G3600 Troubl RENR5910-02-01-ALL

RENR5910-02
October 2002
Troubleshooting
G3600 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
BEN1-Up (Engine)
4ZS1-Up (Engine)
i01658146
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents Jacket Water Pressure (Low) ................................ 68

Jacket Water to Engine Oil Differential Temperature
(Low) ................................................................... 68
Mechanical Noise (Knock) in Engine .................... 69
Troubleshooting Section Noise Coming from Cylinder (Noisy Cylinder
Head) .................................................................. 69
Electronic Troubleshooting
Poor Coolant Flow ................................................ 70
System Overview .................................................. 10
System Voltage ..................................................... 71
Self-Diagnostics .................................................... 16
Short Spark Plug Life ............................................ 71
Electrical Connectors and Functions .................... 16
Starting Motor Runs, Pinion Engages But Does Not
Electronic Service Tools ........................................ 25
Turn the Flywheel ................................................ 71
Engine Monitoring System .................................... 28
Too Much Vibration ............................................... 72
Turbocharger Turbine Temperature (High) ............ 72
Programming Parameters
Programming Parameters ..................................... 29
Troubleshooting with a Diagnostic Code
Customer Passwords ............................................ 29
Diagnostic Codes .................................................. 74
Factory Passwords ................................................ 29
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
Factory Passwords Worksheet ............................. 30
circuit ................................................................... 75
Flash Programming .............................................. 30
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
System Configuration Parameters ........................ 31
to ground ............................................................. 76
Replacing the ECM ............................................... 32
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve
Replacing the ICSM .............................................. 34
malfunction .......................................................... 76
Troubleshooting Data Sheet ................................. 35
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short
to +batt ................................................................ 76
Troubleshooting without a Diagnostic Code
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short
Symptoms ............................................................. 38
to ground ............................................................. 77
Air Starting Motor (Malfunction) ............................ 38
MID 036 - CID 0094 - FMI 03 Fuel Pressure
Crankcase Pressure (High) .................................. 39
open/short to +batt .............................................. 77
Detonation ............................................................ 40
MID 036 - CID 0094 - FMI 08 Fuel Pressure
Driven Equipment (Prevention of Operation) ........ 41
Noisy ................................................................... 77
ECM Will Not Accept Factory Passwords ............. 42
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
Electrohydraulic System Oil Pressure (Low) ......... 42
Electronic Service Tool Will Not Communicate with
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
ECM or ICSM ...................................................... 43
short to ground .................................................... 78
Engine Coolant Level (Low) .................................. 44
MID 036 - CID 0101 - FMI 03 Crankcase Pressure
Engine Coolant Temperature (High) ..................... 44
Engine Coolant Temperature (Low) ...................... 46
MID 036 - CID 0101 - FMI 04 Crankcase Pressure
Engine Cranks but Will Not Start .......................... 47
short to ground .................................................... 79
Engine Misfires, Runs Rough or Is Unstable ........ 49
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure
Engine Oil Filter Differential Pressure ................... 51
Sensor short to +batt .......................................... 79
Engine Oil Level (Low) .......................................... 52
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure
Engine Oil Pressure (Low) .................................... 52
Sensor noisy signal ............................................. 80
Engine Oil Temperature (High) ............................. 53
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure
Engine Overcrank ................................................. 54
Engine Overload ................................................... 55
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet
Engine Overspeed ................................................ 55
Pressure Sensor noisy signal ............................. 81
Engine Pre-Lube Pressure (Low) ......................... 56
MID 036 - CID 0110 - FMI 03 Engine Coolant
Engine Shutdown .................................................. 56
Temperature open/short to +batt ......................... 81
Engine Shutdown (Unexpected) ........................... 57
MID 036 - CID 0110 - FMI 04 Engine Coolant
Engine Shutdown without a Diagnostic Code ....... 58
Temperature short to ground ............................... 81
Engine Starts but Stalls Immediately .................... 59
MID 036 - CID 0168 - FMI 02 System Voltage
Excessive Engine Oil Consumption ...................... 60
intermittent/erratic ............................................... 82
Exhaust Emission Too High/Fuel Consumption Too
MID 036 - CID 0172 - FMI 03 Intake Manifold Air
High ..................................................................... 61
Temp open/short to +batt .................................... 82
Exhaust Port Temperature (High) ......................... 62
MID 036 - CID 0172 - FMI 04 Intake Manifold Air
Exhaust Port Temperature (Low) .......................... 63
Temp short to ground .......................................... 83
Fuel Energy Content ............................................. 63
MID 036 - CID 0174 - FMI 03 Fuel Temperature
Fuel Pressure ....................................................... 64
Gas Temperature (High) ....................................... 64
MID 036 - CID 0174 - FMI 04 Fuel Temperature short
Inlet Air Restriction ................................................ 65
to ground ............................................................. 83
Inlet Air Temperature (High) .................................. 65
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature
Intermittent Engine Shutdown ............................... 66
Jacket Water Inlet Pressure (High) ....................... 67
4
Table of Contents
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature MID 036 - CID 0313 - FMI 06 Ignition Transformer
short to ground .................................................... 84 Primary #13 short ............................................... 96
MID 036 - CID 0190 - FMI 02 Loss of Engine Speed MID 036 - CID 0314 - FMI 05 Ignition Transformer
signal ................................................................... 85 Primary #14 open circuit ..................................... 96
MID 036 - CID 0190 - FMI 08 Engine Speed signal MID 036 - CID 0314 - FMI 06 Ignition Transformer
abnormal ............................................................. 85 Primary #14 short ............................................... 96
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power MID 036 - CID 0315 - FMI 05 Ignition Transformer
Supply short to +batt ........................................... 85 Primary #15 open circuit ..................................... 97
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power MID 036 - CID 0315 - FMI 06 Ignition Transformer
Supply short to ground ........................................ 86 Primary #15 short ............................................... 97
MID 036 - CID 0301 - FMI 05 Ignition Transformer MID 036 - CID 0316 - FMI 05 Ignition Transformer
Primary #1 open circuit ....................................... 86 Primary #16 open circuit ..................................... 98
MID 036 - CID 0301 - FMI 06 Ignition Transformer MID 036 - CID 0316 - FMI 06 Ignition Transformer
Primary #1 short ................................................. 86 Primary #16 short ............................................... 98
MID 036 - CID 0302 - FMI 05 Ignition Transformer MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Primary #2 open circuit ....................................... 87 to +batt ................................................................ 98
MID 036 - CID 0302 - FMI 06 Ignition Transformer MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Primary #2 short ................................................. 87 +batt .................................................................... 99
MID 036 - CID 0303 - FMI 05 Ignition Transformer MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Primary #3 open circuit ....................................... 87 inputs .................................................................. 99
MID 036 - CID 0303 - FMI 06 Ignition Transformer MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open
Primary #3 short ................................................. 88 circuit ................................................................... 99
MID 036 - CID 0304 - FMI 05 Ignition Transformer MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short
Primary #4 open circuit ....................................... 88 to ground ............................................................. 99
MID 036 - CID 0304 - FMI 06 Ignition Transformer MID 036 - CID 0339 - FMI 05 Engine Pre-lube
Primary #4 short ................................................. 89 Pressure Switch open circuit ............................. 100
MID 036 - CID 0305 - FMI 05 Ignition Transformer MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer
Primary #5 open circuit ....................................... 89 Secondary open circuit ..................................... 100
Primary #5 short ................................................. 89 Secondary short to ground ............................... 101
Primary #10 open circuit ..................................... 93 Secondary open circuit ..................................... 104
Primary #10 short ............................................... 93 Secondary short to ground ............................... 105
5
Table of Contents
MID 036 - CID 0409 - FMI 06 Cylinder 9 - Transformer MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation
Secondary short to ground ............................... 107 Sensor open/short to +batt ............................... 119
MID 036 - CID 0410 - FMI 05 Cylinder 10 - MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation
Transformer Secondary open circuit ................. 107 Sensor short to ground ..................................... 119
Transformer Secondary short to ground ........... 108 Sensor short to +batt ........................................ 119
Transformer Secondary short to ground ........... 109 Sensor open/short to +batt ............................... 120
Transformer Secondary short to ground ........... 111 Sensor short to +batt ........................................ 121
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay MID 036 - CID 1513 - FMI 04 Cylinder #13 Detonation
short to +batt ..................................................... 113 Sensor short to ground ..................................... 124
MID 036 - CID 0444 - FMI 05 Start Relay open MID 036 - CID 1514 - FMI 03 Cylinder #14 Detonation
circuit ................................................................. 114 Sensor open/short to +batt ............................... 124
MID 036 - CID 0444 - FMI 06 Start Relay short to MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation
ground ............................................................... 114 Sensor short to ground ..................................... 125
MID 036 - CID 0445 - FMI 03 Run Relay short to MID 036 - CID 1844 - FMI 05 Fuel Actuator open
+batt .................................................................. 114 circuit ................................................................. 125
MID 036 - CID 0524 - FMI 03 Desired Engine Speed MID 036 - CID 1844 - FMI 06 Fuel Actuator short to
Sensor short to +batt ........................................ 115 ground ............................................................... 125
MID 036 - CID 0524 - FMI 04 Desired Engine Speed MID 109 - CID 0253 - FMI 02 Personality Module
Sensor short to ground ..................................... 115 mismatch ........................................................... 126
MID 036 - CID 0525 - FMI 05 Choke Actuator open MID 109 - CID 0591 - FMI 12 EEPROM checksum
circuit ................................................................. 115 fault or ECM not programmed ........................... 126
MID 036 - CID 0525 - FMI 06 Choke Actuator short MID 109 - CID 1040 - FMI 09 ICSM #1 not
to ground ........................................................... 116 communicating on link ...................................... 126
MID 036 - CID 0526 - FMI 05 Wastegate Valve MID 109 - CID 1043 - FMI 02 Cylinder #1 Firing
open .................................................................. 116 Signal noisy ....................................................... 127
MID 036 - CID 0526 - FMI 06 Wastegate Valve MID 109 - CID 1043 - FMI 03 Cylinder #1 Firing
short .................................................................. 116 Signal open/short to +batt ................................. 127
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil MID 109 - CID 1043 - FMI 04 Cylinder #1 Firing
Pressure open/short to +batt ............................ 117 Signal short to ground ....................................... 127
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil MID 109 - CID 1043 - FMI 08 Cylinder #1 Firing
Pressure short to ground .................................. 117 Signal abnormal signal ...................................... 128
MID 036 - CID 1040 - FMI 09 ICSM #1 not MID 109 - CID 1044 - FMI 02 All Cylinders Firing
communicating on link ...................................... 117 Signal noisy ....................................................... 128
MID 036 - CID 1041 - FMI 09 ICSM #2 not MID 109 - CID 1044 - FMI 03 All Cylinders Firing
communicating on link ...................................... 118 Signal open/short to +batt ................................. 129
MID 036 - CID 1501 - FMI 03 Cylinder #1 Detonation MID 109 - CID 1044 - FMI 04 All Cylinders Firing
Sensor open/short to +batt ............................... 118 Signal short to ground ....................................... 129
MID 036 - CID 1501 - FMI 04 Cylinder #1 Detonation MID 109 - CID 1101 - FMI 02 Cylinder #1 Combustion
Sensor short to ground ..................................... 118 Probe noisy ....................................................... 129
6
Table of Contents
MID 109 - CID 1101 - FMI 04 Cylinder #1 Combustion MID 109 - CID 1531 - FMI 04 Cyl #1 Exhaust Port
Probe short to ground ....................................... 130 Temp Sensor short to ground ............................ 141
Probe noisy ....................................................... 130 Temp Sensor open circuit ................................. 142
Probe short to ground ....................................... 131 Temp Sensor short to +batt ............................... 142
Probe noisy ....................................................... 131 Temp Sensor short to ground ............................ 142
Probe short to ground ....................................... 131 Temp Sensor open circuit ................................. 143
Probe noisy ....................................................... 132 Temp Sensor short to +batt ............................... 143
MID 109 - CID 1111 - FMI 02 Cylinder #11 MID 109 - CID 1537 - FMI 03 Cyl #7 Exhaust Port
Combustion Probe noisy ................................... 137 Temp Sensor short to +batt ............................... 147
Combustion Probe short to ground ................... 137 Temp Sensor short to ground ............................ 147
Combustion Probe noisy ................................... 138 Temp Sensor open circuit ................................. 148
Combustion Probe short to ground ................... 138 Temp Sensor short to +batt ............................... 148
Combustion Probe noisy ................................... 138 Temp Sensor short to ground ............................ 148
Combustion Probe short to ground ................... 139 Temp Sensor open circuit ................................. 149
MID 109 - CID 1490 - FMI 03 Rt Turbo Turbine Out MID 109 - CID 1539 - FMI 03 Cyl #9 Exhaust Port
Temp Sens short to +batt .................................. 139 Temp Sensor short to +batt ............................... 149
Temp Sens short to ground ............................... 139 Temp Sensor short to ground ............................ 149
Temp Sens open circuit ..................................... 140 Temp Sensor open circuit ................................. 150
MID 109 - CID 1491 - FMI 03 Rt Turbo Turbine In MID 109 - CID 1541 - FMI 03 Cyl #11 Exhaust Port
Temp Sens short to +batt .................................. 140 Temp Sensor short to +batt ............................... 150
Temp Sens short to ground ............................... 140 Temp Sensor short to ground ............................ 150
Temp Sens open circuit ..................................... 141 Temp Sensor open circuit ................................. 151
MID 109 - CID 1531 - FMI 03 Cyl #1 Exhaust Port MID 109 - CID 1543 - FMI 03 Cyl #13 Exhaust Port
Temp Sensor short to +batt ............................... 141 Temp Sensor short to +batt ............................... 151
7
Table of Contents
MID 109 - CID 1543 - FMI 04 Cyl #13 Exhaust Port MID 110 - CID 1492 - FMI 03 Left Turbo Turbine In
Temp Sensor short to ground ............................ 151 Temp Sens short to +batt .................................. 163
Temp Sensor open circuit ................................. 152 Temp Sens short to ground ............................... 164
Temp Sensor short to +batt ............................... 152 Temp Sens open circuit ..................................... 164
Temp Sensor short to ground ............................ 152 Temp Sensor short to +batt ............................... 164
Temp Sensor open circuit ................................. 153 Temp Sensor short to ground ............................ 165
MID 110 - CID 0253 - FMI 02 Personality Module MID 110 - CID 1532 - FMI 05 Cyl #2 Exhaust Port
mismatch ........................................................... 153 Temp Sensor open circuit ................................. 165
MID 110 - CID 0591 - FMI 12 EEPROM checksum MID 110 - CID 1534 - FMI 03 Cyl #4 Exhaust Port
fault or ECM not programmed ........................... 153 Temp Sensor short to +batt ............................... 165
MID 110 - CID 1041 - FMI 09 ICSM #2 not MID 110 - CID 1534 - FMI 04 Cyl #4 Exhaust Port
communicating on link ...................................... 154 Temp Sensor short to ground ............................ 166
MID 110 - CID 1044 - FMI 02 All Cylinders Firing MID 110 - CID 1534 - FMI 05 Cyl #4 Exhaust Port
Signal noisy ....................................................... 154 Temp Sensor open circuit ................................. 166
Signal open/short to +batt ................................. 154 Temp Sensor short to +batt ............................... 166
Signal short to ground ....................................... 155 Temp Sensor short to ground ............................ 167
Signal abnormal signal ...................................... 155 Temp Sensor open circuit ................................. 167
Combustion Probe short to ground ................... 159 Temp Sensor short to +batt ............................... 170
Combustion Probe noisy ................................... 160 Temp Sensor short to ground ............................ 171
Combustion Probe short to ground ................... 160 Temp Sensor open circuit ................................. 171
Combustion Probe noisy ................................... 161 Temp Sensor short to +batt ............................... 171
Combustion Probe short to ground ................... 161 Temp Sensor short to ground ............................ 172
MID 110 - CID 1116 - FMI 04 Cylinder #16
Combustion Probe short to ground ................... 162 Troubleshooting with an Event Code
MID 110 - CID 1489 - FMI 03 Left Turbo Turbine Out Event Codes ...................................................... 173
Temp Sens short to +batt .................................. 162 E004 Engine Overspeed Shutdown .................... 175
MID 110 - CID 1489 - FMI 04 Left Turbo Turbine Out E013 High Crankcase Pressure Shutdown ........ 175
Temp Sens short to ground ............................... 163 E016 High Engine Coolant Temperature
MID 110 - CID 1489 - FMI 05 Left Turbo Turbine Out Shutdown .......................................................... 175
Temp Sens open circuit ..................................... 163 E017 High Engine Coolant Temperature
Warning ............................................................. 176
8
Table of Contents
E019 High Engine Oil Temperature Shutdown ... 176 E337 High Engine Oil to Engine Coolant Diff
E020 High Engine Oil Temperature Warning ...... 176 Temp ................................................................. 191
E026 High Inlet Air Temperature Shutdown ........ 177 E384 Left Air Inlet Restriction ............................. 192
E027 High Inlet Air Temperature Warning .......... 177 E385 Right Air Inlet Restriction ........................... 192
E038 Low Engine Coolant Temperature E386 Low Engine Coolant or Engine Oil Level ... 192
Warning ............................................................. 177 E401 Cylinder #1 Detonation .............................. 193
E040 Low Engine Oil Pressure Shutdown .......... 177 E402 Cylinder #2 Detonation .............................. 193
E042 Low System Voltage Shutdown ................. 178 E403 Cylinder #3 Detonation .............................. 193
E043 Low System Voltage Warning .................... 178 E404 Cylinder #4 Detonation .............................. 193
E050 High System Voltage Warning ................... 178 E405 Cylinder #5 Detonation .............................. 194
E096 High Fuel Pressure .................................... 178 E406 Cylinder #6 Detonation .............................. 194
E100 Low Engine Oil Pressure Warning ............. 179 E407 Cylinder #7 Detonation .............................. 194
E101 High Crankcase Pressure Warning ........... 179 E408 Cylinder #8 Detonation .............................. 194
E127 Engine Oil Filter Diff Pressure Low E409 Cylinder #9 Detonation .............................. 195
Warning ............................................................. 179 E410 Cylinder #10 Detonation ............................ 195
E128 Engine Oil Filter Diff Pressure Low E411 Cylinder #11 Detonation ............................ 195
Shutdown .......................................................... 180 E412 Cylinder #12 Detonation ............................ 196
E129 Engine Oil Filter Diff Pressure High E413 Cylinder #13 Detonation ............................ 196
Warning ............................................................. 180 E414 Cylinder #14 Detonation ............................ 196
E130 Engine Oil Filter Diff Pressure High E415 Cylinder #15 Detonation ............................ 196
Shutdown .......................................................... 180 E416 Cylinder #16 Detonation ............................ 197
E135 Low Jacket Water Pressure Shutdown ...... 180 E421 Cylinder #1 Detonation Shutdown ............. 197
E200 Continuous Cylinder Misfire ...................... 181 E422 Cylinder #2 Detonation Shutdown ............. 197
E201 Cylinder #1 Intermittent Misfire .................. 181 E423 Cylinder #3 Detonation Shutdown ............. 197
E208 Cylinder #8 Intermittent Misfire .................. 183 E430 Cylinder #10 Detonation Shutdown ........... 200
E209 Cylinder #9 Intermittent Misfire .................. 184 E431 Cylinder #11 Detonation Shutdown ........... 200
E210 Cylinder #10 Intermittent Misfire ................ 184 E432 Cylinder #12 Detonation Shutdown ........... 200
E215 Cylinder #15 Intermittent Misfire ................ 185 E498 Fuel Pressure Present During Initial
E216 Cylinder #16 Intermittent Misfire ................ 186 Cranking ............................................................ 202
E223 High Gas Temperature .............................. 186 E601 Cylinder #1 Continuous Misfire ................. 202
E224 High Jacket Water Inlet Pressure .............. 186 E602 Cylinder #2 Continuous Misfire ................. 203
E225 Engine Overcrank ...................................... 187 E603 Cylinder #3 Continuous Misfire ................. 203
E226 Driven Equipment Not Ready .................... 187 E604 Cylinder #4 Continuous Misfire ................. 203
E229 Fuel Energy Content Setting Low .............. 187 E605 Cylinder #5 Continuous Misfire ................. 203
E230 Fuel Energy Content Setting High ............. 187 E606 Cylinder #6 Continuous Misfire ................. 204
E231 Fuel Quality Out of Range ......................... 188 E607 Cylinder #7 Continuous Misfire ................. 204
E233 Low Engine Pre-Lube Pressure ................ 188 E608 Cylinder #8 Continuous Misfire ................. 204
E242 Engine Overload ........................................ 188 E609 Cylinder #9 Continuous Misfire ................. 205
E243 High Left Turbo Turbine Outlet E610 Cylinder #10 Continuous Misfire ............... 205
Temperature ...................................................... 188 E611 Cylinder #11 Continuous Misfire ............... 205
E244 High Right Turbo Turbine Outlet E612 Cylinder #12 Continuous Misfire ............... 206
E245 High Right Turbo Turbine Inlet E614 Cylinder #14 Continuous Misfire ............... 206
E246 High Left Turbo Turbine Inlet Temperature .. 190 E616 Cylinder #16 Continuous Misfire ............... 207
E264 Emergency Stop Activated ........................ 190 E801 Cylinder #1 High Exhaust Port Temp ........ 207
E266 Low Hydrax Oil Pressure ........................... 190 E802 Cylinder #2 High Exhaust Port Temp ........ 208
E268 Unexpected Engine Shutdown .................. 191 E803 Cylinder #3 High Exhaust Port Temp ........ 208
E269 Customer Shutdown Requested ............... 191 E804 Cylinder #4 High Exhaust Port Temp ........ 208
E270 Driven Equipment Shutdown Requested .. 191 E805 Cylinder #5 High Exhaust Port Temp ........ 209
E806 Cylinder #6 High Exhaust Port Temp ........ 209
9
Table of Contents
E807 Cylinder #7 High Exhaust Port Temp ........ 210 Air/Fuel Pressure Module ................................... 283
E808 Cylinder #8 High Exhaust Port Temp ........ 210 Analog Sensor Signal ......................................... 291
E809 Cylinder #9 High Exhaust Port Temp ........ 211 Analog Sensor Signal ......................................... 300
E810 Cylinder #10 High Exhaust Port Temp ...... 211 Choke Actuator Solenoid .................................... 309
E811 Cylinder #11 High Exhaust Port Temp ...... 212 Choke Actuator Solenoid .................................... 317
E812 Cylinder #12 High Exhaust Port Temp ...... 212 Combustion Sensor ............................................ 325
E813 Cylinder #13 High Exhaust Port Temp ...... 213 Combustion Sensor ............................................ 332
E814 Cylinder #14 High Exhaust Port Temp ...... 213 Cylinder Firing Pulse ........................................... 340
E815 Cylinder #15 High Exhaust Port Temp ...... 213 Cylinder Firing Pulse ........................................... 351
E816 Cylinder #16 High Exhaust Port Temp ...... 214 Desired Speed Input (4 - 20 mA) ........................ 368
E821 Cyl #1 Exhaust Port Temp Deviating High .. 214 Detonation Sensors ............................................ 374
E822 Cyl #2 Exhaust Port Temp Deviating High .. 215 Detonation Sensors ............................................ 386
E823 Cyl #3 Exhaust Port Temp Deviating High .. 215 ECM Output Circuit (Fuel Control) ...................... 400
E824 Cyl #4 Exhaust Port Temp Deviating High .. 215 ECM Output Circuit (Fuel Control) ...................... 412
E825 Cyl #5 Exhaust Port Temp Deviating High .. 216 ECM Output Circuit (Prelubrication Oil Pump) .... 424
E826 Cyl #6 Exhaust Port Temp Deviating High .. 216 ECM Output Circuit (Prelubrication Oil Pump) .... 437
E827 Cyl #7 Exhaust Port Temp Deviating High .. 217 ECM Output Circuit (Starting Motor) ................... 449
E828 Cyl #8 Exhaust Port Temp Deviating High .. 217 ECM Output Circuit (Starting Motor) ................... 460
E829 Cyl #9 Exhaust Port Temp Deviating High .. 218 ECM Status Indicator Output .............................. 470
E830 Cyl #10 Exhaust Port Temp Deviating Electrical Power Supply ...................................... 478
High ................................................................... 218 Electrical Power Supply ...................................... 485
E831 Cyl #11 Exhaust Port Temp Deviating Engine Speed/Timing Sensor ............................. 493
High ................................................................... 219 Engine Speed/Timing Sensor ............................. 499
E832 Cyl #12 Exhaust Port Temp Deviating Fuel Actuator Solenoid ....................................... 506
High ................................................................... 219 Fuel Actuator Solenoid ....................................... 514
E833 Cyl #13 Exhaust Port Temp Deviating Ignition Transformers Primary Circuit .................. 522
High ................................................................... 220 Ignition Transformers Primary Circuit .................. 531
E834 Cyl #14 Exhaust Port Temp Deviating Ignition Transformers Secondary Circuit and Spark
High ................................................................... 220 Plugs ................................................................. 542
E835 Cyl #15 Exhaust Port Temp Deviating Inspecting Electrical Connectors ........................ 546
High ................................................................... 221 Integrated Combustion Sensing Module
E836 Cyl #16 Exhaust Port Temp Deviating (ICSM) ............................................................... 552
High ................................................................... 221 Integrated Combustion Sensing Module
E841 Cyl #1 Exhaust Port Temp Deviating Low .. 222 (ICSM) ............................................................... 556
E842 Cyl #2 Exhaust Port Temp Deviating Low .. 222 Prelubrication System ......................................... 563
E843 Cyl #3 Exhaust Port Temp Deviating Low .. 223 Prelubrication System ......................................... 568
E844 Cyl #4 Exhaust Port Temp Deviating Low .. 223 PWM Sensor ....................................................... 573
E845 Cyl #5 Exhaust Port Temp Deviating Low .. 223 PWM Sensor ....................................................... 586
E846 Cyl #6 Exhaust Port Temp Deviating Low .. 224 Thermocouple Test ............................................. 598
E847 Cyl #7 Exhaust Port Temp Deviating Low .. 224 Thermocouple Test ............................................. 604
E848 Cyl #8 Exhaust Port Temp Deviating Low .. 225 Wastegate Solenoid ............................................ 615
E849 Cyl #9 Exhaust Port Temp Deviating Low .. 225 Wastegate Solenoid ............................................ 623
E850 Cyl #10 Exhaust Port Temp Deviating
Low ................................................................... 226 Index Section
Low ................................................................... 226 Index ................................................................... 633
Low ................................................................... 227
Low ................................................................... 227
Low ................................................................... 228
Low ................................................................... 228
Low ................................................................... 229
Diagnostic Functional Tests

+5V Sensor Voltage Supply ................................ 230
Air/Fuel Pressure Module ................................... 274
10
Troubleshooting Section
Troubleshooting Section The ECM does not have a removable personality

module. The software and maps are changed with
the Caterpillar Electronic Technician (Cat ET) by
flash programming of a file.
Electronic Troubleshooting
Governing of the Engine RPM
i01754066
Desired engine speed is determined by the status
System Overview of the idle/rated switch, of the desired speed input
(analog voltage or 4 to 20 mA), and of parameters
SMCS Code: 1901-038 that are programmed into the software. Actual
engine speed is detected via a signal from the
engine speed/timing sensor. Parameters such as
Control System idle speed and governor gain can be programmed
with Cat ET.
The following components are included in the
control system: The ECM monitors the actual engine speed. The
ECM calculates the difference between the actual
• An Electronic Control Module (ECM) and an engine speed and the desired engine speed. The
emergency stop button in an engine mounted ECM controls the fuel actuator in order to maintain
junction box the desired engine speed. The fuel actuator is
located at the flange of the inlet air manifold.
• Optional remote control panel with a Machine
Information Display System (MIDS) If the actual engine speed is less than the desired
engine speed, the ECM commands the fuel
• Integrated Combustion Sensing Module (ICSM) actuator to move toward the open position in order
to increase the fuel flow. The increase of fuel
• Gas Shutoff Valve (GSOV) accelerates the engine speed.
• Ignition system that is controlled by the ECM Control of Ignition

• Detonation sensor for each two cylinders Each cylinder has an ignition transformer. To
initiate combustion, the ECM sends a pulse of
• A system for prelube that includes the solenoid approximately 108 volts to the primary coil of each
and prelube pump ignition transformer at the appropriate time and for
the appropriate duration. The transformer increases
• Actuators that are hydraulically actuated and the voltage which creates a spark across the spark
electronically controlled for the fuel, for the air plug electrode.
choke, and for the exhaust bypass (wastegate)
The ECM provides variable ignition timing that
• A system for cranking that includes the solenoid is sensitive to detonation. Detonation sensors
and starting motor monitor the engine for excessive detonation. The
engine has one detonation sensor for each two
The ECM controls most of the functions of the adjacent cylinders. The sensors generate data on
engine. The module is an environmentally sealed vibration that is processed by the ECM in order to
unit that is in an engine mounted junction box. The determine detonation levels. If detonation reaches
ECM monitors various inputs from sensors in order an unacceptable level, the ECM retards the ignition
to activate relays, solenoids, etc at the appropriate timing of the affected cylinder or cylinders. If
levels. The ECM supports the following five primary retarding the timing does not limit detonation to an
functions: acceptable level, the ECM shuts down the engine.
• Governing of the engine Levels of detonation can be displayed by the
Machine Information Display System (MIDS) on the
• Control of ignition optional control panel. Alternatively, the “Cylinder
X Detonation Level” screen of Cat ET can also be
• Air/fuel ratio control used. The “X” represents the cylinder number.
• Start/stop control The ECM provides extensive diagnostics for the
ignition system.
• Monitoring of engine operation
11
Air/Fuel Ratio Control

The ECM provides control of the air/fuel mixture
for performance and for efficiency at low
emission levels. The system includes the following
components: maps in the ECM, output drivers in
the ECM, fuel actuator, air choke actuator, exhaust
bypass actuator (wastegate), ICSM, thermocouples,
and combustion sensors. Illustration 1 is a diagram
of the system’s main components and of the
system’s lines of communication.
g00910538
Illustration 1
The desired air/fuel ratio is based on maps that • Combustion feedback

are stored in the ECM. The maps are specific for
different applications, for engine speeds, and for • Prechamber calibration
engine loads.
Error for the inlet manifold air pressure – This is
The engine load is calculated from the fuel flow. For the absolute difference between the actual inlet
example, zero fuel flow is zero load and fuel flow of manifold air pressure and the desired inlet manifold
100 cfm might be 50 percent of the rated load. air pressure.
Note: The calculated engine load varies. Several In each of these modes, the air/fuel ratio is controlled
variables affect the calculated engine load, by either the air choke actuator or the wastegate
including timing, settings for emissions, fuel quality, actuator: only one of the actuators operates at any
and specific gravity of the fuel. time. The active actuator is determined by the ability
to provide the desired inlet manifold air pressure.
The system has five modes of operation for the Both of the actuators regulate the air flow. The
air/fuel ratio: regulation is based on an error that is calculated for
the inlet manifold air pressure. Both of the actuators
• Start-up are controlled by a map for the air/fuel ratio.
• No feedback
• Exhaust port temperature feedback
12
The software is also programmed to correct the

fuel flow according to the temperature of the jacket
water and the engine speed. This occurs when the
coolant temperature is not at the water temperature
regulator’s rated temperature. If the temperature is
cooler than the rating, the fuel in the cylinder head
is also cooler and more dense. Because the denser
fuel provides an air/fuel mixture that is richer than
the desired mixture, the calculation of the fuel flow
is corrected for the lower temperature. This tends
to lean the actual air/fuel ratio. If the temperature is
warmer than the rating, the fuel in the cylinder head
is less dense. Because the warmer fuel provides
a leaner air/fuel mixture, the calculation of the fuel
flow is corrected for the higher temperature. This
tends to richen the air/fuel ratio.
Note: When the engine is operating in combustion

feedback mode, the temperature of the jacket water
only affects the fuel correction factor.
The relationship of the modes of operation to the

engine load and the transitions between the modes
are represented in Illustration 2. The modes of
operation are explained in more detail below.
g00910198
Illustration 2
Schematic of the modes of operation, of transitions, and of the engine load
13
Note: Control of the inlet manifold air pressure is not Normally, the map is calculated in order to provide
determined directly by the engine load. The active a low air/fuel ratio for loads up to approximately 40
actuator is determined by the ability to provide the percent. This provides a mixture that is sufficiently
desired inlet manifold air pressure. rich for operation at low temperatures. The air/fuel
ratio will continue to be controlled by the map
At loads that are less than approximately 40 until the conditions allow operation in one of the
percent, the air/fuel ratio is controlled by the air feedback modes or in the prechamber calibration
choke actuator. The air choke controls the flow of mode.
air during engine start-up. The air choke continues
to control the air flow during the increase in the A low air/fuel ratio is critical for operation after
engine speed and in load. As the engine speed start-up in order to keep the air choke partially
and load are increased, the required inlet manifold closed. Otherwise, the air choke may open fully
air pressure increases. The air choke opens in and the wastegate will control the inlet manifold air
order to provide more combustion air. When the air pressure. This results in a period of misfire and of
choke becomes fully open, the air choke cannot excessive fuel flow. Because of the excessive fuel
further increase the air flow. Then, the wastegate flow, the calculated engine load is excessive.
becomes active.
Programmable “Desired Engine Exhaust Port Temp”
Conversely, the required inlet manifold air pressure parameter – This parameter is set in the Cat ET
is reduced as the engine speed and load are configuration screen. This is the desired exhaust
reduced. As the requirement for combustion air is port temperature for a load of 25 percent. The
reduced, the wastegate opens. When the wastegate control uses this parameter during operation in the
is fully open, the wastegate cannot regulate a exhaust port temperature feedback mode.
smaller quantity of combustion air. Then, the air
choke becomes active again.
During start-up, the air choke is maintained at a

fixed position until ten seconds after the engine
achieves the desired speed. This enables a
correction of the excessive error for inlet manifold air
pressure. The starting position for the air choke is
set in the Cat ET configuration screen. The starting
position depends on the number of cylinders.
Typically, the starting position is closed 60 to 80
percent. If the starting position is set too high, the
engine will not get enough combustion air.
If the starting position is set too high and the engine

speed does not increase to the desired speed, the
programming in the software opens the air choke
in steps until the engine speed increases. This
enables a steady increase of the engine speed until
the desired speed is achieved.
The maximum position for the air choke can also g00914203
Illustration 3
be set in the Cat ET configuration screen. The
maximum position is set in order to enable a Graph of the calculated desired exhaust port temperature
sufficient flow of air for combustion when the engine
is running at no load. Typically, the maximum The calculated desired exhaust port temperature
position is closed 75 to 85 percent. varies from the programmable “Desired Engine
Exhaust Port Temp” by 1 C (1.8 F) per 1 percent
At ten seconds after the engine reaches the desired of engine load. For each 1 percent of engine load
speed, the air/fuel ratio is controlled directly by the below 25 percent, the calculated desired exhaust
map for the air/fuel ratio. No correction factors are port temperature increases by 1 C (1.8 F). For
related to any feedback: this is a correction factor each 1 percent of engine load above 25 percent,
of 100 percent. This mode of operation uses no the calculated desired exhaust port temperature
feedback. decreases by 1 C (1.8 F).
14
Control’s average exhaust port temperature – The The programmed air/fuel ratio control begins to use
ICSM continuously calculates the average exhaust a correction factor in order to modify the air/fuel
port temperature. If the actual temperature of ratio that is specified in the map for the air/fuel ratio.
any cylinder exhaust port is less than 273 C The correction factor is based on an error for the
(523 F), the ICSM substitutes a temperature of exhaust port temperature.
273 C (523 F) for that cylinder. This temperature
is substituted for any number of cylinders with an If the average exhaust temperature is too low, the
exhaust port temperature that is less than 273 C ECM commands the air choke actuator to move
(523 F). The temperature is used in the calculation toward the closed position in order to richen the
of the average for all of the monitored cylinders. air/fuel mixture. Combustion of the richer air/fuel
mixture increases the exhaust port temperatures.
Exhaust port temperature feedback – In this mode
of operation, the air/fuel ratio is controlled in order Combustion feedback – In this mode of operation,
to achieve a desired exhaust port temperature. the air/fuel ratio is controlled in order to achieve the
Each cylinder exhaust port has a thermocouple that desired combustion burn time.
is monitored by an ICSM. The ICSM monitors the
actual exhaust port temperatures for one bank of When the load reaches approximately 40 percent,
cylinders. The ICSM calculates an average exhaust the air/fuel ratio is controlled by the wastegate
port temperature for the bank of cylinders. The ECM actuator which is trimmed by the combustion burn
calculates the desired exhaust port temperature time.
for the load. The ECM sends the desired exhaust
port temperature to the ICSM. The ICSM calculates Combustion burn time – The combustion burn time
the difference between the average exhaust is measured in each cylinder. Each cylinder has a
port temperature and the desired exhaust port combustion sensor. The pulse of the ignition starts a
temperature. The ICSM sends a fuel correction timer in the ICSM. The flame travels in the cylinder
factor to the ECM. The ECM uses the fuel correction from the spark plug to the combustion sensor. The
factor to control the air choke actuator in order to ICSM monitors the voltage across the combustion
maintain the desired exhaust temperature. sensor. When the flame reaches the combustion
sensor, the ionization that surrounds the sensor
After start-up, the exhaust port temperature changes the voltage. When the ICSM detects the
feedback mode is activated for the following change of the sensor’s voltage, the ICSM stops the
conditions: timer. The combustion burn time is a method of
measuring the air/fuel ratio. A rich air/fuel mixture
• The calculated control’s average exhaust port provides a faster combustion burn time. A lean
temperature exceeds the desired exhaust port air/fuel mixture provides a slower combustion burn
temperature. time.
• The calculated control’s average exhaust port Each ICSM calculates an average combustion
temperature ceases to increase. The engine load burn time for all of the cylinders in one bank. The
is less than approximately 40 percent. ECM sends a point from the map of the desired
combustion burn time to the ICSM. The ICSM
• The timer for operation with no feedback expires. calculates the difference between the average
combustion burn time and the desired combustion
The transition to the exhaust port temperature burn time. The ICSM sends a fuel correction factor
feedback mode can also occur for the following to the ECM. The ECM controls the wastegate
circumstances: actuator in order to maintain the desired combustion
burn time.
• The air/fuel ratio is controlled by combustion
feedback. The engine load is reduced to A command for the desired inlet manifold air
approximately 40 percent or less than 40 percent. pressure is sent from the ECM to the wastegate
The transition occurs in a 15 second period. actuator. The actuator adjusts the inlet manifold air
pressure in order to correct the combustion burn
• The engine operation exits the prechamber time.
calibration mode. The engine load is
approximately 40 percent or less than 40 percent.
In this case, the fuel correction factor begins at
100 percent. Then, the fuel correction factor is
adjusted in order to achieve the desired exhaust
port temperature.
15
If the average desired combustion burn time is too When the programmable logic determines that it is
fast, the ECM commands the wastegate actuator to necessary to crank the engine, the ECM supplies
move toward the closed position in order to provide +Battery voltage to the solenoid for the starting
more air for a leaner air/fuel mixture. This provides motor. Rotation of the crankshaft also operates the
a slower combustion burn time. If the average pump for the electrohydraulic actuators. The pump
desired combustion burn time is too slow, the develops hydraulic oil pressure for operation of
ECM commands the wastegate actuator to move the fuel actuator, the air choke actuator, and the
toward the open position in order to provide less wastegate actuator.
air for a richer air/fuel mixture. The richer air/fuel
mixture burns faster. This is a continuous process The engine has an energize-to-run type of Gas
during operation at loads that are greater than Shutoff Valve (GSOV). When the programmable
approximately 40 percent. logic determines that fuel is required to start the
engine or to run the engine, the ECM supplies
The combustion feedback mode is activated for +Battery voltage to the valve’s solenoid.
either of the following conditions:
At one second after the GSOV is energized, the
• The air/fuel ratio is in the exhaust port temperature pressure differential between the fuel and the air
feedback mode. The engine load exceeds is monitored. This parameter is monitored in order
approximately 40 percent. The average exhaust to ensure that no fuel is entering the fuel manifold
port temperature is stable and the desired before the ECM issues a command to the fuel
exhaust port temperature is established. The actuator. If the differential pressure for fuel to air
transition occurs in a 15 second period. is less than 0.5 kPa (0.073 psi), the ECM supplies
+Battery voltage to the fuel actuator’s solenoid.
• The engine operation exits the prechamber
calibration mode and the engine load is greater The ECM controls the fuel actuator by adjusting the
than approximately 40 percent. current flow through the actuator’s solenoid. During
start-up, the combustion chambers are usually filled
Prechamber calibration mode – This mode can be with excessive combustion air. The ECM operates
activated with Cat ET. This mode can be activated the fuel actuator in order to supply sufficient fuel for
during operation at any load. The mode is used for a combustible air/fuel mixture.
adjustment of the precombustion chambers’ needle
valves in order to achieve the desired exhaust The ECM removes the voltage from the starting
emissions. In the prechamber calibration mode, the motor’s solenoid when the programmable
fuel correction factor is maintained at 100 percent. crank terminate speed is reached or when a
After an exit from this mode, the fuel correction programmable cycle crank time has expired. The
factor is adjusted in order to achieve the desired starter motor pinion disengages from the flywheel
air/fuel ratio. ring gear.
Start/Stop Control When the programmable logic determines that an

engine shutdown is necessary, the ECM removes
The ECM contains the logic and the outputs +Battery voltage from the solenoids for the fuel
for control of engine prelubrication, of starting, actuator and for the GSOV. The fuel is shut off.
of shutdown, and of postlube. The customer
programmable logic responds to signals from The prelube system is programmed to perform
the following components: engine control switch, a postlube cycle during engine shutdown. This
emergency stop switch, remote start switch, data supplies the turbocharger with adequate lubrication
link, and other inputs. during shutdown.
To control the engine at the appropriate times, the Monitoring Engine Operation
ECM provides +Battery voltage to the solenoids that
control the prelube pump, the starting motor, and The ECM monitors both the engine operation and
the gas shutoff valve. the electronic system.
When the programmable logic determines that Problems with engine operation cause the ECM
the prelubrication function is necessary, the ECM to generate an event code. The ECM can issue a
supplies +Battery voltage to the solenoid for the warning or a shutdown for events. This depends on
prelube pump. The prelubrication must develop the severity of the condition.
sufficient engine oil pressure before the engine will
crank. The engine has a pressure switch for the
prelube. When the engine oil pressure is sufficient,
the pressure switch closes and the engine can be
cranked.
16
For example, a high pressure pump provides Active Code – An active code indicates that an
hydraulic pressure with oil for the electrohydraulic active problem has been detected. Active codes
system. The oil supply is separate from the engine require immediate attention. Always service active
oil. The high pressure oil supply is monitored by codes prior to servicing logged codes.
a pressure switch. If the pressure drops below an
acceptable level, the ECM generates an event code Logged Code – Every generated code is stored in
and the ECM shuts down the engine. the permanent memory of the appropriate module.
The codes are logged.
The ICSM monitors the combustion sensors and
the thermocouples for the cylinders and for the Logged codes may not indicate that a repair is
turbocharger. The ICSM sends signals regarding needed. The problem may have been temporary.
the parameters to the ECM over the CAT Data Link. The problem may have been resolved since the
If any parameter exceeds the acceptable range, the logging of the code. If the system is powered, it
ECM can initiate a warning or a shutdown. is possible to generate an active diagnostic code
whenever a component is disconnected. When
For more information on event codes, refer to the component is reconnected, the code is no
Troubleshooting, “Troubleshooting with an Event longer active. Logged codes may be useful to help
Code”. troubleshoot intermittent problems. Logged codes
can also be used to review the performance of the
Problems with the electronic system such as engine and of the electronic system.
an open circuit produce a diagnostic code.
For more information, refer to Troubleshooting,
i01754084
“Troubleshooting with a Diagnostic Code”.
Electrical Connectors and
i01783583 Functions
Self-Diagnostics SMCS Code: 1408-038
SMCS Code: 1901-038
Harness Wire Identification
The Electronic Control Module (ECM) and the
Integrated Combustion Sensing Module (ICSM) Caterpillar identifies different wires with eleven
have the ability to detect problems with the different solid colors. Table 1 lists the color codes of
electronic system and with engine operation. When the wiring.
a problem is detected, a code is generated. An
alarm may also be generated. There are two types Table 1
of codes: Color Codes for Wiring
• Diagnostic Code Color

BK Black
• Event
BR Brown
Diagnostic Code – When a problem with the BU Blue
electronic system is detected, the appropriate
module generates a diagnostic code. This indicates GN Green
the specific problem with the circuitry. GY Gray
Event Code – An event code is generated by OR Orange

the detection of an abnormal engine operating PK Pink
condition. For example, an event code will be
generated if the oil pressure is too low. In this case, PU Purple
the event code indicates the symptom of a problem. RD Red
The codes can have two different states: WH White
YL Yellow
• Active
• Logged
17
In addition to the color, the entire length of each

wire is stamped with a specific circuit number that
is repeated on every 25 mm (1 inch) of the wire.
The actual wires are identified on the engine’s
Schematic.
For example, a code of J011-RD on the Schematic

identifies a red wire that is stamped with the
circuit number J011. This particular wire is the
engine harness wire for the primary signal of the
transformer in the number one cylinder.
The Schematic also identifies the size of the wire.

The size or gauge of the wire is called the American
Wire Gauge (AWG). Unless the schematic specifies
a different size, the wire is 16 AWG.
Terminal Box
g00891827
Illustration 4
Terminal box
The engine mounted terminal box is located on the

rear right side of the engine. The Electronic Control
Module (ECM) is inside the terminal box. The
terminal box provides the point of termination for all
of the wiring that is related to the engine’s sensors
and for the ignition system. The terminal box’s
components are identified in Illustrations 5 and 6.
18
g00892898
Illustration 5
Inside of the terminal box
(J2/P2) 70-pin connectors for the ECM (CB2) 6 amp circuit breaker (J5/P5) 70-pin connectors for the sensors on
(J1/P1) 70-pin connectors for the ECM (J3/P3) 70-pin connectors for the customer’s the right side of the engine
(1) Ground strap wiring (4) Ignition wiring for the right side of the
(2) Terminal for the 24 VDC power supply (3) Ignition wiring for the left side of the vee vee engine
(J7) 9-pin service tool connector engine (J4) 47-pin connector for the optional control
(CB1) 16 amp circuit breaker (J6/P6) 70-pin connectors for the sensors on panel or for a customer connector
the left side of the engine (5) Wiring for the electrical power
19
Vee Engines
g00891953
Illustration 6
Front and bottom of the terminal box
(J6) 70-pin connector for the sensors on the left side of the engine
(J5) 70-pin connector for the sensors on the right side of the engine
(J4) 47-pin connector for the optional control panel or for a
customer connector
(6) Emergency stop button
(7) Hole for the ignition wiring on the left side of the vee engine
(8) Hole for the ignition wiring on the right side of the vee engine
(9) Hole for the electrical power supply and/or for the customer’s
wiring to the 70-pin connector (P3)
Sensors
Sensors provide information to the engine control
module and to the integrated combustion sensing g00803846
Illustration 7
modules. The information is used for monitoring Front view of a Vee engine
engine operation. The information enables the (1) Sensor for the outlet pressure of the jacket water
modules to control the engine as efficiently as (2) Sensor for the jacket water coolant temperature
possible over a wide range of operating conditions. (3) Unfiltered engine oil pressure sensor
(4) Engine oil temperature sensor
(5) Filtered engine oil pressure sensor
20
g00825893
Illustration 9
The sensor for the inlet manifold air temperature is installed in
the inlet air manifold between the two center cylinder heads on
the right side of the Vee engine.
(9) Sensor for inlet manifold air temperature
g00825637
Illustration 8
Right side view near the front of a Vee engine
(1) Sensor for the outlet pressure of the jacket water
(6) Detonation sensor
(7) Switch for the inlet pressure of the jacket water
(8) Crankcase pressure sensor
Note: There is one detonation sensor between each

pair or cylinders.
21
g00825717
Illustration 10
Right side view near the rear of a Vee engine
(10) Connector for the electrohydraulic actuators’ pressure switch
(11) Switch for prelube oil pressure
g00825638
Illustration 11
Rear view of a Vee engine
(12) Fuel temperature sensor
(13) Switch for inlet air restriction (left)
(14) Pressure module for inlet air and fuel
(15) Switch for inlet air restriction (right)
(16) Engine speed/timing sensor
22
g00902969
Illustration 12
Right view of a Vee engine
Engine harness connector for the engine oil level switch and the
coolant level switch
In-Line Engines
g00895316
Illustration 14
Right side view near the front of an In-line engine
(6) Inlet air restriction’s switch
(7) Air/fuel pressure module
Note: There is one detonation sensor between each

pair or cylinders.
g00895272
Illustration 13
Front view of an In-line engine
(1) Sensor for jacket water coolant temperature
(2) Sensor for outlet pressure of the jacket water
(3) Unfiltered engine oil pressure sensor
23
g00895279
Illustration 15
Right side view near the front of an In-line engine
(9) Detonation sensor (12) Switch for the inlet pressure of the (14) Connector for the switches for low
(10) Fuel temperature sensor jacket water engine oil level and for low coolant level
(11) Crankcase pressure sensor (13) Switch for the prelube oil pressure
Note: The switches for connector (14) can be

supplied by the customer or by the factory.
g00895328
Illustration 16
In-line engine
(15) Inlet manifold air temperature’s sensor
(16) Electrohydraulic actuator’s pressure
switch
24
Integrated Combustion Sensing Module Vee Engines

(ICSM)
g00843952
Illustration 17
Integrated Combustion Sensing Module (ICSM)
The engine has an Integrated Combustion Sensing

Module (ICSM) for each bank of cylinders. The
ICSM monitors exhaust temperature sensors
and combustion sensors. The ICSM performs
calculations with the data. The ICSM communicates
with the ECM via the CAT Data Link.
Exhaust temperatures are monitored for each

cylinder exhaust port, for the inlet of the g00825730
turbocharger turbine, and for the outlet of the Illustration 18
turbocharger turbine. Vee engine
(17) Temperature sensor for the cylinder exhaust port
(18) Temperature sensor for the exhaust after the turbocharger
(19) Temperature sensor for the exhaust before the turbocharger
(20) Combustion sensor
Note: For each cylinder, there is one temperature

sensor for the exhaust port (17) and one combustion
sensor (20). For each turbocharger, there is one
temperature sensor for the exhaust after the
turbocharger (18) and one temperature sensor for
the exhaust before the turbocharger (19).
25
In-Line Engines i01775381
Electronic Service Tools

SMCS Code: 1901-038
Caterpillar Electronic Service Tools are designed to

help the service technician:
• Obtain data.
• Diagnose problems.
• Read parameters.
• Program parameters.
• Calibrate sensors.
The tools that are listed in Table 2 are required in
order to enable a service technician to perform the
procedures.
g00895336
Illustration 19
In-line engine
(17) Temperature sensor for the exhaust after the turbocharger
(18) Temperature sensor for the exhaust before the turbocharger
g00895356
Illustration 20
In-line engine
(19) Temperature sensor for the cylinder exhaust port
(20) Combustion sensor
Note: For each cylinder, there is one temperature

sensor for the exhaust port (19) and one combustion
sensor (20).
26
Table 2
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) This PC configuration is recommended:
Intel Pentium II 333 mHz processor
64 megabyte of RAM
4.3 GB hard drive
14X speed CD-ROM drive
N/A Personal Computer (PC) This PC configuration has the minimum requirements:
IBM PC compatible 100 MHz processor
32 megabyte of RAM
10 MB of available hard drive space
CD-ROM drive
3.5 inch 1.44-MB floppy disk drive
Windows NT or Windows 95
RS232 port with 16550AF UART
VGA monitor or display
“JERD2124” Software Single user license for Cat ET
Use the most recent version of the software.
“JERD2129” Software Data subscription for all engines
171-4401 Communication Adapter II (1) The communication adapter is connected between the PC (Cat ET)
and the Electronic Control Module (ECM).
196-0055 Serial Cable As (1)(2) This cable connects the PC to the 171-4401 Communication
Adapter II.
160-0141 Serial Cable As (2) This cable connects the PC to the 171-4401 Communication
Adapter II.
207-6845 Adapter Cable As (1)(3) This cable connects the 171-4401 Communication Adapter II to
the 7X-1414 Data Link Cable As.
7X-1701 Communication Adapter The communication adapter is connected between the PC (Cat
ET) and the ECM.
7X-1425 Serial Cable As This cable connects the PC (Cat ET) to the 7X-1701
Communication Adapter.
139-4166 Adapter Cable As This cable connects the 7X-1701 Communication Adapter to the
7X-1414 Data Link Cable As.
7X-1414 Data Link Cable As This cable connects the service tool connector on the engine
mounted terminal box to the 139-4166 Adapter Cable As.
8T-8726 Adapter Cable As This breakout harness is for use between the jacks and the plugs
of the sensors.
151-6320 Wire Removal Tool This tool is used for the removal of pins and sockets from Deutsch
connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
9U-7330 Digital Multimeter The multimeter is used for the testing and the adjusting of electronic
circuits.
7X-1710 Multimeter Probes The probes are used with the multimeter to measure voltage in
wiring harnesses without disconnecting the harnesses.
5P-7277 Voltage Tester The tester is used to test for voltage in circuits, relays, bulbs, wires,
and switches.
(1) This item is included in the 171-4400 Communication Adapter Gp.
(2) Either the 160-0141 or the 196-0055 cable may be used.
(3) Either the 160-0133 or the 207-6845 cable may be used.
27
Note: Either the 171-4401 Communication Adapter

II or the 7X-1700 Communication Adapter Gp can
be used. However, the 7X-1700 Communication
Adapter Gp is no longer serviced.
Caterpillar Electronic Technician

(ET)
The Caterpillar Electronic Technician (ET) is
designed to run on a personal computer. Cat ET
can display the following information:
• Parameters
• Diagnostic codes
• Event codes
• Engine configuration
• Status of the monitoring system
Cat ET can perform the following functions:
• Diagnostic tests
• Sensor calibration g00694774
Illustration 21
• Flash downloading (1) PC
(2) 196-0055 Serial Cable or the 160-0141 Serial Cable
(3) 171-4401 Communication Adapter II
• Set parameters (4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable
Connecting Cat ET with the 171-4401
Communication Adapter II 1. Connect cable (2) to the RS232 serial port of
PC (1).
The battery supplies the communication adapter
with 24 VDC. Use the following procedure to 2. Connect cable (2) to communication adapter (3).
connect Cat ET and the communication adapter
to the engine. 3. Connect cable (4) to communication adapter (3).
4. Connect cable (4) to cable (5).
5. Connect cable (5) to the service tool connector

of the terminal box.
6. Make sure that the engine control switch is in the

ON position. If Cat ET and the communication
adapter do not communicate with the ECM, refer
to Troubleshooting, “Electronic Service Tool Will
Not Communicate with ECM or ICSM”.
Connecting Cat ET with the 7X-1701

Communication Adapter
The battery supplies the communication adapter
with 24 VDC. Use the following procedure to
connect Cat ET and the communication adapter
to the engine.
28
i01754145
Engine Monitoring System

SMCS Code: 1901-038
The Electronic Control Module (ECM) monitors the

operating parameters of the engine. The ECM can
initiate a warning or a shutdown if a specific engine
parameter exceeds an acceptable range. The
default settings for the parameters are programmed
at the factory.
The status of the parameters can be viewed on

the “Service/Monitoring System” screen of the
Caterpillar Electronic Technician (Cat ET). This
screen is also used to change the settings.
To accommodate unique applications and sites,

some parameters may be reprogrammed with Cat
ET. The screens of Cat ET provide guidance for
changing trip points. Use Cat ET to perform the
following activities:
• Select the available responses.

