sockets on
new sensor before you permanently install the each end between terminals B (Sensor return)
sensor. and C (Signal) on the harness connector for the
suspect sensor.
STOP.
C. Restore the electrical power to the ECM.
• Not OK – The voltage is not 11 ± 2 VDC. Proceed
to Test Step 6. Note: Monitor the “Active Diagnostic Codes” screen
on the electronic service tool before installing the
jumper wire and after installing the jumper wire.
156 RENR5089-23
Troubleshooting Section

D. Observe the “Active Diagnostic Codes” screen on C. Restore the electrical power to the ECM.
Cat ET. Wait at least 30 seconds so that any codes
may become active. Look for a 04 diagnostic code. D. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 30 seconds so that any
E. Remove the jumper wire. codes may become active.

F. Remove the electrical power from the ECM. A 03 diagnostic code should be active for the
suspect sensor.
Expected Result:
E. Remove the electrical power from the ECM.
A 04 diagnostic code was active when the jumper
wire was installed. A 03 diagnostic code became F. Check the operation of the ECM by creating a
active when the jumper wire was removed. short circuit at the ECM:

Results: a. Disconnect the appropriate ECM connector.

• OK – A 04 diagnostic code was active when the b. Install a jumper wire between the two terminals
jumper wire was installed. A 03 diagnostic code for the sensor's signal wire and the sensor's
became active when the jumper wire was removed. return wire.
The engine harness and the ECM are OK.
c. Connect the ECM connector.
Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the G. Restore the electrical power to the ECM.
engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active H. Monitor the “Active Diagnostic Code” screen on
diagnostic codes for the new sensor, permanently Cat ET. Wait at least 30 seconds so that any
install the new sensor. Clear any logged diagnostic codes may become active.
codes.
A short circuit diagnostic code (04) should be
Verify that the problem is resolved. active when the wire jumper is installed.

STOP. I. Remove the electrical power from the ECM.

• Not OK – A 04 diagnostic code was active when J. Remove the jumper wire. Return the wiring to the
the jumper wire was installed. The 04 code original configuration.
remained when the jumper wire was removed.
There is a problem with the harness or with the Expected Result:
ECM. Proceed to Test Step 8.
A 03 diagnostic code was active when the signal
Test Step 8. Check the Operation of the wire was removed from the ECM connector. A 04
ECM diagnostic code became active when the signal wire
was connected to the return wire.
A. Remove the electrical power from the ECM.
Results:
B. Check the operation of the ECM by creating an
open at the ECM: • OK – The ECM is operating properly. There is a
problem in the wiring between the ECM and the
a. Disconnect the appropriate ECM connector. sensor connector.

b. Remove the signal wire for the suspect sensor Repair: If the code is active for more than one
from the ECM connector. sensor, the problem is most likely in the return wire
for the sensor. The problem may be in a connector.
c. Remove the return wire for the suspect sensor Repair the return wire and/or the connector.
from the ECM connector. Replace parts, if necessary.

Note: Disconnecting the return wire from the ECM If the code is only active for one sensor, the
will generate an open circuit diagnostic code for problem is most likely in the signal wire for the
all sensors that are connected to the return wire. sensor. Repair the signal wire and/or the connector.
Ignore the additional codes. Troubleshoot the original Replace parts, if necessary.
diagnostic code and clear the codes when you are
finished. Verify that the problem is resolved.

d. Connect the ECM connector. STOP.

RENR5089-23 157
Troubleshooting Section

• Not OK – One of the following conditions exists: The engine will start when only one sensor signal is
The 03 diagnostic code is not active when the present. The engine will not start if the signals from
signal wire is disconnected. The 04 diagnostic both sensors are lost.
code is not active when the wire jumper is installed.
Both sensors are magnetic sensors. The two sensors
Repair: Replace the ECM. Refer to electronic are not interchangeable. Do not switch the positions
troubleshooting Troubleshooting, “Replacing the of the sensors. Replace the sensors as a set. If the
ECM”. Verify that the problem is resolved. sensors are replaced, a timing calibration is not
necessary.
STOP.
If a replacement of the ECM is required, the ECM
parameters and the timing calibration can be
i02533018
transferred from the suspect ECM to the replacement
Engine Speed/Timing Sensor ECM. Timing calibration will not be necessary. This
feature requires the Caterpillar Electronic Technician
Circuit - Test (ET) and this feature is only possible if the existing
ECM can communicate with Cat ET. Use the “Copy
SMCS Code: 1439-038-VF; 1912-038 Configuration - ECM Replacement” feature on Cat
ET.
System Operation Description:
Complete all of the following tasks when you
Use this procedure to troubleshoot any problems with install the speed/timing sensors:
the following sensors:
• Ensure that an O-ring is installed on each sensor.
• Primary engine speed/timing sensor If an O-ring is damaged or missing, replace the
O-ring.
• Secondary engine speed/timing sensor
• Lubricate the O-rings with oil.
This procedure covers the following diagnostic codes:
• Ensure that the sensor assembly is fully seated
• 190-08 Engine Speed signal abnormal into the engine before tightening the bracket bolt.

• 342-08 Secondary Engine Speed signal abnormal • Ensure that each electrical connector is latched
on both sides.
The engine uses two engine speed/timing sensors.
Both sensors detect the reference for engine speed • Ensure that the harness is properly secured, and
and timing from a unique pattern on the camshaft ensure that each tie-wrap is placed in the correct
gear. The Electronic Control Module (ECM) uses location.
the pattern of the pulses in order to determine the
position of the crankshaft. The ECM measures the
time between the pulses that are created by the
sensors as the gears rotate in order to determine rpm.

Under normal operation, the secondary engine

speed/timing sensor is used to determine timing
for starting purposes. The secondary engine
speed/timing sensor is used to determine when
the piston in the No. 1 cylinder is at the top of the
compression stroke. When the timing has been
established, the primary engine speed/timing sensor
is then used to determine engine speed.

When the timing has been established, the ECM

triggers each injector in the correct firing order at the
correct time. The actual timing and duration of each
injection is based on engine rpm and on load.

There is no change in engine performance if the

engine is running and the signal from one sensor is
lost. If the engine is running and the signals from both
sensors are lost, fuel injection is terminated and the
engine is shut down by the ECM.
158 RENR5089-23
Troubleshooting Section

g01267248
Illustration 80
Schematic for the engine speed/timing sensors

Test Step 1. Check for Diagnostic Codes Test Step 2. Check the Installation of the
Sensor Assembly
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector. Refer to electronic A. Remove the electrical power from the ECM.
troubleshooting Troubleshooting, “Electronic
Service Tools”.

B. Restore the electrical power to the ECM.

C. Start the engine and run the engine until the

engine is at normal operating temperature.

Note: If the engine will not start, monitor the engine

rpm on Cat ET while the engine is being cranked. Cat
ET may need to be powered from another battery
while the engine is being cranked.

D. Look for these codes on Cat ET:

Note: Wait at least 30 seconds in order for any codes

to become active.

• 190-08
• 342-08
g01120250
Illustration 81
Expected Result:
Typical left side view
One or both of the diagnostic codes that are listed (1) Engine
above are logged or active. (2) Flanges
(3) Bracket

Note: If the engine will not start and Cat ET displayed

B. Visually inspect the sensor assembly without
0 rpm during cranking, select “No Engine rpm”.
removing the sensor assembly from the engine.
Flanges (2) must be flush against engine (1) in
Results:
order to ensure proper operation.
• No Engine rpm – Engine rpm is not indicated on Inspect bracket (3). Verify that the bracket allows
Cat ET. Proceed to Test Step 2.
the flanges to be flush against the engine.
• -08 code – There is an active diagnostic code or a Verify that the bracket is not bent. If the bracket is
logged diagnostic code for the engine speed/timing
bent or if an obstruction is preventing the sensor
sensor. Proceed to Test Step 4.
assembly from being installed correctly, the engine
will not start.

Note: The bracket cannot be replaced separately.

RENR5089-23 159
Troubleshooting Section

C. Remove the sensor assembly from the engine. 1. Lubricate each O-ring with engine oil.

2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat into

the engine, replace the sensor assembly.

3. Tighten the bracket bolt.

4. Connect the sensor's electrical connectors.

Verify that the connectors are latched on both
sides.

5. Ensure that the harness is properly secured,

and that the tie-wraps are placed in the correct
location.

Verify that the problem is resolved.

STOP.

Test Step 3. Inspect the Electrical

Illustration 82
g01223456 Connectors and the Wiring
Sensor assembly
(4) O-ring

D. Ensure that one O-ring (4) is installed on each

sensor. Check the O-rings for damage. Replace
the O-rings, if necessary.

Results:

• OK – The sensor assembly's components are OK.

Repair: Perform the following procedure in order
to properly install the sensor assembly:

1. Lubricate each O-ring with engine oil.

2. Fully seat the sensor assembly in the engine.

Note: If the sensor assembly will not fully seat into

the engine, replace the sensor assembly.
g01235550
3. Tighten the bracket bolt. Illustration 83
Typical left side view
4. Connect the sensor's electrical connectors. (5) P400 connector for engine timing calibration
Verify that the connectors are latched on both (6) J2/P2 ECM connector
sides. (7) J401/P401 connectors for the primary engine speed/timing
sensor
(8) J402/P402 connectors for the secondary engine speed/timing
5. Ensure that the harness is properly secured, sensor
and that the tie-wraps are placed in the correct
location. A. Thoroughly inspect connectors (5), (6), (7),
and (8). Refer to the diagnostic functional test
Proceed to Test Step 3. Troubleshooting, “Electrical Connectors - Inspect”.

• Not OK – At least one of the sensor assembly's

components is not OK.

Repair: Obtain a new sensor assembly. Perform

the following procedure in order to properly install
the sensor assembly:
160 RENR5089-23
Troubleshooting Section

Expected Result:

All of the connectors, pins and sockets are completely

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

Results:

• OK – The harness and connectors appear to be

OK. Proceed to Test Step 4.

• Not OK – The connectors and/or wiring are not

OK.

Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary. Ensure that all of the
seals are properly in place and ensure that the
connectors are completely coupled. Verify that the
repair eliminates the problem.

STOP.

Test Step 4. Measure the Sensor

Resistance through the Engine Harness
A. Disconnect the J2/P2 ECM connector.

B. If you are troubleshooting a problem with the

primary engine speed/timing sensor, perform the
following procedure:

a. Measure the sensor's resistance between

P2-25 (Primary engine speed/timing +) and
P2-35 (Primary engine speed/timing -).

b. Check for an intermittent open circuit or for

a short circuit by moving the harness while
you take the resistance measurement. Pull
the wires that are directly behind the sensor
or shake the wires that are directly behind the
sensor.
g01144149
Illustration 84
P2 terminations for the engine speed/timing sensors Resistance ............................ 75 to 230 Ohms
(P2-25) Primary engine speed/timing −
(P2-35) Primary engine speed/timing + C. If you are troubleshooting a problem with the
(P2-46) Secondary engine speed/timing + secondary engine speed/timing sensor, perform
(P2-47) Secondary engine speed/timing − the following procedure:
B. Perform a 45 N (10 lb) pull test on each of a. Measure the sensor's resistance between
the wires that are associated with the engine P2-47 (Secondary engine speed/timing +) and
speed/timing sensors. P2-46 (Secondary engine speed/timing -).
C. Check the torque of the allen head screws for the b. Check for an intermittent open circuit or for
ECM connectors. Refer to the diagnostic functional a short circuit by moving the harness while
test Troubleshooting, “Electrical Connectors - you take the resistance measurement. Pull
Inspect” for the correct torque values. the wires that are directly behind the sensor
or shake the wires that are directly behind the
D. Check the harness and the wiring for abrasion sensor.
and for pinch points from each sensor back to the
ECM. Resistance ........................ 600 to 1800 Ohms
RENR5089-23 161
Troubleshooting Section

Expected Result: Results:

The resistance measurement is within the • OK – The reading is within the specification. There
specifications. is a problem with the wiring between the engine
speed/timing sensor and the ECM. There may be
Results: a problem with a connector.

• OK – The resistance measurement is within the Repair: Repair the wiring and/or the connector.
specifications. Neither a short circuit nor an open Replace parts, if necessary. Verify that the problem
circuit is indicated. is resolved.

Repair: Perform the following procedure: STOP.

1. Temporarily install a new ECM. Refer to • Not OK – The reading is not within the
electronic troubleshooting Troubleshooting, specification. There is an electrical problem with
“Replacing the ECM”. the engine speed/timing sensor.

2. Start the engine. Run the engine until the engine Repair: Perform the following procedure in order
is at normal operating temperature. to check and install the new sensor assembly:

3. If the problem is resolved with the test ECM, 1. Before you install the new sensor assembly,
connect the original ECM and verify that the measure the resistance of the new sensors.
problem recurs.
If the resistance measurements of the new
4. If the problem returns with the original ECM, sensors are within the specifications, install the
replace the ECM. new sensor assembly in the engine according
to the following procedure:
Verify that the problem is resolved.
a. Loosen the bolt and remove the bolt that
STOP. holds the sensor assembly to the engine.

• Not OK – The readings are not within the b. Ensure that O-rings are installed on the new
specifications. The sensor resistance is not within sensor assembly. Verify that the O-rings are
the acceptable range when the sensor resistance free of damage.
is measured through the engine harness. Proceed
to Test Step 5. c. Seat the sensor assembly and tighten the
bolt.
Test Step 5. Measure the Resistance of
the Sensor If the sensor will not seat, replace the sensor.

A. Disconnect the harness connector for the suspect d. Ensure that the harness is secured in the
sensor. proper location.

B. Thoroughly inspect the sensor's connectors. Refer 2. Verify that the repair eliminates the problem.
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. STOP.

C. Measure the sensor's resistance between

i02473826
terminals A and B.

Expected Result:
Engine Temperature Sensor
Open or Short Circuit - Test
For the primary engine speed/timing sensor, the
resistance measurement is between 75 and 230 SMCS Code: 1439-038-TA; 1906-038
Ohms. For the secondary engine speed/timing
sensor, the resistance measurement is between 600 System Operation Description:
and 1800 Ohms.
Use this procedure to troubleshoot any suspect
problems with the following sensors:

• Intake manifold air temperature sensor

• Coolant temperature sensor
162 RENR5089-23
Troubleshooting Section

• Fuel temperature sensor

This procedure covers the following diagnostic codes:

• 110-03 Engine Coolant Temperature open/short

to +batt

• 110-04 Engine Coolant Temperature short to

ground

• 172-03 Intake Manifold Air Temp open/short to

+batt

• 172-04 Intake Manifold Air Temp short to ground

• 174-03 Fuel Temperature open/short to +batt
• 174-04 Fuel Temperature short to ground
The troubleshooting procedures for the diagnostic
codes of each temperature sensor are identical.
The temperature sensors are passive sensors that
have two terminals. The temperature sensors do not
require supply voltage from the Electronic Control
Module (ECM).

Pull-up Voltage

The ECM continuously outputs a pull-up voltage

on the circuit for the sensor signal wire. The ECM
uses this pull-up voltage in order to detect an open
in the signal circuit. When the ECM detects the
presence of a voltage that is above a threshold on the
signal circuit, the ECM will generate an open circuit
diagnostic code (-03) for the sensor.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the wires from the sensor
connector to the ECM are not open or shorted to
ground. If the sensor is disconnected at the sensor
connector, the absence of pull-up voltage at the
sensor connector indicates an open in the signal wire
or a short to ground. If the sensor is disconnected at
the sensor connector and the voltage at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.
RENR5089-23 163
Troubleshooting Section

g01234186
Illustration 85
Schematic for the engine temperature sensors

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove the electrical power from the ECM.

g01193815
Illustration 86
Sensor locations (typical left side engine view)
(1) Engine coolant temperature sensor
(2) Intake manifold air temperature sensor
(3) Fuel temperature sensor
(4) J2/P2 ECM connectors

B. Thoroughly inspect the connectors for sensors (1),

(2), and (3). Also, thoroughly inspect connectors
(4). Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”.
164 RENR5089-23
Troubleshooting Section

g01155187
Illustration 88
Connector for the temperature sensors
(1) Sensor signal
(2) Sensor return

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

wires that are associated with the temperature
sensors.

D. Check the allen head screws for each ECM

connector for the proper torque. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.

E. Check the harness and the wiring for abrasions

and for pinch points from each of the temperature
sensors to the ECM connector.

Expected Result:

All connectors, pins, and sockets are completely

coupled and inserted. 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 – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

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

Verify that the repair eliminates the problem.

g01193814
Illustration 87
P2 ECM connector
STOP.
(P2-13) Engine coolant temperature
(P2-30) Common for the engine temperature sensors
Test Step 2. Check for Active Diagnostic
(P2-56) Intake manifold air temperature Codes
(P2-62) Fuel temperature
A. Connect the Caterpillar Electronic Technician (ET)
to the service tool connector.

B. Restore the electrical power to the ECM.

C. 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.
RENR5089-23 165
Troubleshooting Section

D. Look for a 03 diagnostic code or a 04 diagnostic Repair: Temporarily connect a new sensor to the
code. harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic
Expected Result: codes for the new sensor. If there are no active
diagnostic codes for the sensor, permanently
No diagnostic codes are active. install the new sensor. Clear any logged diagnostic
codes. Verify that the repair eliminates the problem.
Results:
STOP.
• OK – No diagnostic codes are active. The problem
appears to be resolved. • Not OK – The 04 diagnostic code is still present.
Leave the sensor disconnected. Proceed to Test
Repair: The problem may have been related Step 5.
to a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to Test Step 4. Create a Short at the Sensor
the diagnostic functional test Troubleshooting, Connector
“Electrical Connectors - Inspect”.
A. Disconnect the suspect sensor at the sensor
STOP. connector.

• Not OK – A 04 diagnostic code is active at this B. Fabricate a jumper wire that can be used to create
time. Proceed to Test Step 3. a short between terminal 1 (signal) and terminal 2
(sensor return) at the suspect sensor's connector.
• Not OK – A 03 diagnostic code is active at this Crimp connector pins to each end of the jumper
time. Proceed to Test Step 4. wire.

Test Step 3. Disconnect the Suspect C. Install the jumper onto the harness side of the
Sensor in Order to Create an Open Circuit sensor connector.

A. Remove the electrical power from the ECM. D. Restore the electrical power to the ECM. Wait at
least 30 seconds for activation of the diagnostic
B. Disconnect the suspect sensor from the engine codes.
harness.
E. Access the “Active Diagnostic Code” screen on
C. Restore the electrical power to the ECM. Wait at Cat ET. Check for an active 04 diagnostic code
least 30 seconds for activation of the diagnostic for the suspect sensor.
codes.
F. Remove the electrical power from the ECM.
D. Access the “Active Diagnostic Codes” screen on
Cat ET and check for an active 03 diagnostic code Expected Result:
for the suspect sensor.
A 04 diagnostic code is now active for the suspect
E. Remove the electrical power from the ECM. sensor.

Expected Result: Results:

A 03 diagnostic code is now active for the suspect • OK – A 03 diagnostic code was active before
sensor. creating the short at the sensor connector. A 04
diagnostic code became active after creating the
Results: short at the sensor connector.

• OK – A 04 diagnostic code was active before Repair: Temporarily connect a new sensor to the
disconnecting the sensor. A 03 diagnostic code harness, but do not install the new sensor in the
became active after the sensor was disconnected. engine. Verify that there are no active diagnostic
There may be a problem with the sensor. codes for the new sensor. If there are no active
diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic
codes.

STOP.

• Not OK – A 03 diagnostic code is still active for the

suspect sensors. Proceed to Test Step 5.
166 RENR5089-23
Troubleshooting Section

Test Step 5. Check the Operation of the Repair: If the code is active for more than one
ECM sensor, the problem is most likely in the return wire
for the sensor. Repair the return wire for the sensor
A. Remove the electrical power from the ECM. or replace the harness.

B. Check the operation of the ECM by creating an If the code is only active for one sensor, the
open at the ECM. problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. Verify
a. Disconnect the P2 ECM connector. that the repair eliminates the problem.

b. Fabricate a jumper wire that is long enough to STOP.

reach from a terminal at the ECM connector
to the engine ground stud. Crimp a connector • Not OK – One of the following conditions exists:
socket to one end of the jumper wire. The 03 diagnostic code is not active when the
sensor signal wire is disconnected. The 04
c. Remove the signal wire for the suspect sensor diagnostic code is not active when the wire jumper
from the P2 ECM connector. Install the jumper is installed.
wire into the terminal location for the signal wire
of the suspect sensor. Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
d. Connect the ECM connectors. ECM”. Verify that the original problem is resolved.

e. Restore the electrical power to the ECM. STOP.

Wait at least 30 seconds for activation of the
diagnostic codes.
i02450553

f. Monitor the “Active Diagnostic Code” screen on

Cat ET. Wait at least 30 seconds for activation
Engine Temperature Sensor
of the code. Open or Short Circuit - Test
An open circuit diagnostic code (03) will be SMCS Code: 1439-038-TA; 1906-038
active for the suspect sensor.
System Operation Description:
C. Check the operation of the ECM by creating a
short at the ECM. Use this procedure to troubleshoot any suspect
problems with the following sensors:
a. Short the jumper wire that is installed into the
P2 ECM connector to engine ground. • Engine coolant temperature sensor
b. Monitor the “Active Diagnostic Code” screen on • Intake manifold air temperature sensor
Cat ET. Wait at least 30 seconds for activation
of the code. This procedure covers the following diagnostic codes:

A short circuit diagnostic code (04) will be • 110-03 Engine Coolant Temperature open/short
active for the suspect sensor. to +batt

c. Remove the electrical power from the ECM. • 110-04 Engine Coolant Temperature short to
ground
D. Remove the wire jumper. Reconnect all wires and
connectors. • 172-03 Intake Manifold Air Temp open/short to
+batt
Expected Result:
• 172-04 Intake Manifold Air Temp short to ground
A 03 diagnostic code is active when the sensor signal
wire is open the ECM connector. A 04 diagnostic The troubleshooting procedures for both temperature
code is active when the jumper wire is shorted to sensors are identical. The temperature sensors
engine ground. are passive sensors that have two terminals. The
temperature sensors do not require supply voltage
Results: from the Electronic Control Module (ECM).

• OK – The ECM is working properly. The problem Pull-up Voltage

is in the wiring between the ECM and the sensor
connector.
RENR5089-23 167
Troubleshooting Section

The ECM continuously outputs a pull-up voltage on

the circuit for the sensor signal wire. The ECM uses
this pull-up voltage in order to detect an open in the
signal circuit. When the ECM detects the presence of
a voltage that is above a threshold on the signal wire,
the ECM will generate a -03 diagnostic code.

If the sensor is disconnected at the sensor connector,

the presence of pull-up voltage at the sensor
connector indicates that the signal wire and the return
wire from the sensor connector to the ECM are good.

If the sensor is disconnected at the sensor connector,

the absence of pull-up voltage at the sensor
connector indicates an open in the signal wire, an
open in the return wire, or a short to ground.

If the sensor is disconnected at the sensor connector

and the voltage on the signal wire at the sensor
connector is different from pull-up voltage, the signal
wire is shorted to another wire in the harness.

g01148488
Illustration 89
Schematic for the engine temperature sensors

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.
168 RENR5089-23
Troubleshooting Section

g01223461
Illustration 90
Typical left side view
(1) Engine coolant temperature sensor
(2) Intake manifold air temperature sensor
(3) J2/P2 ECM connector

B. Thoroughly inspect connectors (3). Inspect the

sensor connectors. Refer to diagnostic functional
tests Troubleshooting, “Electrical Connectors -
Inspect”.

g01223463
Illustration 91
P2 terminations for the engine temperature sensors
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature

g01120369
Illustration 92
Harness connector for the temperature sensors
(1) Signal
(2) Return

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

wires that are associated with the temperature
sensors.

D. Check the torque of the allen head screws for the

ECM connectors. Refer to diagnostic functional
tests Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque values.
RENR5089-23 169
Troubleshooting Section

E. Check the harness and wiring for abrasions and • Not OK – An 04 diagnostic code is active at this
for pinch points from each sensor to the ECM. time. Proceed to Test Step 3.

Expected Result: • Not OK – An 03 diagnostic code is active at this

time. Proceed to Test Step 4.
All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are Test Step 3. Disconnect the Suspect
free of corrosion, of abrasion, and of pinch points. Sensor in Order to Create an Open Circuit
Results: A. Remove the electrical power from the ECM.

• OK – The connectors and wiring are OK. Proceed B. Disconnect the suspect sensor from the engine
to Test Step 2. harness.

• Not OK – There is a problem in the connectors C. Restore the electrical power to the ECM. Wait at
and/or wiring. least 30 seconds for activation of the diagnostic
codes.
Repair: Repair the wiring and/or the connectors.
Replace parts, if necessary. Ensure that all of the D. Access the “Active Diagnostic Codes” screen on
seals are properly in place and ensure that the Cat ET and check for an active 03 diagnostic code
connectors are completely coupled. for the suspect sensor.

Verify that the repair eliminates the problem. E. Remove the electrical power from the ECM.

STOP. Expected Result:

Test Step 2. Check for Active Diagnostic An 03 diagnostic code is now active for the suspect
Codes sensor.

A. Connect the Caterpillar Electronic Technician (ET) Results:

to the service tool connector. Refer to electronic
troubleshooting Troubleshooting, “Electronic • OK – An 04 diagnostic code was active before
Service Tools”. disconnecting the sensor. An 03 diagnostic code
became active after the sensor was disconnected.
B. Restore the electrical power to the ECM. The harness and the ECM are OK. There may be
a problem with the sensor.
C. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes. Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
Note: Wait at least 30 seconds in order for the engine. Verify that there are no active diagnostic
diagnostic codes to become active. codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently
D. Look for an 03 diagnostic code or an 04 diagnostic install the new sensor. Clear any logged diagnostic
code. codes.

Expected Result: Verify that the repair eliminates the problem.

No diagnostic codes are active. STOP.

Results: • Not OK – The 04 diagnostic code is still present.

Leave the sensor disconnected. There is a problem
• OK – No diagnostic codes are active. with the harness or with the ECM. Proceed to Test
Step 7.
Repair: The problem may have been related
to a faulty connection in the harness. Carefully Test Step 4. Check the Pull-up Voltage at
reinspect the connectors and wiring. Refer to the Sensor Connector
diagnostic functional tests Troubleshooting,
“Electrical Connectors - Inspect” for additional A. Remove the electrical power from the ECM.
information.
B. Disconnect the suspect sensor at the sensor
STOP. connector.

C. Restore the electrical power to the ECM.

170 RENR5089-23
Troubleshooting Section

D. Measure the voltage between terminals 1 (Signal) • Not OK – At least one check of the resistance does
and 2 (Return) at the harness connector. not indicate an open circuit. There is a problem
with the wiring. There may be a problem with a
E. Remove the electrical power from the ECM. connector.

Expected Result: Repair: Repair the wiring and/or the connectors.

Replace parts, if necessary.
The voltage is 5.5 ± 0.5 VDC.
Verify that the original problem is resolved.
Results:
STOP.
• OK – The voltage is 5.5 ± 0.5 VDC. The correct
pull-up voltage is present at the harness connector Test Step 6. Create a Short at the Suspect
for the suspect sensor. Sensor Connector
Repair: The open circuit is in the sensor or the A. Remove the electrical power from the ECM.
wire between the sensor and the sensor connector.
Replace the sensor. Do not install the sensor in B. Install a jumper wire between terminals 1 and 2 on
the engine. Verify that no diagnostic codes are the harness connector for the suspect sensor.
active for the suspect sensor before permanently
installing the sensor. C. Restore the electrical power to the ECM.

STOP. D. Wait at least 30 seconds for activation of the 04

diagnostic code.
• Not OK – The voltage is not 5.5 ± 0.5 VDC.
Proceed to Test Step 5. Note: Monitor the “Active Diagnostic Codes” screen
on Cat ET before installing the jumper wire and after
Test Step 5. Check the Signal Wire for a installing the jumper wire.
Short Circuit
E. Remove the jumper wire. Check for an 04
A. Remove the electrical power from the ECM. diagnostic code again.

B. Disconnect the P1 and P2 connectors. F. Remove the electrical power from the ECM.

C. Measure the resistance between the terminal Expected Result:

for the suspect sensor's signal wire at the ECM
connector and all of the remaining terminals on An 04 diagnostic code is active when the jumper wire
the P2 connector. is installed. An 03 diagnostic code is active when the
jumper wire is removed.
D. Measure the resistance between the terminal
for the suspect sensor's signal wire at the ECM Results:
connector and all of the remaining terminals on
the P1 connector. • OK – The engine harness and the ECM are OK.
E. Measure the resistance between the terminal Repair: Temporarily connect a new sensor to the
for the suspect sensor's signal wire at the ECM harness, but do not install the new sensor in the
connector and the engine ground. engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active
F. Connect the J1/P1 and J2/P2 connectors. diagnostic codes for the sensor, permanently
install the new sensor. Clear any logged diagnostic
Expected Result: codes.

Each check of the resistance indicates an open STOP.

circuit.
• Not OK – The 03 diagnostic code remains active
Results: with the jumper in place. There is a problem with
the harness or with the ECM. Proceed to Test Step
• OK – Each check of the resistance indicates an 7.
open circuit. Proceed to Test Step 6.
Test Step 7. Check the Operation of the
ECM
A. Remove the electrical power from the ECM.
RENR5089-23 171
Troubleshooting Section

B. Check the operation of the ECM by creating an • Not OK – One of the following conditions exists:
open circuit at the ECM: The 03 diagnostic code is not active when the
sensor signal wire is disconnected. The 04
a. Remove the signal wire for the suspect sensor diagnostic code is not active when the wire jumper
from the appropriate ECM connector. is installed.

b. Remove terminal P2-30 (Return). Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
Note: Disconnecting the return wire from the ECM ECM”. Verify that the original problem is resolved.
will generate an 03 diagnostic code for all sensors
that are connected to the return wire. Troubleshoot STOP.
the original diagnostic code. Clear the logged
diagnostic codes when you are finished.
i04280511

c. Restore the electrical power to the ECM.

Monitor the “Active Diagnostic Code” screen on
Ether Injection System - Test
Cat ET. Wait at least 30 seconds for activation SMCS Code: 1456-038
of the code.
System Operation Description:
An 03 diagnostic code should be active for the
suspect sensor. Note: Some machines do not support the ether
override, still the "Ether Injection" override is present
C. Check the operation of the ECM by creating a in Cat ET. Cat ET will allow the user to attempt to
short at the ECM: activate the override. However, Cat ET will not accept
the request to activate the override.
a. Install a wire jumper between the terminals for
the sensor signal wire and the return wire. Use this procedure to troubleshoot any suspect
problems with the ether system.
b. Monitor the “Active Diagnostic Code” screen on
Cat ET. Wait at least 30 seconds for activation This procedure covers the following diagnostic codes:
of the code.
Table 24
An 04 diagnostic code should be active when
the wire jumper is installed. Diagnostic Trouble Codes
Code Code Comments
c. Remove the wire jumper. Return all wiring to Description
the original configuration.
2417-05 Ether Injection The code is
Control Solenoid logged.
Expected Result: current low

An 03 diagnostic code is active when the sensor 2417-06 Ether Injection The code is
signal wire is removed from the ECM connector. An Control Solenoid logged.
04 diagnostic code is active when the signal wire is current high
connected to the return wire.
The ether injection system will improve cold weather
Results: starting of the engine. The engine Electronic Control
Module (ECM) controls the ether injection system.
• OK – The ECM is working properly. The problem The ether injection system is disabled if there is an
is in the wiring between the ECM and the sensor active engine shutdown.
connector.
Activation of the ether starting aid is based from a
Repair: If the code is active for more than one map using the coolant temperature, intake manifold
sensor, the problem is most likely in the return wire temperature, and atmospheric pressure. Refer to
for the sensor. Repair the return wire for the sensor Illustration 93.
or replace the harness.

If the code is only active for one sensor, the

problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor.

STOP.
172 RENR5089-23
Troubleshooting Section

g02445796
Illustration 93

The following conditions must be met for the ether

injection system to be enabled:

• Ether injection is set to enabled in Cat ET

• Engine coolant temperature is less than the “Start
Aid Selection Temperature - Coolant”. Refer to
Illustration 93.

• Intake manifold temperature is less than the “Start

Aid Selection Temperature - IMAT.”

• Coolant temperature and intake manifold air

temperature are within 11° C of each other.
RENR5089-23 173
Troubleshooting Section

g01120166
Illustration 94
Schematic
174 RENR5089-23
Troubleshooting Section

Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living

areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or

at temperatures above 49 °C (120 °F).

Discard cylinders in a safe place. Do not puncture

or burn cylinders.

Keep ether cylinders out of the reach of unautho-

rized personnel.

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove the electrical power from the ECM.

B. Thoroughly inspect the ECM connectors J1/P1

and J2/P2. Inspect all of the other connectors for
the circuit. Refer to the diagnostic functional test
Illustration 95
g01120162 Troubleshooting, “Electrical Connectors - Inspect”.
P1 ECM connector
C. Perform a 45 N (10 lb) pull test on each of the
(P1-20) Ether relay wires in the ECM connector that are associated
with the circuit.

D. Check the ECM connector (allen head screw)

for the proper torque. Refer to the diagnostic
functional test Troubleshooting, “Electrical
Connectors - Inspect”.

E. Check the harness and the wiring for abrasion

and for pinch points.

Expected Result:

All connectors, pins, and sockets are coupled

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

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.
RENR5089-23 175
Troubleshooting Section

Repair: Repair the connectors or wiring and/or Test Step 3. Check the Keyswitch Signal
replace the connectors or wiring. Ensure that all of at the Relay Socket
the seals are properly in place and ensure that the
connectors are coupled. A. Verify that the keyswitch is in the ON position.

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Measure the Voltage at the

Ether Relay
Note: The ether canister must be removed prior to
performing this troubleshooting procedure.

A. Remove the ether canister.

B. Remove the ether relay from the socket.

g02462318
Illustration 97
Ether relay socket
(2) Terminal 2 (ground)
(3) Terminal 3 (keyswitch)

B. Measure the voltage between terminals 2 and 3

on the relay socket.

Results:

• OK – The voltage measurement is approximately

equal to battery voltage. Proceed to Test Step 4.

g02462298
• Not OK – The voltage measurement is not
Illustration 96 approximately equal to battery voltage.
Ether relay socket
(1) Terminal 1 (ether command) Repair: There is a problem in the wiring or
(2) Terminal 2 (ground) connectors between the keyswitch and the relay.
Repair the wiring or connectors.
C. Connect a digital voltmeter between terminals 1
and 2 of the relay socket. Terminals 1 and 2 are Proceed to Test Step 4.
for the ether command from the ECM.
Test Step 4. Check the Wiring for the
D. Turn the keyswitch to the ON position. Ether Control
E. Measure the voltage between terminals 1 and 2.

Results:

• OK – The voltage is greater than 10 VDC. Proceed

to Test Step 3.

• Not OK – The voltage is approximately 0 VDC

between terminals 1 and 2.

Repair: There is a problem with the wiring or the

connectors between the ECM and the relay.

Repair the wiring or connectors. Proceed to Test g02462336

Step 3. Illustration 98
Ether relay socket
(3) Terminal 3 (keyswitch)
(5) Terminal 5 (ether control)
176 RENR5089-23
Troubleshooting Section

A. Insert a jumper wire between terminals 3 and 5 on Test Step 5. Measure the Resistance of
the relay socket. The jumper will simulate an ether the Coil for the Ether Relay
command from the ECM.

B. Turn the keyswitch to the ON position.

g02462378
Illustration 101

A. Measure the resistance between pins 1 and 2 on

g02462341
Illustration 99 the ether relay.
Retracted plunger
Results:

• OK – The resistance measurement is

approximately 400 Ω. Reinstall the relay. Proceed
to Test Step 6.

• Not OK – The resistance measurement is not

approximately 400 Ω.

Repair: Replace the relay.

Proceed to Test Step 6.

Test Step 6. Verify the Repair

g02462343
Illustration 100 A. Verify that the ether relay is installed.
Extended plunger
B. Verify that the ether bottle is not installed.
C. Monitor the plunger when the keyswitch is turned
to the ON position. C. Verify that the keyswitch is OFF.

Results: D. Connect a jumper wire between the keyswitch

(P1-70) and the ether output (P1-20) of the P1
• OK – The plunger extends when the keyswitch is connector on the engine ECM.
in the ON position. Remove the jumper wire from
terminals 3 and 5. Proceed to Test Step 5. E. Turn the keyswitch to the ON position.

• Not OK – The plunger does not extend when the F. Observe the plunger on the ether control.
keyswitch is in the ON position.
Results:
Repair: There is an open circuit in the wiring
between terminal 5 of the relay socket and the • OK – The plunger extends when the keyswitch is in
ground for the ether control. The problem may be the ON position. Remove the jumper wire between
in an electrical connector. The open circuit may be P1-70 and P1-20. Return the unit to service. STOP.
inside the ether control. Determine the cause of
the open circuit. Make the necessary repairs.

Proceed to Test Step 5.

RENR5089-23 177
Troubleshooting Section

i02444740

Ether Injection System - Test

SMCS Code: 1456-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the electrical circuit for the ether
injection system.

The ether injection system improves cold weather

starting of the engine. The Electronic Control Module
(ECM) provides total control of the ether injection
system.

An override feature on the Caterpillar Electronic

Technician (ET) allows the technician to activate
the ether system. The test is only functional while
the engine is not running. Activate this feature
by selecting the “Override Parameters” from the
diagnostic menu in Cat ET.

g01222350
Illustration 102
Schematic of the ether injection system

Test Step 1. Inspect the Electrical

Connectors and the Wiring
Breathing ether vapors or repeated contact of
A. Remove the electrical power from the ECM.
ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living

areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or

at temperatures above 49 °C (120 °F).

Discard cylinders in a safe place. Do not puncture

or burn cylinders.

Keep ether cylinders out of the reach of unautho-

rized personnel.
g01167488
To avoid possible injury, be sure the brakes are ap- Illustration 103
plied and all controls are in Hold or Neutral when Location of the J1/P1 connectors (typical engine view)
starting the engine. (1) J1/P1 connectors
178 RENR5089-23
Troubleshooting Section

g01155187
Illustration 106
Terminal locations at the connector for the ether injection solenoid
(Terminal 1) Ether injection solenoid
(Terminal 2) Solenoid return

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

Illustration 104
g01217609 wires that are associated with the ether injection
system.
Components for the ether injection system (typical view)
(2) Ether injection solenoid D. Check the torque of the allen head screws for each
of the ECM connectors. Refer to the diagnostic
B. Thoroughly inspect connectors (1) and (2). Also, functional test Troubleshooting, “Electrical
thoroughly inspect the connectors for solenoid Connectors - Inspect”.
(3). Refer to the diagnostic functional test
Troubleshooting, “Electrical Connectors - Inspect”. E. Check the harness and the wiring for abrasion and
for pinch points from the ether injection solenoid
to the ECM connector.

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The connectors and the wiring appear to be

OK. Proceed to Test Step 2.

• Not OK – The connectors and/or the wiring are

not OK.

Repair: Repair the connectors and/or the wiring.

Replace parts, if necessary. Verify that the problem
is resolved.

STOP.

Test Step 2. Check the Ether Canisters

for Fluid
A. Ensure that the electrical power is removed from
the ECM.