• Program the level for monitoring.
g00694776
Illustration 22 • Program delay times for each response.
(1) PC
(2) 7X-1425 Serial Cable Note: Some parameters are protected by factory
(3) 7X-1701 Communication Adapter passwords. Other parameters can be changed with
(4) 139-4166 Adapter Cable customer passwords.
(5) 7X-1414 Data Link Cable
For instructions on using Cat ET, refer to the User’s
1. Connect cable (2) to the RS232 serial port of Manual that is supplied with the software.
PC (1).
For information on the warnings and shutdowns,
2. Connect cable (2) to communication adapter (3). refer to Troubleshooting, “Troubleshooting with an
Event Code”.
3. Connect cable (4) to communication adapter (3).
For detailed information on system parameters that
4. Connect cable (4) to cable (5). can be programmed and for recommendations
for programming parameters, refer to Systems
5. Connect cable (5) to the service tool connector Operation/Testing and Adjusting, “Engine Monitoring
of the terminal box. System”.
6. Make sure that the engine control switch is in the
ON position. If Cat ET and the communication NOTICE
adapter do not communicate with the ECM, refer Changing the parameters during engine operation can
to Troubleshooting, “Electronic Service Tool Will cause the engine to operate erratically. This can cause
Not Communicate with ECM or ICSM”. engine damage.
Unless the instructions are different, only change

the settings of the parameters when the engine is
STOPPED.
29
Programming Parameters Note: Be sure to record the customer passwords.

Store the passwords securely. The passwords can
have a maximum of eight characters. Alphanumeric
i01754149 characters may be used. The passwords are case
sensitive.
Programming Parameters
3. Enter the password in the “Change Parameter
SMCS Code: 1901-038 Value” dialog box and click on the “OK” button.
Programmable parameters enable the engine to 4. Highlight the “Customer Password #2” parameter.
be configured to meet the requirements of the Click on the “Change” button in the lower right
application. Two types of parameters can be corner of the screen.
programmed into the Electronic Control Module
(ECM): system configuration parameters and 5. Enter the password in the “Change Parameter
monitoring system parameters. Value” dialog box and click on the “OK” button.
The Caterpillar Electronic Technician (Cat ET) is The passwords are now programmed into the
used for viewing the status of parameters and for memory of the Electronic Control Module (ECM).
programming parameters.
Make a copy of Table 3 and record your passwords.
For more information on parameters, refer to Store the passwords securely.
Troubleshooting, “Sytem Configuration Parameters”
and Troubleshooting, “Engine Monitoring System”. Table 3
Customer Passwords
i01726982 Customer Password #1
Customer Passwords Customer Password #2
SMCS Code: 1901

i01727009
Certain monitoring system parameters and system
configuration parameters may be protected with Factory Passwords
customer passwords. Use of the passwords helps
to prevent free access to the modification of the SMCS Code: 1901-038
parameters. If the customer passwords are not
programmed, all of the parameters are unprotected. Factory level security passwords are required for
clearing certain logged events and for changing
The customer passwords can be changed, if certain programmable parameters. Because of the
necessary. The customer passwords or a factory passwords, only authorized personnel can make
password is needed in order to change the changes to some of the programmable items in
customer passwords. If the customer passwords the Electronic Control Module (ECM). When the
are forgotten, factory passwords can be acquired correct passwords are entered, the changes are
from Caterpillar. programmed into the ECM.
After the customer passwords are entered, the Factory passwords are required to program the
passwords are required in order to change certain following shutdowns:
parameters. Once the passwords are entered
successfully, the passwords are not requested • “Engine Overspeed”
again until another screen is accessed or the data
link is interrupted. • “High Engine Oil Temperature”
This feature is enabled by programming two • “High Oil Filter Differential Pressure”
customer passwords. Use the following procedure
to program the passwords. The same procedure is • “Low Oil Filter Differential”
used to change the passwords:
• “High Jacket Water to Engine Oil Temperature
1. Access the “Service/Configuration” screen of the Differential”
Caterpillar Electronic Technician (ET).
The “Enter Factory Passwords” screen on Cat ET
2. Highlight the “Customer Password #1” parameter. will display the following parameters. To obtain the
Click on the “Change” button in the lower right proper passwords, the information must be given to
corner of the screen. an authorized Caterpillar dealer:
30
• Current ECM Table 4

Factory Passwords Worksheet
• Serial number of the service tool
Dealer Code
• Serial number of the engine Customer’s Name
• Serial number of the ECM Address
• Diagnostic clock
• Total Tattletale Telephone Number
• Reason Information from the “Enter Factory Passwords”

Screen on the Caterpillar Electronic Technician (ET)
The old interlock code is required to change the Serial Number for Cat ET
interlock code on a used ECM. The passwords are
controlled by Caterpillar. The passwords may only Engine Serial Number
be obtained by an authorized Caterpillar dealer. ECM Serial Number
The passwords may only be used for one Diagnostic Clock(1)

programming session. After you exit the “Enter Total Tattletale
Factory Passwords” screen on Cat ET, a different
set of passwords will be required before you can Reason Code
program the ECM. Factory Passwords
Factory passwords are not required for the first hour Factory Password (No. 1)
of operation for a new ECM. After the hour expires, Factory Password (No. 2)
factory passwords are required for some of the (1) Do not obtain this information from the service meter.
programming.
i01754150
i01727016
Factory Passwords Worksheet Flash Programming

SMCS Code: 1901-038 SMCS Code: 1901-038
Note: A mistake in recording this information will Software is located in the flash memory of the
result in incorrect passwords. Electronic Control Module (ECM) and in the
Integrated Combustion Sensing Module (ICSM).
The Caterpillar Electronic Technician (Cat ET)
can be used to flash new software into the ECM
and into the ICSM. The flash is accomplished by
transferring the data from Cat ET to the module
via data link wiring. The Software, JERD2124 or
Software, JERD2129 is used.
Flash Programming
If the slowest baud rate of Cat ET is selected, flash
programming can last up to 15 minutes. Be sure to
set the baud rate to the fastest rate for your PC.
To select the baud rate, use the ET

“Utilities/Preferences”. Select the “Communications”
tab and click on “Advanced...”. Then select the
baud rate from the “Advanced Communication
Settings” menu and click the “OK” button.
If a communication error occurs, select a slower

baud rate in order to improve the reliability.
31
1. Connect Cat ET to the service tool connector. “WinFlash” Error Messages

2. Turn the engine control switch to the STOP If you receive any error messages during flash
position. programming, click on the “Cancel” button in order
to stop the process. Access the information about
Cat ET will not flash if the engine control switch the “ECM Summary” under the “Information” menu.
is in the OFF position or in the START position. Make sure that you are flashing the correct file for
your engine.
3. Select “WinFlash” from the “Utilities” menu on
Cat ET.
i01754153
“WinFlash” will try to detect an ECM. System Configuration

4. When an ECM has been detected, the “ECM Parameters
Selector” window will appear. Select the
appropriate ECM and then select “OK”. SMCS Code: 1901-038
The “Flash File Selection” window will appear. The system configuration parameters must be
programmed when the application is installed.
5. The flash files are located on a disk drive and Perform this programming before the initial engine
in a directory. Select the correct disk drive and start-up. Incorrect programming of parameters may
the directory from “Drives” and “Directories” on lead to complaints about performance and/or to
Cat ET. engine damage.
A list of flash files will appear. Data from a gas analysis is required for determining
the correct settings for the fuel quality and for
6. Select the correct file from the list of flash files. the specific gravity of the gas. The data must be
Read the “Description” and the “File Info” in entered into the Caterpillar Software, LEKQ6378,
order to verify that the correct file is selected. “Methane Number Program”.
Select “Open”.
The status of the parameters can be viewed on the
7. Select the “Begin Flash” button in order to “Configuration” screen of the Caterpillar Electronic
program the personality module. Technician (Cat ET).
When the flash is completed, this message will If the Electronic Control Module (ECM) is replaced,
appear: “Flash Completed Successfully”. the appropriate parameters must be copied from
the original ECM. This can be done with the “Copy
8. Program the configuration parameters and the Configuration” feature of Cat ET. Alternatively,
monitoring system parameters. the settings can be recorded on paper and then
programmed into the new module.
The parameters must be programmed in order
to ensure proper engine operation. Refer to Table 5 is a list of the parameters that can be
Troubleshooting, “Programming Parameters”. configured for G3600 Engines.
9. Start the engine and check for proper operation. Table 5

Configuration Parameters for G3600 Engines
a. If a diagnostic code of 268-02 “Check
Programmable Parameters” is generated, Air/Fuel Ratio Control
program any parameters that were not in the “Fuel Quality”
original software.
“Gas Specific Gravity”
b. Access the “Configuration” screen under “Desired Engine Exhaust Port Temp”
the “Service” menu in order to determine
the parameters that require programming. “Maximum Choke Position”
Look under the “Tattletale” column. All of the “Engine Start Choke Position”
parameters should have a tattletale of 1 or
more. If a parameter has a tattletale of 0, “Wastegate (Proportional) Gain Percentage”
program that parameter. “Wastegate (Integral) Stability Percentage”
“Wastegate (Derivative) Compensation Percentage”
“Choke (Proportional) Gain Percentage”
(continued)
32
(Table 5, contd) For instructions on using Cat ET, refer to the User’s
Configuration Parameters for G3600 Engines Manual that is supplied with the software.
“Choke (Integral) Stability Percentage”

NOTICE
“Choke (Derivative) Compensation Percentage” Changing the parameters during engine operation can
cause the engine to operate erratically. This can cause
Speed Control
engine damage.
“Low Idle Speed”
Unless the instructions are different, only change
“Minimum Engine High Idle Speed”
the settings of the parameters when the engine is
“Maximum Engine High Idle Speed” STOPPED.
“Engine Accel. Rate”
“Desired Speed Input Configuration” i01754158
“Governor Type Setting” Replacing the ECM

“Engine Speed Droop”
SMCS Code: 1901-038
“Governor (Proportional) Gain Percentage”
“Governor (Integral) Stability Percentage” The Electronic Control Module (ECM) contains no
moving parts. Failure of the ECM is unlikely. Before
“Governor (Derivative) Compensation Percentage” you replace an ECM, follow the troubleshooting
“Governor Auxiliary 1 (Proportional) Gain Percentage” procedures in this manual in order to be sure that
replacement of the ECM will correct the problem.
“Governor Auxiliary 1 (Integral) Stability Percentage”
“Governor Auxiliary 1 (Derivative) Compensation Verify that the suspect ECM is the cause of the
Percentage” problem. Install a test ECM in place of the suspect
ECM. Transfer the software from the suspect ECM
Start/Stop Control to the test ECM. Program all the parameters for
“Driven Equipment Delay Time” the test ECM in order to match the parameters of
the suspect ECM. The parameters must match.
“Crank Terminate Speed” Refer to the following test steps for details on
“Engine Purge Cycle Time” programming the parameters.
“Engine Cooldown Duration” If the test ECM resolves the problem, reconnect
“Cycle Crank Time”
the suspect ECM. Verify that the problem recurs. If
the problem recurs, replace the suspect ECM with
“Engine Overcrank Time” the test ECM.
“Engine Speed Drop Time”
Note: If the parameters cannot be read from the
“Engine Pre-lube Time Out Period” suspect ECM, the parameters must be obtained
from records or from the factory.
Monitoring and Protection
“High Inlet Air Temp Engine Load Set Point” Perform the following procedure to replace the ECM.
Information for the Electronic Control Module (ECM)
1. Use the “Service/Copy Configuration/ECM
“Engine Serial Number” Replacement” function of the Caterpillar
Electronic Technician (Cat ET).
“Equipment ID”
“Customer Password #1” Save the file. You can select “Load from ECM”.
You may also select the “Print” function in order
“Customer Password #2” to obtain a paper copy of the parameter settings.
“Total Tattletale”
Note: Before you replace an ECM, record all of the
logged events.
For detailed information on the configuration
parameters and for recommendations on a. Connect Cat ET with the communications
programming of the parameters, refer to Systems adapter. Select the “Service/Copy
Operation/Testing and Adjusting, “Electronic Control Configuration/ECM Replacement” screen from
System Parameters”. the pull-down menu.
33
Cat ET will load the configuration parameters Note: Rubber grommets behind the ECM are held in
and the monitoring system parameters of the place by the mounting studs. The grommets help to
suspect ECM. reduce vibration. The grommets may fall when the
ECM is removed. Be sure not to lose the grommets.
b. Select “Load from ECM” from the Cat ET
screen. Select the suspect ECM and select e. Remove the ECM from the terminal box.
“OK”.
3. Install the replacement ECM.
After the loading is complete, Cat ET will
display this message: “The data has been a. Use the mounting hardware to install the
successfully loaded from the ECM”. Select new ECM. Use a mounting nut to fasten the
“OK”. ground strap for the ECM to the upper left
mounting stud. Then install the other three
c. Select “File/Disconnect F8” from the pull-down mounting nuts.
menu.
Check the mounting hardware and the
Note: Do not terminate Cat ET. ECM for correct installation. A correctly
installed ECM will move slightly on the rubber
2. Replace the ECM. grommets. If the ECM cannot move slightly
on the grommets, check that the washers,
a. Turn the engine control switch to the spacers, and grommets are positioned
“OFF/RESET” position. correctly.
b. Use a 4 mm Allen wrench to connect the P1

and P2 connectors to the ECM. Tighten the
screws to a torque of 6 ± 1 N·m (55 ± 9 lb in).
4. Program the configuration parameters and

the monitoring system parameters into the
replacement ECM.
a. Switch circuit breaker (1) to the ON position.
b. Turn the engine control switch to the “STOP”

position.
c. Select “File/Select ECM” from the pull-down

menu.
d. Select the replacement ECM and click “OK”.
e. Select “Service/Copy Configuration/ECM

Replacement” from the pull-down menu. Click
g00842215 “OK” on the window.
Illustration 23
(1) ECM Connector P2 f. Select “Program ECM” from the screen. Select
(2) ECM Connector P1
(3) 16 Amp Circuit Breaker the replacement ECM and click “OK”. If the
(4) Mounting nut correct ECM is shown, select “Yes”.
(5) Ground Strap
g. After the loading is complete, a window with
b. Switch the 16 amp circuit breaker (1) for the the message “Programming Conflict Warning”
ECM to the OFF position. will appear. Select “OK”.
c. Use a 4 mm Allen wrench to disconnect h. A window with the message “Program ECM
connectors (P1) and (P2). Results” will appear. Select “OK”.
d. Remove mounting nut (2) in order to Note: When you program a new ECM, factory
disconnect the ground strap (3). Remove the passwords are not required for the first hour of
three remaining mounting nuts. operation. After one hour, factory passwords are
required for changing the parameters that are
normally protected with factory passwords.
34
i01754163 After the loading is complete, Cat ET will

display this message: “The data has been
Replacing the ICSM successfully loaded from the ECM”. Select
“OK”.
SMCS Code: 1901-038
c. Select “File/Disconnect F8” from the pull-down
The Integrated Combustion Sensing Module (ICSM) menu.
contains no moving parts. Failure of the ICSM is
unlikely. Replacement of the ICSM can consume Note: Do not exit from Cat ET.
much time. Before you replace an ICSM, follow the
troubleshooting procedures in this manual in order 2. Replace the ICSM.
to be sure that replacement of the ICSM will correct
the problem. a. Turn the engine control switch to the
“OFF/RESET” position.
Use the following guidelines to verify that the
suspect ICSM is the cause of the problem:
Install a test ICSM in place of the suspect ICSM.

Transfer the software from the suspect ICSM to
the test ICSM. Program all the parameters for the
test ICSM in order to match the parameters of the
suspect ICSM. The parameters must match. Refer
to the following steps for details on programming
the parameters.
If the test ICSM resolves the problem, reconnect

the suspect ICSM. Verify that the problem recurs.
If the problem recurs, replace the suspect ICSM
with the test ICSM.
g00842289
Illustration 24
Use the following procedure to replace the ICSM: 16 amp circuit breaker for the ECM
Note: If the parameters cannot be read from the b. Switch the 16 amp circuit breaker for the ECM
suspect ICSM, the parameters must be obtained to the OFF position.
from records or from the factory.
1. Use the “Service/Copy Configuration/ECM

Replacement” function of the Caterpillar
Electronic Technician (Cat ET) in order to transfer
the software from the suspect ICSM.
You may also select the “Print” function in order

to obtain a paper copy of the parameter settings.
Note: Before you replace an ICSM, record all of the

logged events.
a. Connect Cat ET with the communications

adapter. Select “Service/Copy
Configuration/ECM Replacement” from Illustration 25 g00842252
the pull-down menu.
(1) 20 pin P72 connector
(2) 14 pin P73 connector
Cat ET will load the configuration parameters (3) Bolt
and the monitoring parameters from the ECM.
c. Disconnect P72 connector (1) and P73
b. Select “Load from ECM” in the lower left connector (2) from the ICSM. Remove four
corner of the screen. Select the suspect ICSM bolts (3) in order to remove the cover.
and select “OK”.
35
Note: Rubber grommets for the ICSM are held in c. Select “File/Select ECM” from the pull-down
place on the mounting studs. The grommets help to menu of Cat ET.
reduce vibration. The grommets may fall when the
ICSM is removed. Be sure not to lose the grommets. d. Select the “Replacement ICSM” and click
“OK”.
Note: A ground strap is connected with one of the
mounting bolts. e. Select “Service/Copy Configuration/ECM
Replacement” from the pull-down menu. Click
“OK” on the window.
f. Select “Program ECM” from the lower left

corner of the screen. Select the replacement
ICSM and click “OK”.
g. After the loading is complete, a window with

the message “Programming Complete” will
appear. Select “OK”.
Note: When you program a new ICSM, factory

passwords are not required. Also, the ICSM does
not require calibration.
g00842267
Illustration 26
i01794002
(4) Connectors for the sensors
(5) Mounting bolts
(6) Ground strap
Troubleshooting Data Sheet
d. Disconnect connectors (4) for the sensors SMCS Code: 1901-038
from the ICSM. Remove four mounting bolts
(5). Detach ground strap (6). To help troubleshoot a gas engine, complete the
information in Table 6. Be sure to include the units
3. Install the replacement ICSM. Orient the 20 pin of measurement.
J72 connector to the upward position.
a. Use the mounting hardware to install the new

ICSM. Be sure to install ground strap (6).
Check the mounting hardware and the

ICSM for correct installation. A properly
installed ICSM will move slightly on the rubber
grommets. If the ICSM cannot move slightly
on the grommets, check that the washers and
grommets are positioned correctly.
b. Connect connectors (4) for the sensors to

the ICSM.
c. Connect P72 connector (1) and P73 connector

(2) to the ICSM.
d. Install the cover and four bolts (3).
4. Program the configuration parameters and

the monitoring system parameters into the
replacement ICSM.
a. Switch the 16 amp circuit breaker for the ECM

ON.
b. Turn the engine control switch to the “STOP”

position.
36
Table 6
Data Sheet for Troubleshooting
Customer and installation
Engine model and driven equipment
Engine serial number Application
Service Compression Altitude “Fuel Quality”
hours ratio setting (LHV)
Fuel Fuel Fuel Pressure to the gas
LHV methane number rate regulator
Fuel Air Brand of oil
flow flow type of oil
Engine Percent Detonation Air
rpm load level restriction
Inlet manifold air pressure Inlet manifold air temperature Actual air/fuel ratio
Desired inlet manifold air pressure Desired air/fuel ratio
Desired combustion burn time
Engine oil pressure Turbocharger exhaust left Exhaust stack
temperature pressure
right
Fuel Air choke Wastegate
command command command
Exhaust stack % O2 PPM of NOx PPM of CO Brand of exhaust
temperature analyzer
Cylinder exhaust (1) (3) (5) (7) (9) (11) (13) (15)
port temperatures
(2) (4) (6) (8) (10) (12) (14) (16)
Needle valve (1) (3) (5) (7) (9) (11) (13) (15)
setting
(2) (4) (6) (8) (10) (12) (14) (16
Cylinder (1) (3) (5) (7) (9) (11) (13) (15)
combustion burn time
(2) (4) (6) (8) (10) (12) (14) (16)
Aftercooler water in Jacket water in Engine oil in
temperature temperature temperature
out out out
Comments
37
Report the Service Information

After you have successfully repaired the engine,
it is important to provide good information about
the repair. The following topics are recommended
for your report:
Complaint – Include a description of the customer’s

complaint in the report.
Cause – Provide a specific description of the cause

of the failure. Include the method that was used
in order to diagnose the problem. If diagnostic
codes or event codes were generated, include all
of the codes and the status of the codes. Indicate
your determination of the problem. For example,
if you performed a diagnostic functional test,
identify the test procedure. For example, a visual
inspection revealed abrasion of a wire in a harness.
Be specific: dynamometer testing of the engine
produced power below specifications at 1000 rpm
due to the loss of an ignition transformer.
Repair – Explain your repair of the problem. For

example, you may have installed a new wiring
harness. You may have replaced the ignition
transformer per instructions from the factory.
The providing of complete, accurate information will

help Caterpillar to provide better service to you and
to the customer.
38
Troubleshooting without a Operator Information

Diagnostic Code Obtain the following information from the operator:
• The occurrence and the time of the occurrence

i01305323
Symptoms • Determine the conditions for the occurrence. The

conditions will include the engine rpm and the
load.
SMCS Code: 1000-038; 1901-038
Some engine symptoms can be unrelated to

• Determine if there are any systems that were
installed by the dealer or the customer that could
the electronic control system. This section is for cause the symptom.
troubleshooting problems that have symptoms
without active diagnostic codes. Conditions such as
poor fuel quality or improperly adjusted valves can
• Determine whether any other occurrences
happened in addition to the symptom.
cause some engine symptoms.
For basic troubleshooting of the engine, perform Diagnostic Codes and Event Codes
the following steps first in order to diagnose a
malfunction. Examine the following information regarding any
codes:
1. Gather information about the complaint from the
operator. • The probable cause of the symptom is correlated
to the code.
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not • The code was generated when the symptom
due to error of the operator. occurred.
3. Perform a visual inspection. Inspect the following • Codes that are repeatedly logged
items:
• The complaint is not due to normal engine
• Fuel supply operation.
• Oil level Other Symptoms

• Oil supply If other occurrences happened in addition to the
symptom, investigate the following conditions:
• Wiring
• The other occurrences are related to the
• Connectors symptom.
4. Check the diagnostic codes and event codes. • The symptoms have a probable cause that is
Repair any active codes. common.
If these inspections do not reveal any problems,
identify the probable causes with the procedures in i01783160
this manual that best describe the symptoms. See
Troubleshooting, “Troubleshooting With A Diagnostic Air Starting Motor
Code” or see Troubleshooting, “Troubleshooting (Malfunction)
With Event Codes”. Check each probable cause
according to the tests that are recommended. SMCS Code: 1451-035
Be sure to check the connectors. This is specially
true for problems that are intermittent. See Probable Causes
Troubleshooting, “Inspecting Electrical Connectors”.
The following conditions can prevent operation of
Narrow the probable cause. Consider the operator the starting motor:
information, the conditions of operation, and the
history of the engine. • Engaged barring device
• Electrical problem
39
• Low supply pressure Relay Valve

• Problem with the lubricator After the starting motor’s pinion is engaged, the
relay valve enables a large volume of supply
• Problem with the starting motor’s control valve pressure to enter the air starting motor. Make
sure that the relay valve is not stuck. Check for
• Problem with the starting motor’s relay valve leaks. Check for debris in the supply line to the
starting motor. Make sure that the air line is properly
• Worn starting motor connected.
Recommended Repairs Worn Starting Motor

Before you remove the starting motor, turn the
Barring Device
crankshaft by hand. Ensure that a mechanical failure
inside the engine is not preventing the crankshaft
Make sure that the barring device is fully
from turning. If the crankshaft will turn by hand, try
disengaged. Inspect the fittings and the air lines
of the interlock for leaks. the starting motor again. If the starting motor does
not turn the crankshaft, remove the starting motor.
Inspect the starting motor for worn parts.
Electrical Problem
Check the starting motor for worn seals. Plug the
There may be a problem with the starting system’s starting motor’s exhaust outlet and attach a source
electrical circuit. Refer to Troubleshooting, “ECM of pressurized air to the inlet. Submerge the starting
Output Circuit (Starting Motor)”. motor in water for a minimum of 30 seconds. If
bubbles rise from the starting motor, replace the
Low Supply Pressure seals.
Determine the cause of the low supply pressure. If a vane is cracked or if the height of a vane is less
Inspect the supply lines for leaks and/or than 32 mm (1.25 inch), install new vanes.
obstructions. Make the necessary repairs.
If any of the rotor bearings are loose or rough,
Check the compressor for proper operation. replace the bearings.
If a tank is used for the supply pressure, make If the rotor’s body is scored, try to smooth the body
sure that the size of the tank is sufficient. Check with emery cloth. If the body cannot be smoothed
the pressure in the tank. with emery cloth, replace the rotor.
Check the pressure regulator for proper adjustment. If the end plate is scored, use emery cloth to
smooth the end plate.
Lubricator
If the cylinder is cracked or if the cylinder is scored
Check the oil level in the lubricator and adjust the deeply, replace the cylinder.
lubricator according to the engine’s Operation and
Maintenance Manual. i01794080
Inspect the fitting of the lubricator to the air line. Crankcase Pressure (High)
Make sure that the fitting is tight and free of leaks.
SMCS Code: 1901-038; 1916
Disassemble the lubricator and clean the parts.
Inspect the parts for good condition. Replace any
parts that are worn or damaged or replace the
Probable Causes
lubricator.
• Plugged crankcase breather
Control Valve • Problem with the crankcase ventilation system
(if equipped)
Check the control valve’s solenoid for proper
operation. Replace the solenoid, if necessary. • Plugged port on the crankcase pressure sensor
• Faulty sensor
• Internal engine problem
40
Recommended Repairs If a problem with a piston is suspected, do

not operate the engine. Remove the crankshaft
Crankcase Breather inspection covers in order to inspect the cylinder
liner for scoring and for scuffing. Use the barring
A plugged crankcase breather will cause excessive device to move the piston to the uppermost position.
crankcase pressure. Leakage of the crankshaft Replace the piston rings and the cylinder liner, if
seal can occur. Sealing of the piston rings can be necessary.
lost. This will enable crankcase blowby to further
increase the crankcase pressure. i01754197
Clean the crankcase breather according to the Detonation

Operation and Maintenance Manual, “Engine
Crankcase Breather - Clean”. SMCS Code: 1901-038
Crankcase Ventilation System Probable Causes

Engines that use bio-gas may have a system for • Excessive load
ventilation of the crankcase. A problem with the
ventilation system can increase the crankcase • Misfire
pressure. Service the ventilation system according
to the literature that is provided by the OEM of the • Adjustment of needle valves for the precombustion
system. chamber
Plugged Port • High inlet air temperature

The crankcase pressure sensor has a port in order • Incorrect air/fuel ratio
to allow the ambient pressure into the sensor. The
port is enclosed under a cap. Remove the cap and • Coolant in a cylinder
inspect the port for obstructions. Clean the port,
when possible. Otherwise, replace the sensor. • Excessive deposits in the combustion chamber
Faulty Sensor • Faulty circuit for the detonation sensor(s)
If you suspect that the crankcase pressure sensor Recommended Repairs
is faulty, replace the sensor with a sensor that is
known to be good. Excessive Load
Internal Engine Problem Make sure that the load is not excessive. Reduce
the load. If necessary, disengage the driven
If the piston rings do not seal, blowby will increase equipment and test the engine.
the crankcase pressure and the problem will
become worse. Performance will deteriorate. The Misfire
engine will have poor combustion. Deposits will
build up on the pistons, on the valves, and in the If a cylinder is misfiring, the other cylinders can be
cylinder heads. Downward pumping of the pistons overloaded. This will cause the other cylinders to
against the increased crankcase pressure will
detonate. To eliminate the detonation, first eliminate
further reduce the performance. the misfire. Refer to Troubleshooting, “Engine
Misfires, Runs Rough or is Unstable”.
To determine whether the piston rings leak, measure
the crankcase blowby. Refer to the Operation
and Maintenance Manual, “Crankcase Blowby- Needle Valves
Measure/Record”.
Misfire can occur in the precombustion chamber
Sticking of the pistons will also increase the if the air/fuel mixture is too lean. If a cylinder is
crankcase pressure. If the problem is not resolved, misfiring, the other cylinders can be overloaded.
piston seizure will result. This will cause the other cylinders to detonate.
41
Determine whether the adjustment of the needle • Deposits on the valve seats
valves is correct. If the needle valves require
adjustment, fully close all of the needle valves. Then • Deposits on the valve faces
open all of the needle valves for four full turns.
Operate the engine and use an emissions analyzer • Deposits on the cylinder walls that are above the
to obtain the correct level of exhaust emissions. upper limit of the piston stroke
Check the Inlet Air Temperature • Signs of internal leaks

High inlet air temperature can cause detonation. Signs of internal leaks include excessive
Check the inlet air temperature. Look for the consumption of engine oil, blue smoke, and
following event codes: excessive detonation.
• E026 High Inlet Air Temperature Shutdown If excessive deposits and/or signs of internal leaks
are found, investigate the cause of the condition.
• E027 High Inlet Air Temperature Warning Make repairs, as needed.
Refer to Troubleshooting, “Inlet Air Temperature Check the Detonation Sensors

(High)”.
A problem with a detonation sensor or the electrical
Air/Fuel Ratio circuit can cause false indications of detonation.
Troubleshoot the detonation sensors. Refer to
An air/fuel mixture that is too rich will cause Troubleshooting, “Detonation Sensors”.
detonation. A change in the fuel energy content
will change the air/fuel ratio. Obtain a fuel analysis. i01775393
Enter the data into Caterpillar Software Program,
LEKQ6378, “Methane Number Program”. Use the Driven Equipment
Caterpillar Electronic Technician to program the
correct LHV and specific gravity of the fuel into the (Prevention of Operation)
ECM.
SMCS Code: 1901-038
The fuel supply pressure must be adequate and
stable. Probable Causes
Make sure that the electrohydraulic actuator for the • The Electronic Control Module (ECM) has
fuel is operating correctly. received a “Start Inhibit” or a “Shutdown” signal.
Verify that the exhaust emissions are correct. • The circuit for the signal is faulty.
Coolant in a Cylinder Recommended Repairs
Under some circumstances, detonation can occur if
a water/glycol solution leaks into a precombustion Check the Driven Equipment
chamber and the coolant is burned. If a water/glycol
solution is used, monitor the cylinder’s exhaust Determine whether the driven equipment has
port temperature. If the temperature is higher than generated a “Start Inhibit” or “Shutdown”
the average, inspect the cylinder for evidence of request. Determine the cause for the request.
coolant leaks in the precombustion chamber. Service the driven equipment according to the
recommendations of the OEM of the equipment.
Note: Significant leaking of any type of coolant will
cause the cylinder to misfire. Check the Circuit for the Input
Check for Deposits in the Cylinders The circuit for the input is routed to the ECM via
one of the customer connectors in the terminal
Overfilling of engine oil can lead to deposits. Make box. Either the 70-pin connector (J3) or the 47-pin
sure that the engine oil level is correct. connector (J4) can be used. Refer to the engine’s
electrical Schematic. Check the wiring between the
Note: Excessive deposits contribute to guttering of driven equipment and the ECM for damage and/or
the valves. corrosion. Refer to Troubleshooting, “Inspecting
Electrical Connectors”. Repair the wiring, as
Use a borescope to inspect the cylinders. Look for needed.
the following conditions:
42
Check the resistance of the circuit. The correct i01754208

resistance of the circuit is 5 ohms or less. If the
resistance is greater than 5 ohms, locate the source Electrohydraulic System Oil
of the excessive resistance. Make repairs, as Pressure (Low)
needed.
SMCS Code: 1901-038
i01775396
ECM Will Not Accept Factory Probable Causes

Passwords • Incorrect setting of the pressure relief valve
SMCS Code: 1901-038 • Stuck pressure relief valve
Probable Causes • Insufficient oil pressure
One of the following items may not be recorded

• Open electrical circuit for the hydraulic oil
pressure switch
correctly on the Caterpillar Electronic Technician
(ET):
Recommended Repairs
• Passwords
Setting of the Pressure Relief Valve
• Serial Numbers
Check the setting of the pressure relief valve. For
• Total Tattletale instructions, refer to Systems Operation/Testing and
Adjusting, “Engine Governing - Adjust”. Adjust the
• Reason Code pressure relief valve, if necessary.
Recommended Repairs Check the Pressure Relief Valve

1. Verify that the correct passwords were entered. If the pressure relief valve is dirty, the valve can
Check every character in each password. Turn become stuck. If the pressure relief valve is stuck
the engine control switch to the OFF/RESET in the open position, the hydraulic oil pressure will
position for 30 seconds and then retry. be too low.
2. Verify that Cat ET is on the “Factory Password” If you suspect that the pressure relief valve is stuck,
screen. disassemble the valve and clean the parts. Replace
parts, if necessary.
3. Verify that the following information from Cat ET
has been recorded correctly: Low Hydraulic Oil Pressure
• Serial Number of the engine Check the hydraulic oil level. Observe the oil level
in the sight gauge on the tank. If necessary, pour oil
• Serial Number of the Electronic Control Module into the tank until the oil level is between the “ADD”
(ECM) and “FULL” marks on the sight gauge.
• Serial Number of the Cat ET The hydraulic oil pressure switch must remain
closed during engine operation. Use a gauge
• Total Tattletale to check the oil pressure of the electrohydraulic
system at the outlet for the hydraulic pump while the
• Reason Code engine is cranking. Check the pressure while the
engine is at normal operating temperature, when
possible. Compare the pressure to the pressure
that is described in Systems Operation/Testing and
Adjusting, “Engine Governing - Adjust”.
If the pressure is too low, inspect the electrohydraulic

system for leaks. Inspect the hydraulic pump. Make
repairs, as needed.
43
Open Electrical Circuit i01661274
Open Circuit in the Hydraulic Oil Pressure Switch Electronic Service Tool Will
Not Communicate with ECM or
Check for proper operation of the hydraulic oil
pressure switch. Disconnect the engine harness ICSM
from the switch. Apply a known pressure to the
electrohydraulic system. While you apply the SMCS Code: 1901-038
pressure, use a ohmmeter between terminals “A”
and “B” on the switch. Observe the status of the Probable Causes
switch’s contact. If the switch does not function
properly, replace the switch. • Electrical power supply
Open Circuit in the Harness for the Hydraulic Oil • Electrical connectors or wiring harness
Pressure Switch
• Communication adapter and/or cables
Use the following procedure to check the harness.
Do not operate the engine during this procedure. • Personal computer
1. Turn the engine control switch to the STOP
position. Recommended Repairs
2. Disconnect the harness connector from the Electrical Power Supply
pressure switch. Use the Caterpillar Electronic
Technician (Cat ET) to observe the “Hydrax Check power to the ECM and/or the ICSM. Refer to
Pressure Switch Status”. Troubleshooting, “Electrical Power Supply”.
The status of the switch should be “Open”. Note: If the modules are not receiving battery
voltage, the modules will not communicate.
3. Attach a jumper wire between terminals “A” and
“B” on the harness connector. Electrical Connectors
4. Use Cat ET to observe the “Hydrax Pressure Check the following components:
Switch Status”.
• Battery connections and ground to the ECM
The status of the switch should be “Closed”. and/or the ICSM
5. Continue to observe the “Hydrax Pressure Switch • Wiring harnesses and the connectors for the ECM
Status”. Wiggle the harness from the harness and/or the ICSM
connector to the ECM.
• Wiring harnesses and the connectors in the
The status of the switch should still be “Closed”. terminal box for the ECM or the ITSM
If the “Hydrax Pressure Switch Status” • Connections for the personal computer and the
momentarily changes to “Open”, the harness has communication adapter
an intermittent circuit.
Refer to Troubleshooting, “Inspecting Electrical
If there is an intermittent circuit, locate the problem. Connectors”.
Make repairs to the harness, when possible. After
the harness is repaired, remove the jumper wire
from the 3-pin connector. Reconnect the connector.
Communication Adapter and/or Cables
If the harness cannot be repaired, replace the 1. Check the condition of the fuse for the
communication adapter.
harness.
2. Disconnect the communication adapter and the
cables from the service tool connector. Then
reconnect the communication adapter.
If you are using the 7X-1700 Communication

Adapter Gp, refer to Special Instruction,
SEHS9264, “Using the 7X1700 Communication
Adapter Group”.
44
If you are using the 171-4401 Communication Test the Switch

Adapter II, refer to Manual, NEHS0758,
“Communication Adapter II User’s Manual”. The coolant level switch must be closed in order for
the engine to operate. The switch is normally open.
3. Verify that battery voltage is present between The switch must be submerged in fluid in order to
terminal A and terminal B of the service tool become closed.
connector. If the communication adapter is not
receiving power, the display will be blank. Disconnect the switch and remove the switch.
Personal Computer Connect an ohmmeter to the switch’s terminals and

measure the continuity. The correct continuity for the
Use the personal computer and the communication normally open switch is greater than 20,000 ohms.
adapter with a different known good ECM. If the
same problem occurs with a different engine, check Continue to monitor the ohmmeter and submerge
the personal computer and the related equipment the switch in water. The correct continuity for the
in order to determine the cause of the problem. closed switch is less than 5 ohms.
If the correct results are not obtained or if the switch

i01779016 does not close, replace the switch.
Engine Coolant Level (Low) If the correct results are obtained, there may be an
open circuit in an electrical connection or in the
SMCS Code: 1395-038 wiring. Use the ohmmeter to measure the resistance
of the wiring. Refer to the engine’s electrical
Probable Causes Schematic. Make repairs, if necessary.
• Low engine coolant level i01754210
• Problem with an electrical connection or with the Engine Coolant Temperature

wiring
(High)
• Problem with the coolant level switch
SMCS Code: 1378-070
Recommended Repairs
Probable Causes
Low Engine Coolant Level
• Low coolant level and/or coolant leakage
Check the coolant level. Add coolant, if necessary.
• Aeration of the coolant
Normally, the engine does not consume any coolant.
Inspect the cooling system for leaks. • Problem with the water pump
If no external leaks are found and the coolant level • High ambient temperature and/or high inlet air
temperature
cannot be maintained, there may be an internal leak.
Make repairs, if necessary. • Insufficient flow of air or coolant through the

radiator or through the heat exchanger
Electrical Connections or Wiring • Faulty water temperature regulators
There may be a problem with an electrical • Faulty coolant temperature sensor and/or circuit
connection or with the wiring. Thoroughly inspect
the electrical connectors and all of the wiring for • Insufficient flow of coolant through the engine
the switch. Refer to Troubleshooting, “Inspecting
Electrical Connectors” and refer to the engine’s • Exhaust restriction
electrical Schematic. Make repairs, if necessary.
• Excessive load
• Incorrect air/fuel ratio
45
• Combustion gas in the coolant Determine the cause of the high air temperature.
Make corrections, when possible.
Recommended Repairs
Check for Insufficient Flow of Air and
Check for a Low Coolant Level and/or Coolant Through the Radiator or Heat
Coolant Leakage Exchanger
Note: Low coolant level can be the effect of Measure the coolant temperature at the inlet for the
overheating rather than the cause. coolant.
Check the coolant level. Radiator
Run the engine to operating temperature. Inspect Check the fins of the radiator for obstructions.
the cooling system for leaks. Check the fan for proper operation.
Determine whether the leak occurs before the If the radiator fins are obstructed, clean the fins.
engine overheats. If the fan does not operate properly, make the
necessary repairs.
Add coolant, if necessary. If leaking is found, make
the necessary repairs. Heat Exchanger
Check for sufficient flow and temperature of the

Check for Aeration of the Coolant cooling water through the heat exchanger. If the
Air can enter the cooling system if the pressure flow of cooling water through the heat exchanger
is insufficient, determine the location of the
cap is not operating properly. Check the operation
obstruction.
of the pressure cap. Replace the pressure cap, if
necessary.
Check the Water Temperature Regulators
Install a ball check valve at the outlet of the water
pump. Start the engine. Open the ball check valve Check the water temperature regulators for proper
in order to check for aeration of the coolant. If air operation. Refer to Systems Operation/Testing and
bubbles are found in the coolant, determine the Adjusting, “Cooling System”.
source of the air.
Replace the water temperature regulators, if
If the coolant has been changed recently, make necessary.
sure that the air has been purged from the cooling
system. Make sure that the cooling system is Check the Coolant Temperature Sensor
properly vented. and/or the Circuit
The supply pressure to the water pump must be Check the reading of the coolant temperature on
sufficient in order to prevent cavitation. Measure the the Caterpillar Electronic Technician (Cat ET). The
supply pressure at the inlet to the water pump. temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable.
Water Pump
If the reading on Cat ET for the coolant temperature
The engine will overheat if the water pump is not is not reasonable, troubleshoot the circuit
operating properly. Measure the coolant pressure at and the coolant temperature sensor. Refer to
the outlet of the water pump. Make sure that the Troubleshooting, “Analog Sensor Signal”.
water pump is in good condition.
Check the Flow of Coolant Through the
Check for High Ambient Temperature Engine
and/or High Inlet Air Temperature
During normal operation, check the inlet pressure
Determine if the ambient air temperature is within of the engine coolant and the outlet pressure of the
the design specifications for the cooling system. engine coolant.
Make sure that the engine’s exhaust does not heat Measure temperatures and pressures at various
the radiator or the heat exchanger. points in the cooling system in order to identify
possible locations of restrictions.
Check for high inlet air temperature. Refer to
Troubleshooting, “Inlet Air Temperature (High)”.
46
If a buildup of deposits restricts the coolant flow, When a suspect cylinder is identified, shut down
clean the cooling system. the engine. Inspect the spark plug for moisture and
for evidence of deposits from coolant. Remove the
If the flow of coolant through the engine is not combustion sensor and insert a borescope through
sufficient, determine the cause of the obstruction. the opening. Inspect the precombustion chamber
Make necessary repairs. for evidence of coolant. If evidence of coolant is
found, replace the seals. Refer to the engine’s
Check the Exhaust Restriction Disassembly and Assembly manual.
Check the back pressure of the exhaust system. i01754215

Refer to the engine’s Technical Marketing
Information. Engine Coolant Temperature
If the back pressure exceeds the specifications for (Low)
the engine, determine the cause of the excessive
back pressure. Make the necessary repairs. SMCS Code: 1901-038
Excessive Load Probable Causes

Make sure that the load is not excessive. Reduce • Faulty jacket water heater
equipment and test the engine. • Faulty coolant temperature sensor and/or circuit
Air/Fuel Ratio • Faulty water temperature regulators
An air/fuel mixture that is too rich will cause Recommended Repairs

overheating. A change in the fuel energy content
will change the air/fuel ratio. Obtain a fuel analysis. Check the Jacket Water Heater
The fuel supply pressure must be adequate and Determine if the jacket water heaters are functioning
stable. properly.
Ensure that the electrohydraulic actuator for the fuel If the jacket water heaters are not functioning
is operating correctly. properly, determine the cause of the malfunction of
the heaters. Make the necessary repairs.
Verify that the exhaust emissions are correct.
Check the Coolant Temperature Sensor
Check for Combustion Gas in the Coolant
and/or the Circuit
The following conditions can indicate that
combustion gas is entering the cooling system: Check the reading of the coolant temperature on
the Caterpillar Electronic Technician (Cat ET). The
temperature should rise steadily as the engine is
• Steam is escaping from the expansion tank. warmed. Ensure that the temperature is reasonable.
• A cylinder is misfiring. If the reading on Cat ET for the coolant temperature
is not reasonable, troubleshoot the circuit
• The cylinder temperature is too hot or too cold. and the coolant temperature sensor. Refer to
If a leaking precombustion chamber is suspected, Troubleshooting, “Analog Sensor Signal”.
operate the engine at a low load. Monitor the
exhaust port temperatures and the combustion burn
times.
47
Check the Water Temperature Regulators Cold Engine

The water temperature regulators should not If the engine is too cold, the engine may not start.
begin to open until jacket water reaches opening Refer to Application and Installation, LEKQ7249,
temperature for the regulators. Allow the engine “Ambient Considerations”.
to cool and then start the engine. Check the hose
at the outlet for the jacket water. If the hose is Excessive Load
warm and normal operating temperature is not
achieved yet, a regulator may be stuck open. A Make sure that the load is not excessive. Reduce
water temperature regulator that is stuck open can the load. If necessary, disengage the driven
result in piston seizure. equipment and test the engine.
Check the operation of the water temperature
regulators according to Systems Operation/Testing
Air Choke
and Adjusting, “Cooling System”. Replace the water
temperature regulators, if necessary. The air choke is maintained at a fixed position
during start-up. If the air choke is closed too far,
there may be insufficient air for combustion. If the
i01775398 air choke is opened too far, the air/fuel mixture may
be too rich for combustion.
Engine Cranks but Will Not
Start Make sure that the programmable “Engine Start
Choke Position” is correct. Refer to Systems
SMCS Code: 1000-038; 1901-038 Operation/Testing and Adjusting, “Electronic Control
System Parameters”.
Probable Causes Inlet Air Restriction

• Slow cranking The air filter elements may be plugged. For
optimum operation, replace the air filter elements
• Cold engine when the inlet air restriction reaches 2.5 kPa
(10 inches of H2O). The maximum allowable inlet air
• Excessive load restriction is 3.75 kPa (15 inches of H2O).
• Incorrect starting position for the air choke If the inlet air restriction is excessive, determine the
cause of the restriction and correct the condition.
• Inlet air restriction
• Problem with the air/fuel mixture Air/Fuel Mixture
• Fuel pressure is present during initial cranking. The following conditions can cause the engine to
malfunction:
• Problem with the gas shutoff valve
• Low fuel pressure
• Electrical connectors or power supply
• High fuel pressure
• No signal from the engine speed/timing sensor
• Poor fuel quality
• Ignition system
• Incorrect air/fuel ratio
Recommended Repairs Make sure that fuel is supplied at a sufficient
pressure that is stable. Make sure that the size of
Slow Cranking the fuel line is sufficient. Inspect the fuel system
for leaks. Inspect the fuel filter, the gas pressure
The cranking speed must be sufficient for engine regulator, the gas shutoff valve, and the gas shutoff
start-up. Inspect the starting system. Make sure valve’s solenoid.
that the air supply has sufficient pressure. If the
starting motor is suspect, refer to Troubleshooting, When possible, interview the operator in order
“Air Starting Motor”. to determine if fuel quality is in question. Try to
determine if the source of the fuel was changed.
48
Check the needle valves for the precombustion The fuel actuator may be stuck. Make sure that the
chambers. If the needle valves are closed, no fuel actuator can move smoothly. Inspect the actuator
is supplied to the precombustion chamber. If the according to Operation and Maintenance Manual,
needle valves are open too far, the air/fuel mixture “Electrohydraulic Actuator - Inspect”. Recondition
will be too rich for combustion. the actuator, if necessary.
If the adjustment of the needle valves is suspect, Gas Shutoff Valve

fully close all of the valves. Open the needle valves
for four full turns. Adjust the needle valves according During cranking, measure the pressure in the fuel
to Systems Operation/Testing and Adjusting, “BTU manifold. The gas pressure must be 1 to 10 kPa
and Precombustion Chamber Adjustments”. (0.15 to 1.5 psi). If the pressure is zero, the gas
shutoff valve may not be operating properly. Refer
Check the position of the air choke’s plate. The to the Operation and Maintenance Manual, “Gas
orientation of the plate is represented by the groove Shutoff Valve - Inspect”.
on the end of the shaft for the choke plate. The
air choke is opened for start-up. If the air choke
is closed, the air/fuel mixture will be too rich for
Electrical Connectors or Power Supply
combustion. If the air choke is open too far, the
air/fuel mixture will be too lean. Make sure that the There may be an intermittent interruption of power.
Check the wiring harnesses and the connectors.
programmable starting position for the air choke is
correct. Inspect the connectors in the terminal box. Inspect
the battery connections and the ground.
During cranking, the fuel actuator begins to open
at approximately 50 rpm. The actuator opens for Inspect the wiring from the battery to the Electronic
approximately 5 to 10 percent of the full travel. If the control Module (ECM). Inspect the wires and
the power relay. Check the power and ground
actuator opens for more than 30 percent, the fuel
connections. Refer to Troubleshooting, “Electrical
pressure is probably too low.
Power Supply”.
Make sure that the actuator and the linkage are
Make sure that the run relay is activated. Refer to
operating properly. For information on maintaining
the actuator, refer to the Operation and Maintenance Troubleshooting, “ECM Status Indicator Output”.
Manual, “Electrohydraulic Actuator - Inspect”. For
information on troubleshooting the actuator, refer to Engine Speed/Timing Sensor
Troubleshooting, “Fuel Actuator Solenoid”.
Make sure that the engine speed/timing sensor
and the timing wheel are installed correctly. If the
Fuel Pressure is Present During Initial
engine speed/timing sensor is suspect, refer to
Cranking Troubleshooting, “Engine Speed/Timing Sensor”.
If fuel pressure is present before the fuel command,
the engine will not start. Ignition System
Under certain conditions, condensation forms on
If an unexpected shutdown or a fast shutdown
the spark plugs after the engine is shut down.
occurred, the fuel actuator may have remained
open. If service was performed on the actuator, The condensation can prevent the engine from
restarting.
the actuator may have remained open. Before you
crank the engine again, make sure that the actuator
is closed. Maintain the spark plug according to Operation and
Maintenance Manual, “Ignition System Spark Plugs
- Check - Adjust”.
Inspect the fuel actuator and the actuator’s linkage.
Inspect the rod ends for damage and/or for wear.
Inspect the ignition transformers for loose
Make sure that the components are fastened
connections, for moisture, for short circuits, and for
securely. Make corrections, if necessary.
open circuits. Inspect the primary wiring and the
secondary electrical connections. For information
Make sure that the linkage is adjusted according to
on troubleshooting the ignition system, refer to
the engine’s Specifications, “Fuel Control”.
Troubleshooting, “Ignition Transformers Primary
Circuit” and Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plug”.
49
Make sure that the correct transformers and spark Cold Cylinder
plugs are installed. Inspect the extenders for signs
or pin holes and arcing. Before you can determine the cause of the cold
cylinder, use the display on the control panel in
order to locate the cold cylinder. You can view the
i01754229
actual combustion burn times and the exhaust port
Engine Misfires, Runs Rough temperatures of the cylinders.
or Is Unstable For detailed information on detection of misfire and

false misfire, refer to Systems Operation/Testing
SMCS Code: 1000-038; 1901-038 and Adjusting, “BTU and Precombustion Chamber
Adjustments”.
Probable Causes
Spark Plug
• Cold cylinder
Under certain conditions, condensation forms on
• Spark plug the spark plugs after the engine is shut down. The
condensation can cause misfire.
• Check valve
A spark plug may require service. Maintain
• Incorrect maximum position for the air choke the spark plug according to Operation and
Maintenance Manual, “Ignition System Spark Plug -
• Incorrect air/fuel ratio Check/Adjust”.
• Needle valve Check Valve

• Spark plug’s extension Passages for the fuel to the precombustion
chamber’s check valve may be blocked by
• Ignition transformer contaminants in the air/fuel mixture. Make sure that
the passages are clean. Make sure that the air and
• Air/fuel pressure module the fuel are properly filtered.
• Gas admission valve Combustion may have leaked past the check
valve’s gasket. During operation, check the
• Precombustion chamber temperature of the supply tube for the needle valve.
If the temperature of the supply tube is higher than
• Fuel supply lines for the precombustion chamber average, combustion is probably leaking into the
cylinder head. Remove the check valve and inspect
• Valve lash the check valve for evidence of combustion on the
outside of the check valve’s body.
• Cylinder head and related components
The check valve may be stuck. The check valve
• Incorrect electrical connection or power supply must move freely in order to allow fuel to enter the
precombustion chamber. Clean the check valve with
• Incorrect connections to the Integrated a nonflammable solvent that will not leave residue.
Combustion Sensing Module (ICSM) Replace the check valve, if necessary.
• Air inlet restriction Air Choke

• Problem with the electrohydraulic system If the air choke opens fully at no load or at a low
load, the air choke cannot provide a further increase
• Driven equipment in the inlet manifold air pressure. The wastegate
will begin to control the inlet manifold air pressure.
Recommended Repairs The result is an excessive flow of fuel and a period
of misfire.
Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine Make sure that the programmable “Maximum
operating temperature, etc), test the engine under Choke Position” is correct. Refer to Systems
the conditions. Troubleshooting the symptom under Operation/Testing and Adjusting, “Electronic Control
other conditions can give misleading results. System Parameters”.
50
Air/Fuel Ratio Precombustion Chamber