B. Remove the ether canister from the ether valve.

C. Determine if the canister is empty.

Expected Result:
g01222387
Illustration 105
The ether canister is not empty.
Terminal locations at the P1 connector for the ether injection
system
(P1-18) Solenoid return
(P1-10) Ether injection solenoid
RENR5089-23 179
Troubleshooting Section

Results: Test Step 4. Check the Operation of the

ECM
• OK – The ether canister is not empty. Remove
the ether canister from the ether valve for the A. Disconnect the J1/P1 ECM connectors.
remainder of this test. Proceed to Test Step 3.
B. Fabricate two jumper wires that are long enough to
• Not OK – The ether canister is empty. provide a test circuit at the ECM. Crimp connector
sockets onto one end of each of the jumper wires.
Repair: Replace the empty ether canister with a
full ether canister. Retry the system. C. Remove the wires from terminal locations P1-18
(digital return) and P1-20 (ether injection solenoid)
STOP. at the ECM connector. Install a jumper wire into
each of these terminal locations.
Test Step 3. Check for Signal Voltage
at the Harness Connector for the Ether D. Connect the J1/P1 ECM connectors.
Injection Solenoid
E. Restore the electrical power to the ECM.
A. Remove the electrical power from the ECM.
F. Proceed to the “Diagnostic Overrides” screen on
B. Disconnect the harness connector at the ether Cat ET.
injection solenoid.
G. Activate the ether injection system. The system
C. Restore the electrical power to the ECM. will activate for ten seconds.

D. Proceed to the “Diagnostic Overrides” screen on H. Check for a signal voltage between the jumper
Cat ET. wires at the ECM connector for the ether injection
solenoid.
E. Activate the ether injection system. The system
will activate for ten seconds. I. Remove the electrical power from the ECM.

F. Check for a signal voltage between the terminals J. Restore all of the wiring to the original
at the harness connector for the ether injection configuration.
solenoid.
Expected Result:
G. Remove the electrical power from the ECM.
The signal voltage is 8.0 ± 0.5 VDC at the ECM for
Expected Result: the ether injection solenoid.

The signal voltage is 8.0 ± 0.5 VDC at the connector Results:

for the ether injection solenoid.
• OK – The signal voltage is 8.0 ± 0.5 VDC at the
Results: ECM.

• OK – The signal voltage is 8.0 ± 0.5 VDC at the Repair: The ECM is producing the correct signal
connector for the ether injection solenoid. for the ether injection solenoid. The ECM is OK.
The problem is in the harness or in a connector
Repair: Voltage is reaching the ether injection between the ECM and the ether injection solenoid.
solenoid. There is a problem with the solenoid. Repair the wiring harness and/or the connector.
Connect a new ether solenoid to the harness. Replace parts, if necessary. Verify that the problem
Verify that the problem has been corrected prior to has been corrected prior to returning the engine
installing the new solenoid. to service.

STOP. STOP.

• Not OK – The signal voltage is not 8.0 ± 0.5 VDC • Not OK – The signal voltage is not 8.0 ± 0.5 VDC
at the connector for the ether injection solenoid. at the ECM.
There is a problem in the harness or in a connector
between the ECM and the connector for the ether
injection solenoid. There may be a problem with
the ECM. Proceed to Test Step 4.
180 RENR5089-23
Troubleshooting Section

Repair: The ECM is not producing the correct

signal voltage. There is a problem with the
ECM. Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
ECM”.

STOP.

i02432719

Fuel Filter Differential Pressure

Switch Circuit - Test
SMCS Code: 1435-038-FI

System Operation Description:

Perform this procedure if you suspect that there is

a problem in the circuit for the fuel filter differential
pressure switch.

This procedure covers the following event codes:

• E390-1 Fuel Filter Restriction Warning

• E390-2 Fuel Filter Restriction Derate
• E390-3 Fuel Filter Restriction Shutdown
The fuel filter differential pressure switch is used
to detect excessive restriction in the fuel filter. The
switch is normally closed. When the fuel pressure
at the switch reaches 103 ± 14 kPa (15 ± 2 psi) the
switch will open. The switch is used in order to detect
a plugged fuel filter element. The Electronic Control
Module (ECM) will alert the operator of the condition.
Use this test in order to verify that the fuel filter
differential pressure switch is operating correctly.

g01214403
Illustration 107
Schematic for fuel filter differential pressure switch

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove electrical power from the ECM.
RENR5089-23 181
Troubleshooting Section

g01214446
Illustration 108
Left side engine view (typical example)
(1) J2/P2 ECM connectors

g01214409
Illustration 110
P2 ECM connector
(P2-65) Fuel filter differential pressure switch
(P2-83) Signal return

g01161069
Illustration 109
Fuel filter base (typical example)
(2) Fuel filter differential pressure switch

B. Thoroughly inspect connectors (1). Also,

thoroughly inspect each connector for switch (2).
g01155187
Refer to the diagnostic functional test Illustration 111
Troubleshooting, “Electrical Connectors - Inspect” Connector for the fuel filter differential pressure switch
for details. (Terminal 1) Fuel filter differential pressure switch
(Terminal 2) Signal return

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

wires in the ECM connector and the sensor
connectors that are associated with the active
diagnostic code.
182 RENR5089-23
Troubleshooting Section

D. Check the allen head screw of each ECM Repair: The wiring between the connector and the
connector for the proper torque. Refer to the ECM is OK. Replace the fuel filter element. Restart
diagnostic functional test Troubleshooting, the engine and check for an event code. If the
“Electrical Connectors - Inspect” for the correct event code is still active, temporarily replace the
torque value. fuel filter differential pressure switch. Verify that the
problem is resolved before permanently replacing
E. Check the harness and wiring for abrasions and the fuel filter differential pressure switch.
for pinch points from the switch back to the ECM.
STOP.
Expected Result:
• Not OK – The event code is still active. There
All connectors, pins, and sockets are completely is an open circuit in the wiring for the fuel filter
coupled and/or inserted. The harness and wiring are differential pressure switch between the connector
free of corrosion, of abrasion, and of pinch points. for the fuel filter differential pressure switch and
the ECM. There may be a problem with the ECM.
Results: Connect the connector for the pressure switch.
Proceed to Test Step 3.
• OK – The harness and wiring appear to be OK.
Proceed to Test Step 2. Test Step 3. Check the ECM
• Not OK – There is a problem in the connectors A. Disconnect the J2/P2 ECM connector.
and/or wiring.
B. Fabricate a jumper wire that is long enough to
Repair: Repair the connectors or wiring and/or create a short between the P2 ECM connector
replace the connectors or wiring. Ensure that all of and the engine ground stud. Crimp a connector
the seals are properly in place and ensure that the socket to one end of the jumper wire.
connectors are completely coupled. Verify that the
repair eliminates the problem. C. Remove the wire from terminal location P2-65
(fuel filter differential pressure switch) at the ECM
STOP. connector. Install the jumper wire into the terminal
location.
Test Step 2. Check the Switch Circuit at
the Harness Connector D. Secure the other end of the jumper wire to the
engine ground stud.
A. Fabricate a jumper wire that is long enough to
short circuit the terminals at the harness connector E. Start the engine. Increase the engine speed to
for the fuel filter differential pressure switch. Crimp high idle.
connector pins to each end of the jumper wire.
F. Check for an event code for the engine fuel filter
B. Disconnect the connector for the fuel filter restriction.
differential pressure switch from the harness.
Install the jumper wire across the terminals on the G. Shut down the engine. Remove electrical power
harness side of this connector. from the ECM.

C. Start the engine. Increase the engine speed to Expected Result:

high idle.
The event code is not active.
D. Check for an event code for the engine fuel filter
restriction. Results:

E. Shut down the engine. Remove electrical power • OK – The event code is not active.
from the ECM.
Repair: The problem is in the harness wiring
Expected Result: between the connector for the fuel filter differential
pressure switch and the P2 ECM connector. Check
The event code is not active. the harness connector to the fuel filter differential
pressure switch for a good connection. Repair the
Results: connectors or wiring and/or replace the connectors
or wiring. Verify that the repair eliminates the
• OK – The event code is not active. problem.

STOP.
RENR5089-23 183
Troubleshooting Section

• Not OK – The event code is still active. • The engine cranks but the engine will not start.
Repair: There is a problem with the ECM. Replace • The engine runs rough.
the ECM. Refer to electronic troubleshooting
Troubleshooting, “Replacing the ECM”. Verify that • The engine is erratic or unstable at idle or running.
the problem is resolved.
• Low power
STOP.
• The following diagnostic codes might be active
codes or logged codes: 164-00, 164-02, 164-03,
i03781969
164-04, 164-11, 42-11, 94-1, and 94-11.
Injection Actuation Pressure - A. Connect the Caterpillar Electronic Technician (ET)
Test to the data link connector.

SMCS Code: 1714-038 B. Turn the keyswitch to the ON position. DO NOT

START THE ENGINE.
System Operation Description:
C. Print the “Lifetime Totals” and the “Configuration”
Use the steps that follow to check the operation of screen.
the HEUI fuel system. Circle the appropriate answers
within the “Results” section of each step. Complete D. Check for active diagnostic codes or logged
the pages. Provide completed pages with any diagnostic codes. The diagnostic codes should
returned part. Return the parts through the normal become active within 30 seconds.
channels.
E. Verify that the engine coolant temperature sensor
Results from the test must be included in the claim for is operating properly. Verify through CAT ET. Refer
related repairs. Failure to follow the proper sequence to Testing and Adjusting, “Cooling System - Test”
of this procedure may result in incorrect results. The or Testing and Adjusting, “Test For The Water
standard warranty may not cover repairs that are Temperature Gauge” for the proper procedure.
performed while using this procedure incorrectly.
Document all active diagnostic codes or logged
diagnostic codes.________________

Expected Result:

Diagnostic codes are not active or logged when

electrical power is restored to the ECM and the
engine is not running.

Results:

• OK – There are no active codes or logged codes.

Proceed to Test Step 2.

• Not OK – Active codes or logged codes are

present.

Repair: Refer to Troubleshooting, “Engine

Pressure Sensor Open or Short Circuit - Test” if
164-03 or 164-04 is active or logged.

Illustration 112
g01181491 Refer to Troubleshooting, “Injection Actuation
Pressure Sensor - Test” if 164-02 is active or
Left side of engine (typical example)
logged.
(1) “J500/P500” Connector for the injection actuation pressure
control valve
(2) Injection actuation pressure sensor
Refer to Troubleshooting, “Injection Actuation
Pressure Control Valve Circuit - Test” if 42-11 is
Test Step 1. Symptoms active or logged.

The following symptoms may occur if there is a Refer to System Operation, Test and Adjusting,
problem with the HEUI fuel system: “Fuel System Pressure - Test” if 94-1 is active or
logged.
184 RENR5089-23
Troubleshooting Section

Proceed to Test Step 2 if 164-00, 164-11 or 94-11 Repair: The injection actuation pressure sensor
is active or logged. may be faulty. Replace the sensor and reconnect
the connector. Clear all diagnostic codes. Verify
STOP. that the repair eliminates the problem.

Test Step 2. Start the Engine If the problem still exists, proceed to Test Step 4.

A. Inspect the engine for oil leaks in the HEUI oil rail. Test Step 4. The Engine Cranks but the
Repair leaks before proceeding. Clearly mark all Engine Will not Start
leaks on returned parts.
A. Observe the status for “Engine Speed”, “Actual
Note: Inspect the area near the high pressure oil rail Injection Actuation Pressure” and “Engine Oil
and the unit injector hydraulic pump. If leakage is Pressure” on Cat ET while the engine is cranking.
found between the transfer pump and the hydraulic Record the following data:
pump, refer to Special Instruction, REHS3830 for
details. If leakage is found between the hydraulic ________________ Engine Speed
pump and the front housing, refer to Special
Instruction, REHS3830 for details on replacing the ________________ Actual injection actuation
seal. pressure

B. Check the engine oil level. If the engine oil level ________________ Desired injection actuation
is low, add oil to the engine. Do not overfill the pressure
engine.
________________ Engine oil pressure
C. Try to start the engine.
________________ Fuel pressure
Expected Result:
________________ Engine coolant temperature
The engine starts.
________________ Observed “Injection Actuation
Results: Output Percent”

• OK – The engine starts. Proceed to Test Step 10. Expected Result:

• Not OK – The engine does not start. Proceed to The observed engine speed is above 100 rpm and
Test Step 3. the actual injection actuation pressure is at least
6 MPa (870 psi) while the engine is cranking.
Test Step 3. Verify the Operation of the
Injection Actuation Pressure Sensor Results:

A. Disconnect the connector for the injection • OK – The observed engine speed is above 100
actuation pressure sensor. Check for evidence rpm and the actual injection actuation pressure is at
of moisture in the connector. Refer to least 6 MPa (870 psi) while the engine is cranking.
Troubleshooting, “Electrical Connectors - Inspect”
for troubleshooting details. Repair: If a 94-11 code is active or logged, there
is a problem with the fuel supply system. Refer
B. Try to start the engine. to System Operation, Test and Adjusting, “Fuel
System Pressure - Test”.
Expected Result:
If a 94-11 code is not active or logged, refer to Test
The engine does not start. Step 5.

Results: • Not OK – The observed engine speed is below

100 rpm.
• OK – The engine does not start. Reconnect the
connector for the actuation pressure sensor. Clear Repair: Refer to Troubleshooting, “Engine Cranks
all diagnostic codes. Proceed to Test Step 4. but Will Not Start”.

• Not OK – The engine starts. STOP.

• Not OK – The observed engine speed is above

100 rpm and the observed engine oil pressure is
below 14 kPa (2 psi).
RENR5089-23 185
Troubleshooting Section

Repair: There is a problem with the engine oil

supply. Refer to System Operation, Test and
Adjusting, “Engine Oil Pressure - Test”.

STOP.

• Not OK – The observed engine speed is above

100 rpm and the observed engine oil pressure
is above 14 kPa (2 psi) and the actual injection
actuation pressure is below 6 MPa (870 psi).
Proceed to Test Step 7.

Test Step 5. Verify Communication

Between the ECM and the Fuel Injectors

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

g01330939
Illustration 114
Location of the connectors for the injector solenoids (C9 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors

A. Turn the key to the “OFF” position. An electrical

shock hazard is present if the key is not in the
“OFF” position.

B. Disconnect the connector for the injector

harness at the valve cover. Check for
evidence of moisture in the connector. Refer to
Troubleshooting, “Electrical Connectors - Inspect”
for troubleshooting details.

C. Crank the engine for 15 seconds.

D. Check Cat ET for logged diagnostic codes that

are related to the injector solenoids.
g01330859 Expected Result:
Illustration 113
Location of the connectors for the injector solenoids (C7 engines)
(1) Connector at the valve cover
There are logged diagnostic codes for injector
(2) J2/P2 ECM connectors solenoids in all cylinders.
(3) Rubber grommet for the injector harness at the valve cover
Results:

• OK – There are logged diagnostic codes for

injector solenoids in all cylinders. The logged codes
indicate communication between the ECM and the
fuel injectors. Turn the key to the “OFF” position.
Reconnect the connector for the injector harness.
Clear all diagnostic codes. Proceed to Test Step 6.

• Not OK – At least one cylinder does not indicate a

logged diagnostic code for the injector solenoid.
186 RENR5089-23
Troubleshooting Section

Repair: There may be a problem with the engine Note: Do not insert any wire that is larger than
harness or ECM. Record the numbers that do not 18 AWG into the P500 harness connector. Do not
indicate a logged diagnostic code for the injector insert the probe for the voltage test lamp into the
solenoid. Turn the key to the “OFF” position. P500 harness connector. These actions will spread
Reconnect the connector for the injector harness. the sockets of the connector which will damage
Clear any diagnostic codes or event codes. Refer the connector. Damaged connectors could cause
to Troubleshooting, “Injector Solenoid Circuit - intermittent connections.
Test”.
B. Insert a 186-3735 Connector Pin into each of the
STOP. P500 harness connector sockets .

Test Step 6. Check the Pressure of the C. Connect a voltage test lamp to the connector pins
Low Pressure Fuel System that are inserted in the P500 connector.

A. Observe the status for “Fuel Pressure” on Cat D. Crank the engine and watch the test lamp.
ET while the engine is cranking. Record the fuel
pressure. Expected Result:

________________ Fuel Pressure The test lamp illuminates while the engine is cranking.

Expected Result: Results:

Observed fuel pressure is above 175 kPa (25 psi) • OK – The test lamp illuminates while the engine
while the engine is cranking. is cranking. The ECM is operating correctly and
the wiring harness to the pump is OK. Proceed to
Results: Test Step 8.

• OK – Observed fuel pressure is above 175 kPa • Not OK – The test lamp does not illuminate while
(25 psi) while the engine is cranking. the engine is cranking.

Repair: Access the “Injector Solenoid Test” in Cat Repair: Refer to Troubleshooting, “Injection
ET. Activate the test. As each solenoid is energized Actuation Pressure Control Valve Circuit - Test” for
by the ECM an audible click can be heard at the information on troubleshooting the circuit.
valve cover. Listen for a click at the valve cover.
Cat ET will indicate the cylinder number as each STOP.
solenoid is being energized. Replace injectors
that do not produce an audible click. Verify the Test Step 8. Check the High Pressure Oil
repair. If all injectors produce an audible click and System for Leaks
the engine will not start, refer to Troubleshooting,
“Engine Cranks but Will Not Start”.

STOP.
Hot oil and components can cause personal in-
jury.
• Not OK – Observed fuel pressure is below 175 kPa
(25 psi) while the engine is cranking.
Do not allow hot oil or components to contact
Repair: There is a problem with the fuel supply skin.
system. Refer to System Operation, Test and
Adjusting, “Fuel System Pressure - Test”.

STOP.
Electrical shock hazard. The electronic unit injec-
Test Step 7. Use a Test Lamp to Check tor system uses 90-120 volts.
for the Presence of Current
A. Remove the valve cover and inspect the high
A. Disconnect the J500/P500 IAPCV connector from pressure oil system for excessive oil leaks or
the unit injector hydraulic pump. discharge.
RENR5089-23 187
Troubleshooting Section

B. Look at the injector bores for any signs of oil • OK – If the unit injector hydraulic pump has
leakage while the engine is being cranked. Inspect already been replaced during this procedure and
the spill ports on the injectors for an excessive the actual injection actuation pressure was below
discharge of oil. All six injectors should discharge 6 MPa (870 psi) in Step “E”, consult your local
the same amount of oil. Excessive leakage or technical communicator for assistance.
discharge can cause issues with the system
pressure. Record the following data: • Not OK – There are excessive oil leaks around the
injector bores or excessive discharge of oil out of
________________Any injectors with excessive the spill port of the injector.
leakage or discharge
Repair: Replace the O-ring on the injector(s)
C. Turn the key to the “OFF” position. A electrical that is leaking around the bore(s) or replace
shock hazard is present if the key is not turned to the damaged injector(s) that is identified with
the “OFF” position. excessive discharge out of the spill ports.

D. Disconnect the connector for the injector Proceed to Test Step 9.

harness at the valve cover. Check for
evidence of moisture in the connector. Refer to Test Step 9. Try to Start the Engine
Troubleshooting, “Electrical Connectors - Inspect”
for troubleshooting details.

E. Crank the engine. Observe the injector bores for

any signs of leakage. Inspect the spill ports on the Electrical shock hazard. The electronic unit injec-
injectors for an excessive discharge of oil. The tor system uses 90-120 volts.
injectors are now disabled and the injectors should
discharge very little oil, which is normal. Observe A. Turn the key to the “OFF” position. A electrical
the status for the “Actual Injection Actuation shock hazard is present if the key is not in the
Pressure” on Cat ET while the engine is cranking. “OFF” position.
Record the following data:
B. Reconnect the connector for the injector harness
________________Any injectors with excessive at the valve cover and install the valve cover.
leakage or discharge
C. Try to start the engine. Observe the status for
________________Actual injection actuation pressure “Actual Injection Actuation Pressure” on Cat ET
while the engine is cranking. Record the actual
F. Clear any diagnostic codes that are logged. injection actuation pressure.