Operate the engine with a different air/fuel mixture Inspect the precombustion chamber. For instructions
in order to determine if the misfiring is affected by on removal and installation, refer to Disassembly
the air/fuel ratio. To change the air/fuel ratio, operate and Assembly, “Prechamber Check Valve - Remove
the engine in the prechamber calibration mode. Use and Install”.
the Caterpillar Electronic Technician to change the
setting of the fuel’s BTU. The precombustion chamber’s gasket and/or the
ignition body’s seals may have allowed coolant to
If the rate of misfiring changes, use an emissions enter the precombustion chamber. Inspect the spark
analyzer and tune the engine according to Systems plug and the precombustion chamber for evidence
Operation/Testing and Adjusting, “BTU and of coolant and residue of liquid crystalline material.
Precombustion Chamber Adjustments”. If the gasket and/or the seals have leaked, clean
the sealing surfaces and install a new gasket and
Needle Valve seals. Also check for coolant leaks at the bottom of
the cylinder head.
Check the needle valves for the precombustion
chambers. If the needle valves are closed, no fuel Remove the combustion sensor and use a
is supplied to the precombustion chamber. If the borescope to view the hole for the spark plug in the
needle valves are open too far, the air/fuel mixture precombustion chamber. For a two-piece ignition
will be too rich for combustion. If the adjustment body / precombustion chamber, the locating pins
of the needle valves is suspect, fully close all of may be broken. This would allow the precombustion
the needle valves. Open the needle valves for four chamber to move and the hole for the spark plug
full turns. Adjust the needle valves according to could be misaligned. If this is the case, remove the
Systems Operation/Testing and Adjusting, “BTU and ignition body and the precombustion chamber in
Precombustion Chamber Adjustments”. order to make the necessary repairs.
Make sure that the fuel lines for the needle valves Fuel Supply Lines for the Precombustion
are not clogged. Chamber
If adjustment of a needle valve does not affect Inspect the fuel supply lines and the passages
operation, the needle valve may be faulty. Replace between the needle valve and the check valve.
the needle valve. Look for signs of debris and carbon buildup. Make
sure that the lines and passages are clean.
Spark Plug Extension
Multiple problems with a check valve for a particular
Inspect the outside of the extension for oil and cylinder can be caused by fuel supply lines and
moisture. Look for holes that are burned through passages that are dirty.
the extension’s insulator. Inspect the extension’s
terminals for corrosion. Valve Lash
Ignition Transformer Check the valve lash. Refer to Systems
Operation/Testing and Adjusting, “Engine Timing
Inspect the ignition transformers for loose Procedures”.
connections, moisture, short circuits, and open
circuits. Inspect the primary wiring and the Cylinder Head and Related Components
secondary electrical connections. For information
on troubleshooting the ignition system, refer to Measure the cylinder compression. Refer to
Troubleshooting, “Ignition Transformers Primary Operation and Maintenance Manual, “Cylinder
Circuit” and Troubleshooting, “Ignition Transformers Pressure - Measure/Record”.
Secondary Circuit and Spark Plug”.
Inspect the components of the valve train for good
Gas Admission Valve condition. Check for signs of damage and/or for
wear to the valves, cylinder head gasket, etc.
Check the gas admission valve lash. Refer to Inspect the condition of the camshafts. If a camshaft
Systems Operation/Testing and Adjusting, “Engine is replaced, new valve lifters must be installed.
Timing Procedures”.
51
Electrical Connection or Power Supply Driven Equipment

There may be an intermittent interruption of power. Make sure that the load is not excessive. Reduce
Check the wiring harnesses and the connectors. the load. If necessary, disengage the driven
Inspect the connectors in the terminal box. Inspect equipment and test the engine.
the battery connections and the ground.
Variation of the load can cause instability. Make sure
Inspect the wiring from the battery to the Electronic that the signal for the engine speed is not corrupted.
Control Module (ECM). Inspect the wires and
the power relay. Check the power and ground
i01754241
connections. Refer to Troubleshooting, “Electrical
Power Supply”. Engine Oil Filter Differential
Incorrect Connections to the ICSM Pressure
If the wiring from the combustion sensors to the SMCS Code: 1308-035
ICSM is not connected correctly, false misfire can
be indicated. The exhaust temperatures will be Probable Causes
normal but the combustion burn times can be
excessive because the ICSM is not monitoring the An indication of high engine oil filter differential
correct firing order. pressure will be caused by either of the following
conditions:
Make sure that the wiring from the cylinders to the
ICSM is correct. • Plugged engine oil filter element
Air Inlet Restriction • Faulty engine oil pressure sensor
The maximum allowable air inlet restriction is • Cold engine oil
3.75 kPa (15 inches of H2O). If the indication is
higher than the maximum permissible restriction, An indication of low engine oil filter differential
clean the filter element or install a new filter element. pressure will be caused by either of the following
Check the restriction again. If the restriction remains conditions:
too high, inspect the air inlet piping for obstructions.
• An engine oil filter element is missing or an
Electrohydraulic System element is damaged.
Make sure that the hydraulic oil is not contaminated. • Faulty engine oil pressure sensor
Make sure that the electrohydraulic actuators are Recommended Repairs

operating properly. During operation at a load that
is less than 50 percent, observe the operation of the Engine Oil Filter Element
air choke actuator. During operation at a load that is
greater than 50 percent, observe the operation of As the engine oil filter elements become plugged,
the wastegate actuator. the engine oil filter differential pressure rises.
Replace the engine oil filters when the engine oil
The governor gain may require adjustment. Refer filter differential pressure reaches 100 kPa (15 psi).
to Systems Operation/Testing and Adjusting,
“Governor Adjustment Procedure”. If an engine oil filter element is missing or the
element is damaged, the unfiltered engine oil will
If a solenoid for an actuator is suspect, switch the cause low engine oil filter differential pressure. Make
solenoid for another solenoid that is known to be sure that elements are installed in the engine oil filter
good. Obtain a new solenoid, if necessary. housings. Inspect the engine oil filter elements for
good condition. Replace any suspect filter element.
Make sure that the linkage moves freely. If any rod
ends are worn, replace the rod ends.
Engine Oil Pressure Sensors
If an actuator is suspect, inspect the actuator
according to Operation and Maintenance Manual, Use the Caterpillar Electronic Technician to compare
“Electrohydraulic Actuator - Inspect”. the readings for the filtered engine oil pressure and
the unfiltered engine oil pressure while the engine
is OFF.
52
If the readings are not approximately zero for both Connect an ohmmeter to the switch’s terminals and
of the sensors, there is a problem with a sensor. measure the continuity. The correct continuity for the
Replace the sensor. normally open switch is greater than 20,000 ohms.
Continue to monitor the ohmmeter and submerge

i01779066
the switch in water. The correct continuity for the
Engine Oil Level (Low) closed switch is less than 5 ohms.
SMCS Code: 1348-038 If the correct results are not obtained or if the switch
does not close, replace the switch.
Probable Causes If the correct results are obtained, there may be an

open circuit in an electrical connection or in the
• Low engine oil level wiring. Use the ohmmeter to measure the resistance
• Problem with an electrical connection or with the Schematic. Make repairs, if necessary.
wiring
• Problem with the coolant level switch i01754254
Engine Oil Pressure (Low)

Recommended Repairs
SMCS Code: 1901-038
Low Engine Oil Level
Probable Causes
Check the engine oil level. Add engine oil, if
necessary. • Low engine oil level
If you suspect that the engine is consuming • Incorrect viscosity
an excessive amount of engine oil, refer
to Troubleshooting, “Excessive Engine Oil • Contaminated engine oil
Consumption”.
• Faulty oil pressure sensors
If the engine has a system for automatically filling
the crankcase with engine oil, check the system’s • Improper circulation of the engine oil
supply. Make sure that the supply of engine oil is
adequate. Make sure that the system is operating • Worn components
correctly.
Make repairs, if necessary. Recommended Repairs
Electrical Connections or Wiring Low Engine Oil Level
There may be a problem with an electrical Check the oil level. Add oil, as needed.
connection or with the wiring. Thoroughly inspect
the electrical connectors and all of the wiring for Contaminated Engine Oil
the switch. Refer to Troubleshooting, “Inspecting
Electrical Connectors” and refer to the engine’s Engine oil that is contaminated with another liquid
electrical Schematic. Make repairs, if necessary. will cause low engine oil pressure. High engine
oil level can be an indication of contamination.
Test the Switch Obtain an analysis of the engine oil. Determine the
reason for contamination of the engine oil and make
The engine oil level switch must be closed in order the necessary repairs. Change the engine oil and
for the engine to operate. The switch is normally the engine oil filter. For the correct engine oil to
open. The switch must be submerged in fluid in use, refer to Operation and Maintenance Manual,
order to become closed. “Engine Oil”.
Disconnect the switch and remove the switch.

53
Incorrect Viscosity Worn Components

Make sure that the engine is supplied with the Excessive clearance at the crankshaft or camshaft
correct engine oil. For the correct engine oil to bearings will cause low engine oil pressure. Also,
use, refer to Operation and Maintenance Manual, inspect the clearance between the rocker arm
“Engine Oil”. shafts and the rocker arms. Check the engine
components for excessive clearance.
Faulty Engine Oil Pressure Sensors
Obtain an analysis of the engine oil. Check the
Use the Caterpillar Electronic Technician to compare analysis for the level of wear metals in the engine oil.
the readings of the filtered engine oil pressure and
the unfiltered engine oil pressure while the engine i01754263
is OFF. Both readings should be close to zero
pressure. Engine Oil Temperature (High)
If a reading is significantly different from zero, SMCS Code: 1378-070
replace the suspect engine oil pressure sensor.
Probable Causes
Improper Circulation of the Engine Oil
• Contaminated engine oil
Several factors could cause improper circulation of
the engine oil: • Problem with the engine oil temperature regulators
• The engine oil filter is clogged. Replace the • Problem with the engine oil temperature sensor
engine oil filter.
• Problem with the circuit for the aftercooler and
• An engine oil line or a passage for engine oil is engine oil cooler
disconnected or broken.
• Insufficient flow of coolant or engine oil through
• The engine oil cooler is clogged. Thoroughly the engine oil cooler
clean the engine oil cooler.
• Mechanical friction
• There is a problem with a piston cooling jet.
Breakage, a restriction, or incorrect installation
of a piston cooling jet will cause seizure of the Recommended Repairs
piston.
Contaminated Engine Oil
• The inlet screen of the suction tube for the engine
oil pump can have a restriction. This restriction Engine oil that is contaminated with another liquid
will cause cavitation and a loss of engine oil can cause low engine oil temperature. High engine
pressure. Check the inlet screen on the suction oil level can be an indication of contamination.
tube and remove any material that may be Obtain an analysis of the engine oil. Determine the
restricting engine oil flow. reason for contamination of the engine oil and make
the necessary repairs. Change the engine oil and
• The suction tube is drawing in air. Check the joints the engine oil filter. For the correct engine oil to
of the tube for cracks or a damaged O-ring seal. use, refer to Operation and Maintenance Manual,
“Engine Oil”.
• There is a problem with the engine oil pump.
Check the gears of the engine oil pump for Check the Engine Oil Temperature
excessive wear. Engine oil pressure is reduced
by gears that have too much wear. Regulators
Make sure that the engine oil temperature regulators
• The engine oil pump’s pressure regulating valve open according to the correct values. Refer to
or a bypass valve is stuck in the open position.
Clean the valve. Replace parts, if necessary. Specifications, “Engine Oil Temperature Regulators”.
• The priority valve is stuck in the open position.

Clean the priority valve.
54
Check the Engine Oil Temperature • There is a problem with the relay for the starting
Sensor motor’s solenoid.
Check the reading of the engine oil temperature • The ignition system is not functioning.
on the Caterpillar Electronic Technician (Cat ET).
Compare the reading to a reading from a separate • The quality of the gas does not match the “Fuel
device. The temperature should rise steadily as the Quality” parameter.
engine is warmed.
Recommended Repairs
If the reading on Cat ET for the engine oil
temperature is not reasonable, replace the engine Excessive Load
oil temperature sensor.
Make sure that the load is not excessive. Reduce
Check the Cooling System the load. If necessary, disengage the driven
equipment and test the engine.
Make sure that the heat exchanger for the engine
oil cooler and the aftercooler is operating properly. Crank Cycle
The heat exchanger must be properly sized for
the ambient conditions. Check the plumbing for
Note: A maximum of one crank cycle per overcrank
obstructions. is recommended.
Check the Flow Through the Engine Oil Make sure that the engine can be cranked for
Cooler a sufficient amount of time. Use the Caterpillar
Electronic Technician to check the “Cycle Crank
Run the engine at normal operating temperature. Time” and the “Overcrank Time” parameters.
Determine the pressure differential for the coolant Remember that the purge cycle is part of the
and for the engine oil between the inlet and the total crank cycle. Reprogram the parameters,
outlet of the engine oil cooler. For comparative data, if necessary. For instructions, refer to Systems
refer to the Technical Marketing Information for the Operation/Testing and Adjusting, “Electronic Control
engine. System Parameters”.
If the pressure differential between the inlet and the Check the Gas Supply to the Engine
outlet of the engine oil cooler exceeds the data that
is published for the engine, there is an insufficient Check for low gas pressure. If the gas pressure is
flow of coolant or of engine oil through the engine low, refer to Troubleshooting, “Fuel Pressure”.
oil cooler. Clean the engine oil cooler.
If the gas shutoff valve is closed, refer to Operation
Mechanical Friction and Maintenance Manual, “Gas Shutoff Valve -
Inspect”.
Friction of gears and/or of bearings will raise the
engine oil temperature. Measure the engine oil Check the Status of the Relay for the
temperature at various locations in order to locate
Starting Motor’s Solenoid
the hot spot. Obtain an analysis of the engine oil.
Make the necessary repairs.
Attempt to start the engine while you observe the
status of the relay for the starting motor’s solenoid
i01754269 on the control panel’s display.
Engine Overcrank If the status of the relay for the starting motor’s
solenoid indicates that the engine should crank but
SMCS Code: 1901-038 no cranking occurs, troubleshoot the starting circuit.
Refer to Troubleshooting, “ECM Output Circuit
Probable Causes (Starting Motor)”.
If the engine should crank and cranking occurs,

• Excessive load check the engine rpm.
• The programmed crank cycle time is insufficient.
• The gas supply to the engine is insufficient.
55
Check the Engine RPM Obtain a Fuel Analysis and Program the
Fuel Energy Content
The Electronic Control Module (ECM) must detect a
minimum of 50 rpm before the gas and the ignition Obtain an analysis of the gas in order to determine
are supplied to the engine. Monitor the engine the LHV. Program the correct LHV for the “Fuel
speed while you crank the engine. Quality” configuration parameter.
The minimum recommended cranking speed is 80 If the quality of the gas is not consistent, obtain
rpm. several analyses over a period of time. Program
the “Fuel Quality” configuration parameter to the
The maximum recommended cranking speed is average value of the LHV.
150 rpm.
i01754360
Ignition System
Check for active diagnostic codes that relate to
Engine Overspeed
the ignition system. If there is at least one active SMCS Code: 1000-038; 1901-038
diagnostic code that relates to the ignition system,
troubleshoot the diagnostic code.
Probable Causes
Check the Fuel Quality
• Slow governor response
Compare the Low Heat Value (LHV) of the gas
supply to the “Fuel Quality” parameter that is • Low trip point for engine overspeed
programmed by the customer into the ECM. The
ECM uses the setting for start-up and for air/fuel • Binding of the electrohydraulic actuator for the
ratio control at low loads. fuel
If the LHV of the fuel does not match the “Fuel • Energy of the driven equipment
Quality” parameter that is programmed into the
ECM, program the ECM with the correct setting for Recommended Repairs
the “Fuel Quality” parameter.
Check for Slow Governor Response
i01643832
If an engine overspeed occurs during start-up or
Engine Overload when the load is reduced, the governor response
may be slow.
SMCS Code: 1901-038
Observe the “Speed Governor Adjustment” screen
on the Caterpillar Electronic Technician (Cat ET).
Probable Causes Look for the engine response to the worst cases for
step-loading and unloading.
• Driven equipment
Use “Throttle Bump” feature of Cat ET in order
• Misfire to disturb steady state engine operation. If the
undershoot or the overshoot of the engine speed
• The LHV of the gas or the specific gravity of the is excessive, adjust the governor’s gain. Refer
gas is significantly different from the value that is
to Systems Operation/Testing and Adjusting,
programmed.
“Electronic Control System Parameters”.
Recommended Repairs Check the Trip Point

Driven Equipment Note: Do not program the trip point for engine
overspeed higher than the maximum ratings of the
Make sure that the load is not excessive. Reduce driven equipment.
the load.
The trip point or engine overspeed may be too low.
Misfire Verify that the trip point for the engine overspeed
is properly programmed.
A cold cylinder will cause the other cylinders to
overload. Refer to Troubleshooting, “Engine Misfires,
Runs Rough or Is Unstable”.
56
This parameter requires a factory password in order Check the Exhaust

to change the trip point. Change the trip point to an
acceptable speed. For a prelube pump that operates with pressurized
air, make sure that the exhaust is not restricted.
Check for Binding of the Electrohydraulic
Actuator Check the Engine Oil Supply
Slide the electrohydraulic actuator’s rod in and out Check the engine oil level. Add oil until the oil level
while you feel the motion. If the motion is sticky is between the “ADD” and “FULL” marks on the oil
and/or rough, investigate the cause of the binding. level gauge. Inspect the lubrication system for leaks.
Make the necessary repairs. Refer to Operation and
Maintenance Manual, “Electrohydraulic Actuator - If the supply of engine oil is correct, look for leaks
Recondition”. in the oil lines for the prelube pump. Make sure that
the supply of engine oil is not obstructed. Make
repairs, as needed.
Check the Driven Equipment
Determine if the driven equipment has additional Check the Power Source for the Prelube
inputs of energy that could drive the engine beyond Pump
the rated rpm. Make corrections to the installation in
order to prevent the overspeed from recurring. Make sure that the output for the prelube pump is
activated. Refer to Troubleshooting, “ECM Output
Circuit (Prelubrication Oil Pump)”.
i01640899
Engine Pre-Lube Pressure Check the Prelube Pump’s Pressure

(Low) Switch
SMCS Code: 1901-038 The prelube pump’s pressure switch must close
before the starting motor relay will be energized.
Make sure that the switch operates correctly. Refer
Probable Causes to Troubleshooting, “Prelubrication System”.
• Low air supply pressure Inspect the Prelube Pump

• Low level of lubricant in the lubricator The prelube pump may have a mechanical problem.
Inspect the prelube pump. For instructions on
• Restriction of the prelube pump’s exhaust removal and disassembly, refer to Disassembly and
Assembly, SENR5535.
• Problem with the supply of engine oil
• Electrical problem i01775404
• Problem with the prelube pump’s pressure switch Engine Shutdown

• Problem with the pump SMCS Code: 1901-038
Recommended Repairs Probable Causes

Check the Air Supply Pressure • The “Emergency Stop” button is pressed.
For a prelube pump that operates with pressurized • The circuit for the emergency stop or the normal
stop switch is faulty.
air, make sure that the air supply pressure is
adequate. Inspect the system for leaks.
• Either switch is activated by excessive vibration.
Check the Lubricator
For a prelube pump that operates with pressurized
air, make sure that the lubricator is adequately filled
with the correct lubricant.
57
Recommended Repairs • A shutdown has been requested by the driven

equipment.
Emergency Stop
• There is a problem with the “Run” relay.
Ask the operator if the stop was intentional. Make
sure that the reason for the stop has been corrected. • The “Crank Terminate Speed” is incorrectly
Reset the control system. Resume normal operation. programmed.
If the stop was accidental, reset the control system. • The “Cycle Crank Time” is incorrectly
Resume normal operation. programmed.
Check the Circuit for the Stop Switches • The “Engine Overcrank Time” is incorrectly
programmed.
Note: The circuit for the normal stop switch and the
circuit for the emergency stop switch must remain • The delay time for the driven equipment is
excessive.
closed in order for the engine to run.
Inspect the wiring between the switches and the Recommended Repair
connector of the Electronic Control Module (ECM).
Look for damage and/or for corrosion. Refer to Check the Circuit for the GSOV
Troubleshoot for the following diagnostic codes:
Troubleshoot the engine control switch according to
Troubleshooting, “Electrical Power Supply”. • 17-05 Fuel Shutoff Valve open circuit
Inspect the Stop Switches • 17-06 Fuel Shutoff Valve short to ground
Inspect the stop switches for evidence of damage • 17-12 Fuel Shutoff Valve malfunction
that has been caused by vibration. Disassemble the
switches. Inspect the components for looseness, Refer to Troubleshooting, “ECM Output Circuit (Fuel
cracks, and abrasion. Use an ohmmeter and toggle Control)”. Make repairs, as needed.
the switches in order to check for proper electrical
operation. Check the Inputs to the ECS
Replace any faulty components. Troubleshoot for the “336-02 Incorrect ECS Switch
inputs” diagnostic code.
i01727612
Refer to Troubleshooting, “Electrical Power Supply”.
Engine Shutdown Make repairs, as needed.
(Unexpected) Check the Relay for the Prelube
SMCS Code: 1901-038
Troubleshoot for the following diagnostic codes:
Probable Causes • 338-05 Pre-Lube Relay open circuit

• There is a problem with the Gas Shutoff Valve • 338-06 Pre-Lube Relay short to ground
(GSOV).
Refer to Troubleshooting, “ECM Output Circuit
• Incorrect input(s) to the Engine Control Switch (Prelubrication Oil Pump)”. Make repairs, as
(ECS) needed.
• There is a problem with the relay for the prelube. Check the Pressure Switch for the
• There is a problem with the switch for the prelube. Prelube
Troubleshoot for the “339-05 Engine Pre-Lube
• There is a problem with the “Crank Terminate” Pressure Switch open circuit” diagnostic code.
relay.
Refer to Troubleshooting, “Prelubrication System”.
• There is a problem with the relay for the starting Make repairs, as needed.
motor.
58
Check the “Crank Terminate” Relay If the “Cycle Crank Time” is insufficient, the “Engine
Overcrank Time” can elapse before the engine is
Troubleshoot for the “443-03 Crank Terminate Relay able to start.
short to +batt” diagnostic code.
Use Cat ET to check the “Cycle Crank Time”. Use
Refer to Troubleshooting, “ECM Status Indicator Cat ET to increase the time, if necessary.
Output”. Make repairs, as needed.
Check the “Engine Overcrank Time”
Check the “Start” Relay
The “Engine Overcrank Time” is a parameter that
Troubleshoot for the following diagnostic codes: can be configured. This parameter determines the
length of time for the crank cycle. If the engine does
• 444-05 Start Relay open circuit not start within the programmed “Engine Overcrank
time”, the attempt to start is terminated. An “E225
• 444-06 Start Relay short to ground (3) Engine Overcrank” event is generated.
Refer to Troubleshooting, “ECM Output Circuit If the “Cycle Crank Time” is insufficient, the “Engine
(Starting Motor)”. Make repairs, as needed. Overcrank Time” can elapse before the engine is
able to start.
Check for a Request for a Shutdown by
Use Cat ET to check the “Engine Overcrank Time”.
the Driven Equipment Use Cat ET to increase the “Engine Overcrank
Time”, if necessary.
Determine whether a shutdown for the driven
equipment has been requested. Refer to
Troubleshooting, “Driven Equipment”. Make Check the “Driven Equipment Delay
corrections, as needed. Time”
Check the “Run” Relay The “Driven Equipment Delay Time” is a parameter
that can be configured. The ECM provides a switch
Troubleshoot for the “445-03 Run Relay short to input for the driven equipment in order to delay
+batt” diagnostic code. engine start-up until the driven equipment is ready.
The ECM will not attempt to start the engine until
Refer to Troubleshooting, “ECM Status Indicator the switch input for the driven equipment closes
Output”. Make repairs, as needed. to ground and the prelubrication (if equipped) is
complete.
Check the “Crank Terminate Speed” An event code is generated if the “Driven Equipment
Delay Time” elapses without closure of the switch
The “Crank Terminate Speed” is a parameter that
input. To disable this feature, program the delay
can be configured. The Electronic Control Module
time to zero.
(ECM) disengages the starting motor when the
engine exceeds the programmed “Crank Terminate
If the programmed delay time is too long, the engine
Speed”. The default value of 250 rpm should be
may not start. Use Cat ET to check the “Driven
sufficient for all applications. Equipment Delay Time”. Use Cat ET to program the
delay time to a reasonable amount of time.
If the “Crank Terminate Speed” is too slow, the
engine will shut down. Use the Caterpillar Electronic
Technician (ET) to check the programmed “Crank i01775415
Terminate” speed. Use Cat ET to adjust the “Crank
Terminate Speed”, if necessary. Engine Shutdown without a
Diagnostic Code
Check the “Cycle Crank Time”
SMCS Code: 1000-038; 1901-038
The “Cycle Crank Time” is a parameter that can
be configured. This parameter determines the time
for engagement of the starting motor and the gas
Probable Causes
shutoff valve during the crank cycle. If the engine
does not start within the programmed “Cycle Crank • The battery power to the Electronic Control
Time”, the attempt to start is suspended for an Module (ECM) is lost.
equal “Rest” cycle.
• There is a problem with the fuel supply.
59
Recommended Repairs The following conditions can cause the engine to

malfunction:
Battery Power to the ECM
• Low fuel pressure
1. Refer to Troubleshooting, “Electrical Power
Supply”. • High fuel pressure
2. Inspect the ground strap and the battery for • Poor fuel quality
connections that are loose and/or corroded.
Make sure that the fuel pressure is correct.
3. Inspect the ECM and the terminal box for proper When possible, interview the operator in order
installation of the connectors. to determine if fuel quality is in question. Try to
determine if the source of the fuel was changed.
4. Check the circuit breaker for the ECM in the
terminal box. Inspect the fuel system components: fuel filter, gas
pressure regulator, gas shutoff valve, and actuator
for the fuel. Verify that the system’s components are
Fuel Supply operating correctly.
• Check the fuel supply pressure. Replace the fuel filter, if necessary.
• Inspect the fuel lines for foreign objects and for
obstructions that can block the fuel supply. Electrical Connectors or Power Supply
• Make sure that the fuel actuator is operating Check the wiring harnesses and the connectors.
properly. Refer to Operation and Maintenance Inspect the connectors in the terminal box. Inspect
Manual, SEBU7563, “Electrohydraulic Actuator the battery connections and the ground. Refer to
- Inspect”. Troubleshooting, “Inspecting Electrical Connectors”.
• Inspect the gas shutoff valve according to Inspect the wiring from the battery to the Electronic
Operation and Maintenance Manual, SEBU7563, Control Module (ECM). Refer to the engine’s
“Gas Shutoff Valve - Inspect”. Electrical System Schematic. Inspect the wires
and the power relay. Check the power and ground
connections to the ECM. Refer to Troubleshooting,
i01775440 “Electrical Power Supply” for more information.
Engine Starts but Stalls Engine Speed/Timing Sensor
Immediately
Make sure that the engine speed/timing sensor is
SMCS Code: 1000-038; 1901-038 installed correctly. Refer to Troubleshooting, “Engine
Speed/Timing Sensor”.
Probable Causes Make sure that the timing wheel is correctly installed.
• Fuel supply
Ignition System
• Electrical connectors or power supply
Inspect the ignition transformers for loose
• Engine speed/timing sensor connections, moisture, short circuits, and open
circuits. Inspect the primary wiring and the
• Ignition system secondary electrical connections.
• Excessive load Make sure that the correct transformers and spark
plugs are installed. Inspect the extenders for signs
or pin holes and arcing.
Recommended Repairs
Maintain the spark plug according to the engine’s
Fuel Supply Operation and Maintenance Manual.
Make sure that fuel is supplied at a sufficient Excessive Load

pressure that is stable. Make sure that the size of
the fuel line is sufficient. Inspect the fuel system Make sure that the load is not excessive. Reduce
for leaks. the load. If necessary, disengage the driven
60
i01641523 External Leak

Excessive Engine Oil Check for leakage at the seals at each end of
Consumption the crankshaft. Look for leakage at the gasket
for the engine oil pan and all lubrication system
SMCS Code: 1300-038; 1901-038 connections. Look for any leaking from the
crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty
Probable Causes crankcase breather will cause high pressure in the
crankcase. A dirty crankcase breather will cause
• Incorrect engine oil level the gaskets and the seals to leak.
• External leak Measure the crankcase blowby according to the

engine’s Operation and Maintenance Manual,
• Internal leak “Crankcase Blowby - Measure/Record”.
• Worn components Internal Leak

• Extended operation at low loads There are several possible ways for engine oil to
leak into the combustion chambers:
• Excessive crankcase ventilation (bio-gas)
• Leakage between worn valve guides and valve
Recommended Repairs stems
Incorrect Engine Oil Level • Worn components or damaged components

(pistons, piston rings, or dirty passages for
Overfilling the crankcase will increase the engine oil)
consumption of engine oil. Make sure that the
engine oil level is correct. • Incorrect installation of the compression ring
and/or the intermediate ring
When the engine crankcase is full, engine oil will be
initially consumed at a relatively rapid rate. The rate • Leakage past the seal rings in the turbocharger
of consumption is reduced as the engine oil level
decreases. A crankcase that is always maintained at • Overfilling of the crankcase
the full level will have a faster rate of consumption.
• Incorrect dipstick or guide tube
If the engine has a system for automatically filling
the crankcase with engine oil, check the level for Signs of internal leaks include high consumption of
the system. Adjust the system in order to provide engine oil, blue smoke, and excessive detonation.
engine oil to a level that is less than the full level.
Make sure that the supply of engine oil is adequate. If the pistons are suspected, check the cylinder
compression. Refer to the engine’s Operation
and Maintenance Manual, “Cylinder Pressure -
Extended Operation with Low Loads Measure/Record”.
Extended operation at low idle or extended
operation at a reduced load will cause increased oil Worn Components
consumption and carbon buildup in the cylinders.
This will occur if the engine is usually operated at a Excessively worn engine components and damaged
torque that is significantly below the rated power. engine components can result from the following
conditions:
The engine can be operated at a low load. However,
engine operation at a low load is limited. For • Contaminated engine oil
information on operation with a low load, refer to
the engine’s Operation and Maintenance Manual, • Incorrect fuel system settings
“Engine Operation”.
• Contamination from the inlet air
Inspect the suspect system. Make the necessary
repairs.
61
Check the Crankcase Ventilation Adjust the engine operation according to Systems
(Bio-Gas) Operation/Testing and Adjusting, “BTU and
Precombustion Chamber Adjustments”.
For engines that use bio-gas, the crankcase
ventilation may be excessive. This will draw some Fuel System Leaks
of the engine oil out of the atmosphere from the
crankcase. Reduce the ventilation. Always use a gas detector to determine the
presence of gaseous fuel. If a leak is found,
contact your local provider of gas immediately for
i01775459
assistance.
Exhaust Emission Too
Gas Admission Valve Lash
High/Fuel Consumption
Too High Adjust the gas admission valve lash according to
Systems Operation/Testing and Adjusting, “Engine
SMCS Code: 1901-038 Timing Procedures”.
Probable Causes Check Valve

The check valve may be stuck. The check valve
• Misfire must move freely in order to prevent fuel from
continuously entering the precombustion chamber.
• Incorrect air/fuel ratio Inspect the check valve. Clean the check valve with
a nonflammable solvent that will not leave residue.
• Fuel system leaks Replace the check valve, if necessary.
• Improper gas admission valve lash
Needle Valve
• A check valve is stuck in the open position.
Check the needle valves for the precombustion
• Incorrect adjustments of the needle valves chambers. If the needle valves are open too far, the
air/fuel mixture will be too rich. If the adjustment
• Deposits in the combustion chamber of the needle valves is suspect, fully close all of
the needle valves. Open the needle valves for four
full turns. Adjust the needle valves according to
Recommended Repairs Systems Operation/Testing and Adjusting, “BTU and
Misfire
If adjustment of a needle valve does not affect
Although the fuel does not ignite, fuel is still operation, the needle valve may be faulty. Replace
supplied to a cold cylinder. The other cylinders the needle valve.
must burn more fuel in order to maintain the
load. This increases fuel consumption. Refer to Deposits
Troubleshooting, “Engine Misfires, Runs Rough or Is
Unstable”. Deposits that are burned in the combustion
chamber will increase the exhaust emissions. An
Air/Fuel Ratio internal leak of engine oil or coolant can be burned
with the air and fuel.
If the setting for the fuel’s LHV is too low, the air/fuel
ratio will be too rich. Obtain a gas analysis. Enter the Inspect the combustion chambers according to
data into Caterpillar Software, LEKQ6378, “Methane Operation and Maintenance Manual, “Cylinders
Number Program”. Use ET to program the results - Inspect”. Inspect the spark plug and the
for the “Fuel Quality” and “Gas Specific Gravity” precombustion chamber for evidence of coolant
parameters. For more information, refer to Systems and residue of liquid crystalline material. If the
Operation/Testing and Adjusting, “Electronic Control gasket and/or the seals have leaked, clean the
System Parameters”. sealing surfaces and install a new gasket and seals.
Also check for coolant leaks at the bottom of the
If the quality of the gas is inconsistent, obtain cylinder head.
several analyses over a period of time. Program
the “Fuel Quality” parameter to the average value
of the LHV.
62
Excessive consumption of engine oil may indicate Air/Fuel Ratio

an internal leak. Inspect the cylinder heads
for evidence of leaking engine oil. Inspect An air/fuel mixture that is too rich will increase the
the turbocharger. Engine oil that leaks from a exhaust temperature. A change in the fuel energy
turbocharger can mix with the inlet air. content will change the air/fuel ratio.
If the setting for the fuel’s LHV is too low, the air/fuel
i01754362
ratio will be too rich. Obtain a gas analysis. Enter
Exhaust Port Temperature the data into Caterpillar Software, LEKQ6378,
“Methane Number Program”. Use the Caterpillar
(High) Electronic Technician to program the results for
the “Fuel Quality” and “Gas Specific Gravity”
SMCS Code: 1901-038 parameters. For more information, refer to Systems
Operation/Testing and Adjusting, “Electronic Control
Probable Causes System Parameters”.
If the quality of the gas is inconsistent, obtain

• Problem with a thermocouple several analyses over a period of time. Program
the “Fuel Quality” parameter to the average value
• Incorrect gas admission valve lash of the LHV.
• Excessive load Adjust the engine operation according to Systems
Operation/Testing and Adjusting, “BTU and
• Exhaust restriction Precombustion Chamber Adjustments”.
• A buildup of deposits in the cylinder or internal
oil leaks Excessive Load
• Problem with exhaust valves Make sure that the load is not excessive. Reduce
• Missing retainer for a gas admission valve equipment and test the engine.
Recommended Repairs Measure the Exhaust Restriction

Measure the exhaust restriction during engine
Check for Suspect Thermocouples operation with a load. For data that is specific to the
engine, refer to the Technical Marketing Information.
Observe the temperatures from the thermocouples
after the engine is shut off. Investigate the cause of the exhaust restriction.
Perform adjustments and/or make repairs, as
When the engine is operating properly, the needed.
temperatures from similar locations are reduced at
a similar rate. Also, the temperatures from similar
locations are comparable. Check for Deposits in the Cylinder and
Check for Internal Oil Leaks
If any discrepancies are found, switch the suspect
thermocouple for another thermocouple. If the Use a borescope to inspect the cylinders. Look for
temperature problem follows the thermocouple, the following conditions:
replace the thermocouple.
• Deposits on the valve seats
If the temperature problem stays at the original
location of the suspect thermocouple, investigate • Deposits on the valve faces
the cause of the high temperature.
• Deposits on the cylinder walls that are above the
Gas Admission Valve Lash upper limit of the piston stroke
Adjust the gas admission valve lash according to • Signs of internal oil leaks
Systems Operation/Testing and Adjusting, “Engine
Timing Procedures”. Other signs of internal oil leaks include high oil
consumption and blue smoke.
63
Note: Excessive deposits contribute to guttering of If any discrepancies are found, switch the suspect
the valves. thermocouple for another thermocouple. If the
temperature problem follows the thermocouple,
If excessive deposits and/or signs of internal replace the thermocouple.
oil leaks are found, investigate the cause of the
condition. Make repairs, as needed. If the temperature problem stays at the original
location of the suspect thermocouple, investigate
Check the Exhaust Valves the cause for the low temperature.
Measure the suspect cylinder pressure in order to Gas Admission Valve Lash
check for problems that are related to the exhaust
valves. Refer to the Operation and Maintenance Adjust the gas admission valve lash according to
Manual, “Cylinder Pressure - Measure/Record”. Systems Operation/Testing and Adjusting, “Engine
Timing Procedures”.
Gas Admission Valve
Check the Cylinder Compression
If the retainer is missing from the gas admission
valve’s support assembly, the air/fuel mixture will Measure the cylinder pressures of the suspect bank
be too rich. High exhaust temperatures will result. in order to check for problems that are related to
Make sure that the retainer for the gas admission compression.
valve’s support assembly is installed.
If low compression is found, investigate the cause
of the low compression. Make repairs, as needed.
i01783523
Exhaust Port Temperature i01754365

(Low) Fuel Energy Content
SMCS Code: 1901-038
SMCS Code: 1901-038
Probable Causes Probable Causes

• Misfire • The LHV of the gas or the specific gravity of the
gas is significantly different from the value that is
• Problem with a thermocouple programmed into the Electronic Control Module
(ECM).
• Incorrect gas admission valve lash
• Some type of condensation is forming in the gas.
• Low cylinder compression
Recommended Repairs Recommended Repairs

Obtain a Gas Analysis and Program the
Check for Misfire
“Fuel Quality” Parameter
Operation with a low load can result in low exhaust
temperatures. Operate the engine at low idle or Obtain a gas analysis. Enter the data into Caterpillar
near low idle in order to identify a misfire problem. Software, LEKQ6378, “Methane Number Program”.
Use the Caterpillar Electronic Technician to program
Troubleshoot the cause of the misfire. Refer to the results for the ECM “Fuel Quality” and “Gas
Troubleshooting, “Engine Misfires, Runs Rough or Is Specific gravity” parameters. For more information,
Unstable”. refer to Systems Operation/Testing and Adjusting,
“Electronic Control System Parameters”.
Check for Suspect Thermocouples If the quality of the gas is inconsistent, obtain
several analyses over a period of time. Program
Observe the temperatures from the thermocouples the “Fuel Quality” parameter to the average value
after the engine is shut off.
of the LHV.
When the engine is operating properly, the Adjust the engine operation according to Systems
temperatures from similar locations are reduced at
a similar rate. Also, the temperatures from similar
locations are comparable.
64
Check the Equipment that Treats the Gas Adjust the Gas Pressure Regulator
Check the equipment that treats the gas before Make sure that fuel is supplied at a sufficient
the gas is delivered to the engine. Any kind of pressure that is stable. For the correct pressures,
condensation in the gas will change the fuel energy refer to Systems Operation/Testing and Adjusting,
content. Make sure that the filter and the dryer “Fuel System”.
for the gas operate properly. Replace parts and
repair the equipment, if necessary. Refer to the If the gas pressure regulator cannot be adjusted to
service literature that is provided by the OEM of the the correct setting, repair the regulator or replace
equipment. the regulator.
i01783528
Fuel System
Fuel Pressure Make sure that the size of the fuel supply line is
sufficient.
SMCS Code: 1250-035
Inspect the fuel system components: fuel supply
line, fuel filter, gas pressure regulator, gas shutoff
Probable Causes valve, and electrohydraulic actuator for the fuel.
• Problem with the air/fuel pressure module Observe the fuel pressure and strike the gas
pressure regulator with a soft hammer. If the fuel
• Plugged fuel filter pressure changes, inspect the internal parts of the
regulator for wear. Inspect the diaphragm for leaks.
• Fuel system leaks Make sure that the valve moves freely. The valve
must seat correctly.
• Incorrect setting of the gas pressure regulator
Inspect the electrohydraulic actuator for the fuel
• Problem with a fuel system component according to Operation and Maintenance Manual,
“Electrohydraulic Actuator - Inspect”.
Recommended Repairs
i01642198
Air/Fuel Pressure Module
Gas Temperature (High)
Use a separate device to measure the fuel pressure.
Compare the measured fuel pressure to the fuel SMCS Code: 1901-038
pressure on the control panel’s display.
If the control panel’s display is questionable, switch Probable Causes

the air/fuel pressure module with a module that is
known to be good. Verify that the problem is solved. • Problem with the equipment that treats the gas
• Problem with the fuel temperature sensor
Fuel Filter
Measure the fuel filter’s differential pressure Recommended Repairs
according to Operation and Maintenance Manual,
“Fuel System Fuel Filter Differential Pressure - Inspect the Equiment
Check”. Replace the filter element, if necessary.
Check for proper operation of the equipment
Fuel System Leaks that treats the gas prior to the engine. Repair
the equipment, as needed. Refer to the service
Always use a gas detector to determine the information that is provided by the OEM of the
presence of gaseous fuel. If a leak is found, equipment.
contact your local provider of gas immediately for
assistance.
65
Check the Fuel Temperature Sensor Connect an ohmmeter to terminals “A” and “B” on
the switch’s connector and measure the continuity.
Allow the fuel temperature sensor to cool and The correct continuity for the normally open switch
remove the sensor. Check the reading for the sensor is greater than 20,000 ohms.
on the control panel’s display. If the sensor is OK,
the reading on the control panel’s display and the Continue to monitor the ohmmeter and
ambient temperature will be approximately equal. apply a vacuum pressure of 5 ± 0.6 kPa
(20 ± 2.30 inches of H2O) to the switch. The correct
If the reading is not correct, switch the suspect continuity for the closed switch is less than 5 ohms.
sensor with a sensor that is known to be good.
Verify that the problem is solved. If the correct results are not obtained or if the switch
does not close for the specified vacuum pressure,
replace the switch.
i01779103
Inlet Air Restriction If the correct results are obtained, there may be a
short circuit in an electrical connection or in the
SMCS Code: 1050-038 wiring. Use the ohmmeter to measure the resistance
Schematic. Make repairs, if necessary.
Probable Causes
• Inlet air restriction i01649761
• Problem with an electrical connection or with the

Inlet Air Temperature (High)
wiring
SMCS Code: 1901-038
• Problem with the switch for the inlet air restriction
Probable Causes
Recommended Repairs
• High ambient air temperature
Inlet Air Restriction • High temperature of the coolant for the separate
circuit
Excessive inlet air restriction is usually caused by
a clogged air filter. • Lean operation
For optimum operation, replace the air filter • High inlet air restriction and/or high altitude
elements when the inlet air restriction reaches
2.5 kPa (10 inches of H2O). The maximum allowable • Faulty inlet air temperature sensor and/or circuit
inlet air restriction is 3.75 kPa (15 inches of H2O).
• Insufficient flow of cooling water through the
If the inlet air restriction is excessive, determine the aftercooler
cause of the restriction and correct the condition.
Replace the air filter element, if necessary.
Recommended Repairs
Electrical Connections or Wiring
High Ambient Air Temperature
There may be a problem with an electrical
connection or with the wiring. Inspect the electrical Determine if the ambient air temperature is within
connectors and all of the wiring for the switch. the design specifications for the cooling system.
Connectors” and refer to the engine’s electrical Determine the cause of the high air temperature.
Schematic. Make repairs, if necessary. Make corrections, when possible.
Test the Switch Coolant Temperature
The switch is normally open. Excessive inlet air Refer to Troubleshooting, “Engine Coolant
restriction causes vacuum pressure to close the Temperature (High)”.
switch.
Disconnect the switch for the inlet air restriction and

remove the switch.
66
Lean Operation If there is a high differential between the inlet

temperature and the outlet temperature of the
If the air/fuel mixture is too lean, compression of the coolant for the aftercooler, perform the following
higher volume of air through the turbocharger will procedures:
increase the temperature. Correct the air/fuel ratio.
• Check the water circuit of the aftercooler for
Check for High Inlet Air Restriction obstructions.
and/or High Altitude
• Make sure that the water temperature regulators
are operating properly.
When inlet air pressure is low, the turbocharger
works harder in order to achieve the desired
inlet manifold pressure. This increases inlet air • Check the water pump for proper operation.
temperature.
• Make repairs, if necessary.
Measure the inlet air pressure while the engine is
operating under load. For specific data, refer to the i01775473
Technical Marketing Information for the engine.
Intermittent Engine Shutdown
Inlet Air Restriction
SMCS Code: 1000-038; 1901-038
Check for plugged air filters. Check for obstructions
to the air inlet. Note: Use this procedure only if the engine shuts
down completely and the engine must be restarted.
Replace the air filters and/or remove the obstruction
from the air inlet. Probable Causes
High Altitude • Active engine shutdown
Make sure that the settings for the engine are • Electrical connectors
correct for the altitude.
• Circuit breaker
Check the Temperature Sensor and/or
the Circuit • Fuel supply
Allow the sensor to cool and remove the sensor. • Ignition transformer
Check the reading for the inlet air temperature.
If the sensor is OK, the reading and the ambient Recommended Repairs
temperature are approximately equal.
Active Engine Shutdown
If the reading is not correct, switch the sensor with
a sensor that is known to be good. Verify that the
Use the control panel’s display to check for any
problem is solved.
active engine shutdowns and/or for logged engine
shutdowns. Determine the reason for the shutdown.
Check for Sufficient Flow of Cooling After correcting the problem, cycle the engine
Water Through the Aftercooler control switch to the OFF/RESET position for at least
15 seconds before you try to restart the engine.
Check the inlet temperature of the coolant for the
aftercooler. Compare the reading to the regulated Electrical Connectors
temperature. If the temperature is OK, check
the outlet temperature of the coolant. A high 1. Check the wiring harnesses and the connectors.
temperature differential indicates an insufficient flow Inspect the connectors in the terminal box.
rate. Inspect the battery connections and the ground.
Make sure that the performance of the radiator or Connectors”.
the heat exchanger is correct.
67
2. Use the control panel’s display to check for i01754368

a diag168-02 System Voltage Intermittent
diagnostic code. If this diagnostic code is Jacket Water Inlet Pressure
logged, proceed to Troubleshooting, “Electrical (High)
Power Supply”.
SMCS Code: 1901-038
3. Inspect the wiring from the battery to the
Electronic Control Module (ECM). Refer to the
engine’s electrical system Schematic. Inspect Probable Causes
the wires and the power relay. Check the power
and ground connections to the ECM. Refer to • There is a problem with the circuit for the pressure
Troubleshooting, “Electrical Power Supply”. switch at the jacket water pump’s inlet.
Circuit Breakers • The pressure at the jacket water pump’s inlet is

excessive.
Check the circuit breaker in the terminal box. The
circuit breaker may exceed the trip point due to Recommended Repairs
overheating. Reset the circuit breaker if the circuit
breaker is tripped. Check the Circuit of the Pressure Switch
for the Inlet of the Jacket Water Pump
Fuel Supply
The contact for the switch’s terminals “A” and
Check the fuel lines for the following problems: “B” is normally open. The contact for the switch’s
restrictions, obstructions, collapsed lines, and terminals “B” and “C” is normally closed.
pinched lines. If problems are found with the fuel
lines, repair the lines and/or replace the lines. If the pressure at the inlet for the jacket water pump
rises to 462 ± 41 kPa (67 ± 6 psi), the contact for
Check the fuel quality. Any type of condensation the switch’s terminals “A” and “B” is closed and
in the fuel will affect the quality of the fuel. Obtain the contact for terminals “B” and “C” is opened.
a fuel analysis. Make sure that the equipment that An E224 High Jacket Water Inlet Pressure event is
treats the fuel is operating correctly. Refer to the generated.
service information that is provided by the OEM of
the equipment. If the contacts are abnormally shorted or opened,
the event code can be generated. Check the
Inspect the fuel filter. Replace the fuel filter, if connectors and the wiring for damage or corrosion.
necessary. Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
Check the fuel pressure. Refer to Systems
Operation/Testing and Adjusting, “Fuel System” for If a problem with the connectors and/or the wiring is
the correct pressure values. If the fuel pressure is found, make repairs, as needed. Replace parts, if
still low, check the gas pressure regulator. necessary.
Make sure that the gas shutoff valve is operating
correctly. If the gas shutoff valve is suspect, refer to
Check the Inlet Pressure of the Jacket
Operation and Maintenance Manual, “Gas Shutoff Water Pump
Valve - Inspect”.
Use a gauge to check the pressure at the inlet for
the jacket water pump.
Ignition Transformer
If the pressure is less than 462 ± 41 kPa (67 ± 6 psi)
Check the ignition transformer. Refer to
but the event code E224 High Jacket Water Inlet
Troubleshooting, “Ignition Transformers Primary Pressure is occurring, replace the pressure switch.
Circuit” and Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plugs”.
If a pressure of at least 462 ± 41 kPa (67 ± 6 psi)
is measured at the inlet for the jacket water, the
high pressure may be caused by excessive head
pressure. The high pressure could also be caused
by obstructions in the coolant passages after the
jacket water pump. Inspect the system. Make
repairs, as needed.
68
i01754382 i01783530
Jacket Water Pressure (Low) Jacket Water to Engine Oil

SMCS Code: 1901-038
Differential Temperature (Low)
SMCS Code: 1901-038
Probable Causes
• Low coolant level
Probable Causes
• Insufficient flow of coolant • High engine oil temperature or low engine coolant
temperature
Recommended Repairs • Faulty temperature sensor(s)

Check the Coolant Level and Inspect the • Faulty water temperature regulators
Cooling System for Leaks
Recommended Repairs
Check coolant level. If the coolant level is low,
inspect the cooling system for leaks. Check the Engine Oil Temperature and
If the coolant level is low, fill the cooling system. If
the Engine Coolant Temperature
leaks are found, make the necessary repairs.
Observe the temperature of the engine oil and the
engine coolant on the control panel’s display.
Check the Flow of Coolant
If the engine oil temperature is high, refer to
Use the Caterpillar Electronic Technician (Cat ET) to Troubleshooting, “Engine Oil Temperature (High)”.
observe the pressure at the jacket water outlet with
the engine OFF. Then observe the reading during If the temperature of the engine coolant is low, refer
engine operation. to Troubleshooting, “Engine Coolant Temperature
(Low)”.
If the reading is not reasonable or if the reading is
not within specifications, install a pressure gauge
near the pressure sensor at the jacket water outlet.
Check the Temperature Sensors
Compare the gauge reading with the reading from
Cat ET. Use a separate device to measure the temperatures
of the engine oil and the engine coolant. Compare
If the readings from the comparative gauge do not the measured temperatures to the readings on the
agree approximately with Cat ET, troubleshoot the control panel’s display.
circuit for the pressure sensor at the jacket water
outlet. Refer to Troubleshooting, “PWM Sensor”. If a reading is incorrect, switch the suspect sensor
with a sensor that is known to be good. Verify that
the problem is solved.
If the readings from the comparative gauge agree
approximately with Cat ET, check the following
components: Check the Water Temperature Regulators
• Check the water temperature regulators for The water temperature regulators should not
proper operation. begin to open until jacket water reaches opening
temperature for the regulators. Allow the engine to
• Check for plugging of the radiator or the heat cool and then start the engine. Check the tube at
exchanger. the outlet for the jacket water. If the tube is warm
and normal operating temperature is not achieved
• Inspect the jacket water pump for damage to the yet, a regulator may be stuck open.
impeller.
Check the water temperature regulators according
• Inspect the jacket water pump for cavitation. to Systems Operation/Testing and Adjusting,
“Cooling System”. Replace the water temperature
Make the necessary repairs. regulators, if necessary.
69
i01783536 Crankshaft
Mechanical Noise (Knock) in Inspect the crankshaft and the related components.
Engine Inspect the main bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are
SMCS Code: 1000-038; 1901-038 in the correct position.
Look for worn thrust plates and wear on the

Probable Causes crankshaft.
• Driven equipment Check the bolts of the counterweights. Refer to

Specifications, “Crankshaft”.
• Cylinder head and related components
Piston
• Connecting rod bearing
Make sure that the piston pin is correctly installed.
• Gear train The retaining rings must be secure.
• Crankshaft and related components Inspect the condition of the pistons according
to Guidelines for Reusable Parts and Salvage
• Piston Operations.
• Detonation
Detonation
Recommended Repairs Check the control panel’s display for the
occurrence of detonation. Refer to Troubleshooting,
Driven Equipment “Detonation”.
Inspect the alignment and the balance of the driven

equipment. Inspect the coupling. If necessary, i01783538
disconnect the driven equipment and test the Noise Coming from Cylinder
engine.
(Noisy Cylinder Head)
Cylinder Head and Related Components
SMCS Code: 1000-038; 1290-038
Inspect the components of the valve train. Check for
signs of damage and/or wear to the valves, valve Probable Causes
bridges, valve lifters, cylinder head gasket, etc.
Inspect the condition of the camshafts. If a camshaft • Incorrect bridge and/or valve lash
is replaced, new valve lifters must be installed.
• Insufficient lubrication
Connecting Rod Bearing
• Problem in the cylinder head and/or related
Inspect the connecting rod bearings and the components
crankshaft’s bearing surfaces. Inspect the engine
oil filters for debris from the bearings. Install new • Problem with the bolts for the precombustion
parts, if necessary. chamber
Gear Train Recommended Repairs

Inspect the condition of the gear train. Valve Bridge and Valve Lash
Inspect the engine oil filters for nonferrous material. Check the valve bridge and valve lash according to
Flaking of nonferrous material could indicate worn Systems Operation/Testing and Adjusting, “Engine
gear train bearings. Timing Procedures”.
Insufficient Lubrication
Inspect the valve train for sufficient lubrication. The
passages for the engine oil must be clean.
70
Cylinder Head and Related Components Recommended Repairs

Measure the cylinder compression. Refer to the Check the Coolant Level and Inspect the
engine’s Operation and Maintenance Manual,
“Cylinder Pressure - Measure/Record”. Cooling System for Leaks
Inspect the components of the valve train: valves, Check coolant level. If the coolant level is low,
valve springs, locks, and valve rotators. inspect the cooling system for leaks.
Inspect the contact surfaces of the rocker arm and If the coolant level is low, fill the cooling system. If
valve bridge. leaks are found, make the necessary repairs.
Inspect the pushrods. Water Pump

Check for free movement of the valves. If the valves Remove the water pump for inspection. Refer
do not move freely, look for these conditions: to Disassembly and Assembly, “Water Pump -
Remove”. Repair the water pump, if necessary.
• A valve stem is bent.
Aftercooler
• The camshaft lifters are damaged or the lifters
are worn. If the flow of coolant through the aftercooler is
restricted, clean the aftercooler core.
• The camshaft is damaged or the camshaft is
worn. Check the Flow of Coolant
• A retaining bolt for a rocker shaft is loose or the Use the Caterpillar Electronic Technician (Cat ET) to
bolt is broken. observe the pressure at the jacket water outlet with
the engine OFF. Then observe the reading during
Replace components that are worn and/or engine operation.
damaged.
If the reading is not reasonable or if the reading is
If a camshaft is replaced, new valve lifters must be not within specifications, install a pressure gauge
installed. near the pressure sensor at the jacket water outlet.
Compare the gauge reading with the reading from
Bolts for the Precombustion Chamber Cat ET.
Inspect the bolts for the precombustion chamber. If the readings from the comparative gauge do
Make sure that the bolts are not loose or broken. not agree approximately with Cat ET, replace the
Replace the bolts, if necessary. pressure sensor.
If the readings from the comparative gauge agree

i01754383
approximately with Cat ET, check the following
Poor Coolant Flow components:
SMCS Code: 1000-038; 1901-038 • Check the water temperature regulators for
proper operation.
Probable Causes • Check for plugging of the radiator or of the heat
exchanger.
• Low coolant level
• Inspect the water pump for damage to the
• Problem with the water pump impeller.
• Restriction through the aftercooler Make the necessary repairs.
• Insufficient flow of coolant

• Buildup of scale in the cooling system
71
Scale Buildup Incorrect Air/Fuel Ratio

Drain the cooling system. Clean the cooling system. Adjust the engine according to Systems
Fill the cooling system with new coolant. Maintain Operation/Testing and Adjusting, “BTU and
the cooling system properly. For instructions, refer Precombustion Chamber Adjustments”.
to the engine’s Operation and Maintenance Manual,
“Cooling System Coolant (DEAC) - Change”. Incorrect Spark Plug Gap
i01368006
Set the spark plug gap according to Specifications,
“Gas Engine Ignition”.
System Voltage
Excessive Load
SMCS Code: 1901-038
Higher loads reduce the service life of spark plugs.
Probable Causes Determine whether the engine has been operating
beyond the recommended rated load.
There is a problem with the electrical system.
Contamination of the Air/Fuel Mixture
Recommended Repairs Make sure that the equipment that treats the fuel
prior to the engine is operating properly. Refer to
Troubleshoot the electrical system. Refer to
the service information that is provided by the OEM
Troubleshooting, “Electrical Power Supply”.
of the equipment.
i01783540 Make sure that the air and the fuel are properly
filtered. There must be no leaks that allow
Short Spark Plug Life contamination to enter the systems.
SMCS Code: 1555-038 If a turbocharger is leaking engine oil, the engine

oil can contaminate the inlet air. Inspect the
Probable Causes turbocharger for leaks.
• Faulty spark plug i01643431
• Incorrect spark plug Starting Motor Runs, Pinion

• Incorrect air/fuel ratio Engages But Does Not Turn
the Flywheel
• Incorrect spark plug gap
SMCS Code: 1451-038; 1453-038
• Excessive load
• Contamination of the air/fuel mixture Probable Causes
• Static load
Recommended Repairs
• Accessory equipment
Faulty Spark Plug
• Slow starting motor
Inspect the spark plug for wear. Look for evidence
of combustion leaks above the gasket. Check the • Problem with the starting motor
insulator for cracks.
• Internal engine problem
If the spark plug is worn and/or damaged, install
a new spark plug. Recommended Repairs
Incorrect Spark Plug Static Load
Install the spark plug that is listed in the engine’s Use a barring device in order to determine if the
Parts Manual, “Ignition Gp - Gas Engine”. crankshaft can be rotated. If necessary, disconnect
the driven equipment and test the engine.
72
Accessory Equipment Driven Equipment

If the engine is driving accessory equipment such Inspect the mounting bolts for the driven equipment.
as an air compressor, determine whether the Inspect the alignment and the balance of the driven
accessory equipment is preventing the crankshaft equipment. Inspect the coupling. If necessary,
from rotating. disconnect the driven equipment and test the
engine.
Use a barring device in order to determine if the
crankshaft can be rotated. If necessary, disconnect Engine Mounts or Isolators
the accessory equipment and test the engine.
Inspect the condition of the engine mounts. Look
Slow Starting Motor or Problem with the for proper installation. Make sure that the bolts are
Starting Motor secure. Make sure that the isolators are in good
condition.
Refer to Troubleshooting, “Air Starting Motor”.
Vibration Damper
Internal Engine Problem
Inspect the vibration damper for damage. Look for
Remove the spark plugs and inspect the cylinders evidence of overheating and leaks. Make sure that
for fluid. If fluid is found in the cylinder, determine the vibration damper is fastened securely.
the cause of the leak and make the necessary
repairs. i01783541
If the crankshaft will not rotate, the engine must be Turbocharger Turbine
disassembled in order to check for these types of
internal problems: Temperature (High)
SMCS Code: 1052-038
• Contact of the valves and the pistons
• Piston seizure Probable Causes
• Bearing seizure • Low load
• Damage to the crankshaft • Excessive load
i01643470
• High inlet manifold temperature
Too Much Vibration • Incorrect air/fuel ratio
SMCS Code: 1000-038; 1901-038 • Exhaust restriction
• Problem with a valve
Probable Causes
• Misfire, rough operation, or instability Recommended Repairs
• Driven equipment Low Load
• Engine mounts or isolators At loads that are less than 50 percent, the inlet air
is controlled by the air choke actuator. If the air/fuel
• Vibration damper mixture is too lean, compression of the higher
volume of air through the turbocharger will increase
the temperature. Correct the air/fuel ratio.
Recommended Repairs
Misfire or Rough Operation Excessive Load
Make sure that the load is not excessive. Reduce
Refer to Troubleshooting, “Engine Misfires, Runs
Rough or Is Unstable”.
73
Check for Event Codes for High Inlet

Manifold Air Temperature
Use the control panel’s display to check for the
following event codes:
• E026 (3) High Inlet Air Temperature (shutdown)

• E027 (1) High Inlet Air Temperature (warning)
If one or more of the codes is active, refer to
Troubleshooting, “Inlet Air Temperature (High)”.
Air/Fuel Ratio
An air/fuel mixture that is too rich will increase the
exhaust temperature. A change in the fuel energy
content will change the air/fuel ratio. Obtain a fuel
analysis.
The fuel supply pressure must be adequate and

stable.
Adjust the engine according to Systems

Verify that the exhaust emissions are correct.
Measure the Exhaust Restriction

Measure the exhaust restriction during engine
operation with a load. For data that is specific to the
engine, refer to the Technical Marketing Information.
Investigate the cause of the exhaust restriction.

Perform adjustments and/or make repairs, as
needed.
Problem with a Valve

Make sure that the inlet valves, the exhaust valves,
and the gas admission valves are in good condition.
Check the cylinder compression. Refer to Operation
and Maintenance Manual, “Cylinder Pressure -
Measure/Record”.
74
Troubleshooting with a Table 7

Failure Mode Identifiers
Diagnostic Code
FMI Description of Failure
00 “Data valid but above normal operating
i01754390
range”
Diagnostic Codes 01 “Data valid but below normal operating
range”
SMCS Code: 1901-038
02 “Data erratic, intermittent or incorrect”
Diagnostic codes alert the operator that a problem 03 “Voltage above normal or shorted high”
in the electronic system has been detected.
Diagnostic codes also indicate the nature of the 04 “Voltage below normal or shorted low”
problem to the service technician. The Caterpillar 05 “Current below normal or open circuit”
Electronic Technician (Cat ET) is a software program
that is designed to run on a personal computer. 06 “Current above normal or grounded
Diagnostic codes may be viewed on a personal circuit”
computer that has Cat ET software. Diagnostic 07 “Mechanical system not responding
codes consist of three identifiers: module identifier properly”
(MID), component identifier (CID), and failure mode
08 “Abnormal frequency, pulse, or period”
identifier (FMI).
09 “Abnormal update”
Module Identifier (MID) – The MID is a code with two
10 “Abnormal rate of change”
or three digits that indicates the electronic module
which generated the diagnostic code. The MID 11 “Failure mode not identifiable”
for the engine’s Electronic Control Module (ECM)
is 036. Because Vee engines have two Integrated 12 “Bad device or component”
Combustion Sensing Modules (ICSM), there are two 13 “Out of calibration”
module identifiers. The MID for the “#1” ICSM on
the Vee engine’s right side is 109. In-line engines 14 “Not used”
have one ICSM which is also identified as 109. The 15 “Not used”
MID for the “#2” ICSM on the Vee engine’s left side
is 110. Some electronic displays do not display the 16 “Parameter not available”
MID because the module which generates the code 17 “Module not responding”
is obvious.
18 “Sensor supply fault”
Component Identifier (CID) – The CID is a number 19 “Condition not met”
with three or four digits. The CID indicates the
component that generated the code. For example, 20 “Not used”
the CID number 0017 identifies the fuel shutoff
valve. Note: Do not confuse diagnostic codes with event
codes. For information on event codes, refer to
Failure Mode Identifier (FMI) – The FMI is a two digit Troubleshooting, “Troubleshooting with an Event
code that indicates the type of failure. Table 7 is a Code”.
list of the failure mode identifiers that are adapted
from the “SAE J1587” standard. Illustration 27 represents the operating range of an
oil temperature sensor. The diagram is a reference.
Do not use the diagram to troubleshoot the oil
temperature sensor.
75
This information is a valuable indicator for

troubleshooting intermittent problems. Any logged
diagnostic codes will automatically be deleted if no
additional occurrences are recorded in 100 hours.
Some diagnostic codes may be easily triggered.
Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the
failure of the ECM. Diagnostic codes that are
logged repeatedly may indicate a problem that
needs special investigation.
Note: Always clear logged diagnostic codes after

investigating and correcting the problem which
generated the code.
i01775337
g00791619
MID 036 - CID 0017 - FMI 05
Illustration 27
Typical operating range of an oil temperature sensor
Fuel Shutoff Valve open circuit
(1) In these areas, the output voltage of the sensor is too high SMCS Code: 1901-038
or too low. The output is outside of the normal range. The
electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 C (216 F) is higher Conditions Which Generate This Code:
than normal. The output voltage of the sensor will generate an
event code for a warning, a derating, or a shutdown for high oil • The output from the Electronic Control Module
temperature. The sensor does not have an electronic problem.
(3) This area represents the normal operating temperature for the
(ECM) to the gas shutoff valve’s solenoid is OFF.
engine oil. The normal output voltage of the sensor is between
0.2 and 4.1 volts. • When no electrical load is provided, a resistor
in the gas shutoff valve’s solenoid rises to the
+Battery side.
Active Diagnostic Codes
Note: This code cannot be detected by the ECM
An active diagnostic code represents a problem
when the output for the gas shutoff valve’s solenoid
with the electronic control system. Correct the
is ON. The output is normally ON when the engine
problem as soon as possible.
control switch is in the START position and the
engine RPM is greater than zero.
When an active diagnostic code is generated, the
“Active Alarm” indicator (“Engine Control Alarm
System Response:
Status” on Cat ET) is activated in order to alert the
operator. If the condition that generated the code is
No fuel is provided to the engine. The alarm output
momentary, the message disappears from the list
is activated. The code is logged.
of active diagnostic codes. The diagnostic code
becomes logged.
Possible Performance Effect:
Logged Diagnostic Codes The engine will not start due to the lack of fuel.
When the ECM generates a diagnostic code the Troubleshooting:

ECM logs the code in permanent memory. The
ECM has an internal diagnostic clock. The ECM will The most likely cause is one of the following
record the following information when a code is conditions:
generated:
• An open circuit in the harness or in the gas
• The hour of the first occurrence of the code shutoff valve’s solenoid
• The hour of the last occurrence of the code • A short circuit to the +Battery in the harness or in
the gas shutoff valve’s solenoid
• The number of occurrences of the code
Perform the following diagnostic procedure: “ECM
Output Circuit (Fuel Control)”
76
Results: i01741131
• OK – STOP. MID 036 - CID 0017 - FMI 12

Fuel Shutoff Valve malfunction
i01775478
SMCS Code: 1901-038
MID 036 - CID 0017 - FMI 06
Conditions Which Generate This Code:
Fuel Shutoff Valve short to
ground The driver in the Electronic Control Module (ECM)
for the gas shutoff valve is OFF but the engine still
SMCS Code: 1901-038 runs.
Conditions Which Generate This Code: System Response:
• The output for the gas shutoff valve’s solenoid The ECM will disable the ignition system and the
is ON. gas shutoff valve in order to shut down the engine.
The shutdown output is activated. The code is
• The Electronic Control Module (ECM) detects logged.
excessive current on the output for the gas shutoff
valve’s solenoid. Possible Performance Effect:
Note: This condition cannot be detected by the ECM The engine is shut down.
when the output for the gas shutoff valve’s solenoid
is OFF. The output is normally OFF when the engine Troubleshooting:
control switch is in the OFF/RESET position.
System Response: Output Circuit (Fuel Control)”
The ECM will continue attempting to energize the Results:

relay. The engine may shut down due to a lack of
fuel. The alarm output is activated. The code is • OK – STOP.
logged.
i01727944
MID 036 - CID 0041 - FMI 03 8
The engine will not start due to the lack of fuel.
Volt DC Supply short to +batt
Troubleshooting:
SMCS Code: 1901-038
The condition is probably caused by a short circuit
in the harness or by an internal short circuit in the Conditions Which Generate This Code:
gas shutoff valve’s solenoid.
The voltage supply from the Electronic Control
Perform the following diagnostic procedure: “ECM Module (ECM) to one of the following sensors has
Output Circuit (Fuel Control)” exceeded the normal range.
Results: • Detonation sensors
• OK – STOP. • Sensor for inlet manifold air pressure

• Sensor for engine coolant pressure
System Response:
Default values are assumed for the inputs to the

ECM from all of the 8 volt analog sensors. All of the
diagnostic codes for the 8 volt analog sensors to
the ECM are disabled while this code is active.
77
The fuel is shut off. The shutdown output is i01775509

activated. The code is logged.
MID 036 - CID 0094 - FMI 03
Possible Performance Effect: Fuel Pressure open/short to
Since the engine protection is disabled, the engine +batt
is shut down.
SMCS Code: 1901-038
Troubleshooting:
Perform the following diagnostic procedure: “+8V
Sensor Voltage Supply” The duty cycle is higher than the maximum limit and
the frequency is lower than the minimum limit for the
Results: fuel side of the air/fuel pressure module.
• OK – STOP. System Response:

i01727976 logged.
MID 036 - CID 0041 - FMI 04 8 Possible Performance Effect:
Volt DC Supply short to ground
Because the Electronic Control Module (ECM) is
SMCS Code: 1901-038 unable to calculate the fuel flow, the engine is shut
down.
Troubleshooting:
The voltage supply from the Electronic Control
Module (ECM) to one of the following sensors is Perform the following diagnostic procedure:
below the normal range. “Air/Fuel Pressure Module”
• Detonation sensors Results:
• Sensor for inlet manifold air pressure • OK – STOP.

• Sensor for engine coolant pressure i01775529
System Response: MID 036 - CID 0094 - FMI 08

Default values are assumed for the inputs to the Fuel Pressure Noisy
ECM from all of the 8 volt analog sensors. All of the
diagnostic codes for the 8 volt analog sensors to SMCS Code: 1901-038
the ECM are disabled while this code is active.
The fuel is shut off. The shutdown output is
activated. The code is logged. The duty cycle or the frequency for the fuel’s side
of the air/fuel pressure module is higher than the
Possible Performance Effect: maximum limit.
Since the engine protection is disabled,the engine System Response:

is shut down.
Troubleshooting: logged.
Perform the following diagnostic procedure: “+8V Possible Performance Effect:

Sensor Voltage Supply”
Because the ECM is unable to calculate the fuel
Results: flow, the engine is shut down.
• OK – STOP. Troubleshooting:
Perform the following diagnostic procedure:

“Air/Fuel Pressure Module”
78
Results: i01728444

Engine Oil Pressure short to
i01728439 ground
MID 036 - CID 0100 - FMI SMCS Code: 1924-038
03 Engine Oil Pressure
open/short to +batt
The signal from the filtered oil pressure sensor to
SMCS Code: 1924-038 the Electronic Control Module (ECM) is less than
0.2 VDC for at least five seconds.
Additionally, neither of the following diagnostic
The signal from the filtered oil pressure sensor to codes are active:
the Electronic Control Module (ECM) is greater than
4.8 VDC for at least five seconds.
• 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
codes are active:
to ground
to +batt System Response:
• 262 - 04 5 Volt Sensor DC Power Supply short The ECM assumes the last valid value for the engine
to ground oil pressure. The monitoring of the oil pressure is
disabled. This disables the engine protection for
System Response: low oil pressure and excessive oil pressure.
The ECM assumes the last valid value for the engine The fuel is shut off. The shutdown output is
oil pressure. The monitoring of the oil pressure is activated. The code is logged.
disabled. This disables the engine protection for
low oil pressure and excessive oil pressure. Possible Performance Effect:
The fuel is shut off. The shutdown output is Since the engine protection is disabled, the engine
activated. The code is logged. is shut down.
Possible Performance Effect: Troubleshooting:
Since the engine protection is disabled, the engine Perform the following diagnostic procedure: “Analog
is shut down. Sensor Signal”
Troubleshooting: Results:
This condition indicates an open circuit or a short
circuit to a positive voltage source.
• OK – STOP.
Perform the following diagnostic procedure: “Analog

Sensor Signal”
Results:
• OK – STOP.
79
i01775705 i01775709
MID 036 - CID 0101 - FMI MID 036 - CID 0101 - FMI 04
03 Crankcase Pressure Crankcase Pressure short to
open/short to +batt ground
Conditions Which Generate This Code: Conditions Which Generate This Code:
The signal from the crankcase pressure sensor to The signal from the crankcase pressure sensor to
the Electronic Control Module (ECM) is greater than the Electronic Control Module (ECM) is less than
4.5 VDC for at least five seconds. 0.5 VDC for at least five seconds.
Additionally, neither of the following diagnostic Additionally, neither of the following diagnostic
codes are active: codes are active:
• 262 - 03 5 Volt Sensor DC Power Supply short • 262 - 03 5 Volt Sensor DC Power Supply short
to +batt to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short • 262 - 04 5 Volt Sensor DC Power Supply short
to ground to ground
System Response: System Response:
The ECM assumes the last valid value for the The ECM assumes the last valid value for the
crankcase pressure. The monitoring of the crankcase pressure. The monitoring of the
crankcase pressure is disabled. This disables the crankcase pressure is disabled. This disables the
engine protection for high crankcase pressure. engine protection for high crankcase pressure.
The shutdown output is activated. The code is The shutdown output is activated. The code is
logged. logged.
Possible Performance Effect: Possible Performance Effect:
The engine is shut down. The engine is shut down.
Troubleshooting: Troubleshooting:
This condition indicates either an open circuit or a Perform the following diagnostic procedure: “Analog
short circuit to a positive voltage source. Sensor Signal”
Perform the following diagnostic procedure: “Analog Results:

Sensor Signal”
• OK – STOP.
Results:
i01626914
• OK – STOP.
MID 036 - CID 0106 - FMI 03 Air
Inlet Pressure Sensor short to
+batt
SMCS Code: 1901-038
The duty cycle for the inlet manifold air pressure is

greater than the maximum possible value for more
than 2.67 ms during a 1.5 second interval.
80
Additionally, neither of the following diagnostic i01793903

codes are active:
MID 036 - CID 0109 - FMI
• 41 - 03 8 Volt DC Supply short to +batt 03 Coolant Outlet Pressure
• 41 - 04 8 Volt DC Supply short to ground open/short to +batt
System Response: SMCS Code: 1901-038
The shutdown output is activated. The code is S/N: BKE1-Up

logged. S/N: BEN1-Up
Possible Performance Effect: S/N: 4ZS1-Up
The engine is shut down. Conditions Which Generate This Code:
Troubleshooting: The duty cycle of the pressure sensor for the outlet
of the engine coolant is greater than the maximum
This condition indicates the possibility of an open limit.
circuit or a short circuit.
Perform the following diagnostic procedure: codes are active:
• 41 - 03 8 Volt DC Supply short to +batt
Results:
• 41 - 04 8 Volt DC Supply short to ground
• OK – STOP.
System Response:
i01626920
The alarm output is activated. The code is logged.
MID 036 - CID 0106 - FMI 08 Air Possible Performance Effect:
Inlet Pressure Sensor noisy
The engine performance is not affected.
signal
SMCS Code: 1901-038 Troubleshooting:
Conditions Which Generate This Code: The condition indicates a possible open circuit or
a short circuit.
The duty cycle or the frequency of the signal for the
inlet manifold air pressure is out of range. Perform the following diagnostic procedure: “PWM
Sensor”
System Response:
Results:
logged. • OK – STOP.
The engine is shut down.
Troubleshooting:

Results:
• OK – STOP.
81
i01691110 The fuel is shut off. The shutdown output is

MID 036 - CID 0109 - FMI
08 Engine Coolant Outlet Possible Performance Effect:
Pressure Sensor noisy signal Since the engine protection is disabled, the engine
is shut down.
SMCS Code: 1901-038
Troubleshooting:
This condition indicates the possibility of an open
The duty cycle or the frequency of the signal from circuit or a short circuit.
the pressure sensor for the outlet of the engine
coolant is out of range. Perform the following diagnostic procedure: “Analog
Sensor Signal”
codes are active: Results:
• 41 - 03 8 Volt DC Supply short to +batt • OK – STOP.

i01728447
System Response:
MID 036 - CID 0110 - FMI 04
The alarm output is activated. The code is logged. Engine Coolant Temperature
Possible Performance Effect: short to ground
The engine performance is not affected. SMCS Code: 1906-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: “PWM The signal from the engine coolant temperature
Sensor” sensor to the Electronic Control Module (ECM) is
less than 0.2 VDC for at least five seconds.
Results:
System Response:
• OK – STOP. The ECM assumes the last valid value for the
engine coolant temperature. The monitoring of the
i01728446 coolant temperature is disabled. This disables the
engine protection for low coolant temperature and
MID 036 - CID 0110 - FMI 03 high coolant temperature.
Engine Coolant Temperature The fuel is shut off. The shutdown output is
open/short to +batt activated. The code is logged.
SMCS Code: 1906-038 Possible Performance Effect:
Conditions Which Generate This Code: Since the engine protection is disabled, the engine
is shut down.
The signal from the engine coolant temperature
sensor to the Electronic Control Module (ECM) is Troubleshooting:
greater than 4.8 VDC for at least five seconds.
System Response: Sensor Signal”
The ECM assumes the last valid value for engine Results:
coolant temperature. The monitoring of the coolant
temperature is disabled. This disables the engine • OK – STOP.
protection for low coolant temperature and high
coolant temperature.
82
i01728450 i01728451
MID 036 - CID 0168 - MID 036 - CID 0172 - FMI 03

FMI 02 System Voltage Intake Manifold Air Temp
intermittent/erratic open/short to +batt
The Electronic Control Module (ECM) has been The Electronic Control Module (ECM) has been
powered for at least 5 seconds. The engine is powered for at least five seconds. The signal from
running. Either of the two following conditions occur: the inlet manifold temperature sensor to the ECM
is greater than 4.8 VDC for at least five seconds.
• The battery voltage is less than 6 VDC for a Additionally, neither of the following diagnostic
minimum of 0.060 seconds. The voltage returns codes are active:
to the normal range within 0.015 seconds.
• There are three voltage readings of less than 6 to +batt
VDC within 7 seconds.
• 262 -04 5 Volt Sensor DC Power Supply short to
System Response: ground
The alarm output is activated. The code is logged. System Response:
Note: If battery voltage is lost and the voltage does The ECM assumes the last valid value for the inlet
not return, the ECM will not log this diagnostic code. manifold air temperature. The monitoring of the
The engine will shut down. inlet manifold air temperature is disabled. This
disables the engine protection for high inlet manifold
Possible Performance Effect: air temperature. The air/fuel ratio control cannot
compensate for the inlet air temperature.
The intermittent problem may not affect engine
operation. However, the engine may experience The fuel is shut off. The shutdown output is
speed burps, intermittent shutdowns, and/or activated. The code is logged.
complete shutdowns.
Troubleshooting:
“Electrial Power Supply” Troubleshooting:
Results: The condition indicates a possible open circuit or a

short circuit to a positive voltage source.
• OK – STOP.
Sensor Signal”
Results:
• OK – STOP.
83
i01728453 Additionally, neither of the following diagnostic

codes are active:
MID 036 - CID 0172 - FMI 04
Intake Manifold Air Temp short • 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
to ground
SMCS Code: 1901-038 to ground
The signal from the inlet manifold temperature The ECM assumes the last valid value for the fuel
sensor to the Electronic Control Module (ECM) is temperature. The monitoring of the fuel temperature
less than 0.2 VDC for at least five seconds. is disabled. This disables the engine protection for
high fuel temperature.
codes are active: The shutdown output is activated. The code is
logged.
to +batt Possible Performance Effect:
• 262 - 04 5 Volt Sensor DC Power Supply short The engine is shut down.
to ground
Troubleshooting:
System Response:
This condition indicates either an open circuit or a
The ECM assumes the last valid value for the inlet short circuit to a positive voltage source.
manifold air temperature. The monitoring of the
inlet manifold air temperature is disabled. This Perform the following diagnostic procedure: “Analog
disables the engine protection for high inlet manifold Sensor Signal”
air temperature. The air/fuel ratio control cannot
compensate for the inlet air temperature. Results:
The fuel is shut off. The shutdown output is • OK – STOP.
Possible Performance Effect: i01775716
The engine is shut down. MID 036 - CID 0174 - FMI 04

Fuel Temperature short to
Troubleshooting:
ground
Sensor Signal” SMCS Code: 1901-038
Results: Conditions Which Generate This Code:
The signal from the fuel temperature sensor to the

• OK – STOP. Electronic Control Module (ECM) is less than 0.5
VDC.
i01775713
MID 036 - CID 0174 - FMI 03 codes are active:
Fuel Temperature open/short
to +batt to +batt
SMCS Code: 1901-038 • 262 - 04 5 Volt Sensor DC Power Supply short
to ground
The signal from the fuel temperature sensor to the

Electronic Control Module (ECM) is greater than 4.5
VDC for at least five seconds.
84
System Response: Possible Performance Effect:
The ECM assumes the last valid value for the fuel Since engine protection is disabled, the engine is
temperature. The monitoring of the fuel temperature shut down.
is disabled. This disables the engine protection for
high fuel temperature. Troubleshooting:
The shutdown output is activated. The code is The condition indicates a possible open circuit or a
logged. short circuit to a positive voltage source.
Possible Performance Effect: Perform the following diagnostic procedure: “Analog

Sensor Signal”
Results:
Troubleshooting:
• OK – STOP.
Sensor Signal”
i01728458
Results: MID 036 - CID 0175 - FMI 04

• OK – STOP. Engine Oil Temperature short
to ground
i01728456
SMCS Code: 1901-038
MID 036 - CID 0175 - FMI
03 Engine Oil Temperature Conditions Which Generate This Code:
open/short to +batt The signal from the engine oil temperature sensor
to the Electronic Control Module (ECM) is less than
SMCS Code: 1901-038 0.2 VDC for at least five seconds.
Conditions Which Generate This Code: Additionally, neither of the following diagnostic
codes are active:
The signal from the engine oil temperature sensor
to the Electronic Control Module (ECM) is greater • 262 - 03 5 Volt Sensor DC Power Supply short
than 4.8 VDC for at least five seconds. to +batt
Additionally, neither of the following diagnostic • 262 - 04 5 Volt Sensor DC Power Supply short
codes are active: to ground
• 262 - 03 5 Volt Sensor DC Power Supply short System Response:

to +batt
The ECM assumes the last valid value for the engine
• 262 - 04 5 Volt Sensor DC Power Supply short oil temperature. The monitoring of the engine oil
to ground temperature is disabled. Also, monitoring for a high
difference in temperature between the engine oil
System Response: and the engine coolant is disabled. This disables
the engine protection for both parameters.
The ECM assumes the last valid value for the engine
oil temperature. The monitoring of the engine oil The shutdown output is activated. The code is
temperature is disabled. Also, the monitoring for a logged.
high difference in temperature between the engine
oil and the engine coolant is disabled. This disables Possible Performance Effect:
the engine protection for both parameters.
Since engine protection is disabled, the engine is
The shutdown output is activated. The code is shut down.
logged.
85
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: “Analog If the engine is not running, the engine will not start.
Sensor Signal” If the engine is running, the engine is shut down.
Results: Troubleshooting:
• OK – STOP. Perform the following diagnostic procedure: “Engine

Speed/Timing Sensor”
i01653982
Results:
MID 036 - CID 0190 - FMI 02
• OK – STOP.
Loss of Engine Speed signal
SMCS Code: 1912-038 i01728460

MID 036 - CID 0262 - FMI 03 5
Volt Sensor DC Power Supply
The crankshaft is rotating faster than the cranking
speed and the signal from the engine speed/timing
short to +batt
sensor is lost for at least one second.
SMCS Code: 1408-038-NS
System Response:
The supply voltage from the Electronic Control
logged.
Module (ECM) to the sensors for the following
Possible Performance Effect: parameters is exceeding the normal level:
If the engine is not running, the engine will not start. • Inlet manifold air temperature
If the engine is running, the engine is shut down.
• Engine oil temperature
Troubleshooting:
• Filtered engine oil pressure
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor” • Unfiltered engine oil pressure
System Response:
Results:
All of the inputs to the ECM for the 5 volt analog
• OK – STOP. sensors assume default values. All other diagnostic
codes for the 5 volt analog sensors are disabled
i01653992 while this diagnostic code is active. The “Status”
screen of Caterpillar Electronic Technician (ET)
MID 036 - CID 0190 - FMI 08 indicates a “Sensor Supply Fault” for each sensor.
Engine Speed signal abnormal This indicates that the sensors are not operating
due to an active diagnostic code.
SMCS Code: 1912-038
The shutdown indicator is activated. The code is
Conditions Which Generate This Code: logged.
The crankshaft is rotating faster than the cranking Possible Performance Effect:
speed. The signal from the engine speed/timing
sensor is lost but the signal returns within one Since engine protection is disabled, the engine is
second. shut down.
System Response: Troubleshooting:
The shutdown output is activated. The code is Perform the following diagnostic procedure: “+5V
logged. Sensor Voltage Supply”
86
Results: i01762729

Ignition Transformer Primary
i01728462 #1 open circuit
MID 036 - CID 0262 - FMI 04 5 SMCS Code: 1901-038
Volt Sensor DC Power Supply
short to ground
The primary circuit of the transformer is diagnosed
SMCS Code: 1408-038-NS with an open circuit.
The supply voltage from the Electronic Control The alarm output is activated. The code is logged.
Module (ECM) to the sensors for the following
parameters is less than the normal level: Possible Performance Effect:
• Inlet manifold air temperature The cylinder will misfire.
• Engine oil temperature Troubleshooting:
• Filtered engine oil pressure One of the following conditions is the source of the
diagnostic code:
• Unfiltered engine oil pressure
System Response:
• An open circuit in the wiring between the
Electronic Control Module (ECM) and the
transformer
All of the inputs to the ECM for the 5 volt analog
sensors assume default values. All other diagnostic
codes for the 5 volt analog sensors are disabled
• An open circuit within the primary winding of the
transformer
while this diagnostic code is active. The “Status”
screen of the Caterpillar Electronic Technician (ET)
indicates a “Sensor Supply Fault” for each sensor.
• An internal failure of the ECM
This indicates that the sensors are not operating Perform the following diagnostic procedure: “Ignition
due to an active diagnostic code. Transformers Primary Circuit”
The shutdown output is activated. The code is Results:
logged.

• OK – STOP.
Since engine protection is disabled, the engine is i01763010

shut down.
MID 036 - CID 0301 - FMI 06
Troubleshooting: Ignition Transformer Primary
The condition indicates a possible short circuit to #1 short
ground or a short circuit between the sensor supply
and the return. SMCS Code: 1901-038
Perform the following diagnostic procedure: “+5V Conditions Which Generate This Code:
Sensor Voltage Supply”
The path for the circuit driver of the transformer is
Results: diagnosed with a short circuit.

87
Possible Performance Effect: Results:
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01763021
One of the following conditions is the source of the

diagnostic code:
MID 036 - CID 0302 - FMI 06
• A short circuit in the wiring between the Electronic #2 short
Control Module (ECM) and the transformer
SMCS Code: 1901-038
• A short circuit within the primary winding of the
transformer Conditions Which Generate This Code:
• An internal failure of the ECM The path for the circuit driver of the transformer is
diagnosed with a short circuit.
Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
System Response:
Results:
• OK – STOP. Possible Performance Effect:
i01762758 The cylinder will misfire.
MID 036 - CID 0302 - FMI 05 Troubleshooting:

Ignition Transformer Primary One of the following conditions is the source of the
#2 open circuit diagnostic code:
SMCS Code: 1901-038 • A short circuit in the wiring between the Electronic
The primary circuit of the transformer is diagnosed transformer
with an open circuit.
System Response:
The alarm output is activated. The code is logged. Transformers Primary Circuit”
Possible Performance Effect: Results:
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01762766

diagnostic code:
MID 036 - CID 0303 - FMI 05
• An open circuit in the wiring between the #3 open circuit
transformer
SMCS Code: 1901-038
• An open circuit within the primary winding of the Conditions Which Generate This Code:
transformer
• An internal failure of the ECM with an open circuit.
88
System Response: • A short circuit within the primary winding of the

transformer
The cylinder will misfire. Transformers Primary Circuit”
One of the following conditions is the source of the • OK – STOP.

diagnostic code:
i01762778
transformer
MID 036 - CID 0304 - FMI 05
• An open circuit within the primary winding of the #4 open circuit
transformer
SMCS Code: 1901-038
Results:
System Response:
• OK – STOP.
i01763029
MID 036 - CID 0303 - FMI 06
The cylinder will misfire.
#3 short Troubleshooting:
SMCS Code: 1901-038 One of the following conditions is the source of the
diagnostic code:
The path for the circuit driver of the transformer is Electronic Control Module (ECM) and the
diagnosed with a short circuit. transformer
System Response: • An open circuit within the primary winding of the

transformer

diagnostic code:
• A short circuit in the wiring between the Electronic

89
i01763033 Troubleshooting:
MID 036 - CID 0304 - FMI 06 One of the following conditions is the source of the
Ignition Transformer Primary diagnostic code:
#4 short • An open circuit in the wiring between the
SMCS Code: 1901-038 transformer
Conditions Which Generate This Code: • An open circuit within the primary winding of the
transformer
diagnosed with a short circuit. • An internal failure of the ECM
System Response: Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting: i01763043

MID 036 - CID 0305 - FMI 06
diagnostic code: Ignition Transformer Primary
• A short circuit in the wiring between the Electronic #5 short
SMCS Code: 1901-038
• A short circuit within the primary winding of the Conditions Which Generate This Code:
transformer
• An internal failure of the ECM diagnosed with a short circuit.
Transformers Primary Circuit” System Response:
Results: The alarm output is activated. The code is logged.

• OK – STOP.
i01762805
Troubleshooting:
MID 036 - CID 0305 - FMI 05
Ignition Transformer Primary One of the following conditions is the source of the
diagnostic code:
#5 open circuit
SMCS Code: 1901-038 Control Module (ECM) and the transformer
Conditions Which Generate This Code: • A short circuit within the primary winding of the
transformer
with an open circuit. • An internal failure of the ECM
System Response: Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
90
i01762875 Possible Performance Effect:

MID 036 - CID 0306 - FMI 05 The cylinder will misfire.
Troubleshooting:
#6 open circuit
SMCS Code: 1901-038 diagnostic code:
Conditions Which Generate This Code: • A short circuit in the wiring between the Electronic
with an open circuit. • A short circuit within the primary winding of the
transformer
System Response:
Possible Performance Effect: Transformers Primary Circuit”
The cylinder will misfire. Results:
Troubleshooting: • OK – STOP.
diagnostic code: i01762944

MID 036 - CID 0307 - FMI 05
Electronic Control Module (ECM) and the Ignition Transformer Primary
transformer
#7 open circuit
• An open circuit within the primary winding of the SMCS Code: 1901-038
transformer
S/N: BLB1-Up
S/N: BKE1-Up
Transformers Primary Circuit” S/N: BEN1-Up
• OK – STOP. The primary circuit of the transformer is diagnosed

i01763045 System Response:
MID 036 - CID 0306 - FMI 06 The alarm output is activated. The code is logged.
#6 short
SMCS Code: 1901-038
Troubleshooting:
The path for the circuit driver of the transformer is diagnostic code:
System Response:
transformer
91
• An open circuit within the primary winding of the i01762969

transformer
MID 036 - CID 0308 - FMI 05
• An internal failure of the ECM Ignition Transformer Primary
Perform the following diagnostic procedure: “Ignition #8 open circuit
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
• OK – STOP. S/N: BKE1-Up
S/N: BEN1-Up
i01763068
MID 036 - CID 0307 - FMI 06 Conditions Which Generate This Code:
Ignition Transformer Primary The primary circuit of the transformer is diagnosed

#7 short
SMCS Code: 1901-038 System Response:
S/N: BLB1-Up The alarm output is activated. The code is logged.
S/N: BKE1-Up Possible Performance Effect:

S/N: BEN1-Up The cylinder will misfire.
Conditions Which Generate This Code: Troubleshooting:
The path for the circuit driver of the transformer is One of the following conditions is the source of the
diagnosed with a short circuit. diagnostic code:
System Response:
The alarm output is activated. The code is logged. transformer
transformer
Troubleshooting:
One of the following conditions is the source of the Transformers Primary Circuit”
diagnostic code:
Results:
• OK – STOP.
transformer

Results:
• OK – STOP.
92
i01763077 i01762971
MID 036 - CID 0308 - FMI 06 MID 036 - CID 0309 - FMI 05
Ignition Transformer Primary Ignition Transformer Primary
#8 short #9 open circuit
S/N: BLB1-Up S/N: BLB1-Up
S/N: BKE1-Up S/N: BKE1-Up
S/N: BEN1-Up Conditions Which Generate This Code:
Conditions Which Generate This Code: The primary circuit of the transformer is diagnosed
diagnosed with a short circuit. System Response:
System Response: The alarm output is activated. The code is logged.
The alarm output is activated. The code is logged. Possible Performance Effect:
Possible Performance Effect: The cylinder will misfire.
The cylinder will misfire. Troubleshooting:
Troubleshooting: One of the following conditions is the source of the
diagnostic code:
diagnostic code: • An open circuit in the wiring between the
• A short circuit in the wiring between the Electronic transformer
• A short circuit within the primary winding of the transformer
transformer
Perform the following diagnostic procedure: “Ignition Transformers Primary Circuit”
Results:
Results:
• OK – STOP.
• OK – STOP.
93

#9 short
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
S/N: BKE1-Up One of the following conditions is the source of the
diagnostic code:
The path for the circuit driver of the transformer is Electronic Control Module (ECM) and the
System Response: • An open circuit within the primary winding of the

transformer

diagnostic code:
i01763093
Control Module (ECM) and the transformer MID 036 - CID 0310 - FMI 06
• A short circuit within the primary winding of the Ignition Transformer Primary
transformer #10 short
• An internal failure of the ECM SMCS Code: 1901-038
Perform the following diagnostic procedure: “Ignition S/N: BLB1-Up
S/N: BKE1-Up
Results:
• OK – STOP. The path for the circuit driver of the transformer is
i01762975
System Response:
MID 036 - CID 0310 - FMI 05
Ignition Transformer Primary The alarm output is activated. The code is logged.
#10 open circuit Possible Performance Effect:
SMCS Code: 1901-038 The cylinder will misfire.
S/N: BLB1-Up Troubleshooting:
S/N: BKE1-Up
Conditions Which Generate This Code: diagnostic code:
The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the Electronic
with an open circuit. Control Module (ECM) and the transformer
94
• A short circuit within the primary winding of the i01763100

transformer
MID 036 - CID 0311 - FMI 06
• An internal failure of the ECM Ignition Transformer Primary
Perform the following diagnostic procedure: “Ignition #11 short
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
i01762978
MID 036 - CID 0311 - FMI 05 The path for the circuit driver of the transformer is
#11 open circuit System Response:
SMCS Code: 1901-038 The alarm output is activated. The code is logged.
S/N: BLB1-Up Possible Performance Effect:

S/N: BKE1-Up The cylinder will misfire.
The primary circuit of the transformer is diagnosed One of the following conditions is the source of the
with an open circuit. diagnostic code:
System Response:

transformer
Troubleshooting: Perform the following diagnostic procedure: “Ignition
diagnostic code: Results:
• An open circuit in the wiring between the • OK – STOP.
transformer

transformer

Results:
• OK – STOP.
95

#12 open circuit
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
S/N: BKE1-Up One of the following conditions is the source of the
diagnostic code:
The primary circuit of the transformer is diagnosed Control Module (ECM) and the transformer
System Response: transformer
The alarm output is activated. The code is logged. • An internal failure of the ECM
Possible Performance Effect: Perform the following diagnostic procedure: “Ignition
Results:
Troubleshooting:
• OK – STOP.
diagnostic code: i01762996
• An open circuit in the wiring between the MID 036 - CID 0313 - FMI 05
transformer Ignition Transformer Primary
#13 open circuit
transformer SMCS Code: 1901-038
• An internal failure of the ECM S/N: BLB1-Up
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Results: with an open circuit.

i01763119
MID 036 - CID 0312 - FMI 06 Possible Performance Effect:
Ignition Transformer Primary The cylinder will misfire.

#12 short Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up diagnostic code:
S/N: BKE1-Up • An open circuit in the wiring between the

Conditions Which Generate This Code: transformer
The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
96
• An internal failure of the ECM i01763001
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0314 - FMI 05
Transformers Primary Circuit” Ignition Transformer Primary
Results: #14 open circuit
• OK – STOP. SMCS Code: 1901-038
S/N: BLB1-Up
i01763123
MID 036 - CID 0313 - FMI 06
Ignition Transformer Primary The primary circuit of the transformer is diagnosed
#13 short
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up
diagnosed with a short circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:

transformer
Troubleshooting:
transformer
diagnostic code:
• A short circuit in the wiring between the Electronic Transformers Primary Circuit”
Results:
transformer
• OK – STOP.
i01763128
Transformers Primary Circuit” MID 036 - CID 0314 - FMI 06
Results:
#14 short
• OK – STOP.
SMCS Code: 1901-038
S/N: BLB1-Up

97
System Response: • An internal failure of the ECM

The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:
i01763133
diagnostic code: MID 036 - CID 0315 - FMI 06
• A short circuit in the wiring between the Electronic Ignition Transformer Primary
#15 short
• A short circuit within the primary winding of the SMCS Code: 1901-038
transformer
S/N: BLB1-Up
Transformers Primary Circuit” The path for the circuit driver of the transformer is
Results:
System Response:
• OK – STOP.
i01763004
MID 036 - CID 0315 - FMI 05
#15 open circuit Troubleshooting:
SMCS Code: 1901-038 One of the following conditions is the source of the
diagnostic code:
S/N: BLB1-Up
Conditions Which Generate This Code: Control Module (ECM) and the transformer
The primary circuit of the transformer is diagnosed • A short circuit within the primary winding of the
with an open circuit. transformer
System Response: • An internal failure of the ECM

The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:

diagnostic code:

transformer

transformer
98

#16 open circuit
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
Conditions Which Generate This Code: diagnostic code:
with an open circuit. • A short circuit in the wiring between the Electronic
System Response:
transformer
Possible Performance Effect: • An internal failure of the ECM

diagnostic code: • OK – STOP.
• An open circuit in the wiring between the i01728557

transformer MID 036 - CID 0323 - FMI 03
Shutdown Lamp short to +batt
transformer SMCS Code: 1901-038
• An internal failure of the ECM Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition The Electronic Control Module (ECM) detects
Transformers Primary Circuit” excessive current for the shutdown output.
Results: Note: This diagnostic condition cannot be detected
when the shutdown output is OFF.
• OK – STOP.
System Response:
i01763142
The ECM limits the current for the shutdown output
MID 036 - CID 0316 - FMI 06 to 0.3 amperes. The code is logged.
Ignition Transformer Primary Possible Performance Effect:
#16 short
The engine operation is not affected.
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
Conditions Which Generate This Code: Status Indicator Output”
The path for the circuit driver of the transformer is Results:
• OK – STOP.
99
i01728563 Results:
MID 036 - CID 0324 - FMI 03 • OK – STOP.
Warning Lamp short to +batt
i01775739
SMCS Code: 1901-038
MID 036 - CID 0338 - FMI 05
Pre-Lube Relay open circuit
The Electronic Control Module (ECM) detects
excessive current for the alarm output. SMCS Code: 1319-038
Note: This diagnostic condition cannot be detected Conditions Which Generate This Code:
when the alarm output is OFF.
An open circuit or a short circuit to the +Battery
System Response: side is detected while the output from the Electronic
Control Module (ECM) to the prelube pump’s
The ECM limits the current for the alarm output to solenoid is OFF.
0.3 amperes. The code is logged.
Note: This diagnostic condition can only be
Possible Performance Effect: detected by the ECM when the output for the
prelube pump’s solenoid is OFF. The output is
The engine operation is not affected. normally OFF when the engine control switch is in
the STOP position and/or when the prelube pressure
Troubleshooting: switch is CLOSED.
Perform the following diagnostic procedure: “ECM System Response:

Status Indicator Output”
An internal resistor rises to the +Battery side when
Results: no electrical load is present. This indicates an open
circuit in the harness or the solenoid. The alarm
output is activated. The code is logged.
• OK – STOP.
i01775737
The prelubrication will probably be disabled.
MID 036 - CID 0336 - FMI 02
Incorrect ECS Switch inputs Troubleshooting:
SMCS Code: 1901-038 Perform the following diagnostic procedure: “ECM

Output Circuit (Prelubrication Oil Pump)”
Results:
an invalid combination of these inputs: switched • OK – STOP.
+Battery, start, stop, and auto. This indicates a
problem with the engine control switch. i01775740
System Response: MID 036 - CID 0338 - FMI

The shutdown output is activated. The code is 06 Pre-Lube Relay short to
logged. ground
Possible Performance Effect: SMCS Code: 1319-038
Troubleshooting: The Electronic Control Module (ECM) detects
excessive current for the output to the prelube
Perform the following diagnostic procedure: pump’s solenoid. This indicates a possible short
“Electrical Power Supply” circuit to the −Battery side.
100
Note: This diagnostic condition can only be detected Troubleshooting:

by the ECM when the output for the prelube pump’s
solenoid is ON. The output is normally ON when the Perform the following diagnostic procedure:
engine control switch is in the START position and “Prelubrication System”
the prelube pressure switch is still OPEN.
Results:
System Response:
• OK – STOP.
The ECM will continue to attempt to energize the
prelube pump’s solenoid. The alarm output is
i01685945

MID 036 - CID 0401 - FMI
05 Cylinder 1 - Transformer
Secondary open circuit
Troubleshooting: SMCS Code: 1901-038
Output Circuit (Prelubrication Oil Pump)”
The transformer’s secondary circuit is diagnosed
Results:
i01728588 The status of the transformer’s secondary output is

set to 120 percent. The alarm output is activated
MID 036 - CID 0339 - FMI 05 and the code is logged.
Engine Pre-lube Pressure Possible Performance Effect:
Switch open circuit
SMCS Code: 1901-038
Troubleshooting:
The prelube pressure switch is OPEN. The oil problem:
pressure that is measured from the engine oil
pressure sensor is greater than 50 kPa (7.25 psi). • There is a problem with the transformer’s ground.
System Response: • The winding of the transformer’s secondary circuit
is open.
The Electronic Control Module (ECM) normally
monitors the prelube pressure switch. In this case, • There is a problem with the connection to the
the engine oil pressure sensor will be monitored. spark plug’s terminal post.
This determines if the prelube pump is supplying oil
to the engine. • The spark plug has internal damage or an open
circuit.
If an “E233 (3) Low Engine Prelube Pressure” event
is active, the output to the starting motor will not be • The spark plug gap is too wide.
energized and the engine will not start.
The alarm output is activated. The code is logged. Transformers Secondary Circuit and Spark Plugs”
The output to the prelube relay remains energized
until the engine control switch is turned to the STOP Results:
position.
• OK – STOP.

101

MID 036 - CID 0401 - FMI The cylinder will misfire.
Troubleshooting:
Secondary short to ground
SMCS Code: 1901-038 problem:
Conditions Which Generate This Code: • There is a problem with the transformer’s ground.
The transformer’s secondary circuit is diagnosed • The winding of the transformer’s secondary circuit
with a short circuit. is open.
System Response: • There is a problem with the connection to the

spark plug’s terminal post.
The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated • The spark plug has internal damage or an open
and the code is logged. circuit.
Possible Performance Effect: • The spark plug gap is too wide.
The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Transformers Secondary Circuit and Spark Plugs”
Troubleshooting:
Results:
problem: • OK – STOP.
• The spark plug is fouled.
i01632192
• The spark plug gap is closed. MID 036 - CID 0402 - FMI
• The winding of the transformer’s secondary circuit 06 Cylinder 2 - Transformer
is shorted.
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1901-038

• OK – STOP. with a short circuit.

MID 036 - CID 0402 - FMI The status of the transformer’s secondary output is
05 Cylinder 2 - Transformer set to zero percent. The alarm output is activated
and the code is logged.
SMCS Code: 1901-038
Troubleshooting:
with an open circuit. One of the following conditions is the source of the
problem:
System Response:
set to 120 percent. The alarm output is activated • The spark plug gap is closed.
102
• The winding of the transformer’s secondary circuit i01632203

is shorted.
MID 036 - CID 0403 - FMI
Perform the following diagnostic procedure: “Ignition 06 Cylinder 3 - Transformer
Results:
SMCS Code: 1901-038
• OK – STOP.
i01685955 The transformer’s secondary circuit is diagnosed
with a short circuit.
MID 036 - CID 0403 - FMI
05 Cylinder 3 - Transformer System Response:
Secondary open circuit The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated
SMCS Code: 1901-038 and the code is logged.
Conditions Which Generate This Code: Possible Performance Effect:
The transformer’s secondary circuit is diagnosed The cylinder will misfire.
Troubleshooting:
System Response:
The status of the transformer’s secondary output is problem:
• The spark plug gap is closed.
• The winding of the transformer’s secondary circuit
is shorted.
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
problem:
Results:
• There is a problem with the transformer’s ground.
• OK – STOP.
is open.
i01685958
• There is a problem with the connection to the
spark plug’s terminal post. MID 036 - CID 0404 - FMI
• The spark plug has internal damage or an open
circuit. Secondary open circuit
• The spark plug gap is too wide. SMCS Code: 1901-038
• OK – STOP.
103
The status of the transformer’s secondary output is One of the following conditions is the source of the
set to 120 percent. The alarm output is activated problem:
Troubleshooting: is shorted.
One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
problem: Transformers Secondary Circuit and Spark Plugs”
• There is a problem with the transformer’s ground. Results:
• The winding of the transformer’s secondary circuit • OK – STOP.

is open.
i01685960
spark plug’s terminal post. MID 036 - CID 0405 - FMI
• The spark plug has internal damage or an open 05 Cylinder 5 - Transformer
circuit.
i01632257 The status of the transformer’s secondary output is

MID 036 - CID 0404 - FMI and the code is logged.
06 Cylinder 4 - Transformer Possible Performance Effect:
Generation of the diagnostic code does not affect
SMCS Code: 1901-038 engine performance. However, the engine will
probably misfire. This will cause the engine to run
Conditions Which Generate This Code: rough. The engine may shut down.
The transformer’s secondary circuit is diagnosed Troubleshooting:

System Response: problem:
The status of the transformer’s secondary output is • There is a problem with the transformer’s ground.
and the code is logged. • The winding of the transformer’s secondary circuit
is open.
The cylinder will misfire. spark plug’s terminal post.

circuit.
104
• The spark plug gap is too wide. i01685964
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0406 - FMI
Transformers Secondary Circuit and Spark Plugs” 05 Cylinder 6 - Transformer
Results: Secondary open circuit

i01632261
MID 036 - CID 0405 - FMI with an open circuit.
System Response:
SMCS Code: 1901-038 set to 120 percent. The alarm output is activated
with a short circuit. The cylinder will misfire.
set to zero percent. The alarm output is activated problem:


is open.
Troubleshooting:
problem:
circuit.
• The spark plug gap is too wide.
• The winding of the transformer’s secondary circuit Transformers Secondary Circuit and Spark Plugs”
is shorted.
Results:
• OK – STOP.
Results:
• OK – STOP.
105

MID 036 - CID 0406 - FMI The status of the transformer’s secondary output is
06 Cylinder 6 - Transformer set to 120 percent. The alarm output is activated
SMCS Code: 1901-038
Troubleshooting:
with a short circuit. One of the following conditions is the source of the
problem:
System Response:
set to zero percent. The alarm output is activated • The winding of the transformer’s secondary circuit
and the code is logged. is open.
Possible Performance Effect: • There is a problem with the connection to the
Troubleshooting: circuit.
One of the following conditions is the source of the • The spark plug gap is too wide.
problem:
• The spark plug is fouled. Transformers Secondary Circuit and Spark Plugs”
• The spark plug gap is closed. Results:

is shorted.
Perform the following diagnostic procedure: “Ignition i01632278

MID 036 - CID 0407 - FMI
Results: 06 Cylinder 7 - Transformer
• OK – STOP. Secondary short to ground
SMCS Code: 1901-038
i01685988
S/N: BLB1-Up
MID 036 - CID 0407 - FMI S/N: BKE1-Up
S/N: BEN1-Up
SMCS Code: 1901-038
S/N: BLB1-Up The transformer’s secondary circuit is diagnosed
S/N: BKE1-Up
System Response:
S/N: BEN1-Up
Conditions Which Generate This Code: set to zero percent. The alarm output is activated
106
Possible Performance Effect: • The winding of the transformer’s secondary circuit

is open.
Troubleshooting: spark plug’s terminal post.
One of the following conditions is the source of the • The spark plug has internal damage or an open
problem: circuit.
• The spark plug is fouled. • The spark plug gap is too wide.
• The spark plug gap is closed. Perform the following diagnostic procedure: “Ignition
is shorted. Results:
Perform the following diagnostic procedure: “Ignition • OK – STOP.

i01632318
Results:
MID 036 - CID 0408 - FMI
• OK – STOP.
i01685995 Secondary short to ground
05 Cylinder 8 - Transformer S/N: BLB1-Up
Secondary open circuit S/N: BKE1-Up
SMCS Code: 1901-038 S/N: BEN1-Up
S/N: BLB1-Up Conditions Which Generate This Code:
S/N: BKE1-Up
S/N: BEN1-Up with a short circuit.
The transformer’s secondary circuit is diagnosed The status of the transformer’s secondary output is
with an open circuit. set to zero percent. The alarm output is activated
System Response:
set to 120 percent. The alarm output is activated The cylinder will misfire.
Troubleshooting:
The cylinder will misfire. problem:
Troubleshooting: • The spark plug is fouled.