Expected Result: ________________ Actual injection actuation

pressure
There are no excessive oil leaks around injector
bores. Also, there is no excessive discharge of oil Expected Result:
from the spill ports of the injector.
The engine starts.
Results:
Results:
• OK – There are no excessive oil leaks around
injector bores. Also, there is no excessive • OK – The engine starts. STOP.
discharge of oil from the spill ports of the injector.
• Not OK – The engine does not start and actual
Repair: If the unit injector hydraulic pump has not injection actuation pressure is above 6 MPa
been replaced during this procedure, replace the (870 psi). Proceed to Test Step 5.
pump and repeat steps “E” and “F”. The engine will
need to be cranked for a significant length of time • Not OK – The engine does not start and actual
in order to fill the pump with oil after the pump is injection actuation pressure is below 6 MPa
replaced. Clear all diagnostic codes. (870 psi).
If the unit injector hydraulic pump has been
replaced during this procedure, and the actual
injection actuation pressure was at least 6 MPa
(870 psi) in Step “E”, proceed to Test Step 9.
188 RENR5089-23
Troubleshooting Section

Repair: If the unit injector hydraulic pump has not Results:

been replaced, replace the pump and try to start
the engine. The engine will need to be cranked for • OK – The customer has not exceeded the
a significant length of time in order to fill the pump suggested oil change interval.
with oil after the pump has been replaced. Clear all
diagnostic codes. Repair: Refer to Systems Operation, Testing and
Adjusting, “Fuel System Pressure - Test” and
If the engine does not start, proceed to Test Step 5. Systems Operation/Testing and Adjusting, “Engine
Oil Pressure - Test” in order to verify that the
• Not OK – If the unit injector hydraulic pump has observed fuel pressure and engine oil pressures
already been replaced in a previous test, stop are acceptable.
and consult your local technical communicator for
assistance. If a 94-1 diagnostic code is active or if a 94-1
diagnostic code is logged, a problem in the fuel
Test Step 10. Check the Low Pressure supply system has occurred. Refer to Systems
Fuel and Oil System Pressures Operation, Testing and Adjusting, “Fuel System
Pressure - Test”. Make necessary repairs. Verify
Extended oil drain intervals may cause elevated that the repair eliminates the problem.
levels of soot in the engine oil. The elevated levels
of soot may also deplete the additive package of the If the problem still exists, proceed to Test Step 11.
oil. This can affect the operation of the high pressure
oil system. • Not OK – The customer has exceeded the
suggested oil change interval.
Note: Refer to the engine's Operation and
Maintenance Manual for the recommended engine oil Repair: If the customer has exceeded the
change interval and refill capacities. suggested oil change interval, ask the customer
to authorize an oil change with a new filter.
Oil changes are not covered by the warranty.
After the engine oil and the oil filter have been
changed, operate the engine until normal operating
Escaping fluid under pressure, even a pinhole size temperature has been reached. Operate the engine
leak, can penetrate body tissue, causing serious at 1200 to 1500 rpm for 15 minutes. This will purge
injury, and possible death. If fluid is injected into any trapped air or debris that is in the system.
your skin, it must be treated immediately by a doc-
tor familiar with this type of injury. If the problem still exists, or if the problem reoccurs
in a short period of time, repeat Test Step 10.
Always use a board or cardboard when checking
for a leak. Test Step 11. Use “Injection Actuation
Pressure Test” on Cat ET to Check the
A. Start the engine. System
B. Observe the status for “Fuel Pressure” and A. Install the 8T-0852 Pressure Gauge in an
“Engine Oil Pressure” on Cat ET while the engine accessible port in the high pressure part of the
is running. Record the following data: injection actuation system.

________________ Observed fuel pressure from Cat B. Start the engine.

ET
C. Access the “Injection Actuation Pressure Test” in
________________ Observed engine oil pressure the “Diagnostics Menu” of Cat ET and begin the
from Cat ET test.

________________ Drain interval Note: The “Injection Actuation Pressure Test” can
be used to increase the injection actuation pressure.
________________ Miles or Kilometers since the last Also, the “Injection Actuation Pressure Test” can be
oil change used to decrease the injection actuation pressure.
The test adjusts the oil pressure of the injection
Expected Result: actuation system in predefined steps. Step forward
through all predefined steps in the test. Next, step
The customer has not exceeded the suggested oil backward through all predefined steps in the test.
change interval.
D. Record the pressure readings from the pressure
gauge and from Cat ET in Table25.
RENR5089-23 189
Troubleshooting Section

Table 25
Step Manual pressure gauge Actual injection actuation Difference
pressure from Cat ET
1
2
3
4
3
2
1

Expected Result: Note: There may be a short lag in the reaction to

the injection pressure. The pressure change should
The pressure that is measured with the pressure occur within two seconds of each command.
gauge for each step and the pressure that is
displayed on Cat ET for each step are within B. Record the actual injection actuation pressure,
1379 kPa (200 psi). the desired injection actuation pressure and the
percent output from Cat ET in Table 26.
Note: Under some situations, the injection actuation
pressure may not change. This step compares the
pressure reading from the pressure gauge to the
pressure reading that is displayed on Cat ET.

Results:

• OK – The pressure that is measured with the

pressure gauge for each step and the pressure
that is displayed on Cat ET for each step are
within 1379 kPa (200 psi). The injection actuation
pressure sensor is operating properly.

Repair: Do not replace the sensor.

Proceed to Test Step 12.

• Not OK – The pressure that is measured with the

pressure gauge for each step and the pressure
that is displayed on Cat ET for each step are not
within 1379 kPa (200 psi).

Repair: The injection actuation pressure sensor

may be faulty. Replace the sensor and repeat this
test step.

If the problem still exists, verify the accuracy of the

pressure gauge. Reinstall the original sensor and
proceed to Test Step 12.

Test Step 12. Perform the “Injection

Actuation Pressure Test” at Low Idle
A. Start the engine. Run the “Injection Actuation
Pressure Test” at low idle only. Step forward
through all predefined steps in the test. Next, step
backward through all the predefined steps in the
test.
190 RENR5089-23
Troubleshooting Section

Table 26
Low Idle
Step Actual injection Desired injection actuation Difference (A-B) Percent Output from Cat ET
actuation pressure pressure from Cat ET (B)
from Cat ET (A)
1
2
3
4
3
2
1

Expected Result: A. Remove the valve cover and inspect the high
pressure oil system for excessive oil leaks or
The actual injection actuation pressure is no more discharge.
than 1379 kPa (200 psi) above the desired injection
actuation pressure for each step. Also, the injection B. Start the engine and allow the engine to idle. Look
actuation pressure does not fluctuate more than at the injector bores for any signs of oil leakage.
±1000 kPa (±145 psi). Inspect the spill ports on the injectors for an
excessive discharge of oil. All six injectors should
Results: discharge the same amount of oil. Excessive
leakage or discharge can cause issues with the
• OK – The actual injection actuation pressure is no system pressure.
more than 1379 kPa (200 psi) above the desired
injection actuation pressure for each step. Also, C. While the engine is at low idle, perform the
the actual injection actuation pressure does not “Injection Actuation Pressure Test” in Cat ET.
fluctuate more than ±1000 kPa (±145 psi). Proceed Run the test at the highest pressure in order to
to Test Step 13. maximize any possible leaks. Observe the status
for “Actual Injection Actuation Pressure” on Cat
• Not OK – One of the actual injection actuation ET. Record the following data:
pressures is more than 1379 kPa (200 psi) above
the desired injection actuation pressure on at least ________________ Any injectors with excessive
one step, or the actual injection actuation pressure leakage or discharge
fluctuates more than ±1000 kPa (±145 psi).
________________ Actual injection actuation
Repair: Replace the unit injector hydraulic pump. pressure at low idle
After the pump has been replaced, the engine
will need to be cranked for a significant length D. Turn the key to the “OFF” position. A electrical
of time in order to fill the pump with oil. Clear all shock hazard is present if the key is not turned to
diagnostic codes or event codes. Verify that the the “OFF” position.
repair eliminates the problem.
E. Disconnect the connector for the injector
If the problem still exists, proceed to Test Step 13. harness at the valve cover. Check for
evidence of moisture in the connector. Refer to
Test Step 13. Check the High Pressure Troubleshooting, “Electrical Connectors - Inspect”
Oil System for Excessive Leaks for troubleshooting details.

F. Crank the engine. Observe the injector bores for

any signs of leakage. Inspect the spill ports on
the injectors for an excessive discharge of oil.
Hot oil and components can cause personal in- The injectors are now disabled and the injectors
jury. should discharge very little oil, which is normal.
Do not allow hot oil or components to contact
skin.
RENR5089-23 191
Troubleshooting Section

G. While the engine is cranking, perform the “Injection C. Install the 8T-0852 Pressure Gauge in an
Actuation Pressure Test” in Cat ET. Run the test accessible port in the high pressure portion of the
at the highest pressure in order to maximize any injection actuation system.
possible leaks. Observe the status for “Actual
Injection Actuation Pressure” on Cat ET. Record D. Disconnect the connector for the injection
the following data: actuation pressure sensor and plug a spare
injection actuation pressure sensor into the engine
________________Any injectors with excessive harness. Allow the spare sensor to hang on the
leakage or discharge side of the engine.

________________ Actual injection actuation Note: This configuration allows the unit injector
pressure while the engine is cranking hydraulic pump to build maximum pressure. The
engine will not start in this configuration.
H. Clear any diagnostic codes that are logged.
E. Install a 224-9282 Adapter Cable As in
Expected Result: series with the P500 connector. Reconnect the
P500/J500 connector.
There are no excessive oil leaks around injector
bores. Also, there is no excessive discharge of oil Note: There must be a continuous electrical
from the spill ports of the injector. connection between the ECM and the unit injector
hydraulic pump. The improper connection or the
Results: incomplete connection of the adapter cable may
provide incorrect results.
• OK – There are no excessive oil leaks around
injector bores. Also, there is no excessive F. Connect a multimeter that is capable of measuring
discharge of oil from the spill ports of the injector. current that is 0 to 1,000 milliampere in series with
Proceed to Test Step 14. the adapter cable. Select the lowest current range
for the multimeter that is greater than one amp.
• Not OK – There are excessive oil leaks around
injector bores or there is an excessive discharge of Note: If the multimeter is not set to the correct scale,
oil from the spill ports of the injector. the following measurement may provide misleading
results.
Repair: Replace the O-ring on the injector(s)
that is leaking around the bore(s) or replace the G. Crank the engine and record the following data:
damaged injector(s) that is identified with excessive
discharge out of the spill ports. . ________________Observed pressure reading from
the pressure gauge
Verify that the repair eliminates the problem. If the
problem remains after the repair, proceed to Test Note: If the gauge fluctuates use the average.
Step 14.
________________ Observed engine speed from Cat
Test Step 14. Check the Oil Pressure at ET
the Pump (High Pressure Pump Test)
________________Observed “Injection Actuation
A. Turn the key to the “OFF” position. A electrical Output Percent” from Cat ET
shock hazard is present if the key is not turned to
the “OFF” position. ________________ Current reading from the
multimeter
B. Reconnect the connector for the injector harness
at the valve cover and install the valve cover. Expected Result:

The oil pressure is above 29.5 MPa (4278 psi) and

the current is above 400 mA.
Escaping fluid under pressure, even a pinhole size
leak, can penetrate body tissue, causing serious Results:
injury, and possible death. If fluid is injected into
your skin, it must be treated immediately by a doc- • OK – The oil pressure is above 29.5 MPa
tor familiar with this type of injury. (4278 psi) and the current is above 400 mA.
Leave the system in the present configuration and
Always use a board or cardboard when checking proceed to Test Step 15.
for a leak.
• Not OK – The oil pressure is below 29.5 MPa
(4278 psi) and the current is above 400 mA.
192 RENR5089-23
Troubleshooting Section

Repair: Replace the unit injector hydraulic pump. If Repair: Replace the unit injector hydraulic pump.
the drive gear on the pump is loose, do not attempt After the pump has been replaced, the engine
to tighten the drive gear and reuse the pump. will need to be cranked for a significant length
After the pump has been replaced, the engine of time in order to fill the pump with oil. Clear all
will need to be cranked for a significant length diagnostic codes or event codes. Verify that the
of time in order to fill the pump with oil. Clear all repair eliminates the problem. If the problem still
diagnostic codes or event codes. Verify that the exists, consult your local technical communicator
repair eliminates the problem. for assistance.

If the problem still exists, consult your local STOP.

technical communicator for assistance.
Test Step 16. Use the “Cylinder Cutout
STOP. Test” on Cat ET to Check the Fuel
Injectors
• Not OK – The current is below 400 mA.
The troubleshooting indicates that the unit injector
Repair: Refer to Troubleshooting, “Injection hydraulic pump is working properly. Record the
Actuation Pressure Control Valve Circuit - Test”. following data:

STOP. Engine symptoms (misfire,

________________
excessive smoke, low power, runs rough)
Test Step 15. Disconnect J500/P500 and
Check the Oil Pressure ________________ Conditions when the engine
symptom occurs, (high load, idle, cold start,
A. Disconnect the J500/P500 connector at the unit acceleration, etc)
injector hydraulic pump.
________________ The frequency of the engine
B. Crank the engine and record the following data. symptoms (intermittent, constant, etc)

Note: The pressure readings may vary between A. Perform a cylinder cutout procedure if the
gauges. test has not already been performed or if any
other repairs have been completed since the
________________Observed pressure reading from most recent cylinder cutout procedure. Refer to
the pressure gauge Troubleshooting, “Injector Solenoid Circuit - Test”
for troubleshooting details.
________________ Observed engine speed from Cat
ET Expected Result:

________________ Observed “Injection Actuation The injectors are operating properly according to the
Output Percent” from Cat ET “Injector Solenoid Circuit - Test”. Also, the engine
symptoms are still present.
Expected Result:
Results:
The oil pressure is below 8 MPa (1160 psi).
• OK – The injectors are operating properly
Results: according to the “Injector Solenoid Circuit - Test”.
Also, the engine symptoms are still present.
• OK – The oil pressure is below 8 MPa (1160 psi).
Return the system to the original configuration and Repair: Consult your local technical communicator
proceed to Test Step 16. for assistance.

• Not OK – The oil pressure is above 8 MPa STOP.

(1160 psi). The unit injector hydraulic pump is
faulty. • Not OK – The “Injector Solenoid Circuit - Test”
indicates faulty injectors.

Repair: Replace the faulty injectors. Verify that the

repair eliminates the problem. If the problem still
exists, consult your local technical communicator
for assistance.

STOP.
RENR5089-23 193
Troubleshooting Section

i02548622

Injection Actuation Pressure

Control Valve Circuit - Test
SMCS Code: 1714-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the Injection Actuation Pressure
Control Valve (IAPCV).

This procedure covers the following diagnostic codes:

• 42-05 Injector Actuation Valve open circuit

• 42-06 Injector Actuation Valve short to ground
The IAPCV is internal to the unit injector hydraulic
pump. The IAPCV is a precision displacement control
actuator. This actuator changes the pump outlet flow
that is based on the control current that is supplied by
the Electronic Control Module (ECM). The variable
displacement unit injector hydraulic pump pressurizes
only the amount of high pressure oil that is needed.

The ECM software contains performance maps. The

performance maps have a desired actuation pressure
for every engine operating condition. The ECM sends
a control current to the IAPCV. This signal creates an
actual actuation pressure that matches the desired
actuation pressure. If the actual actuation pressure
does not match the desired actuation pressure, the
ECM will increase the control current or the ECM will
decrease the control current to the IAPCV in order to
adjust pump outlet flow.

The following problems can cause a 05 diagnostic

code:

• An open circuit in the wiring

• An open circuit in the IAPCV
• A short to ground on the return wire
The following problems can cause a 06 diagnostic
code:

• The control wire has a short to the +Battery.

• The return wire has a short to the +Battery.
• A short circuit in the IAPCV
• A short to ground on the control wire
194 RENR5089-23
Troubleshooting Section

g01275408
Illustration 115
Schematic for the injection actuation pressure control valve

Test Step 1. Inspect the Electrical

Connectors and the Wiring
A. Remove the electrical power from the ECM.

g01223470
Illustration 116
Typical left side view
(1) J500/P500 connector
(2) J2/P2 connectors

B. Thoroughly inspect connectors (1) and (2). Refer

to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
g01223476
Illustration 117
P2 terminations for the IAPCV
(P2-10) Return
(P2-20) Control

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

wires that are associated with the IAPCV.
RENR5089-23 195
Troubleshooting Section

D. Check the torque of the allen head screws for the Repair: If one of the above codes is logged
ECM connectors. Refer to the diagnostic functional and the engine is not running properly, refer
test Troubleshooting, “Electrical Connectors - to Troubleshooting, “Troubleshooting without a
Inspect” for the correct torque values. diagnostic code”.

E. Check the harness and wiring for abrasion and for If the engine is running properly at this time, there
pinch points from the IAPCV back to the ECM. may be an intermittent problem in a harness
that is causing the codes to be logged. Refer to
Note: Ensure that the seal is installed on the harness the diagnostic functional test Troubleshooting,
connector for the injection actuation pressure control “Electrical Connectors - Inspect”.
valve.
STOP.
Expected Result:
Test Step 3. Measure the Resistance of
All connectors, pins, and sockets are completely the Injection Actuation Pressure Control
coupled and/or inserted. The harness and wiring are Valve's Solenoid
free of corrosion, of abrasion, and of pinch points.
A. Remove the electrical power from the ECM.
Results:
B. Disconnect the IAPCV connectors.
• OK – The connectors and the wiring are OK.
Proceed to Test Step 2. Note: Ensure that the seal on the P500 connector
remains on the connector when the connector is
• Not OK – There is a problem with the connectors disconnected.
and/or the wiring.
C. Measure the resistance between terminals 1
Repair: Repair the connectors or wiring and/or (Control) and 2 (Return) on the IAPCV. Record the
replace the connectors or wiring. Ensure that all of value of the resistance measurement.
the seals are properly in place and ensure that the
connectors are completely coupled. Expected Result:

Verify that the repair eliminates the problem. The resistance measurement is between 6.5 and
10.5 Ohms.
STOP.
Results:
Test Step 2. Check for Active Diagnostic
Codes • OK – The resistance measurement is between
6.5 and 10.5 Ohms. Connect the J500/P500
A. Connect the Caterpillar Electronic Technician connectors. Proceed to Test Step 4.
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”. • Not OK – The resistance measurement is not
between 6.5 and 10.5 Ohms. The solenoid's
B. Restore the electrical power to the ECM. resistance is not within the specification.

C. Start the engine. Repair: Replace the unit injector hydraulic pump.
Verify that the problem is resolved.
D. Observe the “Active Diagnostic” screen on Cat ET.
Wait at least 30 seconds so that any codes may STOP.
become active. Look for the code that is 05 or 06.
Test Step 4. Check the Wiring for an Open
Expected Result: Circuit
One of the above codes is active. A. Remove the electrical power from the ECM.

Results: B. Disconnect the J2/P2 connectors.

• Active code – One of the above codes is active. C. Measure the resistance between terminals P2-20
Proceed to Test Step 3. (Control) and P2-10 (Return).