One of the following conditions is the source of the • The spark plug gap is closed.
problem:

107

is shorted.
MID 036 - CID 0409 - FMI
Perform the following diagnostic procedure: “Ignition 06 Cylinder 9 - Transformer
Results:
SMCS Code: 1901-038
• OK – STOP. S/N: BLB1-Up
i01686000
S/N: BKE1-Up
MID 036 - CID 0409 - FMI Conditions Which Generate This Code:
05 Cylinder 9 - Transformer The transformer’s secondary circuit is diagnosed
Secondary open circuit with a short circuit.
S/N: BLB1-Up The status of the transformer’s secondary output is

S/N: BKE1-Up and the code is logged.
The transformer’s secondary circuit is diagnosed The cylinder will misfire.
Troubleshooting:
System Response:
The status of the transformer’s secondary output is problem:
is shorted.
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
problem:
Results:
• OK – STOP.
is open.
i01686011
spark plug’s terminal post. MID 036 - CID 0410 - FMI 05
Cylinder 10 - Transformer
circuit. Secondary open circuit
Perform the following diagnostic procedure: “Ignition S/N: BLB1-Up

Transformers Secondary Circuit and Spark Plugs” S/N: BKE1-Up
• OK – STOP. The transformer’s secondary circuit is diagnosed

108
The status of the transformer’s secondary output is The cylinder will misfire.
and the code is logged. Troubleshooting:
Possible Performance Effect: One of the following conditions is the source of the
problem:
Troubleshooting:
problem: • The winding of the transformer’s secondary circuit
is shorted.
• The winding of the transformer’s secondary circuit Transformers Secondary Circuit and Spark Plugs”
is open.
Results:
spark plug’s terminal post. • OK – STOP.
• The spark plug has internal damage or an open i01686017
circuit.
MID 036 - CID 0411 - FMI 05
Cylinder 11 - Transformer
Perform the following diagnostic procedure: “Ignition Secondary open circuit
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
• OK – STOP.
S/N: BKE1-Up
i01632343 Conditions Which Generate This Code:
MID 036 - CID 0410 - FMI 06 The transformer’s secondary circuit is diagnosed
Cylinder 10 - Transformer with an open circuit.
Secondary short to ground System Response:
SMCS Code: 1901-038 The status of the transformer’s secondary output is
S/N: BLB1-Up set to 120 percent. The alarm output is activated
S/N: BKE1-Up
with a short circuit. Troubleshooting:
System Response: One of the following conditions is the source of the

problem:
set to zero percent. The alarm output is activated • There is a problem with the transformer’s ground.
is open.
109
• There is a problem with the connection to the i01686022

MID 036 - CID 0412 - FMI 05
• The spark plug has internal damage or an open Cylinder 12 - Transformer
circuit.
SMCS Code: 1901-038
Transformers Secondary Circuit and Spark Plugs” S/N: BLB1-Up
S/N: BKE1-Up
Results:
• OK – STOP.
i01632349
MID 036 - CID 0411 - FMI 06 System Response:

Cylinder 11 - Transformer The status of the transformer’s secondary output is
Secondary short to ground set to 120 percent. The alarm output is activated
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
The transformer’s secondary circuit is diagnosed problem:
System Response:

is open.

circuit.
Troubleshooting:
• The spark plug is fouled. Results:
• The spark plug gap is closed. • OK – STOP.
is shorted.

Results:
• OK – STOP.
110
i01632360 i01686029
Cylinder 12 - Transformer Cylinder 13 - Transformer
Secondary short to ground Secondary open circuit
S/N: BKE1-Up Conditions Which Generate This Code:
Conditions Which Generate This Code: The transformer’s secondary circuit is diagnosed
with a short circuit. System Response:
System Response: The status of the transformer’s secondary output is
The status of the transformer’s secondary output is and the code is logged.
and the code is logged. Possible Performance Effect:
Possible Performance Effect: The cylinder will misfire.
The cylinder will misfire. Troubleshooting:
Troubleshooting: One of the following conditions is the source of the
problem:
problem: • There is a problem with the transformer’s ground.
• The spark plug is fouled. • The winding of the transformer’s secondary circuit
is open.
• The winding of the transformer’s secondary circuit spark plug’s terminal post.
is shorted.
Perform the following diagnostic procedure: “Ignition circuit.
Results:
• OK – STOP. Transformers Secondary Circuit and Spark Plugs”
Results:
• OK – STOP.
111

MID 036 - CID 0413 - FMI 06 The status of the transformer’s secondary output is
Cylinder 13 - Transformer set to 120 percent. The alarm output is activated
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
problem:
System Response: • There is a problem with the transformer’s ground.
The status of the transformer’s secondary output is • The winding of the transformer’s secondary circuit
is open.
The cylinder will misfire. • The spark plug has internal damage or an open
circuit.
Troubleshooting:
problem:
is shorted. i01632392
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0414 - FMI 06
Transformers Secondary Circuit and Spark Plugs” Cylinder 14 - Transformer
Results: Secondary short to ground
S/N: BLB1-Up
i01686036
MID 036 - CID 0414 - FMI 05
Cylinder 14 - Transformer The transformer’s secondary circuit is diagnosed
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up
with an open circuit. The cylinder will misfire.
112
Troubleshooting: • The spark plug gap is too wide.


is shorted.

MID 036 - CID 0415 - FMI 06
Transformers Secondary Circuit and Spark Plugs” Cylinder 15 - Transformer
Results:
SMCS Code: 1901-038
• OK – STOP.
S/N: BLB1-Up
i01686039
MID 036 - CID 0415 - FMI 05
Cylinder 15 - Transformer with a short circuit.
Secondary open circuit System Response:
SMCS Code: 1901-038
S/N: BLB1-Up set to zero percent. The alarm output is activated
with an open circuit. The cylinder will misfire.
set to 120 percent. The alarm output is activated problem:
Troubleshooting: is shorted.
• There is a problem with the transformer’s ground. Results:

is open.


circuit.
113
i01686042 i01632407
Cylinder 16 - Transformer Cylinder 16 - Transformer
Secondary open circuit Secondary short to ground
The transformer’s secondary circuit is diagnosed The transformer’s secondary circuit is diagnosed
with an open circuit. with a short circuit.
The status of the transformer’s secondary output is The status of the transformer’s secondary output is
set to 120 percent. The alarm output is activated set to zero percent. The alarm output is activated
and the code is logged. and the code is logged.
The cylinder will misfire. The cylinder will misfire.
One of the following conditions is the source of the One of the following conditions is the source of the
problem: problem:
• There is a problem with the transformer’s ground. • The spark plug is fouled.
• The winding of the transformer’s secondary circuit • The spark plug gap is closed.
is open.
• There is a problem with the connection to the is shorted.
• The spark plug has internal damage or an open Transformers Secondary Circuit and Spark Plugs”
circuit.
Results:
• OK – STOP.
i01728635

• OK – STOP. Crank Terminate Relay short
to +batt
SMCS Code: 1901-038

excessive current for the crank terminate relay.
Note: This diagnostic condition cannot be detected

when the output for the crank terminate relay is
OFF. The output is normally OFF when the engine
control switch is in the STOP position.
114
System Response: i01775763
The ECM will limit the current for the crank terminate MID 036 - CID 0444 - FMI 06
relay to 0.3 amperes. The alarm output is activated. Start Relay short to ground
The code is logged.
SMCS Code: 1426-038
Troubleshooting:
Status Indicator Output” The Electronic Control Module (ECM) detects
excessive current for the output of the starting
Results: motor’s solenoid.
• OK – STOP. Note: This diagnostic condition can only be detected

by the ECM when the output for the starting motor’s
i01775761
solenoid is ON. The output is normally ON when
the engine control switch is turned from the STOP
MID 036 - CID 0444 - FMI 05 position to the START position. The output is ON
until the crank terminate relay is energized.
Start Relay open circuit
System Response:
SMCS Code: 1426-038
The ECM will continue to attempt to energize the
Conditions Which Generate This Code: starting motor’s solenoid. The alarm output is
The output from the Electronic Control Module
(ECM) for the starting motor’s solenoid is OFF. An Possible Performance Effect:
open circuit or a short circuit to the +Battery is
detected. The engine will probably be unable to crank.
Note: This diagnostic condition can only be detected Troubleshooting:
by the ECM when the output for the starting motor’s
solenoid is OFF. The output is normally OFF when This condition indicates an short circuit in the
the engine control switch is in the STOP position or harness or the solenoid.
when the crank terminate relay is energized.
System Response: Output Circuit (Starting Motor)”
An internal resistor rises to the +Battery side when Results:
no electrical load is present. The alarm output is
• OK – STOP.
i01728646
The engine will be unable to crank.
MID 036 - CID 0445 - FMI 03
Troubleshooting: Run Relay short to +batt
The harness or the solenoid probably has an open SMCS Code: 1901-038
circuit.
Output Circuit (Starting Motor)” The Electronic Control Module (ECM) detects
excessive current for the run relay.
Results:
Note: This diagnostic condition cannot be detected
• OK – STOP. when the output for the “Run” relay is OFF. The
output is normally OFF when the engine control
switch is in the STOP position.
115
The ECM will limit the current to 0.3 amperes. MID 036 - CID 0524 - FMI 04
The “Status” screen of the Caterpillar Electronic Desired Engine Speed Sensor
Technician (ET) will display “Relay Fault”. The code
is logged. short to ground
Perform the following diagnostic procedure: “ECM Conditions Which Generate This Code:
Status Indicator Output”
The Electronic Control Module (ECM) has been
Results: powered up for at least five seconds. The current
to the ECM for the desired speed input is less than
• OK – STOP. 2 mA for more than five seconds.
System Response:
i01728651
When the “Idle/Rated” switch is in the “Rated”
MID 036 - CID 0524 - FMI 03 position, the ECM assumes a default value for the
Desired Engine Speed Sensor desired engine speed.
short to +batt The alarm output is activated. The code is logged.
Conditions Which Generate This Code: The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed”
The Electronic Control Module (ECM) has been that is programmed on the “Service/Configuration”
powered up for at least five seconds. The current to screen of the Caterpillar Electronic Technician (ET).
the ECM for the desired speed input is greater than
22 mA for more than five seconds. Troubleshooting:
System Response: The diagnostic code is generated by one of the
following conditions:
When the “Idle/Rated” switch is in the “Rated”
position, the ECM assumes a default value for the
desired engine speed.
• An open circuit or a short circuit to ground

• An open circuit or a short circuit to the +Battery
Possible Performance Effect: “Desired Speed Input (4 - 20 mA)”
The default value for the desired engine speed is Results:
equal to the “Minimum Engine High Idle Speed”
that is programmed on the “Service/Configuration”
screen of the Caterpillar Electronic Technician (ET).
• OK – STOP.
The diagnostic code is generated by one of the MID 036 - CID 0525 - FMI 05
following conditions: Choke Actuator open circuit
• A short circuit to the +Battery side SMCS Code: 1901-038
• A short circuit to ground Conditions Which Generate This Code:

Perform the following diagnostic procedure: The circuit driver for the electrohydraulic actuator’s
“Desired Speed Input (4 - 20 mA)” solenoid is energized. The Electronic Control
Module (ECM) detects no current from the actuator
Results: or a current that is less than the normal level. This
is caused by one of the following conditions:
• OK – STOP.
116
• There is an open circuit in either the high side or Results:

the low side.
• OK – STOP.
• The low side is shorted to ground.
i01775959
System Response:

MID 036 - CID 0526 - FMI 05
logged. Wastegate Valve open
Troubleshooting: The circuit driver for the electrohydraulic actuator’s

solenoid is energized. The Electronic Control
Perform the following diagnostic procedure: “Choke Module (ECM) detects no current from the actuator
Actuator Solenoid” or a current that is less than the normal level. This
is caused by one of the following conditions:
Results:
• There is an open circuit in either the high side or
• OK – STOP. the low side.
• The low side is shorted to ground.

i01775823
System Response:
MID 036 - CID 0525 - FMI
06 Choke Actuator short to The shutdown output is activated. The code is
logged.
ground
SMCS Code: 1901-038
Troubleshooting:
The circuit driver for the electrohydraulic actuator’s
Module (ECM) detects a current from the actuator “Wastegate Actuator Solenoid”
that is greater than the normal level. This is caused
by one of the following conditions:
Results:
• There is a short circuit between the high side and • OK – STOP.
the low side.
• The high side is shorted to ground. i01775963
• The high side is shorted to the +Battery side. MID 036 - CID 0526 - FMI 06
System Response:
Wastegate Valve short
SMCS Code: 1057-038
logged. Conditions Which Generate This Code:
Possible Performance Effect: The circuit driver for the electrohydraulic actuator’s
The engine is shut down. Module (ECM) detects a current from the actuator
that is greater than the normal level. This is caused
Troubleshooting: by one of the following conditions:
Perform the following diagnostic procedure: “Choke
Actuator Solenoid”
• There is a short circuit between the high side and
the low side.
117
• The high side is shorted to ground. Results:
• The high side is shorted to the +Battery side. • OK – STOP.

System Response:
i01728669

logged.
MID 036 - CID 0542 - FMI 04
Unfiltered Engine Oil Pressure
short to ground
SMCS Code: 1924-038
The signal to the Electronic Control Module (ECM)
“Wastegate Actuator Solenoid” from the sensor for unfiltered engine oil pressure is
less than 0.2 VDC for at least five seconds. Also,
Results:
neither of the following diagnostic codes are active:
• OK – STOP. • 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
i01728660
MID 036 - CID 0542 - FMI 03 to ground
Unfiltered Engine Oil Pressure System Response:
open/short to +batt
The ECM assumes the last valid value for unfiltered
SMCS Code: 1924-038 engine oil pressure. Monitoring for restriction of the
oil filters is disabled.
The signal to the Electronic Control Module (ECM)
from the sensor for unfiltered engine oil pressure is Troubleshooting:
greater than 4.8 VDC for at least five seconds. Also,
neither of the following diagnostic codes are active: Perform the following diagnostic procedure: “Analog
Sensor Signal”
to +batt Results:
• 262 - 04 5 Volt Sensor DC Power Supply short • OK – STOP.

to ground
i01775966
System Response:
The ECM assumes the last valid value for unfiltered

MID 036 - CID 1040 - FMI 09
engine oil pressure. Monitoring for restriction of the ICSM #1 not communicating
oil filters is disabled. on link
SMCS Code: 1901-038
Possible Performance Effect: Conditions Which Generate This Code:
Engine operation is not affected. The Electronic Control Module (ECM) has been
powered for at least five seconds and the ECM did
Troubleshooting:
not receive ten consecutive messages from the
right side ICSM.
Sensor Signal”
118
The shutdown output is activated. The code is MID 036 - CID 1501 - FMI 03
logged. Cylinder #1 Detonation Sensor
Possible Performance Effect: open/short to +batt
The engine is shut down. SMCS Code: 1901-038
Perform the following diagnostic procedure: The run relay and the crank terminate relay are
“Integrated Combustion Sensing Module (ICSM)” energized. The input of a signal from a detonation
sensor to the Electronic Control Module (ECM) is
Results: greater than 4.8 VDC for ten seconds.
• OK – STOP. Neither of the following diagnostic codes are active:

i01775971
MID 036 - CID 1041 - FMI 09 • 0041 - 04 8 Volt DC Supply short to ground
ICSM #2 not communicating System Response:
on link The shutdown output is activated. The code is
logged.
SMCS Code: 1901-038
S/N: BLB1-Up Possible Performance Effect:
S/N: BKE1-Up The engine is shut down.
The Electronic Control Module (ECM) has been Perform the following diagnostic procedure:
powered for at least five seconds and the ECM did “Detonation Sensors”
not receive ten consecutive messages from the left
side ICSM. Results:
System Response: • OK – STOP.

i01741177
logged.

MID 036 - CID 1501 - FMI 04
Cylinder #1 Detonation Sensor
The engine is shut down. short to ground
Perform the following diagnostic procedure: Conditions Which Generate This Code:
“Integrated Combustion Sensing Module (ICSM)”
The run relay and the crank terminate relay
Results: are energized. The input of the signal from the
detonation sensor to the Electronic Control Module
• OK – STOP. (ECM) is less than 1.0 VDC for ten seconds.
Neither of the following diagnostic codes are active:

119
Perform the following diagnostic procedure: The run relay and the crank terminate relay
“Detonation Sensors” are energized. The input of the signal from the
Results: (ECM) is less than 1.0 VDC for ten seconds.
• OK – STOP. Neither of the following diagnostic codes are active:

i01741181
MID 036 - CID 1502 - FMI 03 • 0041 - 04 8 Volt DC Supply short to ground
Cylinder #2 Detonation Sensor System Response:
open/short to +batt The shutdown output is activated. The code is
logged.
SMCS Code: 1901-038
The run relay and the crank terminate relay are
energized. The input of a signal from a detonation Troubleshooting:
greater than 4.8 VDC for ten seconds. Perform the following diagnostic procedure:
“Detonation Sensors”
Results:
• OK – STOP.
Possible Performance Effect: short to +batt
S/N: BEN1-Up
Troubleshooting:
S/N: 4ZS1-Up
“Detonation Sensors” Conditions Which Generate This Code:
Results: The run relay and the crank terminate relay are
energized. The input of a signal from a detonation
• OK – STOP. sensor to the Electronic Control Module (ECM) is
greater than 4.8 VDC for ten seconds.

120
• 0041 - 04 8 Volt DC Supply short to ground Results:

i01741187
logged.

MID 036 - CID 1505 - FMI 03
open/short to +batt
Troubleshooting:
SMCS Code: 1901-038
Results: energized. The input of a signal from a detonation
• OK – STOP. greater than 4.8 VDC for ten seconds.
i01777852 Neither of the following diagnostic codes are active:
MID 036 - CID 1503 - FMI 04 • 0041 - 03 8 Volt DC Supply short to +batt
Cylinder #3 Detonation Sensor • 0041 - 04 8 Volt DC Supply short to ground
short to ground
System Response:
SMCS Code: 1901-038
S/N: BEN1-Up logged.
S/N: 4ZS1-Up
Troubleshooting:
are energized. The input of the signal from the
(ECM) is less than 1.0 VDC for ten seconds.
Results:
• OK – STOP.
i01741197
System Response:
MID 036 - CID 1505 - FMI 04
The shutdown output is activated. The code is Cylinder #5 Detonation Sensor
logged.
short to ground
SMCS Code: 1901-038
Troubleshooting:
Perform the following diagnostic procedure: are energized. The input of the signal from the
“Detonation Sensors” detonation sensor to the Electronic Control Module
121
Neither of the following diagnostic codes are active: Results:

• 0041 - 04 8 Volt DC Supply short to ground i01741203

logged.
short to ground
SMCS Code: 1901-038
Troubleshooting:
Results:
• OK – STOP. • 0041 - 03 8 Volt DC Supply short to +batt
i01741202 • 0041 - 04 8 Volt DC Supply short to ground
Cylinder #6 Detonation Sensor The shutdown output is activated. The code is
open/short to +batt logged.
Conditions Which Generate This Code: The engine is shut down.
The run relay and the crank terminate relay are Troubleshooting:
sensor to the Electronic Control Module (ECM) is Perform the following diagnostic procedure:
greater than 4.8 VDC for ten seconds. “Detonation Sensors”
Neither of the following diagnostic codes are active: Results:

• 0041 - 04 8 Volt DC Supply short to ground i01777835

logged. short to +batt
The engine is shut down. S/N: BEN1-Up
Troubleshooting: S/N: 4ZS1-Up
122
Neither of the following diagnostic codes are active: Troubleshooting:
• 0041 - 03 8 Volt DC Supply short to +batt Perform the following diagnostic procedure:
Results:
System Response:
• OK – STOP.
logged.
i01741207
Possible Performance Effect: MID 036 - CID 1509 - FMI 03

The engine is shut down. Cylinder #9 Detonation Sensor
Troubleshooting:
open/short to +batt
SMCS Code: 1901-038
“Detonation Sensors” S/N: BLB1-Up
Results: S/N: BKE1-Up
• OK – STOP. Conditions Which Generate This Code:

i01777854 energized. The input of a signal from a detonation
MID 036 - CID 1507 - FMI 04 sensor to the Electronic Control Module (ECM) is
short to ground
SMCS Code: 1901-038 • 0041 - 03 8 Volt DC Supply short to +batt
S/N: BEN1-Up • 0041 - 04 8 Volt DC Supply short to ground
S/N: 4ZS1-Up System Response:
Conditions Which Generate This Code: The shutdown output is activated. The code is
logged.
are energized. The input of the signal from the Possible Performance Effect:
(ECM) is less than 1.0 VDC for ten seconds. The engine is shut down.
Neither of the following diagnostic codes are active: Troubleshooting:
• 0041 - 03 8 Volt DC Supply short to +batt Perform the following diagnostic procedure:
Results:
System Response:
• OK – STOP.
logged.

123

MID 036 - CID 1509 - FMI 04 • 0041 - 03 8 Volt DC Supply short to +batt
short to ground
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up logged.
S/N: BKE1-Up
are energized. The input of the signal from the Troubleshooting:
(ECM) is less than 1.0 VDC for ten seconds. Perform the following diagnostic procedure:
Results:
• OK – STOP.
i01741210
System Response:
MID 036 - CID 1510 - FMI
logged. 04 Cylinder #10 Detonation
Sensor short to ground
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
S/N: BKE1-Up
“Detonation Sensors” Conditions Which Generate This Code:
Results: The run relay and the crank terminate relay

• OK – STOP. (ECM) is less than 1.0 VDC for ten seconds.

MID 036 - CID 1510 - FMI • 0041 - 03 8 Volt DC Supply short to +batt
03 Cylinder #10 Detonation
Sensor open/short to +batt
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up logged.
S/N: BKE1-Up
energized. The input of a signal from a detonation Troubleshooting:
greater than 4.8 VDC for ten seconds. Perform the following diagnostic procedure:
124
Results: i01741219
• OK – STOP. MID 036 - CID 1513 - FMI

i01741213 Sensor short to ground
03 Cylinder #13 Detonation S/N: BLB1-Up
SMCS Code: 1901-038
S/N: BLB1-Up are energized. The input of the signal from the
Conditions Which Generate This Code: (ECM) is less than 1.0 VDC for ten seconds.
The run relay and the crank terminate relay are Neither of the following diagnostic codes are active:

System Response:
• 0041 - 04 8 Volt DC Supply short to ground logged.
The shutdown output is activated. The code is The engine is shut down.
logged.
Troubleshooting:
The engine is shut down. “Detonation Sensors”
• OK – STOP.
Results: i01741222
• OK – STOP. MID 036 - CID 1514 - FMI

SMCS Code: 1901-038
S/N: BLB1-Up


125
• 0041 - 03 8 Volt DC Supply short to +batt i01775977
• 0041 - 04 8 Volt DC Supply short to ground MID 036 - CID 1844 - FMI 05
Fuel Actuator open circuit
System Response:
SMCS Code: 1901-038
logged. Conditions Which Generate This Code:
Possible Performance Effect: The circuit driver for the electrohydraulic actuator’s
The engine is shut down. Module (ECM) detects no current from the actuator
or a current that is less than the normal level. This
Troubleshooting: is caused by one of the following conditions:
Perform the following diagnostic procedure: • There is an open circuit in either the high side or
“Detonation Sensors” the low side.
Results: • The low side is shorted to ground.
i01741227
logged.
MID 036 - CID 1514 - FMI
Sensor short to ground The engine is shut down.
S/N: BLB1-Up Perform the following diagnostic procedure: “Fuel

Actuator Solenoid”
Results:
are energized. The input of the signal from the • OK – STOP.
i01775979
MID 036 - CID 1844 - FMI 06
• 0041 - 03 8 Volt DC Supply short to +batt Fuel Actuator short to ground
• 0041 - 04 8 Volt DC Supply short to ground SMCS Code: 1901-038
System Response: Conditions Which Generate This Code:
The shutdown output is activated. The code is The circuit driver for the electrohydraulic actuator’s
logged. solenoid is energized. The Electronic Control
Module (ECM) detects a current from the actuator
Possible Performance Effect: that is greater than the normal level. This is caused
by one of the following conditions:
• There is a short circuit between the high side and
Troubleshooting: the low side.
Perform the following diagnostic procedure: • The high side is shorted to ground.
• The high side is shorted to the +Battery side.
Results:
• OK – STOP.
126
logged. EEPROM checksum fault or
Possible Performance Effect: ECM not programmed
Perform the following diagnostic procedure: “Fuel The right side Integrated Combustion Sensing
Actuator Solenoid” Module (ICSM) detects a problem within the EPROM
circuit.
Results:
System Response:
• OK – STOP.
The code is logged.

MID 109 - CID 0253 - FMI 02 The ICSM may not function. If the ICSM does not
Personality Module mismatch function, the engine is shut down.

S/N: BLB1-Up Replace the ICSM. Follow the instructions in
Troubleshooting, “Replacing the ICSM”.
S/N: BKE1-Up
Results:
The software for the right side Integrated • OK – STOP.

Combustion Sensing Module (ICSM) does not
match the software for the left side ICSM. i01783567

ICSM #1 not communicating
logged. on link
The engine is shut down. S/N: BLB1-Up

S/N: BKE1-Up
Troubleshooting:
“Integrated Combustion Sensing Module (ICSM)” The Electronic Control Module (ECM) and the
Results: have been powered for at least five seconds and
the left side ICSM did not receive ten consecutive
• OK – STOP. messages from the right side ICSM.
System Response:

logged.
127
The engine is shut down. MID 109 - CID 1043 - FMI

03 Cylinder #1 Firing Signal
Troubleshooting:
open/short to +batt
“Integrated Combustion Sensing Module (ICSM)” SMCS Code: 1901-038
• OK – STOP. During normal operation, the Integrated Combustion

Sensing Module (ICSM) continuously sends a signal
of 13 V. The Electronic Control Module (ECM)
i01783561 grounds the 13 V signal for the duration of ignition.
The ICSM interprets the grounding of the signal as
MID 109 - CID 1043 - FMI 02 the firing signal.
Cylinder #1 Firing Signal noisy
If the 13 V signal is not grounded, the ICSM does
SMCS Code: 1901-038 not receive the firing signal and the ICSM generates
the diagnostic code.
System Response:
One of the following conditions is detected by the
Integrated Combustion Sensing Module (ICSM): Monitoring of the combustion burn time is lost. The
alarm output is activated. The code is logged.
• Electrical noise has been generated on the
conductor that carries the firing signal. Possible Performance Effect:
• The frequency of the firing signal is not within the The exhaust emissions are not controlled by the
specified limits. engine control system.
Monitoring of the combustion burn time for the Perform the following diagnostic procedure:
cylinder is lost. The alarm output is activated. The “Cylinder Firing Pulse”
code is logged.
Results:
• OK – STOP.
The exhaust emissions are not controlled by the
engine control system.
i01776013
Troubleshooting: MID 109 - CID 1043 - FMI 04

Perform the following diagnostic procedure: Cylinder #1 Firing Signal short
“Cylinder Firing Pulse” to ground
Results: SMCS Code: 1901-038
During normal operation, the Integrated Combustion

grounds the 13 V signal for the duration of ignition.
The ICSM interprets the grounding of the signal
as the firing signal. When the 13 V signal returns
to the high side, the ICSM starts the timer for the
combustion burn time.
128
If the 13 V signal remains grounded, the ICSM Troubleshooting:

cannot interpret the firing signal and the ICSM
generates the diagnostic code. Perform the following diagnostic procedure:
“Cylinder Firing Pulse”
System Response:
Results:
Monitoring of the combustion burn time is lost. The
alarm output is activated. The code is logged. • OK – STOP.
i01630987

MID 109 - CID 1044 - FMI 02 All
Cylinders Firing Signal noisy
Troubleshooting:
SMCS Code: 1901-038
“Cylinder Firing Pulse” Conditions Which Generate This Code:
Results: One of the following conditions is detected by the

ICSM:
• OK – STOP.
• Electrical noise has been generated on the
conductor that carries the firing signal.
i01783575
MID 109 - CID 1043 - FMI • The frequency of the firing signal is not within the
specified limits.
08 Cylinder #1 Firing Signal
System Response:
abnormal signal
SMCS Code: 1901-038 alarm output is activated. The code is logged.
The “Cylinder #1 Firing Signal” represents the
ignition of the first cylinder in the engine. The “All
Cylinders Firing Signal” represents the ignitions of
the remaining cylinders in the engine. The “Cylinder
Troubleshooting:
#1 Firing Signal” is a reference for the “All Cylinders
Firing Signal”. Perform the following diagnostic procedure:
If the input for the “Cylinder #1 Firing Signal”
is switched with the input for the “All Cylinders Results:
Firing Signal”, the “Cylinder #1 Firing Signal” is
too frequent. The Integrated Combustion Sensing
Module (ICSM) generates the diagnostic code. • OK – STOP.
System Response:


129
i01776019 If the 13 V signal remains grounded, the ICSM

cannot interpret the firing signal and the ICSM
MID 109 - CID 1044 - FMI 03 generates the diagnostic code.
All Cylinders Firing Signal
System Response:
open/short to +batt
SMCS Code: 1901-038 alarm output is activated. The code is logged.
During normal operation, the Integrated Combustion The exhaust emissions are not controlled by the
Sensing Module (ICSM) continuously sends a signal engine control system.
grounds the 13 V signal for the duration of ignition. Troubleshooting:
the firing signal. Perform the following diagnostic procedure:
If the 13 V signal is not grounded, the ICSM does
not receive the firing signal and the ICSM generates Results:
• OK – STOP.
System Response:
Monitoring of the combustion burn time is lost. The i01783581

MID 109 - CID 1101 - FMI 02
Possible Performance Effect: Cylinder #1 Combustion Probe
The exhaust emissions are not controlled by the noisy
SMCS Code: 1901-038
Troubleshooting:
“Cylinder Firing Pulse” One of the following conditions is detected by the
Integrated Combustion Sensing Module (ICSM):
Results:
• The signal from the combustion sensor is received
before combustion.
• OK – STOP.
i01776024 within 1.8 milliseconds of the signal for ignition.
MID 109 - CID 1044 - FMI 04 All System Response:
Cylinders Firing Signal short
The combustion burn time for the cylinder is
to ground excluded from the average combustion burn time
and from the calculation for the fuel correction
SMCS Code: 1901-038 factor. Diagnostics for the cylinder misfire are not
available.
The code is logged.
During normal operation, the Integrated Combustion
Sensing Module (ICSM) continuously sends a signal Possible Performance Effect:
grounds the 13 V signal for the duration of ignition. The engine performance is not directly affected.
The ICSM interprets the grounding of the signal
as the firing signal. When the 13 V signal returns Troubleshooting:
to the high side, the ICSM starts the timer for the
combustion burn time. One of the following conditions is probably the
cause of the diagnostic code:
130
• The wiring for the combustion sensor is damaged. i01763162
• The wiring for the ignition is damaged. MID 109 - CID 1102 - FMI 02
Cylinder #2 Combustion Probe
• The combustion sensor is damaged.
noisy
• The extender is not properly contacting the
combustion sensor. SMCS Code: 1901-038
Perform the following diagnostic procedure: S/N: BEN1-Up

“Combustion Sensor” S/N: 4ZS1-Up
• OK – STOP. One of the following conditions is detected by the

i01631195
MID 109 - CID 1101 - FMI 04 before combustion.
Cylinder #1 Combustion Probe • The signal from the combustion sensor is received
short to ground within 1.8 milliseconds of the signal for ignition.
Conditions Which Generate This Code: The combustion burn time for the cylinder is
excluded from the average combustion burn time
The signal from the combustion sensor to the ICSM and from the calculation for the fuel correction
is less than the minimum acceptable value. factor. Diagnostics for the cylinder misfire are not
available.
System Response:
The code is logged.
excluded from the average combustion burn time Possible Performance Effect:
factor. Diagnostics for the cylinder misfire are not The engine performance is not directly affected.
available.
Troubleshooting:
The code is logged.
One of the following conditions is probably the
Possible Performance Effect: cause of the diagnostic code:
The engine performance is not directly affected. • The wiring for the combustion sensor is damaged.
Troubleshooting: • The wiring for the ignition is damaged.
Perform the following diagnostic procedure: • The combustion sensor is damaged.
“Combustion Sensor”
Results: combustion sensor.
• OK – STOP. Perform the following diagnostic procedure:

Results:
• OK – STOP.
131

MID 109 - CID 1102 - FMI 04 The combustion burn time for the cylinder is
Cylinder #2 Combustion Probe excluded from the average combustion burn time
short to ground factor. Diagnostics for the cylinder misfire are not
available.
SMCS Code: 1901-038
The code is logged.
S/N: BEN1-Up
S/N: 4ZS1-Up Possible Performance Effect:
Conditions Which Generate This Code: The engine performance is not directly affected.
The signal from the combustion sensor to the Troubleshooting:

Integrated Combustion Sensing Module (ICSM) is
less than the minimum acceptable value. One of the following conditions is probably the
System Response:
• The wiring for the combustion sensor is damaged.
excluded from the average combustion burn time • The wiring for the ignition is damaged.
factor. Diagnostics for the cylinder misfire are not • The combustion sensor is damaged.
available.
The code is logged. combustion sensor.
Possible Performance Effect: Perform the following diagnostic procedure:

The engine performance is not directly affected.
Results:
Troubleshooting:
• OK – STOP.
“Combustion Sensor” i01783590

• OK – STOP. Cylinder #3 Combustion Probe
short to ground
i01783588
SMCS Code: 1901-038
MID 109 - CID 1103 - FMI 02
noisy The signal from the combustion sensor to the
SMCS Code: 1901-038 less than the minimum acceptable value.
One of the following conditions is detected by the The combustion burn time for the cylinder is
Integrated Combustion Sensing Module (ICSM): excluded from the average combustion burn time
• The signal from the combustion sensor is received factor. Diagnostics for the cylinder misfire are not
before combustion. available.
• The signal from the combustion sensor is received The code is logged.
within 1.8 milliseconds of the signal for ignition.
132
Possible Performance Effect: • The extender is not properly contacting the

combustion sensor.
Troubleshooting: “Combustion Sensor”
Perform the following diagnostic procedure: Results:

• OK – STOP.
Results:
i01763194
• OK – STOP.
MID 109 - CID 1104 - FMI 04
i01763165 Cylinder #4 Combustion Probe
MID 109 - CID 1104 - FMI 02 short to ground
Cylinder #4 Combustion Probe SMCS Code: 1901-038
noisy S/N: BEN1-Up
SMCS Code: 1901-038 S/N: 4ZS1-Up
S/N: BEN1-Up
S/N: 4ZS1-Up
The signal from the combustion sensor to the
Conditions Which Generate This Code: Integrated Combustion Sensing Module (ICSM) is
less than the minimum acceptable value.
Integrated Combustion Sensing Module (ICSM): System Response:
• The signal from the combustion sensor is received The combustion burn time for the cylinder is
before combustion. excluded from the average combustion burn time
• The signal from the combustion sensor is received factor. Diagnostics for the cylinder misfire are not
within 1.8 milliseconds of the signal for ignition. available.
System Response: The code is logged.
The combustion burn time for the cylinder is Possible Performance Effect:
and from the calculation for the fuel correction The engine performance is not directly affected.
factor. Diagnostics for the cylinder misfire are not
available. Troubleshooting:
The code is logged. Perform the following diagnostic procedure:

Results:
• OK – STOP.
Troubleshooting:


• The wiring for the ignition is damaged.
133
i01783603 i01783604
Cylinder #5 Combustion Probe Cylinder #5 Combustion Probe
noisy short to ground
One of the following conditions is detected by the The signal from the combustion sensor to the
Integrated Combustion Sensing Module (ICSM): Integrated Combustion Sensing Module (ICSM) is
before combustion. System Response:
within 1.8 milliseconds of the signal for ignition. excluded from the average combustion burn time
System Response: factor. Diagnostics for the cylinder misfire are not
available.
excluded from the average combustion burn time The code is logged.
factor. Diagnostics for the cylinder misfire are not Possible Performance Effect:
available.
The code is logged.
Troubleshooting:
The engine performance is not directly affected. “Combustion Sensor”
One of the following conditions is probably the • OK – STOP.

i01763174
MID 109 - CID 1106 - FMI 02
• The combustion sensor is damaged. noisy
• The extender is not properly contacting the SMCS Code: 1901-038
combustion sensor.
S/N: BEN1-Up
“Combustion Sensor” S/N: 4ZS1-Up


before combustion.

134
System Response: The code is logged.
The combustion burn time for the cylinder is Possible Performance Effect:
and from the calculation for the fuel correction The engine performance is not directly affected.
available. Troubleshooting:
The code is logged. Perform the following diagnostic procedure:

Results:
• OK – STOP.
Troubleshooting:
i01783627
cause of the diagnostic code: MID 109 - CID 1107 - FMI 02
• The wiring for the combustion sensor is damaged. Cylinder #7 Combustion Probe
noisy
SMCS Code: 1901-038
S/N: BLB1-Up
combustion sensor. S/N: BKE1-Up
Perform the following diagnostic procedure: S/N: BEN1-Up

Results:
• OK – STOP.
i01763612 before combustion.
MID 109 - CID 1106 - FMI 04 • The signal from the combustion sensor is received
Cylinder #6 Combustion Probe within 1.8 milliseconds of the signal for ignition.
short to ground System Response:
SMCS Code: 1901-038 The combustion burn time for the cylinder is
S/N: BEN1-Up
S/N: 4ZS1-Up factor. Diagnostics for the cylinder misfire are not
available.
The code is logged.
Integrated Combustion Sensing Module (ICSM) is Possible Performance Effect:
System Response:
Troubleshooting:
excluded from the average combustion burn time One of the following conditions is probably the
and from the calculation for the fuel correction cause of the diagnostic code:
available. • The wiring for the combustion sensor is damaged.
135
• The wiring for the ignition is damaged. i01763182
• The combustion sensor is damaged. MID 109 - CID 1108 - FMI 02

combustion sensor. noisy
Perform the following diagnostic procedure: SMCS Code: 1901-038
S/N: BEN1-Up
Results:
i01783635
short to ground within 1.8 milliseconds of the signal for ignition.

S/N: BLB1-Up The combustion burn time for the cylinder is
S/N: BKE1-Up excluded from the average combustion burn time
S/N: BEN1-Up factor. Diagnostics for the cylinder misfire are not
available.
The code is logged.
Integrated Combustion Sensing Module (ICSM) is Possible Performance Effect:
System Response:
Troubleshooting:
excluded from the average combustion burn time One of the following conditions is probably the
and from the calculation for the fuel correction cause of the diagnostic code:
The code is logged. • The wiring for the ignition is damaged.
Possible Performance Effect: • The combustion sensor is damaged.
The engine performance is not directly affected. • The extender is not properly contacting the
combustion sensor.
Troubleshooting:
Perform the following diagnostic procedure: “Combustion Sensor”
Results:
Results:
• OK – STOP.
• OK – STOP.
136
i01763625 • The signal from the combustion sensor is received

MID 109 - CID 1108 - FMI 04
Cylinder #8 Combustion Probe System Response:
short to ground The combustion burn time for the cylinder is
SMCS Code: 1901-038 and from the calculation for the fuel correction
S/N: BEN1-Up available.
Conditions Which Generate This Code: The code is logged.
less than the minimum acceptable value. The engine performance is not directly affected.
excluded from the average combustion burn time cause of the diagnostic code:
The code is logged. • The wiring for the ignition is damaged.
Possible Performance Effect: • The combustion sensor is damaged.
The engine performance is not directly affected. • The extender is not properly contacting the
combustion sensor.
Troubleshooting:
Results:
Results:
• OK – STOP.
• OK – STOP.
i01783644
i01783640 MID 109 - CID 1109 - FMI 04

MID 109 - CID 1109 - FMI 02 Cylinder #9 Combustion Probe
Cylinder #9 Combustion Probe short to ground
noisy SMCS Code: 1901-038
SMCS Code: 1901-038 S/N: BLB1-Up
S/N: BLB1-Up S/N: BKE1-Up
S/N: BKE1-Up
Conditions Which Generate This Code: The signal from the combustion sensor to the
One of the following conditions is detected by the less than the minimum acceptable value.

before combustion.
137
The combustion burn time for the cylinder is One of the following conditions is probably the
factor. Diagnostics for the cylinder misfire are not • The wiring for the combustion sensor is damaged.
available.
The code is logged.
The engine performance is not directly affected. combustion sensor.
Troubleshooting: Perform the following diagnostic procedure:

“Combustion Sensor” Results:
Results: • OK – STOP.
• OK – STOP. i01783746
i01783665 MID 109 - CID 1111 - FMI 04

MID 109 - CID 1111 - FMI 02 Cylinder #11 Combustion
Probe noisy SMCS Code: 1901-038
System Response:
before combustion. The combustion burn time for the cylinder is
• The signal from the combustion sensor is received and from the calculation for the fuel correction
within 1.8 milliseconds of the signal for ignition. factor. Diagnostics for the cylinder misfire are not
available.
System Response:
The code is logged.
available.
Troubleshooting:
The code is logged.
Possible Performance Effect: “Combustion Sensor”
The engine performance is not directly affected. Results:
• OK – STOP.
138
i01783799 i01783839
Cylinder #13 Combustion Cylinder #13 Combustion
Probe noisy Probe short to ground
available.
available.
The code is logged.
Troubleshooting:

i01783841
MID 109 - CID 1115 - FMI 02
Cylinder #15 Combustion
• The combustion sensor is damaged. Probe noisy
combustion sensor.
S/N: BLB1-Up
“Combustion Sensor” Conditions Which Generate This Code:
Results: One of the following conditions is detected by the
• OK – STOP.
before combustion.

139
The combustion burn time for the cylinder is The engine performance is not directly affected.
and from the calculation for the fuel correction Troubleshooting:
available. Perform the following diagnostic procedure:
The code is logged.
Results:
• OK – STOP.
i01784152
Troubleshooting:

MID 109 - CID 1490 - FMI 03 Rt
cause of the diagnostic code: Turbo Turbine Out Temp Sens
short to +batt
SMCS Code: 1901-038
The voltage of the signal from the thermocouple to
• The extender is not properly contacting the the Integrated Combustion Sensing Module (ICSM)
combustion sensor.
is greater than the maximum acceptable value. This
indicates a short circuit to the +Battery side.
“Combustion Sensor” System Response:
Results: Monitoring of the port’s temperature is lost. Also,
protection for the port is lost. The code is logged.
• OK – STOP.
i01783878
Engine operation is not affected.
MID 109 - CID 1115 - FMI 04
Troubleshooting:
Probe short to ground Perform the following diagnostic procedure:
“Thermocouple Test”
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
• OK – STOP.
The signal from the combustion sensor to the i01784195

less than the minimum acceptable value. MID 109 - CID 1490 - FMI 04 Rt
Turbo Turbine Out Temp Sens
System Response:
short to ground
excluded from the average combustion burn time SMCS Code: 1901-038
factor. Diagnostics for the cylinder misfire are not Conditions Which Generate This Code:
available.
The code is logged. the Integrated Combustion Sensing Module (ICSM)
is less than the minimum acceptable value. This
indicates one of the following conditions:
140
• A short circuit to the −Battery side i01784256
• A short circuit to the ground MID 109 - CID 1491 - FMI 03 Rt

Turbo Turbine In Temp Sens
System Response:
short to +batt
Monitoring of the port’s temperature is lost. Also,
protection for the port is lost. The code is logged. SMCS Code: 1901-038
Engine operation is not affected. The voltage of the signal from the thermocouple to
the Integrated Combustion Sensing Module (ICSM)
Troubleshooting: is greater than the maximum acceptable value. This
“Thermocouple Test” System Response:
Results: Monitoring of the port’s exhaust temperature is lost.

Also, protection for the port is lost. The code is
• OK – STOP. logged.

i01784229
MID 109 - CID 1490 - FMI 05 Rt
Turbo Turbine Out Temp Sens Troubleshooting:
open circuit Perform the following diagnostic procedure:
SMCS Code: 1901-038
Results:
The current of the signal from the thermocouple to

• OK – STOP.
is less than the minimum acceptable value. This i01784273
indicates an open circuit.
MID 109 - CID 1491 - FMI 04 Rt
System Response: Turbo Turbine In Temp Sens
Monitoring of the port’s temperature is lost. Also, short to ground
SMCS Code: 1901-038
Troubleshooting: the Integrated Combustion Sensing Module (ICSM)
Perform the following diagnostic procedure: indicates one of the following conditions:
• A short circuit to the −Battery side
Results:
• A short circuit to the ground
• OK – STOP.
System Response:

141
Possible Performance Effect: System Response:
Engine operation is not affected. Monitoring of the port’s temperature is lost. Also,
Troubleshooting:
“Thermocouple Test” Engine operation is not affected.
• OK – STOP. Perform the following diagnostic procedure:

i01784275
Results:
MID 109 - CID 1491 - FMI 05 Rt
• OK – STOP.
Turbo Turbine In Temp Sens
open circuit i01784280
SMCS Code: 1901-038 MID 109 - CID 1531 - FMI 04 Cyl

#1 Exhaust Port Temp Sensor
short to ground
the Integrated Combustion Sensing Module (ICSM) SMCS Code: 1901-038
indicates an open circuit. Conditions Which Generate This Code:
System Response: The voltage of the signal from the thermocouple to

Monitoring of the port’s temperature is lost. Also, is less than the minimum acceptable value. This
protection for the port is lost. The code is logged. indicates one of the following conditions:
Possible Performance Effect: • A short circuit to the −Battery side

Engine operation is not affected. • A short circuit to the ground
Troubleshooting: System Response:
Perform the following diagnostic procedure: Monitoring of the port’s temperature is lost. Also,
“Thermocouple Test” protection for the port is lost. The code is logged.
Results: Possible Performance Effect:
• OK – STOP. Engine operation is not affected.
Troubleshooting:
i01784277
MID 109 - CID 1531 - FMI 03 Cyl Perform the following diagnostic procedure:
short to +batt Results:
SMCS Code: 1901-038 • OK – STOP.

142

MID 109 - CID 1531 - FMI 05 Cyl Engine operation is not affected.
Troubleshooting:
open circuit
SMCS Code: 1901-038 “Thermocouple Test”
Conditions Which Generate This Code: Results:
The current of the signal from the thermocouple to • OK – STOP.

indicates an open circuit. i01763693
System Response: MID 109 - CID 1532 - FMI 04 Cyl

protection for the port is lost. The code is logged. short to ground
S/N: BEN1-Up
S/N: 4ZS1-Up
Troubleshooting:
“Thermocouple Test” The voltage of the signal from the thermocouple to
Results: is less than the minimum acceptable value. This
• OK – STOP.
i01763667
MID 109 - CID 1532 - FMI 03 Cyl System Response:
short to +batt Monitoring of the port’s temperature is lost. Also,
SMCS Code: 1901-038
S/N: BEN1-Up
S/N: 4ZS1-Up
Troubleshooting:
The voltage of the signal from the thermocouple to “Thermocouple Test”
is greater than the maximum acceptable value. This Results:
• OK – STOP.
System Response:

143
#2 Exhaust Port Temp Sensor “Thermocouple Test”
open circuit Results:
S/N: BEN1-Up
i01784288
S/N: 4ZS1-Up
MID 109 - CID 1533 - FMI 04 Cyl
The current of the signal from the thermocouple to short to ground
is less than the minimum acceptable value. This SMCS Code: 1901-038
System Response:
Monitoring of the port’s temperature is lost. Also, the Integrated Combustion Sensing Module (ICSM)
protection for the port is lost. The code is logged. is less than the minimum acceptable value. This
Troubleshooting:
System Response:
“Thermocouple Test” Monitoring of the port’s temperature is lost. Also,
Results:
• OK – STOP.
i01784286
Troubleshooting:
MID 109 - CID 1533 - FMI 03 Cyl
short to +batt Results:
SMCS Code: 1901-038
• OK – STOP.
i01784291
the Integrated Combustion Sensing Module (ICSM) MID 109 - CID 1533 - FMI 05 Cyl
indicates a short circuit to the +Battery side. #3 Exhaust Port Temp Sensor
open circuit
System Response:
SMCS Code: 1901-038
protection for the port is lost. The code is logged. Conditions Which Generate This Code:
Possible Performance Effect: The current of the signal from the thermocouple to
Engine operation is not affected. is less than the minimum acceptable value. This
144
Monitoring of the port’s temperature is lost. Also, MID 109 - CID 1534 - FMI 04 Cyl
protection for the port is lost. The code is logged. #4 Exhaust Port Temp Sensor
Engine operation is not affected. SMCS Code: 1901-038
Troubleshooting: S/N: BEN1-Up

S/N: 4ZS1-Up
“Thermocouple Test” Conditions Which Generate This Code:
Results: The voltage of the signal from the thermocouple to
• OK – STOP. is less than the minimum acceptable value. This
i01763708
MID 109 - CID 1534 - FMI 03 Cyl
#4 Exhaust Port Temp Sensor • A short circuit to the ground
short to +batt System Response:
SMCS Code: 1901-038 Monitoring of the port’s temperature is lost. Also,

S/N: BEN1-Up
S/N: 4ZS1-Up
Troubleshooting:
the Integrated Combustion Sensing Module (ICSM) Perform the following diagnostic procedure:
is greater than the maximum acceptable value. This “Thermocouple Test”
Results:
System Response:

• OK – STOP.
i01763717
MID 109 - CID 1534 - FMI 05 Cyl
Engine operation is not affected. #4 Exhaust Port Temp Sensor
Troubleshooting: open circuit
S/N: BEN1-Up
Results: S/N: 4ZS1-Up

145
Perform the following diagnostic procedure: The voltage of the signal from the thermocouple to
“Thermocouple Test” the Integrated Combustion Sensing Module (ICSM)
Results: indicates one of the following conditions:
• OK – STOP. • A short circuit to the −Battery side

i01784316
System Response:
MID 109 - CID 1535 - FMI 03 Cyl
#5 Exhaust Port Temp Sensor Monitoring of the port’s temperature is lost. Also,
short to +batt
SMCS Code: 1901-038
Troubleshooting:
Results:
System Response:

• OK – STOP.
i01784325
MID 109 - CID 1535 - FMI 05 Cyl
Engine operation is not affected. #5 Exhaust Port Temp Sensor
Troubleshooting: open circuit
Results:
• OK – STOP. the Integrated Combustion Sensing Module (ICSM)
System Response:


146
Perform the following diagnostic procedure: MID 109 - CID 1536 - FMI 04 Cyl
“Thermocouple Test” #6 Exhaust Port Temp Sensor
Results: short to ground
S/N: BEN1-Up
i01763723
S/N: 4ZS1-Up
MID 109 - CID 1536 - FMI 03 Cyl
short to +batt The voltage of the signal from the thermocouple to
SMCS Code: 1901-038 is less than the minimum acceptable value. This
S/N: BEN1-Up
S/N: 4ZS1-Up

System Response:
the Integrated Combustion Sensing Module (ICSM) Monitoring of the port’s temperature is lost. Also,
is greater than the maximum acceptable value. This protection for the port is lost. The code is logged.
System Response:
protection for the port is lost. The code is logged. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
Results:
Troubleshooting:

• OK – STOP.
i01763730
Results:
MID 109 - CID 1536 - FMI 05 Cyl
• OK – STOP. #6 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1901-038
S/N: BEN1-Up
S/N: 4ZS1-Up

147
Troubleshooting: S/N: BLB1-Up

S/N: BKE1-Up
“Thermocouple Test” S/N: BEN1-Up
• OK – STOP. The voltage of the signal from the thermocouple to

i01784508
MID 109 - CID 1537 - FMI 03 Cyl
short to +batt • A short circuit to the ground
S/N: BLB1-Up Monitoring of the port’s temperature is lost. Also,

S/N: BKE1-Up
S/N: BEN1-Up
Troubleshooting:
Results:
System Response:

• OK – STOP.
Troubleshooting:

Results:
• OK – STOP.
148

Troubleshooting:
open circuit
S/N: BLB1-Up Results:
S/N: BKE1-Up
• OK – STOP.
S/N: BEN1-Up
i01763748

MID 109 - CID 1538 - FMI 04 Cyl
the Integrated Combustion Sensing Module (ICSM) #8 Exhaust Port Temp Sensor
short to ground
SMCS Code: 1901-038
System Response:
S/N: BEN1-Up
Possible Performance Effect: The voltage of the signal from the thermocouple to
Engine operation is not affected. is less than the minimum acceptable value. This
Troubleshooting:
“Thermocouple Test” • A short circuit to the ground
Results: System Response:
• OK – STOP. Monitoring of the port’s temperature is lost. Also,

i01763737
MID 109 - CID 1538 - FMI 03 Cyl
short to +batt Troubleshooting:
SMCS Code: 1901-038 Perform the following diagnostic procedure:

S/N: BEN1-Up
Results:
• OK – STOP.
System Response:

149

Troubleshooting:
open circuit
S/N: BEN1-Up Results:
• OK – STOP.
the Integrated Combustion Sensing Module (ICSM) i01784516
indicates an open circuit. MID 109 - CID 1539 - FMI 04 Cyl
System Response:
short to ground
Possible Performance Effect: S/N: BLB1-Up

S/N: BKE1-Up
Troubleshooting:
Perform the following diagnostic procedure: the Integrated Combustion Sensing Module (ICSM)
“Thermocouple Test” is less than the minimum acceptable value. This
Results:
• OK – STOP.
i01784514
System Response:
MID 109 - CID 1539 - FMI 03 Cyl
#9 Exhaust Port Temp Sensor protection for the port is lost. The code is logged.
short to +batt
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
S/N: BKE1-Up
Conditions Which Generate This Code: “Thermocouple Test”
Results:
indicates a short circuit to the +Battery side. • OK – STOP.
System Response:

150

Troubleshooting:
open circuit
S/N: BKE1-Up
• OK – STOP.
i01784522
indicates an open circuit. #11 Exhaust Port Temp Sensor
short to ground
System Response:
SMCS Code: 1901-038
protection for the port is lost. The code is logged. S/N: BLB1-Up
Possible Performance Effect: S/N: BKE1-Up
Engine operation is not affected. Conditions Which Generate This Code:
Troubleshooting: The voltage of the signal from the thermocouple to

Perform the following diagnostic procedure: is less than the minimum acceptable value. This
“Thermocouple Test” indicates one of the following conditions:
Results: • A short circuit to the −Battery side
• OK – STOP. • A short circuit to the ground

System Response:
i01784521
MID 109 - CID 1541 - FMI 03 Cyl protection for the port is lost. The code is logged.
short to +batt
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
S/N: BKE1-Up Perform the following diagnostic procedure:
Results:
the Integrated Combustion Sensing Module (ICSM) • OK – STOP.
System Response:

151

Troubleshooting:
open circuit
S/N: BKE1-Up
• OK – STOP.
i01784526
indicates an open circuit. #13 Exhaust Port Temp Sensor
short to ground
System Response:
SMCS Code: 1901-038
protection for the port is lost. The code is logged. S/N: BLB1-Up
Engine operation is not affected. The voltage of the signal from the thermocouple to
Troubleshooting: is less than the minimum acceptable value. This
“Thermocouple Test” • A short circuit to the −Battery side
Results: • A short circuit to the ground

i01784525 protection for the port is lost. The code is logged.
MID 109 - CID 1543 - FMI 03 Cyl Possible Performance Effect:
short to +batt
Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up Perform the following diagnostic procedure:
Results:
the Integrated Combustion Sensing Module (ICSM) • OK – STOP.
System Response:

152

Troubleshooting:
open circuit
• OK – STOP.
indicates an open circuit. MID 109 - CID 1545 - FMI 04 Cyl
System Response:
short to ground
Possible Performance Effect: S/N: BLB1-Up
Engine operation is not affected. Conditions Which Generate This Code:
Troubleshooting: The voltage of the signal from the thermocouple to

Perform the following diagnostic procedure: is less than the minimum acceptable value. This
“Thermocouple Test” indicates one of the following conditions:
Results: • A short circuit to the −Battery side
• OK – STOP. • A short circuit to the ground

System Response:
i01784529
MID 109 - CID 1545 - FMI 03 Cyl protection for the port is lost. The code is logged.
#15 Exhaust Port Temp Sensor Possible Performance Effect:
short to +batt
SMCS Code: 1901-038
Troubleshooting:
S/N: BLB1-Up
The voltage of the signal from the thermocouple to Results:
indicates a short circuit to the +Battery side. • OK – STOP.
System Response:

153
#15 Exhaust Port Temp Sensor “Integrated Combustion Sensing Module (ICSM)”
S/N: BLB1-Up
i01784536
MID 110 - CID 0591 - FMI 12
EEPROM checksum fault or
is less than the minimum acceptable value. This ECM not programmed
SMCS Code: 1901-038
System Response:
S/N: BLB1-Up
Monitoring of the port’s temperature is lost. Also, S/N: BKE1-Up
The left side Integrated Combustion Sensing Module
Engine operation is not affected. (ICSM) detects a problem within the EPROM circuit.
Perform the following diagnostic procedure: The shutdown output is activated. The code is
“Thermocouple Test” logged.
• OK – STOP. The ICSM may not function. If the ICSM does not
function, the engine is shut down.
i01784533
Troubleshooting:
MID 110 - CID 0253 - FMI 02
Replace the ICSM. Follow the instructions in
Personality Module mismatch Troubleshooting, “Replacing the ICSM”.
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
• OK – STOP.
S/N: BKE1-Up
The software for the left side Integrated Combustion

Sensing Module (ICSM) does not match the
software for the right side ICSM.
System Response:

logged.