• No active codes – Neither of the above codes are

active.
196 RENR5089-23
Troubleshooting Section

Expected Result: Results:

The resistance measurement is within two Ohms of • OK – All of the resistance measurements indicate
the value that was measured in the previous Test an open circuit. Proceed to Test Step 6.
Step.
• Not OK – At least one resistance measurement
Results: does not indicate an open circuit. There is a
problem with a wiring harness. There may be a
• OK – The resistance measurement is within two problem with a connector.
Ohms of the value that was measured in the
previous Test Step. Proceed to Test Step 5. Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the problem
• Not OK – The resistance measurement is not is resolved.
within two Ohms of the value that was measured
in the previous Test Step. There is a problem with STOP.
the wiring harness. There may be a problem with a
connector. Test Step 6. Check the ECM by Cranking
the Engine
Repair: Repair the wiring and/or the connector.
Replace parts, if necessary. Verify that the problem Note: This Test Step may activate additional
is resolved. diagnostic codes. Ignore the codes and monitor the
test lamp. Clear the codes at the end of the Test Step.
STOP.
A. Verify that the IAPCV connectors are
Test Step 5. Check the Wiring for a Short disconnected.
Circuit
Note: Do not insert any wire that is larger than
A. Disconnect the IAPCV connectors. 18 AWG into the IAPCV harness connector. Do
not insert the probe for the voltage test lamp into
Note: Ensure that the seal on the IAPCV connector the harness connector. These actions will spread
remains on the connector when the connector is the sockets of the connector which will damage
disconnected. the connector. Damaged connectors could cause
intermittent connections.
B. Disconnect the P1 connector.
B. Insert a Deutsch connector pin into each socket
C. Measure the resistance between the points that of the IAPCV harness connector.
are listed in Table 27. Be sure to wiggle the wires
in the harnesses as you make each resistance C. Connect a voltage test lamp to the connector pins
measurement. that are inserted in the IAPCV connector. Crank
the engine and observe the test lamp.
Table 27
Resistance Measurements for the Wiring Harness Expected Result:
Connector and Terminal The voltage test lamp illuminates when the engine
Terminal is cranking.
P2-20 (Control) All of the other terminals on
the P2 connector Results:
All of the terminals on the P1
connector • OK – The voltage test lamp illuminates when the
engine is cranking. Remove the connector pins
Engine ground from the IAPCV connector. Connect all of the
electrical connectors. Clear any diagnostic codes.
P2-10 (Return) All of the other terminals on
the P2 connector Proceed to Test Step 7.

All of the terminals on the P1 • Not OK – The voltage test lamp does not illuminate
connector when the engine is cranking.
Engine ground
Repair: Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, “Replacing the
Expected Result: ECM”.
All of the resistance measurements indicate an open STOP.
circuit.
RENR5089-23 197
Troubleshooting Section

Test Step 7. Perform the “Injection • You have been directed to this procedure from
Actuation Pressure Test” Troubleshooting, “Troubleshooting without a
Diagnostic Code”.
A. Disconnect the IAPCV connectors.
• There is an active diagnostic code for an injector
NOTICE solenoid.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two Use this procedure for the following diagnostic codes:
minutes before cranking the engine again.
• 1-05 Cylinder # 1 Injector open circuit
B. Crank the engine three times at 30 seconds • 1-06 Cylinder # 1 Injector short
intervals. This will purge the air from the system.
• 2-05 Cylinder # 2 Injector open circuit
C. Connect the IAPCV connectors.
• 2-06 Cylinder # 2 Injector short
D. Start the engine.
• 3-05 Cylinder # 3 Injector open circuit
E. Run the “Injection Actuation Pressure Test”. The
“Injection Actuation Pressure Test” is located in • 3-06 Cylinder # 3 Injector short
the “Diagnostics” menu on Cat ET. Step through
all of the pressure ranges. • 4-05 Cylinder # 4 Injector open circuit
Note: This is not the “Injection Act Press Driver Test”. • 4-06 Cylinder # 4 Injector short
F. After performing the “Injection Actuation Pressure • 5-05 Cylinder # 5 Injector open circuit
Test”, check for the following active diagnostic
codes: • 5-06 Cylinder # 5 Injector short
• 05 • 6-05 Cylinder # 6 Injector open circuit
• 06 • 6-06 Cylinder # 6 Injector short
Expected Result: Perform this procedure under conditions that are
identical to the conditions that exist when the problem
The test is successful. There are no diagnostic codes. occurs. Typically, problems with the injector solenoid
occur when the engine is warmed up and/or when
Results: the engine is under vibration (heavy loads).

• OK – The problem appears to be resolved. The These engines have Electronic Unit Injectors (EUI)
original problem was probably caused by a poor that are hydraulically actuated and electronically
electrical connection. STOP. controlled. The Engine Control Module (ECM) sends
a 105 volt pulse to each injector solenoid. The pulse
• Not OK – There is a problem with the IAPCV. is sent at the proper time and at the correct duration
for a given engine load and speed. The solenoid is
Repair: Replace the unit injector hydraulic pump. mounted on top of the fuel injector body.
Verify that the problem is resolved.
If an open is detected in the solenoid circuit, a
STOP. diagnostic code is generated. The ECM continues
to try to fire the injector. If a short is detected, a
diagnostic code is generated. The ECM will disable
i02527372
the solenoid circuit. The ECM will periodically try
Injector Solenoid Circuit - Test to fire the injector. If the short circuit remains, this
sequence of events will be repeated until the problem
SMCS Code: 1290-038 is corrected.

System Operation Description: When an injector is replaced, program the new

injector code into the ECM. If the ECM is replaced,
Use this procedure for the following conditions: all six injector codes must be programmed into
the new ECM. Refer to programming parameters
• An injector solenoid may have a problem. Troubleshooting, “Injector Trim File”.
198 RENR5089-23
Troubleshooting Section

The Caterpillar Electronic Technician (ET) includes

the following tests that aid in troubleshooting the
injector solenoids:

“Cylinder Cutout Test”

All active diagnostic codes must be repaired before

running the “Cylinder Cutout Test”. Use the “Cylinder
Cutout Test” to diagnose a malfunctioning injector
while the engine is running. When a good injector
is cut out, the “Fuel Position” should change. The
change in the fuel position is caused by the other
injectors that are compensating for the cut out
injector. If a malfunctioning injector is cut out, the
“Fuel Position” will not change. The “Cylinder Cutout
Test” is used to isolate the malfunctioning injector in
order to avoid replacement of good injectors.

“Injector Solenoid Test”

Use the “Injector Solenoid Test” to aid in diagnosing

an open circuit or a short circuit 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 will indicate the status of the solenoid as “OK”,
“Open”, or “Short”.

Note: Refer to Illustration 119. 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 injector solenoids.
RENR5089-23 199
Troubleshooting Section

g01234897
Illustration 118
C9 schematic for the injector solenoids
200 RENR5089-23
Troubleshooting Section

g01146342
Illustration 119
C7 schematic for the injector solenoids

Test Step 1. Inspect the Electrical

Connectors and the Wiring

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

A. Remove the electrical power from the ECM. A

strong electrical shock hazard is present if the
power is not removed.
RENR5089-23 201
Troubleshooting Section

g01143147
Illustration 120
Typical left side view
(1) J300/P300 connectors
(2) J2/P2 connectors

B. Thoroughly inspect connectors (1) and (2). Refer

to the diagnostic functional test Troubleshooting, Illustration 121
g01099568
“Electrical Connectors - Inspect”.
P2 terminals that are associated with the injector solenoids
(P2-99) Injector 5 & 6 supply
(P2-104) Injector 1 & 2 supply
(P2-105) Injector 6 return
(P2-106) Injector 3 return
(P2-107) Injector 5 return
(P2-108) Injector 4 return
(P2-115) Injector 3 & 4 supply
(P2-116) Injector 1 return
(P2-118) Injector 2 return
202 RENR5089-23
Troubleshooting Section

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

wires that are associated with injector solenoids.

D. Check the torque of the allen head screws for the

ECM connectors. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect” for the correct torque values.

E. Check the harness and the wiring for abrasion

and for pinch points from the P300 connector to
the ECM.

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The harness and wiring are OK. Proceed

Illustration 122
g01121687 to Test Step 2.
P300 terminals that are associated with the C9 injector solenoids
(P300-1) Injector 1 supply
• Not OK – There is a problem in the connectors
(P300-2) Injector 2 supply
and/or wiring.
(P300-3) Injector 3 supply
(P300-4) Injector 4 supply Repair: Repair the connectors or wiring and/or
(P300-5) Injector 5 supply replace the connectors or wiring. Ensure that all of
(P300-6) Injector 6 supply the seals are properly in place and ensure that the
(P300-13) Injector 6 return
(P300-14) Injector 5 return connectors are completely coupled.
(P300-15) Injector 4 return
(P300-16) Injector 3 return Verify that the repair eliminates the problem.
(P300-17) Injector 2 return
(P300-18) Injector 1 return
STOP.

Test Step 2. Check for Logged Diagnostic

Codes for the Injector Solenoids
A. Connect Cat ET to the service tool connector. Refer
to electronic troubleshooting Troubleshooting,
“Electronic Service Tools”.

B. Restore the electrical power to the ECM.

C. Check for logged diagnostic codes for the injector

solenoids on Cat ET. Wait at least 30 seconds in
order for the codes to become active.

g01129758 Expected Result:

Illustration 123
P300 terminals that are associated with the C7 injector solenoids One or more diagnostic codes for the injector
(P300-9) Injector 1 supply solenoids are logged.
(P300-10) Injector 2 supply
(P300-11) Injector 3 supply
(P300-12) Injector 4 supply Results:
(P300-7) Injector 5 supply
(P300-8) Injector 6 supply • Logged 05 code – A 05 diagnostic code is logged.
(P300-1) Injector 1 return Proceed to Test Step 4.
(P300-2) Injector 2 return
(P300-3) Injector 3 return
(P300-4) Injector 4 return • Logged 06 code – A 06 diagnostic code is logged.
(P300-6) Injector 5 return Proceed to Test Step 4.
(P300-5) Injector 6 return
RENR5089-23 203
Troubleshooting Section

• No logged codes – No diagnostic codes for the Repair: If the engine is misfiring or if the engine
injector solenoids are logged. Proceed to Test Step has low power, refer to troubleshooting without
3. a diagnostic code Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable” and
Test Step 3. Check the Variation of the refer to troubleshooting without a diagnostic
Injectors between Cylinders code Troubleshooting, “Low Power/Poor or No
Response to Throttle”.
A. Start the engine.
STOP.
B. Allow the engine to warm up to normal operating
temperature 77 °C (171 °F). • Not OK – The cylinder cutout test indicates that at
least one of the injectors is not operating correctly.
C. Access the “Cylinder Cutout Test” by accessing Proceed to Test Step 4.
the following display screens:
Test Step 4. Test the Injector Solenoids
• Diagnostics
A. Start the engine.
• Diagnostic Tests
B. Allow the engine to warm up to normal operating
• Cylinder Cutout Test temperature 77 °C (171 °F).

D. Shut off all parasitic loads such as air compressors C. Stop the engine.
which could affect the results of the test.
D. Restore the electrical power to the ECM.
E. Set the engine speed to 1000 ± 20 rpm.
E. Access the “Injector Solenoid Test” by accessing
F. Select the start button at the bottom of the screen the following display screens:
for the cylinder cutout test on Cat ET.
• Diagnostics
G. Select the “4 Cylinder Cutout Test” which is the
default test. • Diagnostic Tests
H. Follow the instructions that are provided by Cat • Injector Solenoid Test
ET in order to complete the cylinder cutout test.
The cylinder cutout test is interactive so the F. Activate the “Injector Solenoid Test”.
procedure is guided to the finish. The test results
are displayed on Cat ET. G. As each solenoid is energized by the ECM, an
audible click can be heard at the valve cover.
The “4 Cylinder Cutout Test” will not run unless
certain conditions are present. For example, Cat H. Allow the “Injector Solenoid Test” to continue until
ET will not allow the “4 Cylinder Cutout Test” to each cylinder is activated at least two times.
occur when the temperature of the engine coolant
is too low. In this case, warm the engine or perform Expected Result:
the test manually.
All cylinders indicate “OK” on Cat ET.
I. You may manually cut out a cylinder, if necessary.
Highlight a cylinder and select the “Change” button Results:
at the bottom of the screen. The injector for that
cylinder will be disabled. Check for a difference in • OK – There is not an electronic problem with the
the sound, feel, or power of the engine. Also, look injectors at this time.
for a change to the operating parameters that are
displayed on the “Cylinder Cutout Test” screen. Repair: The problem appears to be resolved. The
problem was probably caused by a poor electrical
Expected Result: connection in a connector.

The cylinder cutout test indicates that all of the If the codes continue to be logged, refer to
injectors are operating correctly. the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
Results:

• OK – The cylinder cutout test indicates that all of

the injectors are operating correctly.
204 RENR5089-23
Troubleshooting Section

If the engine is misfiring or if the engine has low • Not OK – Cat ET displays “Short” for the cylinder
power, refer to troubleshooting without a diagnostic with the jumper wire. The harness between the
code Troubleshooting, “Engine Misfires, Runs ECM and the P300 connector does not have an
Rough or Is Unstable” or refer to troubleshooting open circuit. Proceed to Test Step 6.
without a diagnostic code Troubleshooting, “Low
Power/Poor or No Response to Throttle”. Test Step 6. Check the Injector Harness
under the Valve Cover for an Open Circuit
STOP.

• Not OK - Open – Note the cylinder that indicates

“Open”. Proceed to Test Step 5.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
• Not OK - Short – Note the cylinder that indicates
“Short”. Proceed to Test Step 8.
A. Remove the electrical power from the ECM. A
Test Step 5. Check the Harness between strong electrical shock hazard is present if the
the ECM and the Valve Cover Base for an power is not removed.
Open Circuit
B. Remove the valve cover.

C. Disconnect the harness connector from the

Electrical shock hazard. The electronic unit injec- suspect injector.
tor system uses 90-120 volts.
D. Thoroughly clean the terminals on the injector
solenoid and the harness connector.
A. Remove the electrical power from the ECM. A
strong electrical shock hazard is present if the E. Insert the ends of a jumper wire into each socket
power is not removed. in the harness connector for the suspect injector.
This will replace the injector solenoid with a short
B. Disconnect the P300 connector. circuit.

C. Restore the electrical power to the ECM. F. Restore the electrical power to the ECM.

D. Fabricate a jumper wire 100 mm (4 inch) long with G. Perform the “Injector Solenoid Test” at least two
Deutsch pins on both ends of the wire. times.

E. Insert one end of the jumper wire into the P300 Expected Result:
socket for the suspect injector's supply wire. Insert
the other end of the jumper wire into the P300 Cat ET displays “Open” for the cylinder with the
socket for the suspect injector's return wire. This jumper wire.
will replace the injector solenoid with a short
circuit. Results:

F. Perform the “Injector Solenoid Test” at least two • OK – Cat ET displays “Open” for the cylinder
times. with the jumper wire. There is a problem with the
injector harness under the valve cover. There may
G. Repeat this test for each suspect injector. Stop be a problem with a connector.
the “Injector Solenoid Test” before handling the
jumper wire. Repair: Repair the wiring and/or the connector,
when possible. Replace parts, if necessary. Verify
Expected Result: that the problem is resolved.

Cat ET displays “Open” for the cylinder with the STOP.

jumper wire.
• Not OK – Cat ET displays “Short” for the cylinder
Results: with the jumper wire. The wiring is OK.

• OK – Cat ET displays “Open” for the cylinder Repair: Replace the faulty injector. Verify that the
with the jumper wire. There is a problem in the problem is resolved.
wiring between the ECM and the P300 connector.
Proceed to Test Step 7. STOP.
RENR5089-23 205
Troubleshooting Section

Test Step 7. Check the ECM for Proper 2. Perform the “Injector Solenoid Test”.
Operation
If the test ECM fixes the problem, connect the
suspect ECM. If the problem returns with the
suspect ECM, replace the ECM.
Electrical shock hazard. The electronic unit injec- Verify that the problem is resolved.
tor system uses 90-120 volts.
STOP.
A. Remove the electrical power from the ECM. A
strong electrical shock hazard is present if the Test Step 8. Check the Harness between
power is not removed. the ECM and the Valve Cover Base for a
Short Circuit
Note: When the P2 connector is disconnected,
numerous diagnostic codes will be generated when
the electrical power is restored to the ECM. This is
normal. Ignore the codes and clear the codes after Electrical shock hazard. The electronic unit injec-
you complete this Test Step. tor system uses 90-120 volts.
B. Disconnect the P2 connector.
A. Remove the electrical power from the ECM. A
C. Use a jumper wire in order to create a short circuit strong electrical shock hazard is present if the
on J2 between the terminals for the suspect power is not removed.
injector's supply and suspect injector's return.
B. Disconnect the P300 connector.
D. Restore the electrical power to the ECM.
C. Restore the electrical power to the ECM.
E. Perform the “Injector Solenoid Test” at least two
times. D. Perform the “Injector Solenoid Test” at least two
times.
Expected Result:
Expected Result:
Cat ET displays “Short” for the cylinder with the
jumper wire. All cylinders indicate “Open” on Cat ET.

Results: Results:

• OK – Cat ET displays “Short” for the cylinder with • OK – All cylinders indicate “Open” on Cat ET.
the jumper wire. The ECM detected the short Proceed to Test Step 10.
circuit.
• Not OK – One or more cylinders indicate “Short”
Repair: If two injector solenoids that share a on Cat ET. Note the cylinders that indicate “Short”.
supply wire indicate “Open” from the previous step, Proceed to Test Step 9.
the open circuit is probably caused by an open
in the supply wire. There may be a problem in a Test Step 9. Check the ECM for Proper
connector. Operation

Repair the wiring and/or the connector. Replace

parts, if necessary.
Electrical shock hazard. The electronic unit injec-
Verify that the problem is resolved. tor system uses 90-120 volts.
STOP.
A. Remove the electrical power from the ECM. A
• Not OK – Cat ET does not display “Short” for the strong electrical shock hazard is present if the
cylinder with the jumper wire. The ECM did not power is not removed.
detect the short circuit.
Note: When the P2 connector is disconnected,
Repair: Perform the following procedure: numerous diagnostic codes will be generated when
the electrical power is restored to the ECM. This is
1. Temporarily connect a test ECM. Refer to normal. Ignore the codes and clear the codes after
electronic troubleshooting Troubleshooting, you complete this Test Step.
“Replacing the ECM”.
206 RENR5089-23
Troubleshooting Section

B. Disconnect the P2 connector. C. Disconnect the harness connector for each

injector solenoid that indicates a “Short” on Cat
C. Restore the electrical power to the ECM. ET. Ensure that each disconnected connector
does not touch other components and create a
D. Perform the “Injector Solenoid Test” at least two short circuit.
times.
D. Restore the electrical power to the ECM.
Expected Result:
E. Perform the “Injector Solenoid Test” at least two
All injector solenoids indicate “Open” when the P2 times.
connector is disconnected.
Expected Result:
Results:
All of the injector solenoids that were disconnected
• OK – All injector solenoids indicate “Open” when indicate “Open” on Cat ET.
the P2 connector is disconnected. There is a short
circuit in the engine harness. There may be a Results:
problem with a connector.
• OK – All of the injector solenoids that were
Repair: Inspect the connectors for moisture and for disconnected indicate “Open” on Cat ET.
corrosion. Repair the wiring and/or the connector,
when possible. Replace parts, if necessary. Clear Repair: Replace the faulty injector.
all diagnostic codes after you complete this test
step. Perform the “Injector Solenoid Test”.

Verify that the problem is resolved. Verify that the problem is resolved.

STOP. STOP.

• Not OK – At least one injector solenoid does not • Not OK – At least one of the injector solenoids that
indicate “Open”. There is a problem with the ECM. were disconnected still indicate “Short” on Cat ET.
There is a problem with the wiring harness inside
Repair: Perform the following procedure: the valve cover. There may be a problem with a
connector.
1. Temporarily connect a test ECM. Refer to
electronic troubleshooting Troubleshooting, Repair: Inspect the connectors for moisture and for
“Replacing the ECM”. corrosion. Repair the wiring and/or the connector,
when possible. Replace parts, if necessary.
2. Perform the “Injector Solenoid Test”.
Verify that the problem is resolved.
If the test ECM fixes the problem, connect the
suspect ECM. If the problem returns with the STOP.
suspect ECM, replace the ECM.
i02444808
Verify that the problem is resolved.