154

MID 110 - CID 1041 - FMI 09 Monitoring of the combustion burn time is lost. The
ICSM #2 not communicating alarm output is activated. The code is logged.
on link Possible Performance Effect:
SMCS Code: 1901-038 The exhaust emissions are not controlled by the
S/N: BLB1-Up
S/N: BKE1-Up Troubleshooting:
Conditions Which Generate This Code: Perform the following diagnostic procedure:
The Electronic Control Module (ECM) and the
Integrated Combustion Sensing Module (ICSM) Results:
have been powered for at least five seconds and
the right side ICSM did not receive ten consecutive • OK – STOP.
messages from the left side ICSM.
i01776094
System Response:
MID 110 - CID 1044 - FMI 03
logged. All Cylinders Firing Signal
open/short to +batt
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
S/N: BKE1-Up
“Integrated Combustion Sensing Module (ICSM)” Conditions Which Generate This Code:
Results: During normal operation, the Integrated Combustion

• OK – STOP. grounds the 13 V signal for the duration of ignition.
i01784557 the firing signal.
MID 110 - CID 1044 - FMI 02 All If the 13 V signal is not grounded, the ICSM does
Cylinders Firing Signal noisy not receive the firing signal and the ICSM generates
SMCS Code: 1901-038
System Response:
S/N: BLB1-Up
S/N: BKE1-Up alarm output is activated. The code is logged.
One of the following conditions is detected by the The exhaust emissions are not controlled by the
Integrated Combustion Sensing Module (ICSM): engine control system.
• Electrical noise has been generated on the Troubleshooting:

conductor that carries the firing signal.
• The frequency of the firing signal is not within the “Cylinder Firing Pulse”
specified limits.
155
Results: i01784562

All Cylinders Firing Signal
i01776095 abnormal signal
MID 110 - CID 1044 - FMI 04 All SMCS Code: 1091-038
Cylinders Firing Signal short S/N: BLB1-Up
to ground
S/N: BKE1-Up
SMCS Code: 1901-038
S/N: BLB1-Up
The “Cylinder #1 Firing Signal” represents the
S/N: BKE1-Up ignition of the first cylinder. The “All Cylinders Firing
Signal” represents the ignitions of the remaining
Conditions Which Generate This Code: cylinders. The “Cylinder #1 Firing Signal” is a
reference for the “All Cylinders Firing Signal”. The
During normal operation, the Integrated Combustion “Cylinder #1 Firing Signal” is followed by the “All
Sensing Module (ICSM) continuously sends a signal Cylinders Firing Signal”.
grounds the 13 V signal for the duration of ignition. If the input for the “Cylinder #1 Firing Signal” is
The ICSM interprets the grounding of the signal switched with the input for the “All Cylinders Firing
as the firing signal. When the 13 V signal returns Signal”, the Integrated Combustion Sensing Module
to the high side, the ICSM starts the timer for the (ICSM) detects the “Cylinder #1 Firing Signal” more
combustion burn time. frequently than the “All Cylinders Firing Signal”. The
ICSM generates the diagnostic code.
If the 13 V signal remains grounded, the ICSM
cannot interpret the firing signal and the ICSM System Response:
generates the diagnostic code.
System Response: alarm output is activated. The code is logged.
Monitoring of the combustion burn time is lost. The Possible Performance Effect:
Possible Performance Effect: engine control system.
The exhaust emissions are not controlled by the Troubleshooting:
Troubleshooting: “Cylinder Firing Pulse”
Perform the following diagnostic procedure: Results:
Results:
• OK – STOP.
• OK – STOP.
156
i01784564 i01784570
Cylinder #2 Combustion Probe Cylinder #2 Combustion Probe
noisy short to ground
available.
available.
The code is logged.
Troubleshooting:

i01784577
MID 110 - CID 1104 - FMI 02
combustion sensor.
S/N: BLB1-Up
“Combustion Sensor” S/N: BKE1-Up


before combustion.
157
• The signal from the combustion sensor is received System Response:

System Response: excluded from the average combustion burn time
The combustion burn time for the cylinder is factor. Diagnostics for the cylinder misfire are not
excluded from the average combustion burn time available.
factor. Diagnostics for the cylinder misfire are not The code is logged.
available.
The code is logged.
Troubleshooting:
Troubleshooting: “Combustion Sensor”
One of the following conditions is probably the Results:

• OK – STOP.
i01784599
MID 110 - CID 1106 - FMI 02
• The extender is not properly contacting the noisy
combustion sensor.
SMCS Code: 1901-038
“Combustion Sensor” S/N: BLB1-Up

i01784581 Integrated Combustion Sensing Module (ICSM):
MID 110 - CID 1104 - FMI 04 • The signal from the combustion sensor is received
Cylinder #4 Combustion Probe before combustion.
short to ground • The signal from the combustion sensor is received
SMCS Code: 1901-038
S/N: BLB1-Up System Response:
S/N: BKE1-Up The combustion burn time for the cylinder is

Conditions Which Generate This Code: and from the calculation for the fuel correction
The signal from the combustion sensor to the available.
less than the minimum acceptable value. The code is logged.

158

i01784606
MID 110 - CID 1108 - FMI 02
combustion sensor.
S/N: BLB1-Up
“Combustion Sensor” S/N: BKE1-Up

i01784604
Cylinder #6 Combustion Probe • The signal from the combustion sensor is received
short to ground
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up The combustion burn time for the cylinder is
S/N: BKE1-Up and from the calculation for the fuel correction
Conditions Which Generate This Code: available.
The signal from the combustion sensor to the The code is logged.
less than the minimum acceptable value. Possible Performance Effect:
System Response: The engine performance is not directly affected.
The combustion burn time for the cylinder is Troubleshooting:

and from the calculation for the fuel correction One of the following conditions is probably the
factor. Diagnostics for the cylinder misfire are not cause of the diagnostic code:
available.
The code is logged.
Troubleshooting: combustion sensor.
Perform the following diagnostic procedure: Perform the following diagnostic procedure:
“Combustion Sensor” “Combustion Sensor”
159
Results: • The signal from the combustion sensor is received

before combustion.
• OK – STOP.
i01784607
Cylinder #8 Combustion Probe The combustion burn time for the cylinder is
short to ground and from the calculation for the fuel correction
SMCS Code: 1901-038
available.
S/N: BLB1-Up
The code is logged.
S/N: BKE1-Up
Integrated Combustion Sensing Module (ICSM) is Troubleshooting:
System Response: cause of the diagnostic code:
The combustion burn time for the cylinder is • The wiring for the combustion sensor is damaged.
and from the calculation for the fuel correction • The wiring for the ignition is damaged.
available. • The combustion sensor is damaged.
The code is logged. • The extender is not properly contacting the
combustion sensor.
Perform the following diagnostic procedure: • OK – STOP.

Results: i01784611
• OK – STOP.
MID 110 - CID 1110 - FMI 04
i01784610 Probe short to ground
MID 110 - CID 1110 - FMI 02 SMCS Code: 1901-038
Cylinder #10 Combustion S/N: BLB1-Up
Probe noisy S/N: BKE1-Up
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up Integrated Combustion Sensing Module (ICSM) is

160
The combustion burn time for the cylinder is One of the following conditions is probably the
factor. Diagnostics for the cylinder misfire are not • The wiring for the combustion sensor is damaged.
available.
The code is logged.
The engine performance is not directly affected. combustion sensor.
Troubleshooting: Perform the following diagnostic procedure:

“Combustion Sensor” Results:
• OK – STOP. i01784617
i01784613 MID 110 - CID 1112 - FMI 04

MID 110 - CID 1112 - FMI 02 Cylinder #12 Combustion
Probe noisy SMCS Code: 1901-038
System Response:
before combustion. The combustion burn time for the cylinder is
within 1.8 milliseconds of the signal for ignition. factor. Diagnostics for the cylinder misfire are not
available.
System Response:
The code is logged.
available.
Troubleshooting:
The code is logged.
Possible Performance Effect: “Combustion Sensor”

161
Results: i01784650

i01784647 Probe short to ground
MID 110 - CID 1114 - FMI 02 SMCS Code: 1901-038
Cylinder #14 Combustion S/N: BLB1-Up
Probe noisy
SMCS Code: 1901-038
S/N: BLB1-Up Integrated Combustion Sensing Module (ICSM) is
System Response:
Integrated Combustion Sensing Module (ICSM): The combustion burn time for the cylinder is
before combustion. factor. Diagnostics for the cylinder misfire are not
available.
within 1.8 milliseconds of the signal for ignition. The code is logged.
The code is logged.
Results:

• OK – STOP.
One of the following conditions is probably the MID 110 - CID 1116 - FMI 02
cause of the diagnostic code: Cylinder #16 Combustion
• The wiring for the combustion sensor is damaged. Probe noisy
• The wiring for the ignition is damaged. SMCS Code: 1901-038
S/N: BLB1-Up
combustion sensor.
before combustion.
Results:
• OK – STOP. • The signal from the combustion sensor is received

162
The code is logged.
Results:
• OK – STOP.
i01784654
Troubleshooting:

MID 110 - CID 1489 - FMI 03
cause of the diagnostic code: Left Turbo Turbine Out Temp
Sens short to +batt
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
combustion sensor. Conditions Which Generate This Code:
Perform the following diagnostic procedure: The voltage of the signal from the thermocouple to
“Combustion Sensor” the Integrated Combustion Sensing Module (ICSM)
Results: indicates a short circuit to the +Battery side.

i01784653 protection for the port is lost. The code is logged.
MID 110 - CID 1116 - FMI 04 Possible Performance Effect:
Probe short to ground
Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up Perform the following diagnostic procedure:
Results:
Integrated Combustion Sensing Module (ICSM) is • OK – STOP.
System Response:

available.
The code is logged.

163

MID 110 - CID 1489 - FMI 04 Monitoring of the port’s temperature is lost. Also,
Left Turbo Turbine Out Temp protection for the port is lost. The code is logged.
Sens short to ground Possible Performance Effect:
SMCS Code: 1901-038 Engine operation is not affected.
S/N: BKE1-Up

is less than the minimum acceptable value. This • OK – STOP.
i01784669
MID 110 - CID 1492 - FMI 03 Left
• A short circuit to the ground Turbo Turbine In Temp Sens
System Response: short to +batt
Monitoring of the port’s temperature is lost. Also, SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
“Thermocouple Test” is greater than the maximum acceptable value. This
Results:
System Response:
i01784665
MID 110 - CID 1489 - FMI 05
Left Turbo Turbine Out Temp Engine operation is not affected.
Sens open circuit Troubleshooting:
S/N: BLB1-Up
S/N: BKE1-Up Results:
Conditions Which Generate This Code: • OK – STOP.

164

MID 110 - CID 1492 - FMI 04 Left Monitoring of the port’s temperature is lost. Also,
Turbo Turbine In Temp Sens protection for the port is lost. The code is logged.
short to ground Possible Performance Effect:
S/N: BKE1-Up

i01784691
MID 110 - CID 1532 - FMI 03 Cyl
• A short circuit to the ground #2 Exhaust Port Temp Sensor
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784683
MID 110 - CID 1492 - FMI 05 Left
Turbo Turbine In Temp Sens Engine operation is not affected.
open circuit Troubleshooting:
S/N: BLB1-Up

165

MID 110 - CID 1532 - FMI 04 Cyl Monitoring of the port’s temperature is lost. Also,
S/N: BKE1-Up

i01784699
MID 110 - CID 1534 - FMI 03 Cyl
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784695
MID 110 - CID 1532 - FMI 05 Cyl
#2 Exhaust Port Temp Sensor Engine operation is not affected.
S/N: BLB1-Up

166

S/N: BKE1-Up

i01784709
MID 110 - CID 1536 - FMI 03 Cyl
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784706
MID 110 - CID 1534 - FMI 05 Cyl
S/N: BLB1-Up

167

S/N: BKE1-Up

i01784724
MID 110 - CID 1538 - FMI 03 Cyl
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784721
MID 110 - CID 1536 - FMI 05 Cyl
S/N: BLB1-Up

168

S/N: BKE1-Up

i01784767
MID 110 - CID 1540 - FMI 03 Cyl
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784734
MID 110 - CID 1538 - FMI 05 Cyl
S/N: BLB1-Up

169

S/N: BKE1-Up

i01784777
MID 110 - CID 1542 - FMI 03 Cyl
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
Results:
System Response:
i01784771
MID 110 - CID 1540 - FMI 05 Cyl
S/N: BLB1-Up

170

S/N: BKE1-Up

i01784790
MID 110 - CID 1544 - FMI 03 Cyl
S/N: BLB1-Up
Troubleshooting: the Integrated Combustion Sensing Module (ICSM)
Perform the following diagnostic procedure: indicates a short circuit to the +Battery side.
System Response:
Results:
• OK – STOP. protection for the port is lost. The code is logged.

i01784786
MID 110 - CID 1542 - FMI 05 Cyl
#12 Exhaust Port Temp Sensor Troubleshooting:
open circuit Perform the following diagnostic procedure:
SMCS Code: 1901-038
S/N: BKE1-Up • OK – STOP.


171

Troubleshooting:
short to ground
• OK – STOP.
indicates one of the following conditions: MID 110 - CID 1546 - FMI 03 Cyl
short to +batt
SMCS Code: 1901-038
System Response:
S/N: BLB1-Up
Possible Performance Effect: The voltage of the signal from the thermocouple to
Engine operation is not affected. is greater than the maximum acceptable value. This
Troubleshooting:
System Response:
“Thermocouple Test” Monitoring of the port’s temperature is lost. Also,
Results:
• OK – STOP. Engine operation is not affected.
S/N: BLB1-Up

System Response:

172

Conditions Which Generate This Code: Perform the following diagnostic procedure:
the Integrated Combustion Sensing Module (ICSM) Results:
• OK – STOP.
System Response:

Troubleshooting:

Results:
• OK – STOP.
i01784815
MID 110 - CID 1546 - FMI 05 Cyl

open circuit
SMCS Code: 1901-038
S/N: BLB1-Up

173
Troubleshooting with an
Event Code
i01729324
Event Codes
SMCS Code: 1901-038
Use this section for the troubleshooting of problems

that have generated event codes but do not have
active diagnostic codes. When the event code is
generated, the event is active. Any generated code
becomes logged in the permanent memory of the
Electronic Control Module (ECM).
Event codes alert the operator that an abnormal

engine operating condition such as low oil pressure
or high coolant temperature has been detected.
Events do not indicate problems with the electronic g00791619
system. Event codes also indicate the nature of the Illustration 28
problem. The Caterpillar Electronic Technician (ET) Typical operating range of an oil temperature sensor
is designed to run on a personal computer. Event (1) In these areas, the output voltage of the sensor is too high
codes may be viewed on a personal computer that or too low. The output is outside of the normal range. The
has the Cat ET software. electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 C (216 F) is higher
than normal. The output voltage of the sensor will generate an
Illustration 28 represents the operating range of an event code for a warning, a derating, or a shutdown for high oil
oil temperature sensor. The diagram is a reference. temperature. The sensor does not have an electronic problem.
Do not use the diagram to troubleshoot the oil (3) This area represents the normal operating temperature for the
temperature sensor. engine oil. The normal output voltage of the sensor is between
0.2 and 4.1 volts.
The following format is used for event codes:
• “EXXX (X) Description of the code”

The “E” means that the code is an event code. The
“XXX” represents a numeric identifier for the event
code. The fourth “(X)” represents a numeric identifier
for the severity of the code. This is followed by a
description of the code. See the following example:
• “E004 (3) Engine Overspeed Shutdown”

The numbers that indicate the severity of the event
code are defined below:
Warning (1) – This condition represents a serious

problem with engine operation. However, this
condition does not require a deration or a shutdown.
Derate (2) – For this condition, the engine power is

reduced in order to help prevent possible engine
damage.
Shutdown (3) – For this condition, the engine is

shut down in order to help prevent possible engine
damage.
174
These responses to certain events may be Be sure to check the connectors. This is specially
programmed into the ECM. If the responses are true for problems that are intermittent. See
programmed, Cat ET can display the event. If the Troubleshooting, “Inspecting Electrical Connectors”.
responses are not programmed, the display will not
appear. However, the occurrence of any event will Narrow the probable cause. Consider the operator
cause the event code to be logged in the ECM. information, the conditions of operation, and the
history of the engine.
Note: Do not confuse event codes with diagnostic
codes. For information on diagnostic codes, see
Troubleshooting, “Troubleshooting with a Diagnostic
Operator Information
Code”. Obtain the following information from the operator:
Perform the following tasks before you troubleshoot
the event code: • The occurrence and the time of the occurrence
• Gather enough information about the complaint in • Determine the conditions for the occurrence. The
conditions will include the engine rpm and the
order to describe the symptom(s) adequately. load.
• Verify that the complaint is not due to normal • Determine if there are any systems that were
engine operation. installed by the dealer or the customer that could
cause the symptom.
• Repair all active diagnostic codes. See
Troubleshooting, “Troubleshooting With A
Diagnostic Code”. • Determine whether any other occurrences
happened in addition to the symptom.
Troubleshooting Diagnostic Codes and Event Codes

For basic troubleshooting of the engine, perform Examine the following information regarding any
the following steps first in order to diagnose a
codes:
malfunction.
1. Gather information about the complaint from the • The probable cause of the symptom is correlated
to the code.
operator.
2. Verify that the complaint is not due to normal • The code was generated when the symptom
occurred.
engine operation. Verify that the complaint is not
due to error of the operator.
• Codes that are repeatedly logged
3. Perform a visual inspection. Inspect the following
items: • The complaint is not due to normal engine
operation.
• Fuel supply
Other Symptoms
• Oil level
If other occurrences happened in addition to the
• Oil supply symptom, investigate the following conditions:
• Wiring • The other occurrences are related to the

symptom.
• Connectors
• The symptoms have a probable cause that is
4. Check the diagnostic codes and event codes. common.
Repair any active codes.
Active Event Codes
If these inspections do not reveal any problems,
identify the probable causes with the procedures An active event code represents a problem with
in this manual that best describe the symptoms. engine operation. Correct the problem as soon
Check each probable cause according to the tests as possible.
that are recommended.
175
When an event code is active, the “Active Alarm” Troubleshooting:

indicator (“Engine Control Alarm Status” on Cat ET)
is activated in order to alert the operator. If the Refer to Troubleshooting, “Engine Overspeed”.
condition that generated the code is momentary,
the message disappears. The event code will be Results:
logged in the ECM memory.
• OK – STOP.
Active event codes are listed in ascending
numerical order. The code with the lowest number
i01654071
is listed first.
E013 High Crankcase Pressure
Logged Event Codes Shutdown
When the ECM generates an event code the ECM
SMCS Code: 1901-038
logs the code in permanent memory. The ECM has
an internal diagnostic clock. The ECM will record Conditions Which Generate This Code:
the following information when a code is generated:
The engine is running and the crankcase pressure
• The hour of the first occurrence of the code is greater than the setpoint.
• The hour of the last occurrence of the code System Response:
• The number of occurrences of the code The shutdown output is activated. The code is
logged.
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be
used to review the performance of the engine. Any
logged event codes will automatically be deleted The engine is shut down.
if no additional occurrences are recorded in 100
hours.
Troubleshooting:
Logged events are listed in chronological order. The
Refer to Troubleshooting, “Crankcase Pressure
most recent event code is listed first.
(High)”.
Note: Always clear logged event codes after
Results:
investigating and correcting the problem which
generated the code.
• OK – STOP.
i01729333
i01633543
E004 Engine Overspeed E016 High Engine Coolant

Shutdown Temperature Shutdown
The engine rpm has exceeded the trip point that The crank terminate relay is set and the engine has
is programmed into the Electronic Control Module been running for at least 30 seconds. The engine
(ECM) and the delay time has expired. The ECM has coolant temperature has exceeded the trip point
determined that the detected speed is accurate. and the delay time has expired. No other codes for
the engine coolant are active.
System Response:
System Response:
The gas shutoff valve and the ignition are shut
off. The shutdown output is activated. The code is The fuel is shut off. The shutdown output is
logged. activated. The code is logged.
The engine is shut down. The engine is shut down.
176
Refer to Troubleshooting, “Engine Coolant The fuel is shut off. The shutdown output is
Temperature (High)”. activated. The code is logged.
• OK – STOP. The engine is shut off.
Troubleshooting:
i01633545
E017 High Engine Coolant Refer to Troubleshooting, “Engine Oil Temperature

(High)”.
Temperature Warning
Results:
SMCS Code: 1901-038
• OK – STOP.
The crank terminate relay is set and the engine has i01633605
been running for at least 30 seconds. The engine E020 High Engine Oil
coolant temperature has exceeded the trip point
and the delay time has expired. No other codes for Temperature Warning
the engine coolant are active.
SMCS Code: 1901-038
System Response:
The crank terminate relay is set and the engine has
Possible Performance Effect: been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and
The engine operation is not immediately affected. the delay time has expired. No other codes for the
However, if the coolant temperature continues to engine oil temperature are active.
rise, the engine will be shut down.
System Response:
Troubleshooting:
Refer to Troubleshooting, “Engine Coolant
Temperature (High)”. Possible Performance Effect:
Results: The engine operation is not immediately affected.

However, if the engine oil temperature continues to
• OK – STOP. rise, the engine can be shut down.
Troubleshooting:
i01633603
E019 High Engine Oil Refer to Troubleshooting, “Engine Oil Temperature

(High)”.
Temperature Shutdown
Results:
SMCS Code: 1901-038
• OK – STOP.

been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and
the delay time has expired. No other codes for the
engine oil temperature are active.
177
i01633755 Results:
E026 High Inlet Air • OK – STOP.
Temperature Shutdown
i01633757
SMCS Code: 1901-038
E038 Low Engine Coolant
Temperature Warning
been running for at least 30 seconds. The inlet air SMCS Code: 1901-038
temperature has exceeded the trip point and the
delay time has expired. No other codes for the inlet Conditions Which Generate This Code:
air temperature are active.
The crank terminate relay is set and the engine
System Response: has been running for at least 30 seconds. The
temperature of the engine coolant is less than the
The fuel is shut off. The shutdown output is trip point and the delay time has expired. No other
activated. The code is logged. codes for the coolant temperature are active.
The engine is shut down. The alarm output is activated. The code is logged.
Refer to Troubleshooting, “Inlet Air Temperature The engine operation is not immediately affected.
(High)”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Coolant
Temperature (Low)”.
• OK – STOP.
Results:
i01633756
• OK – STOP.
E027 High Inlet Air
Temperature Warning i01633762
SMCS Code: 1901-038 E040 Low Engine Oil Pressure

Conditions Which Generate This Code: Shutdown
The crank terminate relay is set and the engine has SMCS Code: 1901-038
been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the Conditions Which Generate This Code:
delay time has expired. No other codes for the inlet
air temperature are active. The crank terminate relay is set and the engine has
been running for at least 10 seconds. The engine
System Response: oil pressure is less than the trip point and the
delay time has expired. No codes for the engine oil
The alarm output is activated. The code is logged. pressure sensor are active.
The engine operation is not immediately affected. The fuel is shut off. The shutdown output is
However, if the inlet air temperature continues to activated. The code is logged.
rise, the engine may be shut down.
Troubleshooting:
Refer to Troubleshooting, “Inlet Air Temperature
(High)”.
178
Refer to Troubleshooting, “Engine Oil Pressure The engine operation is not immediately affected.
(Low)”. However, if the system voltage continues to be
reduced, the engine will be shut down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “System Voltage”.
i01633763
Results:
E042 Low System Voltage
• OK – STOP.
Shutdown
SMCS Code: 1901-038 i01633766

E050 High System Voltage
Warning
The voltage is less than the trip point and the delay
time has expired. No other codes for the system SMCS Code: 1901-038
voltage are present.
System Response:
The voltage is greater than the trip point and the
The shutdown output is activated. The code is delay time has expired. No other codes for the
logged. system voltage are present.
The engine is shut down. The alarm output is activated. The code is logged.
Refer to Troubleshooting, “System Voltage”. The engine operation is not immediately affected.
However, if the system voltage continues to increase
Results: the circuit breaker will switch OFF and the engine
will be shut down.
• OK – STOP.
Troubleshooting:
i01633765
Refer to Troubleshooting, “System Voltage”.
E043 Low System Voltage Results:
Warning
• OK – STOP.
SMCS Code: 1901-038
Conditions Which Generate This Code: i01633768
The voltage is less than the trip point and the delay
E096 High Fuel Pressure
time has expired. No other codes for the system SMCS Code: 1901-038
voltage are present.
System Response:
The fuel pressure is higher than the trip point and
the delay time has expired.
System Response:

179
The engine operation is not immediately affected. The alarm output is activated. The code is logged.
For proper operation, the fuel pressure must be
stable. Possible Performance Effect:
Troubleshooting: The engine operation is not immediately affected.

However, if the crankcase pressure continues to
Refer to Troubleshooting, “Fuel Pressure”. increase, the engine will be shut down.
• OK – STOP. Refer to Troubleshooting, “Crankcase Pressure

(High)”.
i01633787
Results:
E100 Low Engine Oil Pressure
• OK – STOP.
Warning
SMCS Code: 1901-038 i01633790

E127 Engine Oil Filter Diff
Pressure Low Warning
been running for at least ten seconds. The engine SMCS Code: 1901-038
oil pressure is less than the trip point and the delay
time has expired. There are no active codes for the Conditions Which Generate This Code:
engine oil pressure sensor.
System Response: been running for at least 30 seconds. The engine oil
filter differential pressure is less than the trip point
The alarm output is activated. The code is logged. and the delay time has expired. There are no active
codes for the oil pressure sensors.
System Response:
The engine operation is not immediately affected.
However, if the oil pressure continues to be reduced, The alarm output is activated. The code is logged.
the engine may be shut down.
Troubleshooting:
The engine operation is not immediately affected.
Refer to Troubleshooting, “Engine Oil Pressure However, if the engine oil filter differential pressure
(Low)”. continues to be reduced, the engine may be shut
down.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”.
i01654094
E101 High Crankcase Pressure Results:
Warning • OK – STOP.
SMCS Code: 1901-038
The engine is running and the crankcase pressure

is greater than the setpoint.
180
E128 Engine Oil Filter Diff Refer to Troubleshooting, “Engine Oil Filter
Pressure Low Shutdown Differential Pressure”.
SMCS Code: 1901-038 Results:

been running for at least 30 seconds. The oil filter
differential pressure is less than the trip point and E130 Engine Oil Filter Diff
the delay time has expired. There are no active
codes for the oil pressure sensors. Pressure High Shutdown
The fuel is shut off. The shutdown output is Conditions Which Generate This Code:
Possible Performance Effect: been running for at least 30 seconds. The engine
oil filter differential pressure is greater than the trip
The engine is shut down. point and the delay time has expired. There are no
active codes for the oil pressure sensors.
Troubleshooting:
System Response:
Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”. The fuel is shut off. The shutdown output is
Results:
• OK – STOP. The engine is shut down.
E129 Engine Oil Filter Diff Refer to Troubleshooting, “Engine Oil Filter
Pressure High Warning Differential Pressure”.

been running for at least 30 seconds. The oil filter
differential pressure is greater than the trip point E135 Low Jacket Water
and the delay time has expired. There are no active
codes for the oil pressure sensors. Pressure Shutdown
The alarm output is activated. The code is logged. Conditions Which Generate This Code:
Possible Performance Effect: The crank terminate relay is set and the engine has
been running for at least ten seconds. The pressure
The engine operation is not immediately affected. of the jacket water is less than the trip point and the
However, if the oil filter differential pressure delay time has expired. There are no active codes
continues to increase, the engine may be shut for the pressure sensor at the outlet for the jacket
down. water.
181
The fuel is shut off. The shutdown output is E201 Cylinder #1 Intermittent
activated. The code is logged. Misfire
The engine is shut off. Conditions Which Generate This Code:
Troubleshooting: The engine is operating in the combustion feedback
mode or in the prechamber calibration mode. The
Refer to Troubleshooting, “Jacket Water Pressure Integrated Combustion Sensing Module (ICSM) has
(Low)”. not received 20 percent of the signals from the
cylinder’s combustion sensor during a four minute
Results: period.
i01784832
E200 Continuous Cylinder Possible Performance Effect:

Misfire The engine will run rough.
Conditions Which Generate This Code: Refer to Troubleshooting, “Engine Misfires, Runs
Rough, or Is Unstable”.
The engine is operating in the combustion feedback
mode. At least 50 percent of the cylinders have Results:
continuous misfire. The continuous misfire is
indicated by the following conditions:
• OK – STOP.
• The cylinder has an active “Exhaust Port Temp
Deviating Low” event. i01784834
• The Integrated Combustion Sensing Module E202 Cylinder #2 Intermittent

(ICSM) has not received a signal from the Misfire
cylinder’s combustion sensor for 40 minutes.
SMCS Code: 1901-038
System Response:
logged. The engine is operating in the combustion feedback
Possible Performance Effect: Integrated Combustion Sensing Module (ICSM) has
not received 20 percent of the signals from the
The engine is shut down. cylinder’s combustion sensor during a four minute
period.
Troubleshooting:
System Response:
Rough or Is Unstable”. The alarm output is activated. The code is logged.
• OK – STOP. The engine will run rough.
Troubleshooting:

182
Troubleshooting:
i01784836
E203 Cylinder #3 Intermittent Refer to Troubleshooting, “Engine Misfires, Runs

Misfire
Results:
SMCS Code: 1901-038
• OK – STOP.
The engine is operating in the combustion feedback i01784838

Integrated Combustion Sensing Module (ICSM) has
E205 Cylinder #5 Intermittent
not received 20 percent of the signals from the Misfire
period. SMCS Code: 1901-038
The alarm output is activated. The code is logged. The engine is operating in the combustion feedback
Possible Performance Effect: Integrated Combustion Sensing Module (ICSM) has
The engine will run rough. cylinder’s combustion sensor during a four minute
period.
Troubleshooting:
System Response:
Rough, or Is Unstable”. The alarm output is activated. The code is logged.
Troubleshooting:
i01784837

Misfire
Results:
SMCS Code: 1901-038
• OK – STOP.

period.
System Response:

183
Misfire Rough, or Is Unstable”.

The engine is operating in the combustion feedback i01784846
Integrated Combustion Sensing Module (ICSM) has E208 Cylinder #8 Intermittent
cylinder’s combustion sensor during a four minute Misfire
period.
SMCS Code: 1901-038
System Response: S/N: BLB1-Up
The alarm output is activated. The code is logged. S/N: BKE1-Up
Possible Performance Effect: S/N: BEN1-Up
The engine will run rough. Conditions Which Generate This Code:
Troubleshooting: The engine is operating in the combustion feedback

Refer to Troubleshooting, “Engine Misfires, Runs Integrated Combustion Sensing Module (ICSM) has
Rough, or Is Unstable”. not received 20 percent of the signals from the
Results: period.

i01784843
Misfire The engine will run rough.

S/N: BLB1-Up Refer to Troubleshooting, “Engine Misfires, Runs
S/N: BKE1-Up
S/N: BEN1-Up Results:

period.
System Response:
The engine will run rough.

184

E209 Cylinder #9 Intermittent The engine will run rough.
Misfire
Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up Rough, or Is Unstable”.
mode or in the prechamber calibration mode. The i01784859
not received 20 percent of the signals from the E211 Cylinder #11 Intermittent
cylinder’s combustion sensor during a four minute Misfire
period.
SMCS Code: 1901-038
System Response:
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting: mode or in the prechamber calibration mode. The
Refer to Troubleshooting, “Engine Misfires, Runs not received 20 percent of the signals from the
Rough, or Is Unstable”. cylinder’s combustion sensor during a four minute
period.
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.

E210 Cylinder #10 Intermittent The engine will run rough.
Misfire Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up Rough, or Is Unstable”.
period.
System Response:

185
Misfire Rough, or Is Unstable”.
S/N: BLB1-Up • OK – STOP.

S/N: BKE1-Up
i01784871
The engine is operating in the combustion feedback Misfire
Integrated Combustion Sensing Module (ICSM) has SMCS Code: 1901-038
cylinder’s combustion sensor during a four minute S/N: BLB1-Up
period.
System Response:
The alarm output is activated. The code is logged. mode or in the prechamber calibration mode. The
Possible Performance Effect: not received 20 percent of the signals from the
The engine will run rough. period.
Refer to Troubleshooting, “Engine Misfires, Runs The alarm output is activated. The code is logged.
Results:
• OK – STOP.
Troubleshooting:
i01784867 Refer to Troubleshooting, “Engine Misfires, Runs
Misfire Results:

S/N: BLB1-Up
i01784878
The engine is operating in the combustion feedback Misfire
Integrated Combustion Sensing Module (ICSM) has SMCS Code: 1901-038
cylinder’s combustion sensor during a four minute S/N: BLB1-Up
period.
System Response:
The alarm output is activated. The code is logged. mode or in the prechamber calibration mode. The
Possible Performance Effect: not received 20 percent of the signals from the
The engine will run rough. period.
186
The alarm output is activated. The code is logged. E223 High Gas Temperature
The engine will run rough. Conditions Which Generate This Code:
Troubleshooting: The crank terminate relay is set and the engine

has been running for at least 30 seconds. The
Refer to Troubleshooting, “Engine Misfires, Runs temperature of the gas has exceeded the trip point
Rough, or Is Unstable”. and the delay timer has expired. There are no active
codes for the fuel temperature sensor.
Results:
System Response:
• OK – STOP.

E216 Cylinder #16 Intermittent The engine operation is not immediately affected.
Misfire However, if the fuel temperature continues to
increase, the air/fuel ratio and the inlet manifold air
SMCS Code: 1901-038 temperature can be affected.
Conditions Which Generate This Code: Refer to Troubleshooting, “Gas Temperature (High)”.
The engine is operating in the combustion feedback Results:

Integrated Combustion Sensing Module (ICSM) has • OK – STOP.
period. i01633956
System Response:
E224 High Jacket Water Inlet
Pressure
SMCS Code: 1901-038
Troubleshooting: been running for at least 10 seconds. The trip point
for high pressure at the inlet for the jacket water has
Refer to Troubleshooting, “Engine Misfires, Runs been exceeded and the delay time has expired.
System Response:
Results:
• OK – STOP. activated. The code is logged.
Troubleshooting:
Refer to Troubleshooting, “Jacket Water Inlet

Pressure (High)”.
187
Results: i01633972
• OK – STOP. E229 Fuel Energy Content

Setting Low
i01633959
SMCS Code: 1901-038
E225 Engine Overcrank
SMCS Code: 1901-038
The crank terminate relay is set and the engine
Conditions Which Generate This Code: has been running for at least 30 seconds. The fuel
correction factor is less than the trip point for 20
The engine did not start within the programmed seconds.
parameters for starting.
System Response:
System Response:
The fuel is shut off. Engine cranking is prevented.
The code is logged. Possible Performance Effect:
Possible Performance Effect: The engine performance may be erratic.
The engine will not start. Troubleshooting:
Troubleshooting: Refer to Troubleshooting, “Fuel Energy Content”.
Refer to Troubleshooting, “Engine Overcrank”. Results:
• OK – STOP. i01633976
i01729345
E230 Fuel Energy Content
E226 Driven Equipment Not Setting High
Ready SMCS Code: 1901-038
SMCS Code: 1901-038 Conditions Which Generate This Code:
Conditions Which Generate This Code: The crank terminate relay is set and the engine
has been running for at least 30 seconds. The fuel
The engine is ready to start. However, the Electronic correction factor is greater than the trip point for
Control Module (ECM) has received a signal which 20 seconds.
indicates that the driven equipment is not ready for
the engine to start. System Response:
System Response: The alarm output is activated. The code is logged.
The shutdown output is activated. Engine cranking Possible Performance Effect:

is prevented. The code is logged.
The engine performance may be erratic.
Troubleshooting:
The engine will not start.
Refer to Troubleshooting, “Fuel Energy Content”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Driven Equipment”.
• OK – STOP.
Results:
• OK – STOP.
188
i01746483 Results:
E231 Fuel Quality Out of Range • OK – STOP.
SMCS Code: 1901-038
i01729352
E242 Engine Overload
been running for at least 30 seconds. The Low Heat SMCS Code: 1901-038
Value (LHV) of the fuel is less than the trip point
OR the LHV of the fuel is greater than the trip point Conditions Which Generate This Code:
for 20 seconds.
The calculation by the Electronic Control Module
System Response: (ECM) for the engine load is greater than 110
percent of the rated load.
activated. The code is logged. System Response:
Possible Performance Effect: The alarm output is activated. The code is logged.
The engine is shut off. Possible Performance Effect:
Troubleshooting: The engine power is reduced.
Refer to Troubleshooting, “Fuel Energy Content”. Troubleshooting:
Results: Refer to Troubleshooting, “Engine Overload”.
Results:
• OK – STOP.
• OK – STOP.
i01634004
E233 Low Engine Pre-Lube i01634015
Pressure E243 High Left Turbo Turbine

SMCS Code: 1901-038 Outlet Temperature
Conditions Which Generate This Code: SMCS Code: 1052-038
S/N: BLB1-Up
The prelube oil pressure is less than the trip point
and the delay time has expired. S/N: BKE1-Up
The shutdown output is activated. Starting of the The temperature at the outlet for the left turbocharger
engine is prevented. The signal driver for the turbine has exceeded the trip point and the delay
prelube pump remains activated. The code is time has expired.
logged.
System Response:
The following event codes are logged according to
The engine will not start. the trip points for the temperature:
Troubleshooting: • E243 (1) High Left Turbo Turbine Outlet

Temperature (warning)
Refer to Troubleshooting, “Engine Pre-Lube Pressure
(Low)”. • E243 (3) High Left Turbo Turbine Outlet
Temperature (shutdown)
189
If a warning is generated, the alarm output is Troubleshooting:

activated.
Refer to Troubleshooting, “Turbocharger Turbine
If a shutdown is generated, the shutdown output Temperature (High)”.
is activated.
Results:
• OK – STOP.
If a warning is generated, the engine performance
is not immediately affected.
i01634041
The engine will be shut down if the trip point for the
shutdown is exceeded.
E245 High Right Turbo Turbine
Inlet Temperature
Troubleshooting:
SMCS Code: 1052-038
Temperature (High)”. Conditions Which Generate This Code:
Results: The temperature at the inlet for the right

turbocharger turbine has exceeded the trip point
• OK – STOP. and the delay time has expired.
System Response:
i01634039
E244 High Right Turbo Turbine the trip points for the temperature:
Outlet Temperature
• E245 (1) High Right Turbo Turbine Inlet
SMCS Code: 1052-038 Temperature (warning)
Conditions Which Generate This Code: • E245 (3) High Right Turbo Turbine Inlet
Temperature (shutdown)
The temperature at the outlet for the right
turbocharger turbine has exceeded the trip point If a warning is generated, the alarm output is
and the delay time has expired. activated.
System Response: If a shutdown is generated, the shutdown output

is activated.
the trip points for the temperature: Possible Performance Effect:
• E244 (1) High Right Turbo Turbine Outlet If a warning is generated, the engine performance
Temperature (warning) is not immediately affected.
• E244 (3) High Right Turbo Turbine Outlet The engine will be shut down if the trip point for the
Temperature (shutdown) shutdown is exceeded.

activated.
If a shutdown is generated, the shutdown output Temperature (High)”.
is activated.
Results:
• OK – STOP.
190
i01634043 i01634059
E246 High Left Turbo Turbine E264 Emergency Stop

Inlet Temperature Activated
S/N: BLB1-Up Conditions Which Generate This Code:
S/N: BKE1-Up
The input for the emergency stop is activated.
System Response:
The temperature at the inlet for the left turbocharger
turbine has exceeded the trip point and the delay The gas shutoff valve (GSOV) and the ignition are
shut off. The shutdown output is activated. The
time has expired.
code is logged.
System Response:
the trip points for the temperature: The engine is shut off.
Troubleshooting:
• E246 (1) High Left Turbo Turbine Inlet Temperature
(warning)
Refer to Troubleshooting, “Engine Shutdown”.
• E246 (3) High Left Turbo Turbine Inlet Temperature Results:
(shutdown)
If a warning is generated, the alarm output is • OK – STOP.

activated.
i01634061
If a shutdown is generated, the shutdown output
is activated. E266 Low Hydrax Oil Pressure
If a warning is generated, the engine performance Conditions Which Generate This Code:
The crank terminate relay has been energized for
The engine will be shut down if the trip point for the at least 30 seconds. The pressure switch for the
shutdown is exceeded. electrohydraulic actuator system opens for more
than one second. This indicates no oil pressure to
Troubleshooting: the system.
Refer to Troubleshooting, “Turbocharger Turbine System Response:

Temperature (High)”.
Results: activated. The code is logged.
Troubleshooting:
Refer to Troubleshooting, “Electrohydraulic System

Oil Pressure (Low)”.
Results:
• OK – STOP.
191
i01634063 i01634097
E268 Unexpected Engine E270 Driven Equipment

Shutdown Shutdown Requested
The crank terminate relay is set and the engine The crank terminate relay is set and the engine is
is running. The engine rpm is less than the running. The input requests a shutdown for 200 ms.
programmed speed of the postlube cycle for 200
ms. System Response:
System Response: The fuel is shut off. The shutdown output is

activated. The code is logged. Possible Performance Effect:
Possible Performance Effect: The engine is shut down.
The engine is shut down. Troubleshooting:
Troubleshooting: Refer to Troubleshooting, “Driven Equipment”.
Refer to Troubleshooting, “Engine Shutdown Results:

(Unexpected)”.
• OK – STOP.
Results:
i01634098
• OK – STOP.
E337 High Engine Oil to Engine
i01634093 Coolant Diff Temp
E269 Customer Shutdown SMCS Code: 1901-038
Requested
SMCS Code: 1901-038
Note: The cylinder liner and the piston assembly
Conditions Which Generate This Code: can be damaged by this condition.
The engine is either cranking or running. The input The engine oil temperature is too high or the engine
for the stop is set for 200 ms. coolant temperature is too low. The differential
between the engine oil temperature and the engine
System Response: coolant temperature has exceeded the trip point
and the delay time has expired.
activated. The code is logged. System Response:
Possible Performance Effect: The following event codes are logged according to
the trip points for the temperature:
The engine is shut off.
• E337(1) High Engine Oil to Engine Coolant Diff
Troubleshooting: Temp (warning)
Refer to Troubleshooting, “Engine Shutdown”. • E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown)
Results:
If a warning is generated, the alarm output is
• OK – STOP. activated.
192
If a shutdown is generated, the shutdown output i01778632

is activated.
E385 Right Air Inlet Restriction
SMCS Code: 1087-038
is not immediately affected. Conditions Which Generate This Code:
The engine will be shut down if the trip point for the The switch for the air filter’s inlet air restriction is
shutdown is exceeded. activated.
Refer to Troubleshooting, “Jacket Water to Engine The alarm output is activated.

Oil Differential Temperature (Low)”.
The code is logged.
Results:
• OK – STOP.
The engine may have low power due to the lack
of inlet air. The engine may shut down because of
i01778617 excessive inlet air restriction.
E384 Left Air Inlet Restriction Troubleshooting:
SMCS Code: 1087-038 Refer to Troubleshooting, “Inlet Air Restriction”.
S/N: BLB1-Up
Results:
S/N: BKE1-Up
• OK – STOP.
i01778634
The switch for the air filter’s inlet air restriction is
activated. E386 Low Engine Coolant or
System Response: Engine Oil Level
The alarm output is activated. SMCS Code: 1901-038
The code is logged. Conditions Which Generate This Code:
Possible Performance Effect: The switch input for the engine coolant level and for
the engine oil level is activated.
The engine may have low power due to the lack
of inlet air. The engine may shut down because of System Response:
excessive inlet air restriction.
The shutdown output is activated.
Troubleshooting:
The code is logged.
Refer to Troubleshooting, “Inlet Air Restriction”.
Results:
• OK – STOP.
Troubleshooting:
Determine whether the engine coolant level or the

engine oil level is low. Refer to Troubleshooting,
“Engine Coolant Level (Low)” or refer to
Troubleshooting, “Engine Oil Level (Low)”.
193
Results: Results:
• OK – STOP. • OK – STOP.
i01637607 i01637627
E401 Cylinder #1 Detonation E403 Cylinder #3 Detonation

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
The engine performance may be affected by The engine performance may be affected by
an adjustment of the timing in order to reduce an adjustment of the timing in order to reduce
detonation. detonation.
Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.
Results: Results:
i01637623 i01637634

The level of detonation has exceeded the trip point. The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s There is no active diagnostic code for the cylinder’s
detonation sensor. detonation sensor.
The alarm output is activated. The code is logged. The alarm output is activated. The code is logged.
The engine performance may be affected by The engine performance may be affected by
an adjustment of the timing in order to reduce an adjustment of the timing in order to reduce
detonation. detonation.
Refer to Troubleshooting, “Detonation”. Refer to Troubleshooting, “Detonation”.

194
Results: Results:
i01637642 i01637648

Conditions Which Generate This Code: S/N: BLB1-Up

S/N: BKE1-Up
The level of detonation has exceeded the trip point.
There is no active diagnostic code for the cylinder’s S/N: BEN1-Up
detonation sensor.
System Response:
The alarm output is activated. The code is logged. There is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
The engine performance may be affected by
an adjustment of the timing in order to reduce The alarm output is activated. The code is logged.
detonation.
Troubleshooting:
Refer to Troubleshooting, “Detonation”. an adjustment of the timing in order to reduce
detonation.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Detonation”.
i01637646
Results:
E406 Cylinder #6 Detonation
• OK – STOP.
SMCS Code: 1901-038
i01637651
There is no active diagnostic code for the cylinder’s SMCS Code: 1901-038
detonation sensor.
S/N: BLB1-Up
System Response:
S/N: BKE1-Up
The alarm output is activated. The code is logged. S/N: BEN1-Up
The engine performance may be affected by The level of detonation has exceeded the trip point.
an adjustment of the timing in order to reduce There is no active diagnostic code for the cylinder’s
detonation. detonation sensor.
Refer to Troubleshooting, “Detonation”. The alarm output is activated. The code is logged.
195
The engine performance may be affected by The alarm output is activated. The code is logged.
an adjustment of the timing in order to reduce
detonation. Possible Performance Effect:
Troubleshooting: The engine performance may be affected by

Refer to Troubleshooting, “Detonation”. detonation.
• OK – STOP. Refer to Troubleshooting, “Detonation”.
Results:
i01637653
E409 Cylinder #9 Detonation • OK – STOP.
SMCS Code: 1901-038 i01637663
S/N: BLB1-Up E411 Cylinder #11 Detonation

S/N: BKE1-Up
SMCS Code: 1901-038
Conditions Which Generate This Code: S/N: BLB1-Up
The level of detonation has exceeded the trip point. S/N: BKE1-Up
There is no active diagnostic code for the cylinder’s
detonation sensor. Conditions Which Generate This Code:
System Response: The level of detonation has exceeded the trip point.
The alarm output is activated. The code is logged. detonation sensor.
The engine performance may be affected by The alarm output is activated. The code is logged.
detonation. Possible Performance Effect:
Troubleshooting: The engine performance may be affected by

Refer to Troubleshooting, “Detonation”. detonation.
Results:
i01637657
SMCS Code: 1901-038

S/N: BLB1-Up
S/N: BKE1-Up

detonation sensor.
196
i01637665 Results:
SMCS Code: 1901-038
i01637699
S/N: BLB1-Up
S/N: BKE1-Up
SMCS Code: 1901-038
S/N: BLB1-Up
There is no active diagnostic code for the cylinder’s Conditions Which Generate This Code:
detonation sensor.
System Response: There is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
an adjustment of the timing in order to reduce Possible Performance Effect:
detonation.
Troubleshooting: an adjustment of the timing in order to reduce
detonation.
Troubleshooting:
Results:
• OK – STOP.
Results:
i01637696
• OK – STOP.
i01637702
SMCS Code: 1901-038
S/N: BLB1-Up
SMCS Code: 1901-038
S/N: BLB1-Up
There is no active diagnostic code for the cylinder’s Conditions Which Generate This Code:
detonation sensor.
System Response: There is no active diagnostic code for the cylinder’s
detonation sensor.
System Response:
an adjustment of the timing in order to reduce Possible Performance Effect:
detonation.
Troubleshooting: an adjustment of the timing in order to reduce
detonation.
197
Refer to Troubleshooting, “Detonation”. The engine is shut down.
Results:
i01637706
SMCS Code: 1901-038 i01634746
S/N: BLB1-Up E422 Cylinder #2 Detonation

Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1901-038
detonation sensor. Conditions Which Generate This Code:
System Response: The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable
The alarm output is activated. The code is logged. to control the detonation adequately during the
number of ignition sparks that are allowed. There
Possible Performance Effect: is no active diagnostic code for the cylinder’s
detonation sensor.
an adjustment of the timing in order to reduce System Response:
detonation.
Troubleshooting: activated. The code is logged.
Refer to Troubleshooting, “Detonation”. Possible Performance Effect:
Results: The engine is shut down.
• OK – STOP. Troubleshooting:

i01634664
Results:
Shutdown • OK – STOP.
SMCS Code: 1901-038
i01634838
Conditions Which Generate This Code: E423 Cylinder #3 Detonation

The level of detonation has exceeded the trip point. Shutdown
to control the detonation adequately during the SMCS Code: 1901-038
is no active diagnostic code for the cylinder’s Conditions Which Generate This Code:
detonation sensor.
System Response: Maximum retardation of the timing was unable
to control the detonation adequately during the
The fuel is shut off. The shutdown output is number of ignition sparks that are allowed. There
activated. The code is logged. is no active diagnostic code for the cylinder’s
detonation sensor.
198
The fuel is shut off. The shutdown output is E425 Cylinder #5 Detonation
activated. The code is logged. Shutdown
Troubleshooting: The level of detonation has exceeded the trip point.
Refer to Troubleshooting, “Detonation”. to control the detonation adequately during the
Results: is no active diagnostic code for the cylinder’s
detonation sensor.
• OK – STOP.
System Response:
i01635415
E424 Cylinder #4 Detonation activated. The code is logged.
Shutdown Possible Performance Effect:
SMCS Code: 1901-038 The engine is shut down.
The level of detonation has exceeded the trip point. Refer to Troubleshooting, “Detonation”.
to control the detonation adequately during the Results:
is no active diagnostic code for the cylinder’s
detonation sensor.
• OK – STOP.
The fuel is shut off. The shutdown output is E426 Cylinder #6 Detonation
activated. The code is logged. Shutdown
Troubleshooting: The level of detonation has exceeded the trip point.
Refer to Troubleshooting, “Detonation”. to control the detonation adequately during the
Results: is no active diagnostic code for the cylinder’s
detonation sensor.
• OK – STOP.
System Response:


199
Refer to Troubleshooting, “Detonation”. E428 Cylinder #8 Detonation

Shutdown
Results:
SMCS Code: 1901-038
• OK – STOP.
S/N: BLB1-Up
i01635420 S/N: BKE1-Up
E427 Cylinder #7 Detonation S/N: BEN1-Up
Shutdown Conditions Which Generate This Code:
SMCS Code: 1901-038
S/N: BLB1-Up Maximum retardation of the timing was unable
S/N: BKE1-Up number of ignition sparks that are allowed. There
S/N: BEN1-Up detonation sensor.
The level of detonation has exceeded the trip point. The fuel is shut off. The shutdown output is
Maximum retardation of the timing was unable activated. The code is logged.
number of ignition sparks that are allowed. There Possible Performance Effect:
detonation sensor. The engine is shut down.
The fuel is shut off. The shutdown output is Refer to Troubleshooting, “Detonation”.
Results:

• OK – STOP.
Refer to Troubleshooting, “Detonation”. E429 Cylinder #9 Detonation

Shutdown
Results:
SMCS Code: 1901-038
• OK – STOP.
S/N: BLB1-Up
S/N: BKE1-Up

detonation sensor.
System Response:

200
The engine is shut down. E431 Cylinder #11 Detonation

Shutdown
Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up
Results:
S/N: BKE1-Up
• OK – STOP.
i01635424 The level of detonation has exceeded the trip point.