STOP.
Injector Solenoid Circuit - Test
SMCS Code: 1290-038
Test Step 10. Check the Harness under
the Valve Cover for a Short Circuit System Operation Description:

Use this procedure for the following conditions:

Electrical shock hazard. The electronic unit injec- • A suspected problem with an injector solenoid
tor system uses 90-120 volts.
• You have been directed to this procedure from
Troubleshooting, “Troubleshooting without a
A. Remove the electrical power from the ECM. A Diagnostic Code”.
strong electrical shock hazard is present if the
power is not removed.
• There is an active diagnostic code for an injector
solenoid.
B. Remove the valve cover.
Use this procedure for the following diagnostic codes:
RENR5089-23 207
Troubleshooting Section

• 1-05 Cylinder #1 Injector open circuit “Cylinder Cutout Test”

• 1-06 Cylinder #1 Injector short The “Cylinder Cutout Test” is used on an engine
in order to determine the individual cylinder
• 2-05 Cylinder #2 Injector open circuit performance while the engine is running. As one
or more cylinders are cut out during the test, the
• 2-06 Cylinder #2 Injector short “Cylinder Cutout Test” uses the “Fuel Position” of
each injector in order to evaluate the performance of
• 3-05 Cylinder #3 Injector open circuit the remaining cylinders that are firing. As the different
cylinders are cut out, a comparison of the change in
• 3-06 Cylinder #3 Injector short “Fuel Position” is used to identify cylinders that are
weak or misfiring. One reason for a cylinder that is
• 4-05 Cylinder #4 Injector open circuit weak or misfiring is an injector that is malfunctioning
mechanically.
• 4-06 Cylinder #4 Injector short
During the test, when a good injector is cut out, the
• 5-05 Cylinder #5 Injector open circuit “Fuel Position” of the remaining injectors will show
a consistent change. This consistent change in the
• 5-06 Cylinder #5 Injector short “Fuel Position” is caused by the remaining injectors
that are compensating for the cut out injector. If a
• 6-05 Cylinder #6 Injector open circuit malfunctioning injector is cut out, the “Fuel Position”
will not show a proportional change. This unbalanced
• 6-06 Cylinder #6 Injector short change is the result of the smaller quantity of fuel that
is needed to compensate for the power loss from the
Perform this procedure under conditions that are malfunctioning injector. The “Cylinder Cutout Test” is
identical to the conditions that exist when the problem used to isolate a malfunctioning injector in order to
occurs. Typically, problems with the injector solenoid avoid replacement of injectors that are in good repair.
occur when the engine is warmed up and/or when
the engine is under vibration (heavy loads). Note: Prior to running the “Cylinder Cutout Test”, all
active diagnostic codes must be repaired.
These engines have Electronic Unit Injectors (EUI)
that are mechanically actuated and electronically “Injector Solenoid Test”
controlled. The Engine Control Module (ECM) sends
a 105 volt pulse to each injector solenoid. The pulse Use the “Injector Solenoid Test” to diagnose an open
is sent at the proper time and at the correct duration circuit or a short circuit in the wiring for the injector
for a given engine load and speed. The solenoid is solenoids. While the engine is off, the “Injector
mounted on top of the fuel injector body. Solenoid Test” briefly activates each injector solenoid.
A good solenoid will create an audible click when the
If an open is detected in the solenoid circuit, a solenoid is activated. After performing the test, Cat
diagnostic code is generated. The ECM continues ET will indicate the status of the solenoid as “OK”,
to try to fire the injector. If a short is detected, a “Open”, or “Short”.
diagnostic code is generated. The ECM will disable
the solenoid circuit. The ECM will periodically try
to fire the injector. If the short circuit remains, this
sequence of events will be repeated until the problem
is corrected.

Note: Two injector solenoids share a supply wire.

For this reason, an open circuit or a short circuit in
a supply wire could cause diagnostic codes for two
injector solenoids.

When an injector is replaced, you must program the

new injector trim files into the ECM. If the ECM is
replaced, all injector trim files must be programmed
into the new ECM. Refer to programming parameters
Troubleshooting, “Injector Trim File” for more
information.

The Caterpillar Electronic Technician (ET) includes

the following tests that aid in troubleshooting the
injector solenoids:
208 RENR5089-23
Troubleshooting Section

g01222822
Illustration 124
Schematic for the injector solenoids

Test Step 1. Inspect the Electrical

Connectors and the Wiring

Electrical shock hazard. The electronic unit injec-

tor system uses 90-120 volts.

A. Remove the electrical power from the ECM.

g01200438
Illustration 125
Left side engine view (typical example)
(1) J2/P2 ECM connector
(2) J300/P300 Injector valve cover entry connector

B. Thoroughly inspect connectors (1) and (2). Refer

to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.
RENR5089-23 209
Troubleshooting Section

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The connectors and the wiring appear to be

OK. Proceed to Test Step 2.

• Not OK – There is a problem with the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

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

STOP.

Test Step 2. Check for Logged Diagnostic

Codes for the Injector Solenoids
A. Connect Cat ET to the data link connector. Refer
to electronic troubleshooting Troubleshooting,
“Electronic Service Tools”.

B. Restore the electrical power to the ECM.

C. Check for logged diagnostic codes for the injector

solenoids on Cat ET.

Expected Result:

There are no logged diagnostic codes for the injector

solenoids.

Results:
g01099568
Illustration 126 • OK – No diagnostic codes have been logged. The
Terminal locations at the P2 ECM connector injector solenoids are operating correctly. There
(P2-99) Injector 5 & 6 supply may be a mechanical problem with the injector's
(P2-104) Injector 1 & 2 supply fuel delivery. Proceed to Test Step 3.
(P2-105) Injector 6 return
(P2-106) Injector 3 return • Not OK – One or more diagnostic codes have
(P2-107) Injector 5 return
(P2-108) Injector 4 return
been logged. There may be an electrical problem
(P2-115) Injector 3 & 4 supply in the circuit for the injector. Proceed to Test Step 4.
(P2-116) Injector 1 return
(P2-118) Injector 2 return Test Step 3. Perform the “Cylinder Cutout
Test”
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and each of the wires A. Start the engine.
that are associated with injector solenoids.
B. Allow the engine to warm up to normal operating
D. Check the allen head screw on each ECM temperature (approximately 77 °C (171 °F)).
connector for the proper torque. Refer to the
diagnostic functional test Troubleshooting, C. After the engine is warmed to operating
“Electrical Connectors - Inspect”. temperature, access the “Cylinder Cutout Test” by
accessing the following display screens in order:
E. Check the harness and wiring for abrasions and
for pinch points from the injectors to the ECM. • “Diagnostics”
210 RENR5089-23
Troubleshooting Section

• “Diagnostic Tests” G. As each solenoid is energized by the ECM

an audible click can be heard at the valve
• “Cylinder Cutout Test” cover. Ensure the activation of each solenoid
by comparing the location of the click with the
D. Shut off all parasitic loads such as the air progress that is displayed on Cat ET.
conditioning and the air compressors which could
affect the results of the test. H. Perform the injector solenoid test at least two
times.
E. Select the start button at the bottom of the screen
for the cylinder cutout test on Cat ET. Expected Result:

F. Follow the instructions that are provided in the All cylinders indicate “OK” on Cat ET.
cylinder cutout test. The cylinder cutout tests are
interactive so the procedure is guided to the finish. Results:
The cylinder cutout test will set the correct engine
speed for the application. • OK – There is not an electronic problem with the
injectors at this time.
Expected Result:
Repair: The problem appears to be resolved. The
The variation of the fuel rate for all cylinders is within problem was probably caused by a poor electrical
specifications. connection in a connector.

Results: If the codes continue to be logged, refer to

the diagnostic functional test Troubleshooting,
• OK – The cylinder cutout test indicates that all of “Electrical Connectors - Inspect”.
the injectors are operating correctly.
If the engine is misfiring or if the engine has
Repair: If a problem with the fuel system is low power, refer to the troubleshooting without
suspected and diagnostic codes are not active or a diagnostic code procedure Troubleshooting,
logged, refer to Systems Operation/Testing and “Engine Misfires, Runs Rough or Is Unstable” or
Adjusting for information that is related to the low refer to the troubleshooting without a diagnostic
pressure fuel system. code procedure Troubleshooting, “Low Power/Poor
or No Response to Throttle”.
If a diagnostic code results from running the
“Cylinder Cutout Test”, proceed to Test Step 4. STOP.

• Not OK – The cylinder cutout test indicates that at • Not OK - “Open” – Note the cylinder that indicates
least one of the injectors is not operating correctly. “Open”. Proceed to Test Step 5.
Proceed to Test Step 4.
• Not OK - “Short” – Note the cylinder that indicates
Test Step 4. Perform the “Injector “Short”. Proceed to Test Step 6.
Solenoid Test”
Test Step 5. Check the Harness between
A. Start the engine. the ECM and the Valve Cover Base for an
Open Circuit
B. Allow the engine to warm up to normal operating
temperature (approximately 77 °C (171 °F)).

C. Stop the engine.

Electrical shock hazard. The electronic unit injec-
D. Restore the electrical power to the ECM. tor system uses 90-120 volts.

E. Access the “Injector Solenoid Test” by accessing A. Remove the electrical power from the ECM.
the following display screens in order:
B. Disconnect the J300/P300 injector valve cover
• “Diagnostics” entry connector at the valve cover base.

• “Diagnostic Tests” C. Restore the electrical power to the ECM.

• “Injector Solenoid Test” D. Fabricate a jumper wire that will be long enough
to short circuit the different terminal locations at
F. Activate the “Injector Solenoid Test”. the P300 connector. Crimp connector pins on both
ends of the jumper wire.
RENR5089-23 211
Troubleshooting Section

E. Insert one end of the jumper wire into the P300 Test Step 7. Check the Injector Harness
connector socket for the suspect injector's supply Under the Valve Cover for an Open
wire. Insert the other end of the jumper wire Circuit or a Short Circuit
into the P300 connector socket for the suspect
injector's return wire. This will replace the injector
solenoid with a short circuit.
Electrical shock hazard. The electronic unit injec-
F. Perform the “Injector Solenoid Test” at least two
tor system uses 90-120 volts.
times.

G. Repeat this test for each suspect circuit. Stop A. Remove the electrical power from the ECM.
the “Injector Solenoid Test” before handling the
jumper wire. Restore the wiring to the original B. Remove the valve cover in order to gain access
configuration. to the suspect injector.

Expected Result: C. Disconnect the harness connector from the

suspect injector.
Cat ET displays “Short” for each of the circuits that
were jumpered. D. Thoroughly clean the terminals on the injector
solenoid and on the harness connector.
Results:
E. Use a jumper wire to short circuit the connector
• OK – Cat ET displays “Short” for each circuit that terminals for the suspect injector. This will
was jumpered. The harness between the ECM and effectively replace the injector solenoid with a
the P300 connector does not have an open circuit. short circuit.
Proceed to Test Step 6.
F. Restore the electrical power to the ECM.
• Not OK – Cat ET displays “Open” for the cylinder
with the jumper wire. There is a problem in the G. Perform the “Injector Solenoid Test” at least two
wiring between the ECM and the P300 connector. times.
Proceed to Test Step 7.
Note: The injector solenoid that shares the supply
Test Step 6. Check the Harness between wire of the injector that is short circuited may indicate
the ECM and the Valve Cover Base for a a false test result. Disregard this test result.
Short Circuit
H. Remove the electrical power from the ECM.

I. Remove the jumper wire from the injector

Electrical shock hazard. The electronic unit injec- connector. This will effectively replace the injector
tor system uses 90-120 volts. solenoid with an open circuit.

J. Restore the electrical power to the ECM.

A. Remove the electrical power from the ECM.
K. Perform the “Injector Solenoid Test” at least two
B. Disconnect the P300 connector. times.

C. Restore the electrical power to the ECM. L. Remove the electrical power from the ECM.

D. Perform the “Injector Solenoid Test” at least two Expected Result:

times.
Cat ET displays “Short” for the cylinder with the
Expected Result: jumper wire and “Open” when the jumper wire is
removed.
All of the cylinders indicate “Open” on Cat ET.
Results:
Results:
• OK – Cat ET correctly displays the correct status
• OK – All cylinders indicate “Open” on Cat ET. during the test. The harness wiring is OK.
Proceed to Test Step 7.
Repair: Use a multimeter to check the resistance
• Not OK – One or more cylinders indicate “Short” of the suspect injector solenoid.
on Cat ET. Note the cylinders that indicate “Short”.
Proceed to Test Step 8.
212 RENR5089-23
Troubleshooting Section

The correct resistance of each injector solenoid is c. Perform the “Injector Solenoid Test” at least
1.06 ± 0.05 Ohms. two times.

If the resistance of the solenoid is not within d. Remove the electrical power from the ECM.
specifications replace the faulty injector. Verify that
the problem is resolved. Cat ET displays “Open” for the two injectors
that share the supply wire.
If the resistance of the solenoid is within
specifications the problem may be intermittent. If G. Verify that the ECM detects a short circuit for the
the problem is intermittent, refer to the diagnostic suspect injector:
functional test Troubleshooting, “Electrical
Connectors - Inspect”. Verify that the repair a. Connect the jumper wire to the engine ground
eliminates the problem. stud. Do not touch the jumper wire during the
test. A strong electrical shock hazard is present
STOP. at the jumper wire while the test is running.

• Not OK – Cat ET did not correctly display the b. Restore the electrical power to the ECM.
correct status during the test. There is a problem
with the injector harness under the valve cover. c. Perform the “Injector Solenoid Test” at least
There may be a problem with a connector. two times.

Repair: Repair the wiring and/or the connector, d. Remove electrical power from the engine ECM.
when possible. Replace parts, if necessary. Verify
that the problem is resolved. Cat ET displays “Short” for the two injectors
that share the supply wire.
STOP.
Expected Result:
Test Step 8. Check the ECM for Proper
Operation Cat ET displays the correct status for each test circuit.

Results:

Electrical shock hazard. The electronic unit injec-

• OK – The ECM detects the correct status of the
circuit. There is an open circuit or a short circuit in
tor system uses 90-120 volts. the engine harness. There may be a problem with
a connector.
A. Remove the electrical power from the ECM.
Repair: Inspect the connectors for moisture and for
B. Fabricate a jumper that is long enough to reach corrosion. Repair the wiring and/or the connector,
from the P2 ECM connector to the engine ground when possible. Replace parts, if necessary. Clear
stud. Crimp a socket terminal to one end of the all diagnostic codes after you complete this test
jumper wire. step.

C. Disconnect the P2 connector. Verify that the problem is resolved.

D. Remove the supply wire for the suspect injector STOP.

from the ECM connector. Install the jumper wire
into the socket. • Not OK – The ECM does not detect the correct
status of the circuit.
E. Connect the J2/P2 ECM connector.
Repair: There is a problem with the ECM. Replace
F. Verify that the ECM will detect an open circuit for the ECM. Refer to electronic troubleshooting
the suspect injector: Troubleshooting, “Replacing the ECM”. Verify that
the problem is resolved.
a. Ensure that the jumper wire is not in contact
with a ground source or another circuit. Do not STOP.
touch the jumper wire during the test. A strong
electrical shock hazard is present at the jumper
wire while the test is running.

b. Restore the electrical power to the ECM.

RENR5089-23 213
Troubleshooting Section

i03818131

Low Engine Oil Pressure Lamp

Circuit - Test
SMCS Code: 7431-038

System Operation Description:

The engine oil pressure lamp is used to indicate that

a low oil pressure condition exists and/or a diagnostic
code for low oil pressure has been generated. The
Electronic Control Module (ECM) signals the monitor
to activate the lamp when the following diagnostic
codes are active:

• 286-05 EMS Oil Lamp open/short to ground

• 286-06 EMS Oil Lamp short to +batt
When the ECM determines that the engine oil
pressure is low, the ECM will drive an output to a high
state. The output signal is supplied to the monitor.
The monitor will illuminate a lamp when the output
signal from the ECM is at a high state. The ECM
reduces engine speed to less than 1450 rpm when
the engine oil pressure is low. The ECM will drive the
output to a low state when the engine oil pressure g01117101
Illustration 128
is in a safe range.
P1 ECM connector
When the engine is started, the lamp will turn on for a (P1-28) Low engine oil pressure lamp
minimum of five seconds.
Test Step 1. Inspect Electrical Connectors
And Wiring
A. Thoroughly inspect the J1/P1 ECM connector and
the wiring that is associated with the low engine oil
pressure lamp. Refer to the diagnostic functional
test Troubleshooting, “Electrical Connectors -
Inspect”.

B. Perform a 45 N (10 lb) pull test on P1-28 (low

engine oil pressure lamp).

C. Check the allen head screw on each ECM

connector and the customer connector for the
proper torque. Refer to the diagnostic functional
g02070554
Illustration 127 test Troubleshooting, “Electrical Connectors -
Schematic for low oil pressure lamp Inspect” for the correct torque values.

D. Check the harness and wiring for abrasions and

for pinch points from the battery to the ECM.

Expected Result:

All connectors, pins and sockets are completely

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

Results:

• OK – Proceed to Test Step 2.

214 RENR5089-23
Troubleshooting Section

• Not OK Repair: There may be an intermittent problem with

the wiring and/or the connectors. Repair the lamp
Repair: Repair the connectors or wiring and/or circuit.
replace the connectors or wiring. Ensure that all of
the seals are properly in place and ensure that the STOP.
connectors are completely coupled.
• Not OK – The circuit for the low engine oil pressure
STOP. lamp is not operating correctly at this time. Proceed
to Test Step 4.
Test Step 2. Check the Wiring from the
ECM to the Monitor Test Step 4. Check the Output at the ECM
A. Remove the electrical power from the ECM. A. Remove the electrical power from the ECM.

B. Disconnect the connector J1/P1 for the machine B. Use a Deutsch removal tool to remove the wire
harness. from P1-28 (low engine oil pressure lamp).

C. Check the wiring from P1-28 to terminal 8 of the C. Connect the probe of a multimeter to terminal 28
monitor. Use a multimeter to check for shorts to (low engine oil pressure lamp) and connect the
ground and for open circuits. other probe to engine ground. Set the multimeter
to read resistance.
Expected Result:
D. Start the engine.
The wiring from P1-28 to terminal 8 of the monitor
does not have any open circuits or short circuits. E. The multimeter should indicate high resistance
(open) for the first five seconds after the engine
Results: has started. The multimeter will then read less
than 10 Ohms (short) after the oil pressure
• OK – The wiring for the circuit of the engine oil reaches operating pressure.
pressure lamp is OK. Proceed to Test Step 3.
Expected Result:
• Not OK – There is a problem in the machine wiring.
Repair the machine wiring, as required. STOP. The engine oil pressure is high during the first five
seconds of engine operation and then low after the
Test Step 3. Check For Normal Operation oil pressure reaches operating pressure.
Of The Lamp
Results:
A. Monitor the low engine oil pressure lamp.
• OK – The ECM is operating correctly. There is a
a. Restore the electrical power to the ECM. The problem in the machine wiring or in the monitor.
lamp should turn on for five seconds. Then, the The lamp may be burned out. Replace the lamp
lamp should turn off. and/or repair the machine wiring or the monitor,
as required. STOP.
b. The lamp will remain on if there is an active
diagnostic code. If there is an active diagnostic • Not OK – Temporarily connect a test ECM. Check
code, connect the Caterpillar Electronic the operation of the engine oil pressure lamp when
Technician (ET) in order to read the active the test ECM is installed. If the problem is resolved
diagnostic code. Troubleshoot the problem. with the test ECM, then reconnect the suspect
ECM. If the problem returns with the suspect ECM,
Expected Result: then replace the ECM. STOP.

The low engine oil pressure lamp turns on and the

i04173669
low engine oil pressure lamp turns off per the above
description. Throttle Switch Circuit - Test
Results: SMCS Code: 7332-038
• OK – The circuit for the low engine oil pressure System Operation Description:
lamp appears to operating correctly at this time.
This procedure covers the following diagnostic codes:

• 91-8 Throttle Position signal abnormal

RENR5089-23 215
Troubleshooting Section

Note: A false 98-1 diagnostic code can be generated

when the machine backup switch is switched to the
manual position. The message “BACK UP SWITCH
ON” or “LIMITED MOBILITY MODE” appears on
the display in the cab. When the switch is on, the
engine speed can be controlled with another switch
that overrides the rotary throttle switch. The 98-1
diagnostic code becomes deactivated when the
backup switch is moved to the automatic position.

The throttle switch provides the operator with the

ability to select the desired engine speed. The throttle
switch is a rotary switch with ten positions. The
throttle switch is connected to the four switch inputs
of the engine and hydraulic pump controller. A throttle
command is sent to the engine Electronic Control
Module (ECM) from the engine and hydraulic pump
controller. The throttle command is referred to as a
duty cycle or as a PWM signal. The throttle command
is valid when the following conditions exist:

• The duty cycle is between 5 percent and 95

percent.

• The PWM signal is 1.228 kHz ± 150 Hz.

When a diagnostic code is generated, the ECM
ignores the throttle command. The desired engine
speed is set to the last valid speed that was
recognized by the ECM. When a problem is detected
with the throttle signal, the throttle backup switch is
enabled. The operator can use the throttle backup
switch to set the desired engine speed. If the throttle
backup switch is held in the ACCEL position, the
desired engine speed will increase 200 rpm per
second. If the throttle backup switch is held in the
DECEL position, the engine speed will decrease 200
rpm per second.

g02364936
Illustration 129
Schematic
216 RENR5089-23
Troubleshooting Section

Table 28 shows continuity between the contacts of Test Step 1. Inspect Electrical Connectors
the throttle position switch in each position. and Wiring
Table 28 A. Turn the keyswitch to the OFF position.
Throttle Position Switch
B. Thoroughly inspect the J1/P1 ECM connector
Position Contacts and the J2/P2 ECM connector. Inspect all of the
1 COM, S1 connectors that are associated with the circuit.
2 COM, S1, S2 C. Perform a 45 N (10 lb) pull test on each of the
3 COM, S2 wires in the ECM connector that is associated with
the active diagnostic code.
4 COM, S2, S3
5 COM, S1, S2, S3 D. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting,
6 COM, S1, S3 “Electrical Connectors - Inspect” for details.
7 COM, S3
E. Check the harness and wiring for abrasions and
8 COM, S3, S4 for pinch points from the sensors back to the ECM.
9 COM, S1, S3, S4
Expected Result:
10 COM, S1, S2, S3, S4
All connectors, pins, and sockets are coupled
and/or inserted. The harness and wiring are free of
corrosion, of abrasion, and of pinch points.

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.

• Not OK – There is a problem in the connectors

and/or wiring.

Repair: Repair the connectors or wiring and/or

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

Verify that the repair eliminates the problem.

STOP.

Test Step 2. Check for Active Diagnostic

Codes
A. Connect Caterpillar Electronic Technician (ET) to
the service tool connector.

B. Turn the keyswitch to the ON position.

C. 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.
g01120703
Illustration 130 Expected Result:
P1 ECM connector
(P1-5) Digital return No diagnostic codes are active.
(P1-22) Throttle backup switch
(P1-23) Throttle backup switch
(P1-66) Throttle command
RENR5089-23 217
Troubleshooting Section

Results: Expected Result:

• OK – No diagnostic codes are active. At low idle, the duty cycle is between 5 percent and
10 percent. At high idle, the duty cycle is between 90
Repair: The problem may have been related percent and 95 percent.
to a faulty connection in the harness. Carefully
reinspect the connectors and wiring. Refer to Results:
Troubleshooting, “Electrical Connectors - Inspect”.
• OK – The throttle command is correct. Proceed
STOP. to Test Step 5.

• Not OK – A 91-08 diagnostic code is active at this • Not OK – The throttle command is not correct.
time. Proceed to Test Step 3. There may be a problem with the throttle switch or
the engine and hydraulic pump controller.
Test Step 3. Check the Throttle Signal on
Cat ET Repair: If a problem is suspected with the throttle
position switch, refer to Table 28 for information the
A. Turn the keyswitch to the ON position. switch contacts in each position.

B. Observe the status of “Throttle” on Cat ET. If a problem is suspected with the engine and
hydraulic pump controller, refer to the System
C. Turn the throttle switch and observe the status of Operation manual and the Testing and Adjusting
“Throttle” on Cat ET. manual for the machine.

D. Turn the keyswitch to the OFF position. STOP.

Expected Result: Test Step 5. Check the Throttle Command

at the ECM
The throttle varies from 0 to 100 percent.
A. Turn the keyswitch to the OFF position.
Results:
B. Disconnect the J1/P1 ECM connector.
• OK – The throttle varies from 0 to 100 percent.
The throttle and circuitry are operating correctly. C. Remove the wire F889-WH from ECM connector
P1-66.
Repair: If the problem is intermittent, refer to
Troubleshooting, “Electrical Connectors - Inspect”. D. Reconnect the ECM connectors.

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

• Not OK – The throttle signal did not vary from 0 to F. Use a multimeter to monitor the percent duty cycle
100 percent. Proceed to Test Step 4. of the throttle command. Connect the multimeter
between the wire that was removed from ECM
Test Step 4. Check the Throttle Command connector P1-66 (throttle command) and engine
at the Engine and Hydraulic Pump ground. Adjust the throttle switch from the low idle
Controller position to the high idle position.

A. Remove the wire F889-WH from terminal 44 of the G. Turn the keyswitch to the OFF position.
engine and hydraulic pump controller.
H. Replace all wires to the original configuration.
B. Turn the keyswitch to the ON position.
Expected Result:
C. Use a multimeter to monitor the percent duty cycle
of the throttle command. Connect the multimeter At low idle, the duty cycle is between 5 percent and
between terminal 44 of the engine and hydraulic 10 percent. At high idle, the duty cycle is between 90
pump controller and engine ground. Adjust the percent and 95 percent.
throttle switch from the low idle position to the
high idle position.

D. Turn the keyswitch to the OFF position.

E. Replace all wires to the original configuration.

218 RENR5089-23
Troubleshooting Section

Results: The throttle switch is connected to the four throttle

inputs of the Electronic Control Module (ECM). Each
• OK – The throttle command is correct. The ECM is position generates a specific on/off pattern on the
not processing the command properly. Verify that throttle inputs. A diagnostic code is generated if a
the ECM is receiving the correct battery voltage. If pattern that does not correspond with any of the
the ECM is receiving the correct battery voltage, switch positions is detected.
replace the ECM.
Once a diagnostic code is generated, the ECM
Repair: Refer to Troubleshooting, “Replacing the ignores the throttle input signals and the desired
ECM” before replacing the ECM. engine speed is set to 1000 rpm, unless the actual
engine speed is below 1000 rpm. If the actual engine
STOP. speed is below 1000 rpm, the desired engine speed is
set to the current engine speed. The desired engine
• Not OK – The throttle command is not correct. speed is set to low idle if the engine is not running.

Repair: There is a problem in the harness or Voltage at the inputs to the ECM for the throttle
connectors between the engine and hydraulic switch is 7.5 ± 0.5 VDC when the throttle inputs are
pump control and the ECM. Repair the circuit. open. The voltage is less than 0.5 VDC when the
Verify that the repair eliminates the problem. throttle inputs are closed.

STOP. Caterpillar Electronic Technician (ET) can be used to

view the status of the inputs for the throttle switch.
i02500556

Throttle Switch Circuit - Test

SMCS Code: 7332-038

System Operation Description:

Use this procedure to troubleshoot any suspect

problems with the throttle switch.

This procedure covers the following diagnostic code:

• 91-02 Incorrect Throttle Switch inputs

The throttle switch provides the operator with the
ability to select the desired engine speed. The throttle
switch is a three-position momentary rocker switch.
The three positions are Neutral, Rabbit, and Tortoise.
The throttle switch can be used to select high idle
or low idle. The throttle switch can also be used to
adjust the maximum engine speed.

High Idle – To increase engine speed to high idle,

push the top of the switch (Rabbit) one time and
release the switch.

Low Idle – To decrease engine speed to low idle,

push the bottom of the switch (Tortoise) one time and
release the switch.

Set Maximum Speed – Set the engine speed to

high idle. Push on the decelerator pedal until the
desired speed is reached. When this desired speed is
reached, push on the top of the throttle control switch
and hold for three seconds. This will electronically set
the current engine speed as the maximum operating
speed. The decelerator will function normally in order
to reduce engine speeds below this maximum speed.
In order to return to high idle as maximum speed,
press the top part of the throttle control switch.
RENR5089-23 219
Troubleshooting Section

g01222823
Illustration 131
Schematic for the throttle switch

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove the electrical power from the ECM.

g01186024
Illustration 132
Location of the J1/P1 ECM connector (typical left side engine view)

B. Thoroughly inspect the J1/P1 ECM

connector. Refer to diagnostic functional
tests Troubleshooting, “Electrical Connectors -
Inspect” for details.

g01250533
Illustration 133
Terminal locations at the P1 ECM connector
(P1-22) Throttle input #1 (low)
(P1-23) Throttle input #2 (low par)
(P1-40) Throttle input #3 (high)
(P1-41) Throttle input #4 (high par)
220 RENR5089-23
Troubleshooting Section

B. Restore the electrical power to the ECM.

Note: Wait at least 30 seconds in order for the

diagnostic codes to become active.

C. Observe the status of the throttle inputs on Cat

ET while you operate the throttle switch in each
position.

Table 29
High Low
Throttle Input Neutral “Rabbit” “Tortoise”
“#1 (Low)” Off Off On

g01250541 “#2 (Low Par)” On Off On

Illustration 134
Terminal locations at the throttle switch “#3 (High)” Off On Off
(Terminal 1) Throttle input #1 (low) “#4 (High Par)” On On Off
(Terminal 2) Return
(Terminal 3) Throttle input #4 (high par)
(Terminal 4) Throttle input #2 (low par) Expected Result:
(Terminal 5) Return
(Terminal 6) Throttle input #3 (high)
The status of the throttle switch corresponds with the
table above.
C. Perform a 45 N (10 lb) pull test on each of the
wires in the ECM connector and at the connector
Results:
for the throttle switch.

D. Check the allen head screw for each of the • OK – The status of the throttle switch is correct.
ECM connectors for the proper torque. Refer to
Repair: The throttle switch is functioning properly
Troubleshooting, “Electrical Connectors - Inspect”
at this time. There may be an intermittent electrical
for the correct torque values.
problem in the wiring harness or in a connector.
If an intermittent electrical problem is suspected,
E. Check the harness and wiring for corrosion, for
refer to Troubleshooting, “Electrical Connectors -
abrasion, and for pinch points from the throttle
Inspect” for troubleshooting information.
switch to the ECM.
STOP.
Expected Result:

All connectors, pins, and sockets are completely • Not OK – One or more of the inputs is incorrect.
There is a problem in the circuit for the throttle
coupled and/or inserted. The harness and wiring are
switch. Proceed to Test Step 3.
free of corrosion, of abrasion, and of pinch points.

Results:
Test Step 3. Check the Harness between
the Throttle Switch and the ECM
• OK – The harness and connectors appear to be A. Remove the electrical power from the ECM.
OK. Proceed to Test Step 2.
B. Fabricate a jumper wire that is long enough to
• Not OK – There is a problem in the connectors create a short circuit across the connector for the
and/or wiring.
throttle switch. Crimp spade terminals to each end
of the jumper wire.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of
C. Disconnect the wires for the suspect throttle inputs
the seals are properly in place and ensure that the
from the throttle switch.
connectors are completely coupled.
a. Restore the electrical power to the ECM.
Verify that the repair eliminates the problem.
b. Check the status of the suspect throttle inputs
STOP.
on Cat ET. Refer to Table 29.
Test Step 2. Check the Status of the c. Use the jumper wire to short the wires for the
Throttle Inputs suspect throttle inputs to the return wire at the
switch.
A. Connect the Cat ET to the service tool connector.
RENR5089-23 221
Troubleshooting Section

Note: Wait at least 30 seconds in order for the H. Remove the jumper wire and breakout T.
diagnostic codes to become active. Reconnect all wires and connectors to the original
configuration.
d. Monitor the status of the suspect throttle
input(s) on Cat ET. Expected Result:

D. Remove the jumper wire. Reconnect all wires to The status of the suspect throttle input changes
the original configuration. correctly when the jumper wire is connected.

Expected Result: Results:

The status of the suspect throttle inputs change when • OK – The status of the suspect throttle inputs
the jumper wire is connected. change correctly.

Results: Repair: There is either an open circuit or a short

circuit in the wiring between the ECM and the
• OK – The harness and the ECM are OK. throttle switch. Repair the wiring harness. Verify
that the repair eliminates the problem.
Repair: There is a problem with the throttle switch.
Replace the switch. Verify that the repair eliminates STOP.
the problem.
• Not OK – The status of the suspect throttle inputs
STOP. do not change correctly.

• Not OK – The status of the suspect throttle inputs Repair: The ECM is not responding to the switch
do not change when the jumper wire is installed. inputs. There is a problem with the ECM. Refer to
Verify that the return circuit for the throttle switch Troubleshooting, “Replacing the ECM” before you
is continuous to chassis ground. Ensure that the replace the ECM.
return circuit has a good connection to the chassis
ground. Proceed to Test Step 4. STOP.

Test Step 4. Check the Operation of the

ECM i02473898

A. Remove the electrical power from the ECM.

User Defined Shutdown Input
Circuit - Test
B. Disconnect the J1/P1 ECM connector.
SMCS Code: 1901-038
C. Remove the wires for the suspect throttle input(s)
from the appropriate terminals at the P1 ECM System Operation Description:
connector.
Use this procedure if you suspect that there is a
D. Install a 208-0059 Adapter Cable As (70-Pin problem with the circuit for the user defined shutdown
Breakout) at the J1/P1 ECM connector. switch.

E. Connect the J1/P1 ECM connector. The user defined shutdown can be connected to any
electronic switch or to any mechanical switch in the
F. Restore the electrical power to the ECM. electrical system that would shut down the engine for
any reason. When the signal is grounded, an event
G. Check the status of the suspect throttle inputs on code is logged in memory and the Electronic Control
Cat ET. Module (ECM) disables injection.

a. Use a jumper wire to short the terminals for the The input must be pulled below 0.5 VDC before
suspect throttle inputs between the breakout the ECM will recognize the shutdown signal. Prior
T and engine ground. to the enabling of the user defined shutdown by
the ECM, certain events may be required to be
Note: Wait at least 30 seconds in order for the satisfied by the operator. Examples of these events
diagnostic codes to become active. would include engagement of the parking brake
or a machine ground speed of zero. Refer to the
b. Monitor the status of the suspect throttle inputs machine's Operation and Maintenance Manual for
on Cat ET. the specific events that apply.
222 RENR5089-23
Troubleshooting Section

g01120571
Illustration 135
Schematic

Test Step 1. Inspect Electrical Connectors

and Wiring
A. Remove the electrical power from the ECM.

B. Thoroughly inspect the J1/P1 ECM connector

and the connection to the user defined shutdown
device (customer shutdown switch). Refer to
the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”.

g01120572
Illustration 136
P1 ECM connector
(P1-59) User defined shutdown input

C. Perform a 45 N (10 lb) pull test on the wire in the

ECM connector that is associated with the active
event code.

D. Check the allen head screw for each ECM

connector for the proper torque. Refer to the
diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect” for the correct
torque values.

E. Check the harness and wiring for abrasion and

for pinch points from the user defined shutdown
device to the ECM.

Expected Result:

All connectors, pins, and sockets are completely

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

Results:

• OK – The harness and wiring are OK. Proceed

to Test Step 2.
RENR5089-23 223
Troubleshooting Section

• Not OK – There is a problem in the connectors C. Restore the electrical power to the ECM.
and/or wiring.
D. Observe the status of “User Shutdown” on Cat ET.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of E. Use a suitable piece of wire to short the signal
the seals are properly in place and ensure that the wire at the switch to chassis ground.
connectors are completely coupled. Verify that the
repair eliminates the problem. F. Observe the status of “User Shutdown” on Cat ET.

STOP. Expected Result:

Test Step 2. Check the Status of the User The status of the “User Shutdown” is “OFF” when the
Defined Shutdown Input on Caterpillar wire is not shorted to chassis ground. The status of
Electronic Technician (ET) the “User Shutdown” is “ON” when the wire is shorted
to chassis ground.
A. Verify that the customer shutdown switch is in the
OPEN position. Results:

B. Connect Cat ET to the service tool connector. • OK – The circuit for the “User Shutdown” is
operating correctly. The harness wiring and ECM
C. Restore the electrical power to the ECM. are OK.

D. Observe the status of “User Shutdown” on Cat ET. Repair: Replace the customer shutdown switch.

E. Switch the customer shutdown switch to the STOP.

CLOSED position.
• Not OK – The status of the “User Shutdown” was
F. Observe the status of “User Shutdown” on Cat ET. not correct for one of the test procedures. Proceed
to Test Step 4.
G. Remove the electrical power from the ECM.
Test Step 4. Check the Operation of the
Expected Result: ECM
The status of the “User Shutdown” is “OFF” when A. Remove the electrical power from the ECM.
the switch is in the OPEN position. The status of the
“User Shutdown” is “ON” when the switch is in the B. Disconnect the J1/P1 ECM connector. Remove
CLOSED position. terminal P1-59 from the ECM connector.

Results: C. Fabricate a jumper wire that is long enough to

connect from a terminal at the ECM connector to
• OK – The status of the “User Shutdown” is correct. chassis ground. Crimp a connector terminal to one
end of the jumper wire.
Repair: There may be an intermittent problem.
The problem may have been related to a faulty D. Connect the J1/P1 ECM connector.
connection in the harness or in a connector.
Carefully reinspect the connectors and wiring. Refer E. Restore the electrical power to the ECM.
to the diagnostic functional test Troubleshooting,
“Electrical Connectors - Inspect”. F. Observe the status of “User Shutdown” on Cat ET.

STOP. G. Short the jumper wire in P1-59 to chassis ground.

• Not OK – The status of the “User Shutdown” is H. Observe the status of “User Shutdown” on Cat ET.
not correct for one of the switch positions. Proceed
to Test Step 3. Expected Result:

Test Step 3. Check the Harness between The status of the “User Shutdown” is “OFF” when
the Customer Shutdown Switch and the the jumper wire is not shorted to chassis ground.
ECM The status of the “User Shutdown” is “ON” when the
jumper wire is shorted to chassis ground.
A. Remove the electrical power from the ECM.
Results:
B. Disconnect the signal wire from the customer
shutdown switch. • OK – The ECM is responding to the input correctly.
224 RENR5089-23
Troubleshooting Section

Repair: Repair the connectors or wiring and/or

replace the connectors or wiring between the ECM
and the customer shutdown switch.

STOP.

• Not OK – The status of the “User Shutdown” is

not correct.

Repair: Verify your results. Replace the ECM. Refer

to electronic troubleshooting Troubleshooting,
“Replacing the ECM” before replacing the ECM.

STOP.
RENR5089-23 225
Troubleshooting Section

Calibration Procedures
i03660625

Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1439-524; 1912-524

System Operation Description:

Use this procedure if the diagnostic code in Table

30 is active.