E430 Cylinder #10 Detonation to control the detonation adequately during the
Shutdown number of ignition sparks that are allowed. There
SMCS Code: 1901-038 detonation sensor.
S/N: BLB1-Up System Response:

S/N: BKE1-Up The fuel is shut off. The shutdown output is
Maximum retardation of the timing was unable The engine is shut down.
number of ignition sparks that are allowed. There Troubleshooting:
detonation sensor. Refer to Troubleshooting, “Detonation”.
System Response: Results:
• OK – STOP.

Troubleshooting:
Shutdown
SMCS Code: 1901-038
S/N: BLB1-Up
Results:
S/N: BKE1-Up
• OK – STOP.

detonation sensor.
System Response:

201

Shutdown
Troubleshooting:
SMCS Code: 1901-038
S/N: BLB1-Up
Results:
• OK – STOP.
i01635431
E433 Cylinder #13 Detonation number of ignition sparks that are allowed. There
Shutdown detonation sensor.

S/N: BLB1-Up The fuel is shut off. The shutdown output is
Maximum retardation of the timing was unable The engine is shut down.
number of ignition sparks that are allowed. There Troubleshooting:
detonation sensor. Refer to Troubleshooting, “Detonation”.
System Response: Results:
• OK – STOP.

Troubleshooting:
Shutdown
SMCS Code: 1901-038
S/N: BLB1-Up
Results:
• OK – STOP.
detonation sensor.
System Response:


202
Refer to Troubleshooting, “Detonation”. The shutdown output is activated.
Results: The code is logged.
The engine will not start.

i01635436
E436 Cylinder #16 Detonation Troubleshooting:
Shutdown Refer to Troubleshooting, “Engine Cranks but Will

Not Start”.
SMCS Code: 1901-038
Results:
S/N: BLB1-Up

• OK – STOP.
The level of detonation has exceeded the trip point. i01784899

to control the detonation adequately during the E601 Cylinder #1 Continuous
Misfire
detonation sensor. SMCS Code: 1901-038
The fuel is shut off. The shutdown output is The engine is operating in the combustion feedback
activated. The code is logged. mode. There is an active event for the low
temperature deviation of the cylinder’s exhaust
Possible Performance Effect: port. The Integrated Combustion Sensing Module
(ICSM) has not received a signal from the cylinder’s
The engine is shut down. combustion sensor for 40 minutes.
Refer to Troubleshooting, “Detonation”. The alarm output is activated. The code is logged.
• OK – STOP. The engine runs rough.
i01785824
Troubleshooting:
E498 Fuel Pressure Present Refer to Troubleshooting, “Engine Misfires, Runs

During Initial Cranking
Results:
SMCS Code: 1901-038

• OK – STOP.
The engine is cranking and the pressure switch

for the prelube is closed. The Electronic Control
Module (ECM) has energized the Gas Shutoff Valve
(GSOV) but the ECM has not energized the fuel
actuator’s solenoid. The air/fuel pressure module
detects a differential pressure for fuel to air of at
least 0.5 kPa (0.073 psi).
203
i01784926 Results:
E602 Cylinder #2 Continuous • OK – STOP.
Misfire
i01784997
SMCS Code: 1901-038
E604 Cylinder #4 Continuous
Misfire
mode. There is an active event for the low SMCS Code: 1901-038
port. The Integrated Combustion Sensing Module Conditions Which Generate This Code:
combustion sensor for 40 minutes. The engine is operating in the combustion feedback
mode. There is an active event for the low
System Response: temperature deviation of the cylinder’s exhaust
port. The Integrated Combustion Sensing Module
The alarm output is activated. The code is logged. (ICSM) has not received a signal from the cylinder’s
combustion sensor for 40 minutes.
System Response:
The engine runs rough.
Troubleshooting:
Rough or Is Unstable”. The engine runs rough.

• OK – STOP. Rough or Is Unstable”.
i01784958 Results:
E603 Cylinder #3 Continuous • OK – STOP.
Misfire
i01785026
SMCS Code: 1901-038
Misfire
mode. There is an active event for the low SMCS Code: 1901-038
port. The Integrated Combustion Sensing Module Conditions Which Generate This Code:
combustion sensor for 40 minutes. The engine is operating in the combustion feedback
System Response: temperature deviation of the cylinder’s exhaust
The alarm output is activated. The code is logged. (ICSM) has not received a signal from the cylinder’s
System Response:
Troubleshooting:
Rough or Is Unstable”. The engine runs rough.
204
Refer to Troubleshooting, “Engine Misfires, Runs E607 Cylinder #7 Continuous

Rough or Is Unstable”. Misfire
Results: SMCS Code: 1901-038
• OK – STOP. S/N: BLB1-Up

S/N: BKE1-Up
i01785050
S/N: BEN1-Up
Misfire Conditions Which Generate This Code:
SMCS Code: 1901-038 The engine is operating in the combustion feedback

The engine is operating in the combustion feedback (ICSM) has not received a signal from the cylinder’s
port. The Integrated Combustion Sensing Module System Response:
combustion sensor for 40 minutes. The alarm output is activated. The code is logged.

System Response:
The alarm output is activated. The code is logged. The engine runs rough.
Troubleshooting:
Troubleshooting:
Results:
Rough or Is Unstable”. • OK – STOP.
Results: i01785107
• OK – STOP. E608 Cylinder #8 Continuous

Misfire
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
S/N: BEN1-Up

205
The alarm output is activated. The code is logged. E610 Cylinder #10 Continuous
Misfire
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
S/N: BKE1-Up
Rough or Is Unstable”. Conditions Which Generate This Code:
Results: The engine is operating in the combustion feedback

• OK – STOP. temperature deviation of the cylinder’s exhaust
i01785332 combustion sensor for 40 minutes.
E609 Cylinder #9 Continuous System Response:
Misfire
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
Troubleshooting:
The engine is operating in the combustion feedback Rough or Is Unstable”.
temperature deviation of the cylinder’s exhaust Results:
• OK – STOP.
The alarm output is activated. The code is logged. E611 Cylinder #11 Continuous
Misfire
SMCS Code: 1901-038
S/N: BLB1-Up
Troubleshooting:
S/N: BKE1-Up

System Response:

206
The engine runs rough. E613 Cylinder #13 Continuous

Misfire
Troubleshooting:
SMCS Code: 1901-038
Rough or Is Unstable”. S/N: BLB1-Up
• OK – STOP. The engine is operating in the combustion feedback

i01785351
E612 Cylinder #12 Continuous (ICSM) has not received a signal from the cylinder’s
Misfire
System Response:
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up Possible Performance Effect:
Conditions Which Generate This Code: The engine runs rough.
The engine is operating in the combustion feedback Troubleshooting:

temperature deviation of the cylinder’s exhaust Refer to Troubleshooting, “Engine Misfires, Runs
port. The Integrated Combustion Sensing Module Rough or Is Unstable”.
combustion sensor for 40 minutes. Results:
The alarm output is activated. The code is logged. i01785361
Possible Performance Effect: E614 Cylinder #14 Continuous

The engine runs rough. Misfire
S/N: BLB1-Up
System Response:

207
Refer to Troubleshooting, “Engine Misfires, Runs The alarm output is activated. The code is logged.
Results:
• OK – STOP.
Troubleshooting:
i01785371
E615 Cylinder #15 Continuous Rough or Is Unstable”.
Misfire Results:

S/N: BLB1-Up
i01635494
E801 Cylinder #1 High Exhaust
Port Temp
temperature deviation of the cylinder’s exhaust SMCS Code: 1901-038
(ICSM) has not received a signal from the cylinder’s Conditions Which Generate This Code:
The cylinder exhaust temperature has exceeded
System Response: the trip point and the delay time has expired.
The alarm output is activated. The code is logged. System Response:
Possible Performance Effect: The following event codes are logged according to
• E801 (1) Cylinder #1 High Exhaust Port Temp
Troubleshooting: (warning)
Refer to Troubleshooting, “Engine Misfires, Runs • E801 (3) Cylinder #1 High Exhaust Port Temp
Rough or Is Unstable”. (shutdown)
Results: If a warning is generated, the alarm output is
activated.
• OK – STOP.
If a shutdown is generated, the shutdown output is
i01785374
activated and the fuel is shut off.
E616 Cylinder #16 Continuous Possible Performance Effect:

Misfire If a warning is generated, the engine performance
SMCS Code: 1901-038
S/N: BLB1-Up The engine will be shut down if the trip point for the
Troubleshooting:
mode. There is an active event for the low Refer to Troubleshooting, “Exhaust Port Temperature
temperature deviation of the cylinder’s exhaust (High)”.
(ICSM) has not received a signal from the cylinder’s Results:
• OK – STOP.
208

E802 Cylinder #2 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:
SMCS Code: 1901-038 • E803 (1) Cylinder #3 High Exhaust Port Temp
(warning)
The cylinder exhaust temperature has exceeded (shutdown)
the trip point and the delay time has expired.
System Response: activated.
The following event codes are logged according to If a shutdown is generated, the shutdown output is
the trip points for the temperature: activated and the fuel is shut off.
• E802 (1) Cylinder #2 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E802 (3) Cylinder #2 High Exhaust Port Temp is not immediately affected.
(shutdown)
If a warning is generated, the alarm output is shutdown is exceeded.
activated.
Troubleshooting:
activated and the fuel is shut off. Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
Results:
is not immediately affected. • OK – STOP.
The engine will be shut down if the trip point for the i01635505
E804 Cylinder #4 High Exhaust
Troubleshooting:
Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. SMCS Code: 1901-038

• OK – STOP. the trip point and the delay time has expired.

E803 Cylinder #3 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:
(warning)
The cylinder exhaust temperature has exceeded (shutdown)
activated.
209
If a shutdown is generated, the shutdown output is Results:

• OK – STOP.
i01635511
is not immediately affected. E806 Cylinder #6 High Exhaust
The engine will be shut down if the trip point for the Port Temp
SMCS Code: 1901-038
Troubleshooting:
(High)”. The cylinder exhaust temperature has exceeded
Results:
System Response:
• OK – STOP.
i01635508
E805 Cylinder #5 High Exhaust • E806 (1) Cylinder #6 High Exhaust Port Temp
(warning)
Port Temp
SMCS Code: 1901-038 (shutdown)
Conditions Which Generate This Code: If a warning is generated, the alarm output is
activated.
the trip point and the delay time has expired. If a shutdown is generated, the shutdown output is
System Response:
the trip points for the temperature: If a warning is generated, the engine performance
(warning) The engine will be shut down if the trip point for the
(shutdown) Troubleshooting:
If a warning is generated, the alarm output is Refer to Troubleshooting, “Exhaust Port Temperature
activated. (High)”.
If a shutdown is generated, the shutdown output is Results:

• OK – STOP.

Troubleshooting:

(High)”.
210
i01635512 i01635513
E807 Cylinder #7 High Exhaust E808 Cylinder #8 High Exhaust

Port Temp Port Temp
S/N: BEN1-Up S/N: BEN1-Up
The cylinder exhaust temperature has exceeded The cylinder exhaust temperature has exceeded
the trip point and the delay time has expired. the trip point and the delay time has expired.
The following event codes are logged according to The following event codes are logged according to
the trip points for the temperature: the trip points for the temperature:
• E807 (1) Cylinder #7 High Exhaust Port Temp • E808 (1) Cylinder #8 High Exhaust Port Temp
(warning) (warning)
(shutdown) (shutdown)
If a warning is generated, the alarm output is If a warning is generated, the alarm output is
activated. activated.
If a shutdown is generated, the shutdown output is If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. activated and the fuel is shut off.
If a warning is generated, the engine performance If a warning is generated, the engine performance
is not immediately affected. is not immediately affected.
The engine will be shut down if the trip point for the The engine will be shut down if the trip point for the
shutdown is exceeded. shutdown is exceeded.
Refer to Troubleshooting, “Exhaust Port Temperature Refer to Troubleshooting, “Exhaust Port Temperature
(High)”. (High)”.
Results: Results:
211
i01635546 i01635549
E809 Cylinder #9 High Exhaust E810 Cylinder #10 High

Port Temp Exhaust Port Temp
(warning) (warning)
Results: Results:
212
i01635556 i01635568
E811 Cylinder #11 High E812 Cylinder #12 High

Exhaust Port Temp Exhaust Port Temp
(warning) (warning)
Results: Results:
213

E813 Cylinder #13 High The following event codes are logged according to
Exhaust Port Temp the trip points for the temperature:
(warning)
S/N: BLB1-Up
Conditions Which Generate This Code: (shutdown)
The cylinder exhaust temperature has exceeded If a warning is generated, the alarm output is
the trip point and the delay time has expired. activated.
System Response: If a shutdown is generated, the shutdown output is

• E813 (1) Cylinder #13 High Exhaust Port Temp If a warning is generated, the engine performance
(warning) is not immediately affected.
• E813 (3) Cylinder #13 High Exhaust Port Temp The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.

activated.
If a shutdown is generated, the shutdown output is (High)”.
Results:
• OK – STOP.
i01635578
E815 Cylinder #15 High
Exhaust Port Temp
Troubleshooting:
SMCS Code: 1901-038
(High)”. S/N: BLB1-Up

• OK – STOP. the trip point and the delay time has expired.

E814 Cylinder #14 High The following event codes are logged according to
Exhaust Port Temp the trip points for the temperature:
(warning)
S/N: BLB1-Up
Conditions Which Generate This Code: (shutdown)
The cylinder exhaust temperature has exceeded If a warning is generated, the alarm output is
the trip point and the delay time has expired. activated.
214
If a shutdown is generated, the shutdown output is Troubleshooting:

Possible Performance Effect: (High)”.
If a warning is generated, the engine performance Results:

• OK – STOP.
i01635587
Troubleshooting: E821 Cyl #1 Exhaust Port Temp

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
i01635584 amount of deviation has exceeded the trip point
E816 Cylinder #16 High
Exhaust Port Temp System Response:
SMCS Code: 1901-038 The following event codes are logged according to
S/N: BLB1-Up
• E821 (1) Cyl #1 Exhaust Port Temp Deviating
Conditions Which Generate This Code: High (warning)
The cylinder exhaust temperature has exceeded • E821 (3) Cyl #1 Exhaust Port Temp Deviating
the trip point and the delay time has expired. High (shutdown)
System Response: If a warning is generated, the alarm output is
activated.
the trip points for the temperature: If a shutdown is generated, the shutdown output is
(warning) Possible Performance Effect:
• E816 (3) Cylinder #16 High Exhaust Port Temp If a warning is generated, the engine performance
(shutdown) is not immediately affected.
If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.
• OK – STOP.
215

E822 Cyl #2 Exhaust Port Temp The following event codes are logged according to
Deviating High the trip points for the temperature:
SMCS Code: 1901-038 • E823 (1) Cyl #3 Exhaust Port Temp Deviating
High (warning)
The cylinder exhaust temperature is higher than the High (shutdown)
amount of deviation has exceeded the trip point If a warning is generated, the alarm output is

• E822 (1) Cyl #2 Exhaust Port Temp Deviating If a warning is generated, the engine performance
High (warning) is not immediately affected.
• E822 (3) Cyl #2 Exhaust Port Temp Deviating The engine will be shut down if the trip point for the
High (shutdown) shutdown is exceeded.

activated.
If a shutdown is generated, the shutdown output is (High)”.
Results:
• OK – STOP.
is not immediately affected. i01635604
The engine will be shut down if the trip point for the E824 Cyl #4 Exhaust Port Temp
Deviating High
Troubleshooting:
SMCS Code: 1901-038
(High)”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature is higher than the

amount of deviation has exceeded the trip point

Deviating High the trip points for the temperature:
SMCS Code: 1901-038 • E824 (1) Cyl #4 Exhaust Port Temp Deviating
High (warning)
The cylinder exhaust temperature is higher than the High (shutdown)
216


• OK – STOP.
i01635612

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1901-038
Results:
• OK – STOP.
The cylinder exhaust temperature is higher than the
i01635605 amount of deviation has exceeded the trip point
E825 Cyl #5 Exhaust Port Temp
Deviating High System Response:
SMCS Code: 1901-038 The following event codes are logged according to
The cylinder exhaust temperature is higher than the High (warning)
amount of deviation has exceeded the trip point • E826 (3) Cyl #6 Exhaust Port Temp Deviating
and the delay time has expired. High (shutdown)
System Response: If a warning is generated, the alarm output is

activated.
the trip points for the temperature: If a shutdown is generated, the shutdown output is
High (warning) Possible Performance Effect:
• E825 (3) Cyl #5 Exhaust Port Temp Deviating If a warning is generated, the engine performance
High (shutdown) is not immediately affected.
If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.


• OK – STOP.
217
i01635614 i01635616
E827 Cyl #7 Exhaust Port Temp E828 Cyl #8 Exhaust Port Temp
Deviating High Deviating High
S/N: BEN1-Up S/N: BEN1-Up
The cylinder exhaust temperature is higher than the The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point amount of deviation has exceeded the trip point
and the delay time has expired. and the delay time has expired.
• E827 (1) Cyl #7 Exhaust Port Temp Deviating • E828 (1) Cyl #8 Exhaust Port Temp Deviating
High (warning) High (warning)
High (shutdown) High (shutdown)
Results: Results:
218
i01635618 i01635634
E829 Cyl #9 Exhaust Port Temp E830 Cyl #10 Exhaust Port
Deviating High Temp Deviating High
Results: Results:
219
i01635641 i01635645
E831 Cyl #11 Exhaust Port E832 Cyl #12 Exhaust Port
Temp Deviating High Temp Deviating High
Results: Results:
220
i01635653 i01635656
Results: Results:
221
i01635658 i01635661
Results: Results:
222
i01635664 i01635667
E841 Cyl #1 Exhaust Port Temp E842 Cyl #2 Exhaust Port Temp
Deviating Low Deviating Low
The cylinder exhaust temperature is less than the The cylinder exhaust temperature is less than the
• E841 (1) Cyl #1 Exhaust Port Temp Deviating Low • E842 (1) Cyl #2 Exhaust Port Temp Deviating Low
(warning) (warning)
• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low • E841 (3) Cyl #2 Exhaust Port Temp Deviating Low
(Low)”. (Low)”.
Results: Results:
223

Deviating Low the trip points for the temperature:
SMCS Code: 1901-038 • E844 (1) Cyl #4 Exhaust Port Temp Deviating Low
(warning)
• E844 (3) Cyl #4 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the (shutdown)

• E843 (1) Cyl #3 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance
(warning) is not immediately affected.
• E843 (3) Cyl #3 Exhaust Port Temp Deviating Low The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.

activated.
If a shutdown is generated, the shutdown output is (Low)”.
Results:
• OK – STOP.
is not immediately affected. i01635672
The engine will be shut down if the trip point for the E845 Cyl #5 Exhaust Port Temp
Deviating Low
Troubleshooting:
SMCS Code: 1901-038
(Low)”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature is less than the


Deviating Low the trip points for the temperature:
SMCS Code: 1901-038 • E845 (1) Cyl #5 Exhaust Port Temp Deviating Low
(warning)
The cylinder exhaust temperature is less than the (shutdown)
224

Possible Performance Effect: (Low)”.

• OK – STOP.
i01635677

Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1901-038
Results:
S/N: BLB1-Up
S/N: BEN1-Up
i01635673
E846 Cyl #6 Exhaust Port Temp Conditions Which Generate This Code:
Deviating Low The cylinder exhaust temperature is less than the
SMCS Code: 1901-038 amount of deviation has exceeded the trip point
System Response:
The cylinder exhaust temperature is less than the
average temperature for all of the cylinders. The The following event codes are logged according to
amount of deviation has exceeded the trip point the trip points for the temperature:
System Response: (warning)
The following event codes are logged according to • E847 (3) Cyl #7 Exhaust Port Temp Deviating Low
the trip points for the temperature: (shutdown)
• E846 (1) Cyl #6 Exhaust Port Temp Deviating Low If a warning is generated, the alarm output is
(warning) activated.
• E846 (3) Cyl #6 Exhaust Port Temp Deviating Low If a shutdown is generated, the shutdown output is
(shutdown) activated and the fuel is shut off.
If a warning is generated, the alarm output is Possible Performance Effect:
activated.
If a shutdown is generated, the shutdown output is is not immediately affected.
Possible Performance Effect: shutdown is exceeded.
If a warning is generated, the engine performance Troubleshooting:
The engine will be shut down if the trip point for the (Low)”.
225
Results: i01635683
• OK – STOP. E849 Cyl #9 Exhaust Port Temp

Deviating Low
i01635680
SMCS Code: 1901-038
E848 Cyl #8 Exhaust Port Temp S/N: BLB1-Up
Deviating Low
S/N: BKE1-Up
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up average temperature for all of the cylinders. The
S/N: BEN1-Up amount of deviation has exceeded the trip point
System Response:
average temperature for all of the cylinders. The The following event codes are logged according to
amount of deviation has exceeded the trip point the trip points for the temperature:
System Response: (warning)
The following event codes are logged according to • E849 (3) Cyl #9 Exhaust Port Temp Deviating Low
the trip points for the temperature: (shutdown)

• E848 (1) Cyl #8 Exhaust Port Temp Deviating Low activated.
(warning)
• E848 (3) Cyl #8 Exhaust Port Temp Deviating Low activated and the fuel is shut off.
(shutdown)
If a warning is generated, the alarm output is Possible Performance Effect:

activated.
If a shutdown is generated, the shutdown output is is not immediately affected.
Possible Performance Effect: shutdown is exceeded.
If a warning is generated, the engine performance Troubleshooting:

The engine will be shut down if the trip point for the (Low)”.
Results:
Troubleshooting:
• OK – STOP.
(Low)”.
Results:
• OK – STOP.
226
i01635684 i01635685
Temp Deviating Low Temp Deviating Low
Low (warning) Low (warning)
Low (shutdown) Low (shutdown)
(Low)”. (Low)”.
Results: Results:
227
i01635688 i01635691
Conditions Which Generate This Code: The cylinder exhaust temperature is less than the
The cylinder exhaust temperature is less than the amount of deviation has exceeded the trip point
average temperature for all of the cylinders. The and the delay time has expired.
and the delay time has expired. System Response:
System Response: The following event codes are logged according to
the trip points for the temperature: • E853 (1) Cyl #13 Exhaust Port Temp Deviating
Low (warning)
Low (warning) • E853 (3) Cyl #13 Exhaust Port Temp Deviating
Low (shutdown)
Low (shutdown) If a warning is generated, the alarm output is
activated.
activated. If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. Possible Performance Effect:
Possible Performance Effect: If a warning is generated, the engine performance
is not immediately affected. The engine will be shut down if the trip point for the
shutdown is exceeded. Troubleshooting:
Troubleshooting: Refer to Troubleshooting, “Exhaust Port Temperature
(Low)”.
(Low)”. Results:
• OK – STOP.
228
i01635692 i01635694
Low (warning) Low (warning)
Low (shutdown) Low (shutdown)
(Low)”. (Low)”.
Results: Results:
229
i01635695
E856 Cyl #16 Exhaust Port

Temp Deviating Low
SMCS Code: 1901-038
S/N: BLB1-Up

System Response:


Low (warning)

Low (shutdown)

activated.


Troubleshooting:

(Low)”.
Results:
• OK – STOP.
230
Diagnostic Functional
Tests
i01754416
+5V Sensor Voltage Supply

SMCS Code: 1901-038
S/N: BEN1-Up
S/N: 4ZS1-Up
System Operation Description:
The Electronic Control Module (ECM) supplies 5.0

± 0.5 VDC to the sensors for these parameters:
• Inlet air temperature

• Fuel temperature
• Crankcase pressure
The ECM also provides 5 VDC to the “DESIRED
SPEED” potentiometer on the control panel (if
equipped). A “+5 Volt Sensor DC Power Supply
short to ground” diagnostic code will be activated
if both of these conditions occur:
• The desired speed signal wire is shorted to

ground.
• The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
desired speed.
A “+5 V sensor supply” diagnostic code is probably

caused by a short circuit or by an open circuit in a
harness. The next likely cause is a sensor problem.
The least likely cause is a problem with the ECM.
Logged diagnostic codes provide a historical

record. Before you begin this procedure, use the
Caterpillar Electronic Technician (Cat ET) to print
the logged codes to a file.
This troubleshooting procedure may generate

additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic code.
Clear the diagnostic codes after the problem is
resolved.
231
g00897472
Illustration 29
232
Test Step 1. Inspect the Electrical

Connectors and Wiring
A. Turn the engine control switch to the OFF/RESET
position. Switch the 16 amp circuit breaker for
the ECM to the OFF position.
Note: For the following steps, refer to

g00897505
Illustration 32
Left view
Illustration 30 g00897495 (7) Inlet air temperature sensor
(1) ECM Connectors J1/P1

(2) 16 amp circuit breaker
(3) Connectors J3/P3 for the customer’s connector
(4) Connectors J4/P4 for the optional control panel (if equipped)
or for a customer’s connector
(5) Connectors J5/P5 for the engine harness from the sensors
g00897508
Illustration 33
Front view
g00861762
Illustration 31
(6) Terminal strip in the control panel
233
g00843183
Illustration 35
Harness side of the ECM P1 connector
(P1-2) +5 V supply
(P1-3) Return
g00897510
Illustration 34
Right view
(11) Fuel temperature sensor
B. Thoroughly inspect each of the following g00897525

connectors: Illustration 36
Harness side of the terminal box P5 connector
• ECM J1/P1 connectors (P5-15) Return for the filtered oil pressure sensor
(P5-17) +5 VDC for the filtered oil pressure sensor
(P5-25) Return for the unfiltered oil pressure sensor
• J3/P3, J4/P4, and J5/P5 connectors on the (P5-27) +5 VDC for the unfiltered oil pressure sensor
terminal box (P5-33) Return for the engine oil temperature sensor
(P5-35) +5 VDC for the engine oil temperature sensor
• Each connection for the sensors (P6-37) Return for the fuel temperature sensor
(P6-39) +5 VDC for the fuel temperature sensor
(P5-54) Return for the crankcase pressure sensor
• The terminal strip inside the control panel (if (P5-67) +5 VDC for the crankcase pressure sensor
equipped) (P5-59) Return for the inlet air temperature sensor
(P5-61) +5 VDC for the inlet air temperature sensor
a. Check the torque of the Allen head screw for
the ECM connector and for the P5 connector. b. Perform a 45 N (10 lb) pull test on each of
The proper torque is 6 ± 1 N·m (55 ± 9 lb in). the wires that are associated with the circuit
for the sensors.
c. Check the harnesses and wiring for abrasion

and for pinch points from the sensors to the
ECM.
Expected Result:
All connectors, pins, and sockets are connected

properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
234
Results: • 262-03 5 Volt Sensor DC Power Supply short

to +batt
• OK – All connectors, pins, and sockets are
connected properly. The connectors and the • 262-04 5 Volt Sensor DC Power Supply short
wiring do not have corrosion, abrasion, or pinch to ground
points. The components are in good condition
with proper connections. Proceed to Test Step 2. E. Observe the “Logged Diagnostic” screen on Cat
ET. Look for the same codes.
• Not OK – At least one of the connectors, pins, or
sockets is not connected properly. At least one Expected Result:
connector or wire has corrosion, abrasion, and/or
pinch points. The 262-03 code or the 262-04 code is not active
or logged.
Repair: Perform the necessary repairs and/or
replace parts, if necessary. Results:
STOP. • No codes – There are no active codes or logged

codes. Proceed to Test Step 3.
Test Step 2. Check for Diagnostic Codes
• Active code – The 262-03 code or the 262-04
A. Connect Cat ET to the service tool connector on code is active. Proceed to Test Step 6.
the terminal box.
• Logged code – The 262-03 code or the 262-04
code is not active. However, there is at least one
logged code for the +5 volt sensor supply.
Repair: There may be a problem with the wiring

and/or a connector. Refer to Troubleshooting,
“Inspecting Electrical Connectors”.
Verify that the wiring and/or connectors are OK.

Check for diagnostic codes again. Proceed to
Test Step 3, if necessary.
Test Step 3. Check the Analog Speed

Circuit
g00862185
Illustration 37
Control panel (if equipped)
(1) “DESIRED SPEED” potentiometer
B. Rotate the “DESIRED SPEED” potentiometer (if

equipped) counterclockwise to the minimum
speed position.
C. Switch the 16 amp circuit breaker for the ECM

ON. Turn the engine control switch to the STOP
position.
D. Observe the “Active Diagnostic” screen on Cat

ET. Wait at least thirty seconds so that any codes g00862185
may become activated. Look for these codes: Illustration 38
235
A. Rotate the “DESIRED SPEED” potentiometer (if B. Disconnect the J4 connector from the terminal
equipped) clockwise to the maximum speed box.
position.
B. Observe the “Active Diagnostic” screen on Cat

ET. Wait at least thirty seconds so that any codes
may become activated. Look for these codes:
• 262-03 5 Volt Sensor DC Power Supply short

to +batt

to ground
Expected Result:
The 262-03 code or the 262-04 code is not active.
Results:
• No codes – Rotating the “DESIRED SPEED”

potentiometer clockwise to the maximum speed
position did not cause an active code. The +5 V
sensor voltage supply is operating correctly at Illustration 40 g00862266
this time. Resume normal operation. STOP.
Harness connector J4
(J4-X) Signal wire for the “DESIRED SPEED” potentiometer
• Active code – Rotating the “DESIRED SPEED” (J4-x) Ground
position caused an active code. There is a
C. Measure the resistance from terminal X to x on
problem with the analog speed circuit. Proceed
harness connector J4.
to Test Step 4.
Expected Result:
Test Step 4. Disconnect the J4 Connector
and Check the Control Panel Wiring The resistance is greater than 20,000 ohms.
A. Switch the 16 amp circuit breaker for the ECM Results:
OFF. Turn the engine control switch to the
OFF/RESET position.
• OK – The resistance is greater than 20,000 ohms.
The wiring to the control panel and inside the
control panel appears to be OK. Proceed to Test
Step 5.
• Not OK – The resistance is less than 20,000

ohms. There is a problem with the wiring to the
control panel or inside the control panel.
Repair: Perform the following procedure:
1. Carefully inspect the following items:
• Connector J4
• The harness from connector J4 to the control
panel
• The inside of the control panel

• The terminal strip inside the control panel
g00862213
Illustration 39
J4 connector on the terminal box
236
2. Verify that all connections and terminals are B. Measure the resistance between terminals 16
in good condition and free of moisture. Verify and 69 of connector P1.
that the harness from the J4 connector to the
control panel is in good condition. Expected Result:
3. Perform any necessary repairs or replace The resistance is greater than 20,000 ohms.
Results:
4. Reconnect all of the connectors and perform
this procedure again. Verify that the original • OK – The resistance is greater than 20,000 ohms.
problem is resolved. The wiring inside the terminal box appears to be
OK. The problem appears to be resolved. The
STOP. initial diagnostic code was probably caused by a
poor electrical connection.
Test Step 5. Check the Wiring Inside the
Terminal Box Repair: Reconnect all of the connectors. Resume
normal operation.
STOP.

ohms. There is a problem with a connector and/or
the wiring inside the terminal box.
Repair: Repair the connector and/or wiring, when

possible. Replace the wiring, if necessary.
STOP.
Test Step 6. Isolate the Wiring Harnesses

from the ECM
the ECM OFF.
g00862375
Illustration 41
(1) ECM connector P1
A. Disconnect ECM connector P1.
g00862450
Illustration 43
B. Use a 151-6320 Wire Removal Tool to remove

terminal 2 and terminal 18 from the P1 connector.
Illustration 42 g00862380 C. Switch the 16 amp circuit breaker for the ECM
ECM side of the P1 connector
position.
(P1-16) Signal wire for the “DESIRED SPEED” potentiometer
(P1-69) Ground
D. Use Cat ET to look for active diagnostic codes.
237
Expected Result:
No active codes
Results:
• No codes – The 262-03 code or the 262-04 code

is not active. Disconnecting all of the +5 V wiring
from the ECM eliminated the active “5 Volt Sensor
Supply” diagnostic code. There is a problem
with a connector and/or the wiring in a harness.
Proceed to Test Step 7.

code is active. Disconnecting all of the +5 V
wiring from the ECM did not eliminate the +5 V
diagnostic code. There may be a problem with
the ECM.
Repair: It is unlikely that the ECM has failed.

Exit this procedure and perform this procedure
again. If the problem is not resolved, perform the Illustration 45 g00862185
following steps: Control panel (if equipped)
Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”.
C. Rotate the “DESIRED SPEED” potentiometer (if
If the problem is resolved with the new ECM, equipped) clockwise to the maximum speed
install the original ECM and verify that the position.
problem returns. If the new ECM operates
correctly and the original ECM does not operate D. Switch the 16 amp circuit breaker for the ECM
correctly, replace the original ECM. Refer to ON. Turn the engine control switch to the STOP
Troubleshooting, “Replacing the ECM”. position.
STOP. E. Use Cat ET to look for diagnostic codes.
Test Step 7. Connect the +5 V Wiring for Expected Result:

the Analog Speed Circuit to the ECM
No active codes
position. Switch the 16 amp circuit breaker for Results:
the ECM OFF.
• No codes – The 262-03 code or the 262-04
code is not active. Connecting the wiring for the
analog speed circuit to the ECM did not cause a
diagnostic code. The wiring for the analog speed
circuit appears to be OK. Proceed to Test Step 8.

code is active. Connecting the wiring for the
analog speed circuit to the ECM caused a
diagnostic code. Proceed to Test Step 4.
Test Step 8. Connect the +5 V Wiring for

the Sensors to the ECM
g00862455 position. Switch the 16 amp circuit breaker for
Illustration 44
ECM connector P1 the ECM OFF.
B. Insert terminal 18 into the P1 connector. Pull on

the wire in order to verify that the terminal is fully
inserted into the connector.
238
B. Disconnect the sensors for the following

parameters one at a time. After you disconnect
each sensor, wait for at least thirty seconds and
then observe the “Active Diagnostic” screen on
Cat ET.

g00862457 • Fuel temperature

Illustration 46
ECM connector P1 • Crankcase pressure
B. Insert terminal 2 into the P1 connector. Pull on Note: An “Open Circuit” code will be generated for
the wire in order to verify that the terminal is fully each sensor that is disconnected. This is normal.
inserted into the connector. Clear the codes after you complete this procedure.
C. Switch the 16 amp circuit breaker for the ECM Expected Result:
position. The original “5 Volt Sensor” diagnostic code
is deactivated when a particular sensor is
D. Use Cat ET to look for diagnostic codes. disconnected.
Expected Result: Results:
No active codes • Yes – The original “5 Volt Sensor” diagnostic

code is deactivated when a particular sensor is
Results: disconnected. The sensor and/or the wiring for
the sensor has a short circuit.
code is not active. Connecting the 5 VDC for the Repair: Perform the following procedure:
sensors did not cause a diagnostic code. The
problem appears to be resolved. 1. Reconnect the suspect sensor. Verify that the
diagnostic code recurs.
Repair: The initial diagnostic code was probably
caused by a poor electrical connection. Resume 2. Disconnect the suspect sensor. Verify that the
normal operation. diagnostic code is deactivated.
STOP. If these conditions are true, replace the sensor.
• Active code – The 262-03 code or the 262-04 3. Clear all of the diagnostic codes. Verify that
code is active. Connecting the 5 VDC for the the problem is eliminated.
sensors caused a diagnostic code. Proceed to
Test Step 9. STOP.
Test Step 9. Disconnect the +5 V Sensors • No – The original “5 Volt Sensor” diagnostic code
and Look for Active Diagnostic Codes is still active after all of the +5 V sensors are
disconnected. Do not reconnect the sensors.
A. Observe the “Active Diagnostic” screen on Cat Proceed to Test Step 10.
ET. Verify that the 262-03 code or the 262-04
code is active. Test Step 10. Check the Engine Harness
A. Turn the engine control switch to the OFF
the ECM OFF.
239
B. Disconnect the ECM P1 connector. Verify that all Table 8

of the sensors for the following parameters are Measure the Resistance for the Engine Harness.
disconnected from the engine harness:
Connector and Connector and Terminal
• Inlet air temperature Terminal
P1-2 P1-14 (inlet air temperature)
• Engine oil temperature +5 V supply
P1-17 (engine oil temperature)
• Unfiltered engine oil pressure P1-26 (unfiltered engine oil pressure)
• Filtered engine oil pressure P1-24 (filtered engine oil pressure)

P1-15 (fuel temperature)
P1-25 (crankcase pressure)
• Crankcase pressure P1-3 (analog return)
Ground strap for the engine
P1-69 (−battery terminal)
P1-57 (unswitched +battery terminal)
P1-70 (switched +battery terminal)
Expected Result:
Each check of the resistance is greater than 20,000

ohms.
Results:
g00843355
Illustration 47 • OK – Each check of the resistance is greater
ECM side of the P1 connector than 20,000 ohms. The +5 V wires in the engine
harnesses do not have a problem. The problem
C. Measure the resistance between terminal (2) of appears to be resolved. The initial diagnostic
the P1 connector and the points that are listed in code was probably caused by a poor electrical
Table 8. During each measurement, wiggle the connection.
harnesses in order to check for an intermittent
problem with the harness. Be sure to wiggle the Repair: Reconnect all of the connectors. Resume
harnesses near each of the connectors for the normal operation.
disconnected sensors. Also, wiggle the harness
at the terminal box’s connectors. STOP.
• Not OK – At least one check of the resistance is

less than 20,000 ohms. There is a problem with a
connector and/or at least one of the +5 V wires in
a harness. Proceed to Test Step 11.
Test Step 11. Check the Terminal Box’s

Harness
A. Disconnect the P5 connector. Verify that P1 is
also disconnected. This will isolate the terminal
box’s harness.
240
Repair: Use the following procedure to verify the

problem:
1. Reconnect the engine harness P5 connector

to the terminal box.
2. Measure the resistance between terminal 2 of

the P1 connector and the points that are listed
in Table 9. During each measurement, wiggle
the wires in the terminal box in order to check
for an intermittent problem. Be sure to wiggle
the harnesses near each of the connectors.
Table 10
g00843355 Measure the Resistance for the Engine Harness.

Illustration 48
ECM side of the P1 ECM connector Connector and Connector and Terminal
Terminal
B. Measure the resistance between terminal 2 of P1-2 P1-14 (inlet air temperature)
the P1 connector and the points that are listed in +5 V supply
Table 9. During each measurement, wiggle the P1-17 (engine oil temperature)
wires in the terminal box in order to check for P1-26 (unfiltered engine oil pressure)
an intermittent problem. Be sure to wiggle the
harnesses near each of the connectors. P1-24 (filtered engine oil pressure)
Table 9
Measure the Resistance for the Terminal P1-25 (crankcase pressure)
Box’s Harness. P1-3 (analog return)
Connector and Connector and Terminal Ground strap for the engine
Terminal
+5 V supply P1-57 (unswitched +battery terminal)
P1-26 (unfiltered engine oil pressure)
P1-24 (filtered engine oil pressure) If each check of the resistance is greater
P1-15 (fuel temperature) than 20,000 ohms, the problem appears
to be resolved. The initial diagnostic code
P1-25 (crankcase pressure) was probably caused by a poor electrical
P1-3 (analog return) connection.
Ground strap for the engine If at least one check of the resistance is
P1-69 (unswitched +battery terminal) less than 20,000 ohms, there is a problem
with the engine harness. Repair the engine
P1-57 (−battery terminal) harness, when possible. Replace the harness,
P1-70 (switched +battery terminal) if necessary.
STOP.
Expected Result:
Each check of the resistance is greater than 20,000 less than 20,000 ohms. There is a problem with a
ohms. connector and/or at least one of the +5 V wires in
the terminal box.
Results:
Repair: Repair the terminal box’s harness, when
• OK – Each check of the resistance is greater possible. Replace the harness, if necessary.
than 20,000 ohms. The +5 V wires in the terminal
box do not have a short circuit. There is probably STOP.
a problem with the engine harness.
241
i01754577

SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up

± 0.5 VDC to the sensors for these parameters:

The ECM also provides 5 VDC to the “DESIRED
SPEED” potentiometer on the control panel (if
equipped). A “+5 Volt Sensor DC Power Supply
short to ground” diagnostic code will be activated
if both of these conditions occur:
• The desired speed signal wire is shorted to

ground.
• The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
desired speed.



resolved.
242
g00897575
Illustration 49
243
Schematic for the analog sensors


g00861762
Illustration 51
g00842721
Illustration 50
(1) ECM Connectors J1/P1
(3) Connectors J6/P6 for the harness from the sensors on the left
side of the engine
(4) Connectors J5/P5 for the harness from the sensors on the right
side of the engine
g00843053
Illustration 52
The inlet air temperature sensor is installed in the inlet air manifold
between the two center cylinder heads on the right side of the
engine.
(7) Inlet air temperature sensor
244
g00842958 g00843065
Illustration 53 Illustration 54
Front view Rear view
(8) Unfiltered engine oil pressure sensor (11) Fuel temperature sensor
g00842996
Illustration 55
Right side view near the front of the engine
B. Thoroughly inspect each of the following

connectors:
• ECM J1/P1 connectors

• J4/P4, J5/P5, and J6/P6 connectors on the
terminal box
• Each connection for the sensors

245
• The terminal strip inside the control panel (if

equipped)

the ECM connector, for the P5 connector, and
for the P6 connector. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).
g00843268
Illustration 58
(P6-68) Return for the fuel temperature sensor
(P6-69) +5 VDC for the fuel temperature sensor
b. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the circuit
g00843183
Illustration 56 for the sensors.
(P1-2) +5 V supply
(P1-3) Return and for pinch points from the sensors to the
ECM.
Expected Result:

Results:

connected properly. The connectors and the
wiring do not have corrosion, abrasion, or pinch
with proper connections. Proceed to Test Step 2.
g00897574
Illustration 57
Harness side of the terminal box P5 connector • Not OK – At least one of the connectors, pins, or
sockets is not connected properly. At least one
(P5-15) Return for the engine oil temperature sensor
(P5-17) +5 VDC for the engine oil temperature sensor connector or wire has corrosion, abrasion, and/or
(P5-25) Return for the unfiltered oil pressure sensor pinch points.
(P5-27) +5 VDC for the unfiltered oil pressure sensor
(P5-33) Return for the filtered oil pressure sensor Repair: Perform the necessary repairs and/or
(P5-35) +5 VDC for the filtered oil pressure sensor
(P5-49) Return for the crankcase pressure sensor
replace parts, if necessary.
(P5-51) +5 VDC for the crankcase pressure sensor
(P5-59) Return for the inlet air temperature sensor STOP.
(P5-61) +5 VDC for the inlet air temperature sensor
A. Connect Cat ET to the service tool connector on
the terminal box.
246

code is not active. However, there is at least one
logged code for the +5 volt sensor supply.
Repair: There may be a problem with the wiring


Test Step 3. Check the Analog Speed

Circuit
g00862185
Illustration 59
B. Rotate the “DESIRED SPEED” potentiometer (if

equipped) counterclockwise to the minimum
speed position.

position.

ET. Wait at least thirty seconds so that any codes g00862185
may become activated. Look for these codes: Illustration 60
• 262-03 5 Volt Sensor DC Power Supply short (1) “DESIRED SPEED” potentiometer
to +batt
A. Rotate the “DESIRED SPEED” potentiometer (if
• 262-04 5 Volt Sensor DC Power Supply short equipped) clockwise to the maximum speed
to ground position.
E. Observe the “Logged Diagnostic” screen on Cat B. Observe the “Active Diagnostic” screen on Cat
ET. Look for the same codes. ET. Wait at least thirty seconds so that any codes
Expected Result:
The 262-03 code or the 262-04 code is not active to +batt
or logged.
Results: to ground
• No codes – There are no active codes or logged Expected Result:

codes. Proceed to Test Step 3.
code is active. Proceed to Test Step 6.
247
Results:
• No codes – Rotating the “DESIRED SPEED”

position did not cause an active code. The +5 V
sensor voltage supply is operating correctly at
this time. Resume normal operation. STOP.
• Active code – Rotating the “DESIRED SPEED”

position caused an active code. There is a
problem with the analog speed circuit. Proceed
to Test Step 4.
Test Step 4. Disconnect the J4 Connector

and Check the Control Panel Wiring
A. Switch the 16 amp circuit breaker for the ECM
OFF/RESET position.
g00862266
Illustration 62
Harness connector J4
(J4-X) Signal wire for the “DESIRED SPEED” potentiometer
(J4-x) Ground
C. Measure the resistance from terminal X to x on

harness connector J4.
Expected Result:
The resistance is greater than 20,000 ohms.
Results:

The wiring to the control panel and inside the
control panel appears to be OK. Proceed to Test
Step 5.

g00862213 ohms. There is a problem with the wiring to the
Illustration 61
J4 connector on the terminal box control panel or inside the control panel.
B. Disconnect the J4 connector from the terminal Repair: Perform the following procedure:
box.
1. Carefully inspect the following items:
• Connector J4
• The harness from connector J4 to the control
panel
• The inside of the control panel

• The terminal strip inside the control panel
2. Verify that all connections and terminals are
in good condition and free of moisture. Verify
that the harness from the J4 connector to the
control panel is in good condition.
248
3. Perform any necessary repairs or replace Expected Result:

4. Reconnect all of the connectors and perform
this procedure again. Verify that the original Results:
problem is resolved.
STOP. The wiring inside the terminal box appears to be
OK. The problem appears to be resolved. The
Test Step 5. Check the Wiring Inside the initial diagnostic code was probably caused by a
Terminal Box poor electrical connection.
Repair: Reconnect all of the connectors. Resume

normal operation.
STOP.

the wiring inside the terminal box.

possible. Replace the wiring, if necessary.
STOP.

from the ECM
the ECM OFF.
g00862375
Illustration 63
A. Disconnect ECM connector P1.
g00862450
Illustration 65

Illustration 64
g00862380 terminal 2 and terminal 18 from the P1 connector.
(P1-16) Signal wire for the “DESIRED SPEED” potentiometer ON. Turn the engine control switch to the STOP
(P1-69) Ground
position.
B. Measure the resistance between terminals 16
D. Use Cat ET to look for active diagnostic codes.
and 69 of connector P1.
249
Expected Result:
No active codes
Results:
• No codes – The 262-03 code or the 262-04 code

is not active. Disconnecting all of the +5 V wiring
from the ECM eliminated the active “5 Volt Sensor
Supply” diagnostic code. There is a problem

code is active. Disconnecting all of the +5 V
wiring from the ECM did not eliminate the +5 V
diagnostic code. There may be a problem with
the ECM.

again. If the problem is not resolved, perform the Illustration 67 g00862185
following steps: Control panel (if equipped)
C. Rotate the “DESIRED SPEED” potentiometer (if
If the problem is resolved with the new ECM, equipped) clockwise to the maximum speed
install the original ECM and verify that the position.
correctly and the original ECM does not operate D. Switch the 16 amp circuit breaker for the ECM
correctly, replace the original ECM. Refer to ON. Turn the engine control switch to the STOP
Troubleshooting, “Replacing the ECM”. position.
STOP. E. Use Cat ET to look for diagnostic codes.
Test Step 7. Connect the +5 V Wiring for Expected Result:

the Analog Speed Circuit to the ECM
No active codes
position. Switch the 16 amp circuit breaker for Results:
the ECM OFF.
code is not active. Connecting the wiring for the
analog speed circuit to the ECM did not cause a
diagnostic code. The wiring for the analog speed
circuit appears to be OK. Proceed to Test Step 8.

code is active. Connecting the wiring for the
analog speed circuit to the ECM caused a
Test Step 8. Connect the +5 V Wiring for

the Sensors to the ECM
Illustration 66
ECM connector P1 the ECM OFF.
B. Insert terminal 18 into the P1 connector. Pull on

the wire in order to verify that the terminal is fully
250
B. Disconnect the sensors for the following

parameters one at a time. After you disconnect
each sensor, wait for at least thirty seconds and
then observe the “Active Diagnostic” screen on
Cat ET.

g00862457 • Fuel temperature

Illustration 68
ECM connector P1 • Crankcase pressure
B. Insert terminal 2 into the P1 connector. Pull on Note: An “Open Circuit” code will be generated for
the wire in order to verify that the terminal is fully each sensor that is disconnected. This is normal.
inserted into the connector. Clear the codes after you complete this procedure.
C. Switch the 16 amp circuit breaker for the ECM Expected Result:
position. The original “5 Volt Sensor” diagnostic code
is deactivated when a particular sensor is
D. Use Cat ET to look for diagnostic codes. disconnected.
No active codes • Yes – The original “5 Volt Sensor” diagnostic

Results: disconnected. The sensor and/or the wiring for
code is not active. Connecting the 5 VDC for the Repair: Perform the following procedure:
sensors did not cause a diagnostic code. The
problem appears to be resolved. 1. Reconnect the suspect sensor. Verify that the
caused by a poor electrical connection. Resume 2. Disconnect the suspect sensor. Verify that the
normal operation. diagnostic code is deactivated.
STOP. If these conditions are true, replace the sensor.
• Active code – The 262-03 code or the 262-04 3. Clear all of the diagnostic codes. Verify that
code is active. Connecting the 5 VDC for the the problem is eliminated.
sensors caused a diagnostic code. Proceed to
Test Step 9. STOP.
Test Step 9. Disconnect the +5 V Sensors • No – The original “5 Volt Sensor” diagnostic code
and Look for Active Diagnostic Codes is still active after all of the +5 V sensors are
disconnected. Do not reconnect the sensors.
A. Observe the “Active Diagnostic” screen on Cat Proceed to Test Step 10.
ET. Verify that the 262-03 code or the 262-04
code is active. Test Step 10. Check the Engine
Harnesses
the ECM OFF.
251
B. Disconnect the P1 connector. Verify that all of Table 11

the sensors for the following parameters are Measure the Resistance for the Engine Harness.
disconnected from the engine harness:
• Inlet air temperature Terminal
• Engine oil temperature +5 V supply
• Unfiltered engine oil pressure P1-26 (unfiltered engine oil pressure)
• Filtered engine oil pressure P1-24 (filtered engine oil pressure)

P1-25 (crankcase pressure)
• Crankcase pressure P1-3 (analog return)
Expected Result:

ohms.
Results:
g00843355
Illustration 69 • OK – Each check of the resistance is greater
ECM side of the P1 ECM connector than 20,000 ohms. The +5 V wires in the engine
harnesses do not have a problem. The problem
C. Measure the resistance between terminal (2) of appears to be resolved. The initial diagnostic
the P1 connector and the points that are listed in code was probably caused by a poor electrical
Table 11. During each measurement, wiggle the connection.
problem with the harness. Be sure to wiggle the Repair: Reconnect all of the connectors. Resume
harnesses near each of the connectors for the normal operation.
at the terminal box’s connectors. STOP.

a harness. Proceed to Test Step 11.
Test Step 11. Check the Left Side Harness

A. Disconnect the P6 connector. Verify that all of the
sensors are disconnected.
252
Repair: Repair the left side harness, when

possible. Replace the harness, if necessary.
STOP.