Table 30
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
22-13 “Engine Timing Calibration A timing calibration is required for a The code is logged.
Not Performed” new engine. A timing calibration is also
required after a repair to the front gear
261-13 Engine Timing Calibration train, the camshaft, or the crankshaft
calibration required has been completed. The code may
also become active after replacing
an Electronic Control Module (ECM)
that fails to communicate.
261-11 Engine Timing Offset fault The wiring to the sensors may The code is logged.
have the wrong polarity. There
may be a mechanical problem with
the front gear train.

The ECM has the ability to compensate for Table 31

mechanical differences between the Top Center (TC) Required Special Tools
of the flywheel and the TC of the timing gear on the
camshaft. Part Number Description
7X-1171 Transducer Adapter
An “Engine Timing Calibration Not Performed” code
is activated if a timing calibration is required. 6V-2197 Transducer
7X-1695 Cable As
TC of the Flywheel – The ECM determines the
TC of the flywheel via a signal from a magnetic 170-3519 Harness (1)

transducer. The transducer is installed into the side (1) This item is not required if the engine harness has a connector
of the engine block. The transducer creates a signal for timing calibration.
as a notch on a crankshaft counterweight rotates
past the transducer. Test Step 1. Install the Transducer
Adapter
TC of the Timing Gear – The ECM determines the
TC of the timing gear by signals from the engine A. Remove the electrical power from the ECM.
speed/timing sensors.
B. Use the appropriate engine turning tool to put
Any offset between the TC of the flywheel and the either the No. 1 piston or the No. 6 piston at top
TC of the timing gear is stored into the memory of center. Refer to the Systems Operation/Testing
the ECM. and Adjusting.

Note: A timing calibration will not increase the C. Refer to Table 32. After the top center position has
available engine power. been located, rotate the crankshaft for the number
of degrees that is applicable to your engine model.
Table 31 lists the special tools that are required in Be sure to rotate the crankshaft in the direction of
order to perform this procedure. rotation that is specified in the Table.
226 RENR5089-23
Troubleshooting Section

Table 32 A. Apply clean engine oil to a 2D-6392 O-Ring Seal.

Crankshaft Rotation
Install the O-ring seal on the end of the 6V-2197
Transducer.
Engine Number of Direction of Rotation
Model Degrees B. Push the transducer through the transducer
C7 100 Normal Rotation adapter until the transducer contacts the
crankshaft counterweight.
C-9 85 Normal Rotation
C-10 60 Opposite Normal Rotation C. Withdraw the transducer 1.0 mm (0.04 inch) and
hand tighten the nut on the adapter sleeve in
C11 75 Normal Rotation order to secure the transducer. Move the O-ring
C-12 60 Opposite Normal Rotation seal against the adapter.

C13 75 Normal Rotation Continue to the next test step.

C-15 60 Opposite Normal Rotation
Test Step 3. Connect the 7X-1695 Cable
C15 60 Opposite Normal Rotation As
C-16 60 Opposite Normal Rotation
A. If the engine harness is equipped with a connector
C18 30 Opposite Normal Rotation for timing calibration, connect the 7X-1695 Cable
As to the connector for timing calibration and to
D. Refer to Table 33. Locate the engine's timing the transducer.
calibration port.

Note: In certain applications, the engine uses the port

as a return for the crankcase breather fumes. Detach
the hose fitting in order to install the timing probe.

Table 33
Location of the Timing Calibration Port
Engine Crankshaft Engine Location
Model Counterweight
C7 3 Left Side
C-9 3 Left Side
C-10 8 Right Side
C11 8 Left Side
C-12 8 Right Side
C13 8 Left Side
C-15 2 Left Side
C15 2 Left Side
C-16 2 Left Side
C18 2 Left Side

E. Remove the plug from the timing calibration port. Illustration 137
g01963414

Connecting the 7X-1695 Cable As to an ADEM III ECM

F. Thread the transducer adapter into the port.

Continue to the next test step.

Test Step 2. Install the Transducer

NOTICE
If the crankshaft is not in the correct position when the
transducer is installed, the transducer will be damaged
when the engine is started.
RENR5089-23 227
Troubleshooting Section

d. Install the yellow wire of the 170-3519

Harness into the appropriate location.

Note: Ensure that each wire is installed into the

correct location. The timing calibration will not be
successful if the wires are installed incorrectly.

e. Connect the 7X-1695 Cable As to the

connector for timing calibration and to the
transducer.

Continue to the next test step.

Test Step 4. Start the Engine and Check

for Diagnostic Codes
A. Connect Caterpillar Electronic Technician
(ET) to the service tool connector. Refer to
Troubleshooting, “Electronic Service Tools”.

B. Start the engine and run the engine until the

engine is at the normal operating temperature.

C. Check for active diagnostic codes. Wait at least 30

seconds in order for the codes to become active.

The engine must not have any active diagnostic

g01345359
codes during the timing calibration except for a
Illustration 138 261-13 Engine Timing Calibration required.
Connecting the 7X-1695 Cable As to an ADEM IV ECM
Expected Result:
B. If the engine harness is not equipped with a
connector for timing calibration, perform the There are no active diagnostic codes or there is only
following procedure: a code for timing calibration that is active at this time.

Note: Refer to Illustration 137 or Illustration 138. Results:

The 170-3519 Harness can be connected to the
P1 connector or to the P2 connector. Select the • OK – There are no active diagnostic codes or there
connector with the easiest access. is only a code that is active for timing calibration at
this time. Proceed to Test Step 5.
a.
• Not OK – There is at least one active code that is
Table 34 not a code for timing calibration.
Locations for Connection of the 170-3519 Harness
Repair: Troubleshoot and repair any active
Locations Locations Locations diagnostic codes before you continue with this
on the on the on the P1 procedure.
Wire Color 70−pin P2 120−pin Connector
Connector P2
Connector STOP.

White 22 26 24 Test Step 5. Calibrate the Engine

Yellow 23 36 25 Speed/Timing Sensor
A. Set the engine speed to 1100 ± 50 rpm. The
b. Refer to Table 34. Remove the sealing plugs engine speed must be steady within this rpm
from the appropriate terminals. Do not discard range in order for the calibration to be successful.
the sealing plugs. The sealing plugs may
be reinstalled when the timing calibration is B. After the engine has warmed up, access the
complete. “Timing Calibration” screen on the Cat ET. Access
the following display screens in order:
c. Disregard the pin-outs on the label of the
harness. Install the white wire of the 170-3519 • Service
Harness into the appropriate location.
228 RENR5089-23
Troubleshooting Section

• Calibrations • Verify that the timing calibration probe is installed

correctly.
• Timing Calibration
• Verify that the engine speed is correct and that
C. To calibrate the timing, select “Continue” on Cat the engine speed is stable. If the engine speed
ET. Wait until Cat ET indicates that the timing is is unstable, refer to troubleshooting without
calibrated. a diagnostic code Troubleshooting, “Engine
Misfires, Runs Rough or Is Unstable”.
Expected Result:
• There may be a problem with the transducer or
Cat ET indicates that the timing is calibrated. with the cables. Obtain a new transducer and/or
a new cable and repeat the timing calibration.
Results:
STOP.
• OK – Cat ET indicates that the timing is calibrated.
Repair: Perform the following procedure:

1. Set the engine speed to low idle.

Note: Disconnect the 7X-1695 Cable As before

you exit the “Timing Calibration” screen. Otherwise,
diagnostic codes may be activated.

2. Disconnect the 7X-1695 Cable As.

3. Exit the “Timing Calibration” screen on Cat ET.

4. Remove the electrical power from the ECM.

5. Remove the transducer and remove the adapter.

6. Install the plug into the timing calibration port.

7. If you installed a 170-3519 Harness, you may

remove the harness 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.

If you choose to permanently install 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 2-pin connector in order to prevent moisture
and debris from entering the connector.

8. Return the engine to service.

STOP.

• Not OK – The timing calibration was unsuccessful.

Repair: The following conditions can cause the
timing calibration to fail:

• If the crankshaft and camshaft gears have been

reassembled incorrectly, the timing will not
calibrate.
RENR5089-23 229
Index Section

Index
Numerics CID 0100 FMI 03 Engine Oil Pressure open/short to
+batt..................................................................... 65
5 Volt Engine Pressure Sensor Supply Circuit - CID 0100 FMI 04 Engine Oil Pressure short to
Test ................................................................ 91, 97 ground.................................................................. 65
CID 0110 FMI 03 Engine Coolant Temperature
open/short to +batt............................................... 65
A CID 0110 FMI 04 Engine Coolant Temperature short
to ground.............................................................. 65
Air Inlet Heater Circuit - Test......................... 103, 110 CID 0164 FMI 03 Injector Actuation Pressure voltage
Alternator (Charging Problem and/or Noisy high ...................................................................... 66
Operation)............................................................ 26 CID 0164 FMI 04 Injector Actuation Pressure voltage
Probable Causes ............................................... 26 low ....................................................................... 66
Recommended Actions...................................... 26 CID 0168 FMI 00 System Voltage High................. 66
CID 0168 FMI 01 System Voltage Low.................. 67
CID 0168 FMI 02 System Voltage intermittent/
B erratic................................................................... 67
CID 0172 FMI 03 Intake Manifold Air Temp open/short
Battery ................................................................... 26 to +batt........................................................... 67–68
Probable Causes ............................................... 26 CID 0172 FMI 04 Intake Manifold Air Temp short to
Recommended Actions...................................... 26 ground.................................................................. 68
CID 0174 FMI 03 Fuel Temperature open/short to
+batt..................................................................... 69
C CID 0174 FMI 04 Fuel Temperature short to
ground.................................................................. 69
Calibration Procedures ........................................ 225 CID 0190 FMI 08 Engine Speed signal abnormal.. 69
Can Not Reach Top Engine RPM .......................... 26 CID 0253 FMI 02 Personality Module mismatch ... 69
Probable Causes ............................................... 27 CID 0261 FMI 13 Engine Timing Calibration
Recommended Actions...................................... 27 required................................................................ 70
Cat Data Link Circuit - Test........................... 115, 118 CID 0262 FMI 03 5 Volt Sensor DC Power Supply
CID 0001 FMI 05 Cylinder #1 Injector open short to +batt........................................................ 70
circuit ................................................................... 59 CID 0262 FMI 04 5 Volt Sensor DC Power Supply
CID 0001 FMI 06 Cylinder #1 Injector short .......... 59 short to ground..................................................... 70
CID 0002 FMI 05 Cylinder #2 Injector open CID 0268 FMI 02 Check Programmable
circuit ................................................................... 59 Parameters .......................................................... 71
CID 0002 FMI 06 Cylinder #2 Injector short .......... 60 CID 0274 FMI 03 Atmospheric Pressure open/short
CID 0003 FMI 05 Cylinder #3 Injector open to +batt................................................................. 71
circuit ................................................................... 60 CID 0274 FMI 04 Atmospheric Pressure short to
CID 0003 FMI 06 Cylinder #3 Injector short .......... 60 ground............................................................ 71–72
CID 0004 FMI 05 Cylinder #4 Injector open CID 0286 FMI 05 EMS Oil Lamp open/short to
circuit ................................................................... 61 ground.................................................................. 72
CID 0004 FMI 06 Cylinder #4 Injector short .......... 61 CID 0286 FMI 06 EMS Oil Lamp short to +batt..... 72
CID 0005 FMI 05 Cylinder #5 Injector open CID 0342 FMI 08 Secondary Engine Speed signal
circuit ................................................................... 61 abnormal.............................................................. 72
CID 0005 FMI 06 Cylinder #5 Injector short .......... 62 CID 0617 FMI 05 Air Inlet Heater Relay open/current
CID 0006 FMI 05 Cylinder #6 Injector open below normal ....................................................... 73
circuit ................................................................... 62 CID 0617 FMI 06 Air Inlet Heater Relay
CID 0006 FMI 06 Cylinder #6 Injector short .......... 62 grounded/current above norm ............................. 73
CID 0041 FMI 03 8 Volt DC Supply short to +batt.. 63 CID 1639 FMI 02 Machine Security System
CID 0041 FMI 04 8 Volt DC Supply short to incorrect ............................................................... 73
ground.................................................................. 63 CID 1639 FMI 09 Machine Security System Module
CID 0042 FMI 05 Injector Actuation Valve open not communicating on link ................................... 74
circuit ................................................................... 63 CID 1785 FMI 03 Intake Manifold Pressure Sensor
CID 0042 FMI 06 Injector Actuation Valve short to voltage high ......................................................... 74
ground.................................................................. 63 CID 1785 FMI 04 Intake Manifold Pressure Sensor
CID 0091 FMI 08 Throttle Position signal voltage low........................................................... 74
abnormal.............................................................. 64 CID 1785 FMI 10 Intake Manifold Pressure Signal
CID 0094 FMI 03 Fuel Pressure open/short to abnormal rate of change...................................... 74
+batt..................................................................... 64 CID 2417 FMI 05 Ether Injection Control Solenoid
CID 0094 FMI 04 Fuel Pressure short to ground... 64 current low ........................................................... 75
230 RENR5089-23
Index Section

CID 2417 FMI 06 Ether Injection Control Solenoid Engine Oil in Exhaust System ............................... 36
current high.......................................................... 75 Probable Causes ............................................... 36
Coolant in Engine Oil............................................. 28 Recommended Actions...................................... 36
Probable Causes ............................................... 28 Engine Oil Temperature Is Too High................ 36–37
Recommended Actions...................................... 28 Probable Causes ......................................... 36–37
Coolant Temperature Is Too High .......................... 28 Recommended Actions................................ 36–37
Probable Causes ............................................... 28 Engine Pressure Sensor Open or Short Circuit -
Recommended Repairs ..................................... 29 Test ............................................................ 142, 149
Engine Speed/Timing Sensor - Calibrate ............ 225
Engine Speed/Timing Sensor Circuit - Test......... 157
D Engine Stalls at Low RPM ..................................... 37
Probable Causes ............................................... 37
Diagnostic Codes .................................................. 58 Recommended Actions...................................... 37
Active Diagnostic Codes .................................... 58 Engine Temperature Sensor Open or Short Circuit -
Diagnostic Codes............................................... 58 Test ............................................................ 161, 166
Logged Diagnostic Codes.................................. 59 Engine Vibration .................................................... 38
Diagnostic Functional Tests................................... 91 Probable Causes ............................................... 38
Digital Sensor Supply Circuit - Test ............. 121, 125 Recommended Actions...................................... 38
Engine Will Not Crank ........................................... 39
Probable Causes ............................................... 39
E Recommended Actions...................................... 39
Engine Wiring Information ..................................... 17
E096 High Fuel Pressure ...................................... 82 Harness Wire Identification ................................ 17
E162 High Boost Pressure .................................... 82 Ether Injection System - Test....................... 171, 177
E198 Low Fuel Pressure ....................................... 83 Event Codes .................................................... 76, 79
E265 User Defined Shutdown ............................... 85 Active Event Codes............................................ 76
E360 Low Engine Oil Pressure........................ 85–86 Active of Event Codes........................................ 79
E361 High Engine Coolant Temperature ............... 87 Clearing Event Codes .................................. 77, 80
E362 Engine Overspeed ................................. 88–89 Logged Event Codes ................................... 77, 80
E390 Fuel Filter Restriction ................................... 89 Trip Points for the Monitoring System.......... 77, 80
E539 High Intake Manifold Air Temperature.......... 90 Troubleshooting ........................................... 77, 80
ECM Will Not Accept Factory Passwords.............. 30 Excessive Black Smoke ........................................ 40
Probable Causes ............................................... 30 Probable Causes ............................................... 40
Recommended Actions...................................... 30 Recommended Actions...................................... 40
ECM Will Not Communicate with Other Systems or Excessive Engine Oil Consumption....................... 41
Display Modules ............................................ 30–31 Probable Causes ............................................... 41
Probable Causes ......................................... 30–31 Recommended Actions...................................... 41
Recommended Actions................................ 30–31 Excessive Fuel Consumption ................................ 41
Electrical Connectors - Inspect............................ 129 Probable Causes ............................................... 41
Electrical Power Supply Circuit - Test.......... 134, 138 Recommended Actions...................................... 41
Electronic Service Tool Will Not Communicate with Excessive Valve Lash............................................ 42
ECM..................................................................... 31 Probable Causes ............................................... 42
Probable Causes ............................................... 31 Recommended Actions...................................... 42
Recommended Actions...................................... 31 Excessive White Smoke ........................................ 42
Electronic Service Tools .......................................... 6 Probable Causes ............................................... 42
Caterpillar Electronic Technician (ET).................. 7 Recommended Actions...................................... 43
Optional Service Tools ......................................... 6 Exhaust Temperature Is Too High ......................... 43
PL1000E Communication ECM (If Equipped).... 10 Probable Causes ............................................... 43
Service Tools........................................................ 6 Recommended Actions...................................... 43
Electronic Troubleshooting ...................................... 5
Engine Cranks but Will Not Start ........................... 32
Probable Causes ............................................... 32 F
Recommended Actions...................................... 32
Engine Has Early Wear ......................................... 34 Factory Passwords ................................................ 20
Probable Causes ............................................... 34 Flash Programming ............................................... 20
Recommended Actions...................................... 34 Flash Programming a Flash File ........................ 20
Engine Misfires, Runs Rough or Is Unstable......... 34 Fuel Dilution of Engine Oil ..................................... 44
Probable Causes ............................................... 35 Probable Causes ............................................... 44
Recommended Actions...................................... 35 Recommended Actions...................................... 45
Engine Oil in Cooling System ................................ 35 Fuel Filter Differential Pressure Switch Circuit -
Probable Causes ............................................... 35 Test .................................................................... 180
Recommended Actions...................................... 36
RENR5089-23 231
Index Section

Fuel in Cooling System.......................................... 44 Sensors and Electrical Connectors ................. 13, 16

Probable Causes ............................................... 44 Component Location.................................... 14, 17
Recommended Actions...................................... 44 Service Information Report.................................... 21
Recommendations ............................................. 21
System Configuration Parameters......................... 23
I Parameter Descriptions ..................................... 23
System Configuration Parameters ..................... 24
Important Safety Information ................................... 2 System Overview..................................................... 5
Injection Actuation Pressure - Test ...................... 183 Passwords ........................................................... 6
Injection Actuation Pressure Control Valve Circuit - Programmable Parameters.................................. 6
Test .................................................................... 193 System Operation ................................................ 5
Injector Solenoid Circuit - Test..................... 197, 206
Injector Trim File .................................................... 21
Intermittent Engine Shutdown ............................... 45 T
Probable Causes ............................................... 45
Recommended Actions...................................... 45 Table of Contents..................................................... 3
Intermittent Low Power or Power Cutout......... 46–47 Test ECM Mode ..................................................... 19
Probable Causes ......................................... 46–47 Throttle Switch Circuit - Test........................ 214, 218
Recommended Actions................................ 46–47 Troubleshooting Section.......................................... 5
Troubleshooting with a Diagnostic Code ............... 58
Troubleshooting with an Event Code..................... 76
L Troubleshooting without a Diagnostic Code .......... 26

Low Engine Oil Pressure ....................................... 48

Probable Causes ............................................... 48 U
Recommended Actions...................................... 48
Low Engine Oil Pressure Lamp Circuit - Test ...... 213 User Defined Shutdown Input Circuit - Test......... 221
Low Power/Poor or No Response to Throttle .. 49, 51
Probable Causes ......................................... 49, 51
Recommended Actions................................ 49, 51

Mechanical Noise (Knock) in Engine..................... 53

Probable Causes ............................................... 53
Recommended Repairs ..................................... 53

Noise Coming from Cylinder.................................. 53

Probable Causes ............................................... 53
Recommended Actions...................................... 53

Poor Acceleration or Response....................... 54–55

Probable Causes ......................................... 54–55
Recommended Actions................................ 54–55
Programming Parameters ..................................... 19

Replacing the ECM................................................ 10

Self-Diagnostics..................................................... 12
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