Harness
A. Disconnect the P5 connector. Verify that P6 and
P1 are also disconnected. This will isolate the
terminal box’s harness.
g00846024
Illustration 70
B. Measure the resistance between terminal (69) of

the P6 connector and the points that are listed in
Table 12. During each measurement, wiggle the
problem with the harness. Be sure to wiggle the
harnesses near each of the connectors.
Table 12
Measure the Resistance for the Left Engine Harness.
g00843355
Illustration 71
ECM side of the P1 ECM connector
Terminal
P6-69 P6-55 (shield) B. Measure the resistance between terminal 2 of
+5 V supply the P1 connector and the points that are listed
in Table 13. During each measurement, wiggle
P6-68 (analog return) the wires in the terminal box in order to check for
an intermittent problem. Be sure to wiggle the
Table 13
Measure the Resistance for the Terminal
P1-70 (switched +battery terminal) Box’s Harness.
Expected Result: Terminal
Each check of the resistance is greater than 20,000 P1-2 P1-14 (inlet air temperature)
+5 V supply
ohms. P1-17 (engine oil temperature)
Results: P1-26 (unfiltered engine oil pressure)

P1-24 (filtered engine oil pressure)
• OK – Each check of the resistance is greater
than 20,000 ohms. The +5 V wires in the left side P1-15 (fuel temperature)
harness do not have a problem. Proceed to Test P1-25 (crankcase pressure)
Step 12.
P1-3 (analog return)
• Not OK – At least one check of the resistance Ground strap for the engine
is less than 20,000 ohms. There is probably a
problem with a connector and/or at least one of P1-69 (unswitched +battery terminal)
the +5 V wires in the left side harness. P1-57 (−battery terminal)
253
Expected Result: Table 14

Measure the Resistance for the Harnesses.
ohms. Connector and Connector and Terminal
Terminal
Results: P1-2 P1-14 (inlet air temperature)
+5 V supply
• OK – Each check of the resistance is greater P1-17 (engine oil temperature)
than 20,000 ohms. The +5 V wires in the terminal P1-26 (unfiltered engine oil pressure)
box do not have a short circuit. Proceed to Test
Step 13. P1-24 (filtered engine oil pressure)
less than 20,000 ohms. There is a problem with a P1-25 (crankcase pressure)
connector and/or at least one of the +5 V wires in P1-3 (analog return)
the terminal box.
STOP.
Test Step 13. Check the Right Side
Harness Expected Result:
A. Reconnect connector P5. Verify that connectors Each check of the resistance is greater than 20,000
P1 and P6 are disconnected. ohms.
Results:
• OK – Each check of the resistance is greater than

20,000 ohms. The problem seems to be resolved.
The initial diagnostic code was probably caused
by a poor electrical connection.
Repair: Reconnect all of the connectors and

resume normal operation.
STOP.
• Not OK – At least one check of the resistance

g00843355
is less than 20,000 ohms. Connecting P5 to the
Illustration 72 terminal box causes a resistance check to fail.
ECM side of the P1 ECM connector At least one of the +5 V wires in the right side
harness has a problem.
B. Measure the resistance between terminal 2 of
the P1 connector and the points that are listed in Repair: Repair the right side harness, when
Table 14. During each measurement, wiggle the possible. Replace the harness, if necessary.
problem with the harness. Be sure to wiggle the STOP.
harnesses near each of the connectors for the
at the terminal box’s connectors.
254
i01754585

SMCS Code: 1901-038
S/N: BEN1-Up
S/N: 4ZS1-Up

± 0.8 VDC to these sensors:

• All of the detonation sensors


resolved.
255
g00897589
Illustration 73
Schematic for the 8 V sensors

Connectors and Wiring.
the ECM OFF.

g00897591
Illustration 74
(1) ECM J2/P2 connectors
(3) J5/P5 connectors for the engine harness
256
g00897592 g00897834
Front and top view of the engine
(AA) Top view of the engine
(4) Sensor for engine coolant pressure
(5) Connector for the engine coolant pressure sensor
g00846295
Illustration 78
(P2-54) Return for the detonation sensors
(P2-56) +8 V supply for the detonation sensors
g00897593 (P2-65) +8 V supply for the engine coolant pressure sensor
Illustration 76
(P2-66) Return for the engine coolant pressure sensor
Right side of the engine
(6) 6-pin engine harness connectors for the detonation sensors
(7) Connector for a detonation sensor to the ignition/detonation rail

connectors:
• Connectors J2/P2 for the ECM

• Connectors for the engine coolant pressure
sensor
• Terminal box’s J5/P5 connectors

• 6-pin connectors at the ignition/detonation rail
g00897596
Illustration 79
• All the connectors for the detonation sensors Harness side of the terminal box P5 connector
to the ignition/detonation rail
(P5-40) Shield for the engine coolant pressure sensor
a. Check the torque of the Allen head screw for (P5-43) +8 V supply for the engine coolant pressure sensor
the ECM connector and for the P5 connector. (P5-55) Shield for the right side detonation sensors
The proper torque is 6 ± 1 N·m (55 ± 9 lb in). (P5-56) Return for the right side detonation sensors
(P5-57) +8 V supply for the right side detonation sensors
257
b. Perform a 45 N (10 lb) pull test on each of • Active code – The 41-03 code or the 41-04 code
the wires that are associated with the circuit is active. Proceed to Test Step 3.
for the 8 V sensors.
c. Check the harness and wiring for abrasion code is not active. However, there is at least one
and for pinch points from the sensors to the logged code for the 8 volt sensor supply.
ECM.
Repair: There may be an intermittent problem
Expected Result: with the wiring and/or a connector. Refer
to Troubleshooting, “Inspecting Electrical
All connectors, pins, and sockets are connected Connectors”.
corrosion, abrasion, or pinch points. Verify that the wiring and/or connectors are OK.
Results: Test Step 3, if necessary.
• OK – All connectors, pins, and sockets are Test Step 3. Disconnect the 8 V Sensors
connected properly. The connectors and the and Look for Active Diagnostic Codes.
points. The components are in good condition A. Turn on the “Active Diagnostic” screen on Cat ET.
with proper connections. Proceed to Test Step 2. Verify that the “41-03” or “41-04” code is active.
• Not OK – At least one of the connectors, pins, B. Disconnect each 8 V sensor one at a time.
and sockets is not connected properly. At least After you disconnect each sensor, wait for at
one of the connectors and/or wires has corrosion, least two seconds and then observe the “Active
abrasion, and/or pinch points. Diagnostic” screen on Cat ET.
Repair: Perform the necessary repairs and/or Note: An “Open Circuit” code will be generated for
replace parts, if necessary. each sensor that is disconnected. This is normal.
Clear the codes after you complete this procedure.
STOP.
Expected Result:
The original “8 Volt DC Supply” diagnostic
A. Connect Cat ET to the service tool connector code is deactivated when a particular sensor is
on the terminal box. Switch the 16 amp circuit disconnected.
breaker for the ECM ON. Turn the engine control
switch to the STOP position. Results:
B. Observe the “Active Diagnostic” screen on Cat • Yes – The original “8 Volt DC Supply” diagnostic
ET. Wait at least thirty seconds so that any codes code is deactivated when a particular sensor is
may become activated. Look for these codes: disconnected. The sensor and/or the wiring for
• 41-03 8 Volt DC Supply short to +batt
• 41-04 8 Volt DC Supply short to ground
1. Reconnect the suspect sensor. Verify that the
C. Observe the “Logged Diagnostic” screen on Cat diagnostic code recurs.
ET. Look for the same codes.
2. Disconnect the suspect sensor. Verify that the
Expected Result: diagnostic code is deactivated.
The 41-03 code or the 41-04 code is not active. If these conditions are true, repair the sensor
or the sensor’s harness. Replace parts, if
Results: necessary.
• No codes – The 41-03 code or the 41-04 code is 3. Clear all of the diagnostic codes. Verify that
not active. The +8 volt sensor supply is operating the problem is eliminated.
correctly at this time. The original diagnostic
code was probably caused by a poor electrical STOP.
connection. Resume normal operation. STOP.
258
• No – The original “8 Volt DC Supply” diagnostic Repair: It is unlikely that the ECM has failed.
code is still active after all of the +8 V sensors Exit this procedure and perform this procedure
are disconnected. Do not reconnect the sensors. again. If the problem is not resolved, perform the
Proceed to Test Step 4. following steps:
Test Step 4. Isolate the Wiring Harnesses Temporarily install a new ECM. Refer to
from the ECM Troubleshooting, “Replacing the ECM”.
A. Turn the engine control switch to the OFF/RESET If the problem is resolved with the new ECM,
position. Switch the 16 amp circuit breaker for install the original ECM and verify that the
the ECM OFF. problem returns. If the new ECM operates
correctly and the original ECM does not operate
correctly, replace the original ECM. Refer to
STOP.
Test Step 5. Check the Engine Harness

the ECM OFF.
g00897598
Illustration 80
(P2-56) +8 V supply for the detonation sensors
(P2-65) +8 V supply for the engine coolant pressure sensor

the terminal 56 and 65 from the P2 connector.

position. g00897598
Illustration 81
D. Wait for thirty seconds and then observe the Harness side of the ECM P2 connector
“Active Diagnostics” screen on Cat ET. Determine (P2-56) +8 V supply for the detonation sensors
if a 41-03 code or a 41-04 code is active. (P2-65) +8 V supply for the engine coolant pressure sensor
Expected Result: B. Insert terminals 56 and 65 into the P2 connector.

Pull on each wire in order to verify that the
No active codes terminals are fully inserted into the connector.
Results: C. Disconnect the P2 connector. Verify that all of

the sensors for the following parameters are
• No codes – The 41-03 code or the 41-04 code disconnected from the engine harnesses:
is not active. Disconnecting the +8 V wiring
from the ECM eliminated the active “8 Volt DC • Engine coolant pressure sensor
Supply” diagnostic code. There is a problem in a
connector and/or the wiring in a harness. Proceed • All of the detonation sensors
to Test Step 5.
• Active code – The 41-03 code or the 41-04 code

is active. Disconnecting the +8 V wiring from
the ECM did not eliminate the active “8 Volt
DC Supply” diagnostic code. There may be a
problem with the ECM.
259
Table 15
Points for the Measurement of Resistance
Connector and Terminal Connector and Terminal
P2-65 (+8 VDC) P2-68 (Engine coolant
pressure)
P2-66 (Return)
P2-56 (+8 VDC) P2-36 (Detonation sensor)
P2-37 (Detonation sensor)
P2-54 (Return)
P2-65 (+8 VDC) Engine ground
P2-56 (+8 VDC)
P2-65 (+8 VDC) P1-69 (−Battery terminal)
P2-56 (+8 VDC)
P2-65 (+8 VDC) P1-57 (Unswitched
+Battery)
P2-56 (+8 VDC)
P2-65 (+8 VDC) P1-70 (Switched +Battery)
P2-56 (+8 VDC)
g00897844
Illustration 82
ECM side of the P1 and P2 connectors Expected Result:
Note: For the functions of the terminals, refer to Each check of the resistance is greater than 20,000
Table 15. ohms.
D. Measure the resistance between the terminals Results:

that are listed in Table 15. During each
measurement, wiggle the harnesses in order • OK – Each check of the resistance is greater than
to check for an intermittent problem with the 20,000 ohms. The +8 V wires and connectors
harness. Be sure to wiggle the harnesses near in all of the engine harnesses do not have a
each of the connectors for the sensors and the problem. The problem appears to be resolved.
terminal box. The initial diagnostic code was probably caused

normal operation.
STOP.

is less than 20,000 ohms. There is a problem
260
Test Step 6. Check the Engine Harness Results:

and the Ignition/Detonation Rail Wiring
• OK – Each check of the resistance for the
A. Disconnect the terminal box’s P5 connector. engine harness and the ignition/detonation rail
Thoroughly inspect the P5/J5 connectors for wiring is greater than 20,000 ohms. The +8 volt
corrosion and for moisture. Ensure that the wires in the engine harness and the right side
connectors are in good condition. Verify that ignition/detonation rail do not have a problem.
all of the detonation sensors are disconnected. Proceed to Test Step 9.
Verify that the connector for the engine coolant
pressure is disconnected. This will isolate the • Not OK – At least one check of the resistance is
engine harness and the ignition/detonation rail less than 20,000 ohms. There is a problem with a
wiring. connector and/or the +8 V wires in either the right
side harness or the wiring inside the right side
ignition/detonation rail. Proceed to Test Step 7.
Test Step 7. Check the Wiring in the

Engine Harness
A. Verify that the engine coolant pressure sensor is
disconnected. Verify that the terminal box’s P5
is disconnected. Disconnect the 6-pin connector
from the ignition/detonation rail. This will isolate
the engine harness. Thoroughly inspect the 6-pin
connectors for corrosion and for moisture. Ensure
that the connectors are in good condition.

g00897599
Illustration 83 the P5 connector and each of points that are
Terminal box’s side of the P5 connector listed in Table 17:
For the functions of the terminals, refer to Table 16.
Table 17
B. Measure the resistance between terminal 57 of Points for the Measurement of Resistance
the P5 connector and each of points that are Connector and Terminal Connector and Terminal
listed in Table 16:
P5-57 (+8 V supply for the P5-40 (Shield)
Table 16 detonation sensors)
P5-41 (Return)
P5-42 (Engine coolant
Connector and Terminal Connector and Terminal pressure)
P5-57 (+8 V supply for the P5-40 (Shield) P5-44 (Detonation sensor)
detonation sensors)
P5-41 (Return) P5-45 (Detonation sensor)
P5-42 (Engine coolant P5-46 (Detonation sensor)
pressure)
P5-55 (Shield)
P5-56 (Return)
P5-55 (Shield) Expected Result:
P5-56 (Return)
Ground strap for the engine ohms.
Expected Result:

ohms.
261
Results: Table 18
than 20,000 ohms. The +8 V wires in the Connector and Terminal Connector and Terminal
engine harness do not have a problem when A (+8 V supply) B (Return)
the ignition/detonation rail is disconnected.
There is a problem in the +8 V wiring inside the C (Detonation sensor)
ignition/detonation rail. Proceed to Test Step 8.
D (Detonation sensor)
• Not OK – At least one check of the resistance is E (Detonation sensor)
F (Detonation sensor)
connector and/or at least one of the +8 V wires
in the engine harness. Ground strap for the engine
Repair: Repair the engine harness, when

Expected Result:
STOP.
ohms.
Test Step 8. Check the Wiring Inside the Results:
Ignition/Detonation Rail
A. Verify that the 6-pin connector and all of the
than 20,000 ohms. The +8 V wires inside the
detonation sensors are disconnected from the ignition/detonation rail do not have a problem.
ignition/detonation rail. This will isolate the wiring The problem appears to be resolved. The initial
inside the ignition/detonation rail. diagnostic code was probably caused by a poor
electrical connection.

normal operation.
STOP.

connector and/or at least one of the +8 V wires
inside the ignition/detonation rail.
Repair: The short circuit is probably caused by

a poor electrical connection and/or a wiring
g00846597 problem inside the rail. Repair the electrical
Illustration 84
connection and/or the wiring, when possible.
The 6-pin connector for the detonation sensors is attached to the Replace the rail, if necessary.
ignition/detonation rail.
For the functions of the terminals, refer to Table 18. STOP.
B. Measure the resistance between terminal A of Test Step 9. Check the Terminal Box’s
the 6-pin connector on the ignition/detonation Harness
rail and each of the points that are listed in the
following table: A. Verify that the P5 connector is disconnected.
Also verify that the P2 connector is disconnected.
This will isolate the terminal box’s harness.
262
Table 19
pressure)
P2-66 (Return)
P2-54 (Return)
P2-56 (+8 VDC)
P2-56 (+8 VDC)
+Battery)
P2-56 (+8 VDC)
P2-65 (+8 VDC) P1-70 (Switched +Battery)
P2-56 (+8 VDC)
g00897844
Illustration 85
ECM side of the P1 and P2 connectors Expected Result:
Note: For the functions of the terminals, see Table Each check of the resistance is greater than 20,000
19. ohms.
B. Measure the resistance between the terminals Results:

measurement, wiggle the harnesses in order • OK – Each check of the resistance is greater
to check for an intermittent problem with the than 20,000 ohms. The +8 V wires in the terminal
harness. Be sure to wiggle the harnesses near box do not have a problem. The problem appears
each of the connectors. to be resolved. The initial diagnostic code was
probably caused by a poor electrical connection.

normal operation.
STOP.

less than 20,000 ohms. There is a problem in a
the terminal box.

possible. Replace the terminal box’s harness, if
necessary.
STOP.
263
i01754910

SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up

± 0.8 VDC to these sensors:

• All of the detonation sensors


resolved.
264
g00897873
Illustration 86
Schematic for the 8 V sensors
265

Connectors and Wiring.
the ECM OFF.

g00844902
Illustration 89
(7) P675/J675 6-pin connectors
(8) Connector for a detonation sensor
g00844718
Illustration 87
(1) ECM connector J2/P2
(3) J6/P6 connectors for the harness from the sensors on the left
side of the engine
(4) J5/P5 connectors for the harness from the sensors on the right
side of the engine
g00844905
Illustration 90
Left side of the engine
(9) J676/P676 6-pin connectors
(10) Connector for a detonation sensor

connectors:
• Connectors (J2/P2) for the ECM

• (J215/P215) connectors for the engine coolant
Illustration 88 g00871503 pressure sensor
Right side and top view of the engine
• Terminal box (J5/P5) and (J6/P6) connectors
(5) Sensor for engine coolant pressure
(6) J215/P215 connector for the engine coolant pressure sensor
266
• Ignition/detonation rail (J675/P675) and

(J676/P676) connectors
• All the connectors for the detonation sensors

6 ± 1 N·m (55 ± 9 lb in).
g00846299
Illustration 93
(P6-53) Shield for the left side detonation sensors
(P6-54) Return for the left side detonation sensors
(P6-67) +8 V supply for the left side detonation sensors

for the 8 V sensors.
g00846295
Illustration 91
c. Check the harness and wiring for abrasion
and for pinch points from the sensors to the
(P2-54) Return for the right side detonation sensors
(P2-55) Return for the left side detonation sensors
ECM.
(P2-57) +8 V supply for the left side detonation sensors Expected Result:
(P2-65) +8 V supply for the engine coolant pressure sensor
(P2-66) Return for the engine coolant pressure sensor All connectors, pins, and sockets are connected
Results:


g00846296 pinch points.
Illustration 92
Harness side of the terminal box P5 connector Repair: Perform the necessary repairs and/or
(P5-11) Shield for the engine coolant pressure sensor replace parts, if necessary.
(P5-13) Shield for the right side detonation sensors
(P5-23) Return for the right side detonation sensors
STOP.
(P5-37) +8 V supply for the engine coolant pressure sensor Test Step 2. Check for Diagnostic Codes
A. Connect Cat ET to the service tool connector
on the terminal box. Switch the 16 amp circuit
breaker for the ECM ON. Turn the engine control
switch to the STOP position.
267
B. Observe the “Active Diagnostic” screen on Cat Results:

ET. Wait at least thirty seconds so that any codes
may become activated. Look for these codes: • Yes – The original “8 Volt DC Supply” diagnostic
• 41-03 8 Volt DC Supply short to +batt disconnected. The sensor and/or the wiring for
• 41-04 8 Volt DC Supply short to ground
C. Observe the “Logged Diagnostic” screen on Cat
ET. Look for the same codes. 1. Reconnect the suspect sensor. Verify that the
Expected Result:
2. Disconnect the suspect sensor. Verify that the
The 41-03 code or the 41-04 code is not active. diagnostic code is deactivated.
Results: If these conditions are true, repair the sensor

or the sensor’s harness. Replace parts, if
• No codes – The 41-03 code or the 41-04 code is necessary.
not active. The +8 volt sensor supply is operating
correctly at this time. The original diagnostic 3. Clear all of the diagnostic codes. Verify that
code was probably caused by a poor electrical the problem is eliminated.
connection. Resume normal operation. STOP.
STOP.
is active. Proceed to Test Step 3. • No – The original “8 Volt DC Supply” diagnostic
code is still active after all of the +8 V sensors
• Logged code – The 41-03 code or the 41-04 are disconnected. Do not reconnect the sensors.
code is not active. However, there is at least one Proceed to Test Step 4.
logged code for the 8 volt sensor supply.
Repair: There may be a problem with the wiring from the ECM
“Inspecting Electrical Connectors”. A. Turn the engine control switch to the OFF/RESET
Verify that the wiring and/or connectors are OK. the ECM OFF.
Test Step 3. Disconnect the 8 V Sensors

and Look for Active Diagnostic Codes.
A. Turn on the “Active Diagnostic” screen on Cat ET.
Verify that the “41-03” or “41-04” code is active.
B. Disconnect each 8 V sensor one at a time.

After you disconnect each sensor, wait for at
least two seconds and then observe the “Active
Diagnostic” screen on Cat ET.
Note: An “Open Circuit” code will be generated for

each sensor that is disconnected. This is normal.
Clear the codes after you complete this procedure.
Expected Result:
The original “8 Volt DC Supply” diagnostic

code is deactivated when a particular sensor is Illustration 94
g00862672
disconnected.

the terminal 56, 57, and 65 from the P2 connector.
268

position.
D. Wait for thirty seconds and then observe the

“Active Diagnostics” screen on Cat ET. Determine
if a 41-03 code or a 41-04 code is active.
Expected Result:
No active codes
Results:
• No codes – The 41-03 code or the 41-04 code is g00844743

not active. Disconnecting all of the +8 V wiring Illustration 95
from the ECM eliminated the active “8 Volt DC ECM connector P2
Supply” diagnostic code. There is a problem in a
connector and/or the wiring in a harness. Proceed B. Insert terminals 56, 57, and 65 into the P2
to Test Step 5. connector. Pull on each wire in order to verify that
the terminals are fully inserted into the connector.
is active. Disconnecting all of the +8 V wiring C. Disconnect the P2 connector. Verify that all of
from the ECM did not eliminate the active “8 Volt the sensors for the following parameters are
DC Supply” diagnostic code. There may be a disconnected from the engine harnesses:
• Engine coolant pressure sensor
Exit this procedure and perform this procedure • All of the detonation sensors
again. If the problem is not resolved, perform the
following steps:

If the problem is resolved with the new ECM,

install the original ECM and verify that the
STOP.
Test Step 5. Check the Engine Harnesses

the ECM OFF.
g00844823
Illustration 96
Note: For the functions of the terminals, refer to

Table 20.
269
D. Measure the resistance between the terminals Results:

measurement, wiggle the harnesses in order • OK – Each check of the resistance is greater than
to check for an intermittent problem with the 20,000 ohms. The +8 V wires and connectors
harness. Be sure to wiggle the harnesses near in all of the engine harnesses do not have a
each of the connectors for the sensors and the problem. The problem appears to be resolved.
terminal box. The initial diagnostic code was probably caused
Table 20
Points for the Measurement of Resistance Repair: Reconnect all of the connectors. Resume
normal operation.
P2-65 (+8 VDC) P2-68 (Engine coolant STOP.
pressure)
P2-66 (Return) is less than 20,000 ohms. There is a problem
P2-56 (+8 VDC) P2-36 (Detonation sensor) with a connector and/or the wiring in a harness.
P2-38 (Detonation sensor) Test Step 6. Check the Left Side Harness
and the Left Side Ignition/Detonation Rail
P2-39 (Detonation sensor) Wiring
P2-54 (Return)
A. Disconnect the P6 connector. Thoroughly inspect
P2-57 (+8 VDC) P2-44 (Detonation sensor) the P6/J6 connectors for corrosion and for
P2-45 (Detonation sensor) moisture. Ensure that the connectors are in good
condition. Verify that all of the detonation sensors
P2-46 (Detonation sensor) on the left side of the engine are disconnected.
P2-47 (Detonation sensor) This will isolate the left side harness and the
ignition/detonation rail’s wiring.
P2-55 (Return)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
+Battery)
P2-56 (+8 VDC)
P2-57 (+8 VDC)
g00846626
P2-65 (+8 VDC) P1-70 (Switched +Battery) Illustration 97
P2-56 (+8 VDC) Terminal box side of the P6 connector

For the functions of the terminals, refer to Table 21.
P2-57 (+8 VDC)
Expected Result: the P6 connector and each of the points that are
listed in the following table:
ohms.
270
Table 21 Table 22
Points for the Measurement of Resistance Points for the Measurement of Resistance
Connector and Terminal Connector and Terminal Connector and Terminal Connector and Terminal
P6-67 (+8 V supply) P6-66 (Detonation sensor) P6-67 (+8 V supply) P6-66 (Detonation sensor)
P6-65 (Detonation sensor) P6-65 (Detonation sensor)
P6-54 (Return) P6-54 (Return)
P6-53 (Shield) P6-53 (Shield)
Ground strap for the engine Ground strap for the engine
Expected Result: Expected Result:
Each check of the resistance is greater than 20,000 Each check of the resistance is greater than 20,000
ohms. ohms.
Results: Results:
• OK – Each check of the resistance for the left • OK – Each check of the resistance is greater
harness and for the ignition/detonation rail’s wiring than 20,000 ohms. The +8 V wires in the left
is greater than 20,000 ohms. The +8 volt wires in engine harness do not have a problem when the
the left harness and in the left ignition/detonation ignition/detonation rail is disconnected. There
rail do not have a problem. Proceed to Test Step is a problem in the left ignition/detonation rail.
9. Proceed to Test Step 8.
• Not OK – At least one check of the resistance is • Not OK – At least one check of the resistance is
less than 20,000 ohms. There is a problem in the less than 20,000 ohms. There is a problem with
left harness or in the left ignition/detonation rail. a connector and/or with at least one of the +8 V
Proceed to Test Step 7. wires in the left harness.
Test Step 7. Check the Wiring in the Left Repair: Repair the left harness, when possible.
Side Harness Replace the harness, if necessary.
A. Verify that connector P6 is disconnected. STOP.

Disconnect the P676 connector from the
ignition/detonation rail. This will isolate the left Test Step 8. Check the Wiring in the Left
side harness. Thoroughly inspect the J676/P676 Ignition/Detonation Rail
connectors for corrosion and for moisture. Ensure
that the connectors are in good condition. A. Verify that P676 and all of the left side detonation
sensors are disconnected. This will isolate the
B. Measure the resistance between terminal P6-67 wiring in the left ignition/detonation rail.
and each of points that are listed in the following
table:
271

less than 20,000 ohms. There is a problem with
a connector and/or with at least one of the +8 V
wires in the left ignition/detonation rail.

a poor electrical connection and/or by a wiring
problem inside the rail. Repair the electrical
Replace the rail, if necessary.
STOP.
Test Step 9. Check the Right Side Harness

g00846466 and the Right Side Ignition/Detonation
Illustration 98
Rail Wiring
The J676 connector is attached to the left ignition/detonation rail.
For the functions of the terminals, refer to Table 23. A. Disconnect the P5 connector. Thoroughly inspect
the P5/J5 connectors for corrosion and for
B. Measure the resistance between terminal J676-A moisture. Ensure that the connectors are in good
on the ignition/detonation rail and each of the condition. Verify that all of the detonation sensors
points that are listed in Table 23: on the right side of the engine are disconnected.
Verify that the J215/P215 connector for the
Table 23 engine coolant pressure is disconnected.
Points for the Measurement of Resistance This will isolate the right harness and the
ignition/detonation rail wiring.
J676-A (+8 V supply) J676-B (Return)
J676-C (Detonation
sensor)
J676-D (Detonation
sensor)
J676-E (Detonation
sensor)
J676-F (Detonation
sensor)
g00846643
Expected Result: Illustration 99
Terminal box side of the P5 connector
Each check of the resistance is greater than 20,000 For the functions of the terminals, refer to Table 24.
ohms.
B. Measure the resistance between terminal P5-31
Results: and each of points that are listed in Table 24:
than 20,000 ohms. The +8 V wires in the
ignition/detonation rail do not have a problem.
The problem appears to be resolved. The initial
diagnostic code was probably caused by a poor
electrical connection.

normal operation.
STOP.
272
Table 24 Table 25
Points for the Measurement of Resistance Points for the Measurement of Resistance
Connector and Terminal Connector and Terminal Connector and Terminal Connector and Terminal
P5-31 (+8 V supply) P5-38 (Detonation sensor) P5-31 (+8 V supply) P5-38 (Detonation sensor)
P5-29 (Engine coolant P5-29 (Engine coolant
pressure) pressure)
Ground strap for the engine Ground strap for the engine
Each check of the resistance is greater than 20,000 Each check of the resistance is greater than 20,000
ohms. ohms.
Results: Results:
• OK – Each check of the resistance for the right • OK – Each check of the resistance is greater
harness and the ignition/detonation rail wiring is than 20,000 ohms. The +8 V wires in the right
greater than 20,000 ohms. The +8 volt wires in the harness do not have a problem when the
right harness and in the right ignition/detonation ignition/detonation rail is disconnected. There
rail do not have a problem. Proceed to Test Step is a problem with the +8 V wiring in the right
12. ignition/detonation rail. Proceed to Test Step 11.
• Not OK – At least one check of the resistance is • Not OK – At least one check of the resistance is
less than 20,000 ohms. There is a problem with less than 20,000 ohms. There is a problem with
a connector and/or with the +8 V wires in the a connector and/or with at least one of the +8 V
right harness or in the right ignition/detonation wires in the right harness.
rail. Proceed to Test Step 10.
Repair: Repair the right harness, when possible.
Test Step 10. Check the Wiring in the Replace the harness, if necessary.
Right Side Harness
STOP.
A. Verify that J215 is disconnected. Verify that P5
is disconnected. Disconnect the P675 connector Test Step 11. Check the Wiring In the
from the ignition/detonation rail. This will isolate Right Ignition/Detonation Rail
the right side harness. Thoroughly inspect the
J675/P675 connectors for corrosion and for A. Verify that P675 and all of the right side
moisture. Ensure that the connectors are in good detonation sensors are disconnected. This will
condition. isolate the wiring in the right ignition/detonation
rail.
B. Measure the resistance between terminal P5-31
and each of points that are listed in Table 25:
273

less than 20,000 ohms. There is a problem with
a connector and/or with at least one of the +8 V
wires in the right ignition/detonation rail.

a poor electrical connection and/or by a wiring
problem inside the rail. Repair the electrical
STOP.

g00846597 Harness
Illustration 100
The J675 connector is attached to the right ignition/detonation rail. A. Verify that the P5 and P6 connectors are
For the functions of the terminals, refer to Table 26. disconnected. Also verify that the P2 connector
is disconnected. This will isolate the terminal
B. Measure the resistance between terminal J675-A box’s harness.
on the ignition/detonation rail and each of the
points that are listed in Table 26:
Table 26
J675-A (+8 V supply) J675-B (Return)
J675-C (Detonation
sensor)
J675-D (Detonation
sensor)
J675-E (Detonation
sensor)
P675-F (Detonation
sensor)
Expected Result:

ohms.
Results:
g00844823
• OK – Each check of the resistance is greater Illustration 101
than 20,000 ohms. The +8 V wires in the right
ignition/detonation rail do not have a problem. Note: For the functions of the terminals, refer to
The problem appears to be resolved. The initial Table 27.
diagnostic code was probably caused by a poor
electrical connection. B. Measure the resistance between the terminals
Repair: Reconnect all of the connectors. Resume measurement, wiggle the harnesses in order
normal operation. to check for an intermittent problem. Be sure
to wiggle the harnesses near each of the
STOP. connectors.
274
Table 27 • Not OK – At least one check of the resistance is

Points for the Measurement of Resistance less than 20,000 ohms. There is a problem in a
connector and/or with at least one of the +8 V
Connector and Terminal Connector and Terminal wires in the terminal box.
pressure) Repair: Repair the terminal box’s harness, when
possible. Replace the terminal box’s harness, if
P2-66 (Return) necessary.
STOP.
P2-38 (Detonation sensor) i01754937

Air/Fuel Pressure Module
P2-54 (Return)
SMCS Code: 1901-038
P2-45 (Detonation sensor) S/N: BEN1-Up
P2-46 (Detonation sensor) S/N: 4ZS1-Up

P2-47 (Detonation sensor) System Operation Description:
P2-55 (Return)
Tubes that connect the air/fuel pressure module to
P2-65 (+8 VDC) Engine ground the inlet air manifold and to the fuel manifold enable
P2-56 (+8 VDC) the module to sense the absolute inlet manifold air
pressure and fuel pressure. The module calculates
P2-57 (+8 VDC) the differential pressure between the fuel manifold
P2-65 (+8 VDC) P1-69 (−Battery terminal) and the inlet air manifold. This fuel differential
pressure is the value of the fuel pressure minus the
P2-56 (+8 VDC) value of the inlet manifold air pressure.
P2-57 (+8 VDC)
Pulse Width Modulation (PWM) – This is a digital
P2-65 (+8 VDC) P1-57 (Unswitched signal. The frequency is constant: the widths of the
+Battery) signal’s pulses are varied within a fixed interval
P2-56 (+8 VDC)
(frequency). The variable widths are also called a
P2-57 (+8 VDC) duty cycle. The variable widths enable the signal to
P2-65 (+8 VDC) P1-70 (Switched +Battery) be interpreted as a range of values. This provides a
more accurate status for a parameter than a signal
P2-56 (+8 VDC) that can only be ON or OFF.
P2-57 (+8 VDC)
Expected Result:

ohms.
Results:

than 20,000 ohms. The +8 V wires in the terminal
box do not have a problem. The problem appears
to be resolved. The initial diagnostic code was

normal operation.
STOP.
275
g00852792
Illustration 102
Example of a PWM signal
The air/fuel presure module sends PWM signals that

represent the inlet manifold air pressure and the
fuel differential pressure to the Electronic Control
Module (ECM). The ECM uses the information to
help calculate the fuel flow.
The most likely causes of the diagnostic code are a

poor connection or a problem in a wiring harness.
The next likely cause is a problem with the module.

The troubleshooting procedure may generate

resolved.
276
g00897897
Illustration 103
Schematic for the air/fuel pressure module

g00897899
Illustration 105
Rear view
g00843978
Illustration 104 (4) Harness connector for the air/fuel pressure module
(2) 16 amp circuit breaker for the ECM B. Thoroughly inspect each of the following
(3) Terminal box J6/P6 connectors for the left engine harness connectors:
A. Turn the engine control switch to the OFF/RESET • ECM J1/P1 connectors
the ECM to the OFF position. • Terminal box J6/P6 connectors
Note: For the following steps, refer to • Harness connectors for the air/fuel pressure
Troubleshooting, “Inspecting Electrical Connectors”. module

connectors P1 and P6. The proper torque is
6 ±1 N·m (55 ± 9 lb in).
277
g00844052 g00897900
Harness side of the ECM P1 connector Harness side of the terminal box P6 connector
(10) PWM signal for the inlet manifold air pressure (37) -Battery
(11) PWM signal for the fuel differential pressure (38) PWM signal for the fuel differential pressure
(69) -Battery (45) Keyswitch +Battery
(70) Keyswitch +Battery (46) PWM signal for the inlet manifold air pressure
b. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the circuit for
the air/fuel pressure module.

and for pinch points from the air/fuel pressure
module to the ECM.
Expected Result:

Results:


pinch points.
278
Repair: Perform the necessary repairs and/or If any of the codes are logged and the engine is
replace parts, if necessary. not operating properly, troubleshoot the symptom.
Refer to Troubleshooting, “Troubleshooting without
STOP. a Diagnostic Code”.
Test Step 2. Check for Diagnostic Codes STOP.
A. Switch the 16 amp circuit breaker for the ECM to Test Step 3. Verify the Supply Voltage to
the ON position. Turn the engine control switch the Module
to the STOP position.
B. Observe the “Active Diagnostic” screen on Cat position. Switch the 16 amp circuit breaker for
ET. Wait at least 30 seconds so that any codes the ECM to the OFF position.
• 94-03 Fuel Pressure open/short to +batt

• 94-08 Fuel Pressure noisy
• 106-03 Air Inlet Pressure Sensor short to +batt
• 106-08 Air Inlet Pressure Sensor noisy signal
C. Determine whether any of the same codes are
logged.
Expected Result:
g00844095
None of the above diagnostic codes are active or Illustration 108
logged. Harness connector for the air/fuel pressure module
(A) Keyswitch +Battery
Results: (B) -Battery
(C) PWM signal for the differential pressure of the fuel manifold
• OK (No codes) – None of the above diagnostic and the inlet air manifold
(D) PWM signal for the inlet manifold air pressure
codes are active or logged. The problem seems
to be resolved. The air/fuel pressure module is
operating correctly at this time. B. Disconnect the harness connector from the
air/fuel pressure module.
caused by a poor electrical connection. For C. Switch the 16 amp circuit breaker for the ECM to
intermittent problems, refer to Troubleshooting, the ON position. Turn the engine control switch
“Inspecting Electrical Connectors”. to the STOP position.
STOP. D. Measure the voltage between terminals “A” and

“B” on the harness connector for the air/fuel
pressure module. Wiggle the harness in order to
• Not OK (Active code) – There is an active check for an intermittent problem.
diagnostic code for the air/fuel pressure module.
Expected Result:
• No (Logged code) – There are no active The voltage between terminals “A” and “B” on the
diagnostic codes for the air/fuel pressure module.
However, there is a logged code for the air/fuel harness connector for the air/fuel pressure module
pressure module. is approximately 24 VDC.
Repair: There may be a problem with the wiring Results:

and/or with a connector. Attempt to activate the
code by performing another pull test on the wires • OK – The voltage between terminals “A” and “B”
that are associated with the air/fuel pressure on the harness connector for the air/fuel pressure
module. Refer to Troubleshooting, “Inspecting module is approximately 24 VDC. Proceed to Test
Electrical Connectors”. Step 4.
279
• Not OK – The voltage between terminals “A”

and “B” on the harness connector for the air/fuel
pressure module is not approximately 24 VDC.

supply voltage at the terminal box.
g00843978
Illustration 109
(2) 16 amp circuit breaker for the ECM
(3) Terminal box J6/P6 connectors for the left engine harness
1. Turn the engine control switch to the

OFF/RESET position. Switch the 16 amp circuit
breaker for the ECM to the OFF position. g00897901
Illustration 110
Bottom of the terminal box
2. Disconnect connectors (J6/P6). Terminal box J6 connector
(J6-37) -Battery
3. Switch the 16 amp circuit breaker for the ECM (J6-45) Keyswitch +Battery
to the ON position. Turn the engine control
switch to the STOP position. 4. Measure the voltage between terminals (J6-37)
and (J6-45). Wiggle the harness in the terminal
box in order to check for an intermittent
problem.
The correct voltage between terminals (J6-37)

and (J6-45) is approximately 24 VDC.
If the correct voltage is found on the J6

connector, there is a problem in the wiring
harness between the P6 connector and the
air/fuel pressure module. Repair the harness
or replace the harness.
If the correct voltage is not found on the J6

connector, there may be a problem in the
terminal box. Verify the voltage from the ECM.
a. Turn the engine control switch to the

OFF/RESET position. Switch the 16 amp
circuit breaker for the ECM to the OFF
position.
b. Disconnect the ECM J1/P1 connectors.
c. Switch the 16 amp circuit breaker for the

ECM to the ON position. Turn the engine
control switch to the STOP position.
280
g00844095
Illustration 112
Harness connector for the air/fuel pressure module
(B) -Battery
(C) PWM signal for the fuel differential pressure
B. Connect a jumper wire with the appropriate

connectors on the ends between terminal “A” on
the harness connector for the air/fuel pressure
module and terminal “A” on the module’s
receptacle. Connect another jumper wire
between terminal “B” on the harness connector
Illustration 111 g00849901 for the air/fuel pressure module and terminal “B”
on the module’s receptacle.
ECM J1 connector
(J1-69) -Battery C. Use a multimeter to measure the duty cycle and
(J1-70) Keyswitch +Battery
the frequency of the suspect signal.
d. Measure the voltage between terminals
(J1-69) and (J1-70).
The correct voltage between terminals
(J1-69) and (J1-70) is approximately 24
b. Measure the duty cycle and the frequency
VDC.
between terminals “B” and “C” on the
module’s receptacle.
If the correct voltage is found on the ECM
J1 connector, there is a problem with the
c. Measure the duty cycle and the frequency
terminal box’s wiring. Repair the wiring or
between terminals “B” and “D” on the
replace the wiring.
If the correct voltage is not found on the
Expected Result:
ECM J1 connector, there may be a problem
with the electrical power supply. For further
The duty cycle between terminals “C”, “D” and
information on troubleshooting the electrical
terminal “B” is between 17 and 95 percent and the
power supply, refer to Troubleshooting,
frequency is between 450 and 600 Hz.
“Electrical Power Supply”.
Results:
STOP.
Test Step 4. Check for a Signal from the • Yes – The duty cycle and the frequency of the
suspect signal is correct. The module is operating
Module correctly. Proceed to Test Step 5.
position. Switch the 16 amp circuit breaker for • No – The duty cycle and/or the frequency of the
suspect signal is not correct. The module is not
operating correctly.
281
Repair: Turn the engine control switch to the a. Switch the 16 amp circuit breaker for the ECM
OFF/RESET position. Switch the 16 amp circuit to the ON position. Turn the engine control
breaker for the ECM to the OFF position. Remove switch to the STOP position.
the jumper wires from the connectors for the
air/fuel pressure module module. Replace the b. Insert a 7X-1710 Multimeter Probe into
air/fuel pressure module. terminal (P6-37). Measure the duty cycle and
the frequency between terminals (P6-37) and
STOP. (P6-38). Wiggle the harness in order to check
for an intermittent problem.
Test Step 5. Check for a Signal to the
Terminal Box c. Measure the duty cycle and the frequency
between terminals (P6-37) and (P6-46).
A. Turn the engine control switch to the OFF/RESET Wiggle the harness in order to check for an
position. Switch the 16 amp circuit breaker for intermittent problem.
Expected Result:
B. Remove the jumper wires from the connectors
for the air/fuel pressure module. Reconnect the The duty cycle between terminals (P6-38), (P6-46),
engine harness to the air/fuel pressure module. and (P6-37) is between 17 and 95 percent and the
Results:
• Yes – The duty cycle and the frequency of the

correctly and the harness between the module
and the terminal box P6 connector is OK. There
may be a problem in the terminal box.
Repair: Remove the 7X-1710 Multimeter Probe.

Reinstall the disconnected terminals. Pull on the
wires in order to verify proper installation.
• No – The duty cycle and the frequency of the

suspect signal is not correct. The module is
operating correctly but there is a problem with
a connection and/or the wiring in the engine
harness.

wires in order to verify proper installation. Repair
the harness, when possible. Replace the harness,
if necessary.
g00897902 STOP.
Illustration 113
(P6-37) -Battery
Test Step 6. Check for a Signal at the ECM
(P6-38) PWM signal for the fuel differential pressure
(P6-46) PWM signal for the inlet manifold air pressure A. Turn the engine control switch to the OFF/RESET
C. Use a 151-6320 Wire Removal Tool to remove the ECM to the OFF position.
terminals (P6-38) and (P6-46) from the harness
side of the terminal box P6 connector. Label the
wires.
D. Use a multimeter to check the signals from the

removed terminals.
282
Expected Result:
The duty cycle for terminals (P1-10), (P1-11), and

(P1-69) is between 17 and 95 percent and the
Results:

suspect signal is correct. The ECM is receiving
a valid signal. However, a diagnostic code is
activated for the air/fuel pressure module. There
may be a problem with the ECM.
Repair: Turn the engine control switch to the

breaker for the ECM to the OFF position. Remove
the 7X-1710 Multimeter Probe. Reinstall the
terminals into the P1 connector. Pull on the wires
in order to verify proper installation.
It is unlikely that the ECM has failed. Exit this

procedure and perform this procedure again. If
the condition is not resolved, replace the ECM
according to Troubleshooting, “Replacing the
ECM”. Verify that the problem is resolved.
STOP.
g00870514
Illustration 114
Harness side of the ECM P1 connector • No – The duty cycle and the frequency of the
(P1-10) PWM signal for the inlet manifold air pressure suspect signal is not correct. The module is
(P1-11) PWM signal for the fuel differential pressure operating correctly and the engine harness is
(P1-69) -Battery OK. However, the ECM is not receiving a valid
signal. There is a problem with the wiring in the
B. Use a 151-6320 Wire Removal Tool to remove terminal box.
side of the ECM P1 connector. Label the wires. Repair: Turn the engine control switch to the
C. Use a multimeter to check the signals from the breaker for the ECM to the OFF position. Remove
removed terminals. the 7X-1710 Multimeter Probe. Reinstall the
a. Switch the 16 amp circuit breaker for the ECM in order to verify proper installation.
switch to the STOP position. Repair the connector(s) and/or the wiring, when
possible. Replace the connector(s) and/or the
b. Insert a 7X-1710 Multimeter Probe into wiring, if necessary.
terminal (P1-69). Measure the duty cycle and
the frequency between terminals (P1-69) and STOP.
(P1-10). Wiggle the harness in the terminal
problem.

Wiggle the harness in the terminal box in
order to check for an intermittent problem.
283
i01754995 The air/fuel pressure module sends PWM signals

that represent the inlet manifold air pressure and the
Air/Fuel Pressure Module fuel differential pressure to the Electronic Control
Module (ECM). The ECM uses the information to
SMCS Code: 1901-038 help calculate the fuel flow.
S/N: BLB1-Up
S/N: BKE1-Up poor connection or a problem in a wiring harness.
The next likely cause is a problem with the module.
System Operation Description: The least likely cause is a problem with the ECM.
Tubes that connect the air/fuel pressure module to Logged diagnostic codes provide a historical
the inlet air manifold and to the fuel manifold enable record. Before you begin this procedure, use the
the module to sense the absolute inlet manifold air Caterpillar Electronic Technician (Cat ET) to print
pressure and fuel pressure. The module calculates the logged codes to a file.
the differential pressure between the fuel manifold
and the inlet air manifold. This fuel differential The troubleshooting procedure may generate
pressure is the value of the fuel pressure minus the additional diagnostic codes. Keep your mind on
value of the inlet manifold air pressure. correcting the cause of the original diagnostic code.
Pulse Width Modulation (PWM) – This is a digital resolved.
signal. The frequency is constant: the widths of the
signal’s pulses are varied within a fixed interval
(frequency). The variable widths are also called a
duty cycle. The variable widths enable the signal to
be interpreted as a range of values. This provides a
more accurate status for a parameter than a signal
that can only be ON or OFF.
g00852792
Illustration 115
Example of a PWM signal
284
g00842539
Illustration 116
Schematic for the air/fuel pressure module

g00843984
Illustration 118
(4) Harness connector for the air/fuel pressure module
g00843978
Illustration 117
(1) ECM J1/P1 connectors B. Thoroughly inspect each of the following
(2) 16 amp circuit breaker for the ECM connectors:
position. Switch the 16 amp circuit breaker for • Terminal box J6/P6 connectors
• Harness connectors for the air/fuel pressure
Note: For the following steps, refer to module
connectors P1 and P6. The proper torque is
6 ±1 N·m (55 ± 9 lb in).
285
g00844052 g00844069
(10) PWM signal for the inlet manifold air pressure (11) Keyswitch +Battery
(11) PWM signal for the fuel differential pressure (21) -Battery
(69) -Battery (22) PWM signal for the fuel differential pressure
(70) Keyswitch +Battery (30) PWM signal for the inlet manifold air pressure

the air/fuel pressure module.

and for pinch points from the air/fuel pressure
module to the ECM.
Expected Result:

Results:


pinch points.
286
Repair: Perform the necessary repairs and/or If any of the codes are logged and the engine is
replace parts, if necessary. not operating properly, troubleshoot the symptom.
Refer to Troubleshooting, “Troubleshooting without
STOP. a Diagnostic Code”.
A. Switch the 16 amp circuit breaker for the ECM to Test Step 3. Verify the Supply Voltage to
the ON position. Turn the engine control switch the Module
B. Observe the “Active Diagnostic” screen on Cat position. Switch the 16 amp circuit breaker for
ET. Wait at least 30 seconds so that any codes the ECM to the OFF position.
• 94-03 Fuel Pressure open/short to +batt

• 94-08 Fuel Pressure noisy
• 106-03 Air Inlet Pressure Sensor short to +batt
• 106-08 Air Inlet Pressure Sensor noisy signal
C. Determine whether any of the same codes are
logged.
Expected Result:
g00844095
None of the above diagnostic codes are active or Illustration 121
logged. Harness connector for the air/fuel pressure module
Results: (B) -Battery
(C) PWM signal for the differential pressure of the fuel manifold
• OK (No codes) – None of the above diagnostic and the inlet air manifold
codes are active or logged. The problem seems
to be resolved. The air/fuel pressure module is
operating correctly at this time. B. Disconnect the harness connector from the
air/fuel pressure module.
caused by a poor electrical connection. For C. Switch the 16 amp circuit breaker for the ECM to
intermittent problems, refer to Troubleshooting, the ON position. Turn the engine control switch
“Inspecting Electrical Connectors”. to the STOP position.
STOP. D. Measure the voltage between terminals “A” and

“B” on the harness connector for the air/fuel
pressure module. Wiggle the harness in order to
• Not OK (Active code) – There is an active check for an intermittent problem.
diagnostic code for the air/fuel pressure module.
Expected Result:
• No (Logged code) – There are no active The voltage between terminals “A” and “B” on the
diagnostic codes for the air/fuel pressure module.
However, there is a logged code for the air/fuel harness connector for the air/fuel pressure module
pressure module. is approximately 24 VDC.
Repair: There may be a problem with the wiring Results:

and/or with a connector. Attempt to activate the
code by performing another pull test on the wires • OK – The voltage between terminals “A” and “B”
that are associated with the air/fuel pressure on the harness connector for the air/fuel pressure
module. Refer to Troubleshooting, “Inspecting module is approximately 24 VDC. Proceed to Test
Electrical Connectors”. Step 4.
287
• Not OK – The voltage between terminals “A”

and “B” on the harness connector for the air/fuel
pressure module is not approximately 24 VDC.

supply voltage at the terminal box.
g00843978
Illustration 122

breaker for the ECM to the OFF position. g00844303
Illustration 123
2. Disconnect connectors (J6/P6). Terminal box J6 connector
3. Switch the 16 amp circuit breaker for the ECM (J6-21) -Battery
switch to the STOP position. 4. Measure the voltage between terminals (J6-11)
and (J6-21). Wiggle the harness in the terminal
problem.
The correct voltage between terminals (J6-11)

and (J6-21) is approximately 24 VDC.
If the correct voltage is found on the J6

connector, there is a problem in the wiring
air/fuel pressure module. Repair the harness
or replace the harness.
If the correct voltage is not found on the J6

connector, there may be a problem in the
terminal box. Verify the voltage from the ECM.

OFF/RESET position. Switch the 16 amp
circuit breaker for the ECM to the OFF
position.
b. Disconnect the ECM J1/P1 connectors.
c. Switch the 16 amp circuit breaker for the

ECM to the ON position. Turn the engine
control switch to the STOP position.
288
g00844095
Illustration 125
Harness connector for the air/fuel pressure module
(B) -Battery
(C) PWM signal for the fuel differential pressure
B. Connect a jumper wire with the appropriate

connectors on the ends between terminal “A” on
the harness connector for the air/fuel pressure
module and terminal “A” on the module’s
receptacle. Connect another jumper wire
between terminal “B” on the harness connector
Illustration 124 g00849901 for the air/fuel pressure module and terminal “B”
on the module’s receptacle.
ECM J1 connector
(J1-69) -Battery C. Use a multimeter to measure the duty cycle and
the frequency of the suspect signal.
d. Measure the voltage between terminals
(J1-69) and (J1-70).
The correct voltage between terminals
(J1-69) and (J1-70) is approximately 24
b. Measure the duty cycle and the frequency
VDC.
between terminals “B” and “C” on the
If the correct voltage is found on the ECM
J1 connector, there is a problem with the
terminal box’s wiring. Repair the wiring or
between terminals “B” and “D” on the
replace the wiring.
If the correct voltage is not found on the
Expected Result:
ECM J1 connector, there may be a problem
with the electrical power supply. For further
The duty cycle between terminals “C”, “D” and
information on troubleshooting the electrical
terminal “B” is between 17 and 95 percent and the
power supply, refer to Troubleshooting,
“Electrical Power Supply”.
Results:
STOP.
Test Step 4. Check for a Signal from the • Yes – The duty cycle and the frequency of the
Module correctly. Proceed to Test Step 5.
position. Switch the 16 amp circuit breaker for • No – The duty cycle and/or the frequency of the
suspect signal is not correct. The module is not
operating correctly.
289
Repair: Turn the engine control switch to the a. Switch the 16 amp circuit breaker for the ECM
OFF/RESET position. Switch the 16 amp circuit to the ON position. Turn the engine control
breaker for the ECM to the OFF position. Remove switch to the STOP position.
the jumper wires from the connectors for the
air/fuel pressure module module. Replace the b. Insert a 7X-1710 Multimeter Probe into
air/fuel pressure module. terminal (P6-21). Measure the duty cycle and
the frequency between terminals (P6-21) and
STOP. (P6-22). Wiggle the harness in order to check
for an intermittent problem.
Test Step 5. Check for a Signal to the
Terminal Box c. Measure the duty cycle and the frequency
A. Turn the engine control switch to the OFF/RESET Wiggle the harness in order to check for an
position. Switch the 16 amp circuit breaker for intermittent problem.
Expected Result:
B. Remove the jumper wires from the connectors
for the air/fuel pressure module. Reconnect the The duty cycle between terminals (P6-22), (P6-30),
engine harness to the air/fuel pressure module. and (P6-21) is between 17 and 95 percent and the
Results:

correctly and the harness between the module
and the terminal box P6 connector is OK. There
may be a problem in the terminal box.

wires in order to verify proper installation.
• No – The duty cycle and the frequency of the

suspect signal is not correct. The module is
operating correctly but there is a problem with
a connection and/or the wiring in the engine
harness.

wires in order to verify proper installation. Repair
the harness, when possible. Replace the harness,
if necessary.
g00870486 STOP.
Illustration 126
(P6-22) PWM signal for the fuel differential pressure
Test Step 6. Check for a Signal at the ECM
(P6-30) PWM signal for the inlet manifold air pressure
(P6-21) -Battery A. Turn the engine control switch to the OFF/RESET
C. Use a 151-6320 Wire Removal Tool to remove the ECM to the OFF position.
side of the terminal box P6 connector. Label the
wires.
D. Use a multimeter to check the signals from the

removed terminals.
290
Expected Result:
The duty cycle for terminals (P1-10), (P1-11), and

(P1-69) is between 17 and 95 percent and the
Results:

suspect signal is correct. The ECM is receiving
a valid signal. However, a diagnostic code is
activated for the air/fuel pressure module. There
may be a problem with the ECM.

breaker for the ECM to the OFF position. Remove
the 7X-1710 Multimeter Probe. Reinstall the
in order to verify proper installation.

the condition is not resolved, replace the ECM
STOP.
g00870514
Illustration 127
Harness side of the ECM P1 connector • No – The duty cycle and the frequency of the
(P1-10) PWM signal for the inlet manifold air pressure suspect signal is not correct. The module is
(P1-11) PWM signal for the fuel differential pressure operating correctly and the engine harness is
(P1-69) -Battery OK. However, the ECM is not receiving a valid
signal. There is a problem with the wiring in the
B. Use a 151-6320 Wire Removal Tool to remove terminal box.
side of the ECM P1 connector. Label the wires. Repair: Turn the engine control switch to the
C. Use a multimeter to check the signals from the breaker for the ECM to the OFF position. Remove
removed terminals. the 7X-1710 Multimeter Probe. Reinstall the
a. Switch the 16 amp circuit breaker for the ECM in order to verify proper installation.
switch to the STOP position. Repair the connector(s) and/or the wiring, when
possible. Replace the connector(s) and/or the
b. Insert a 7X-1710 Multimeter Probe into wiring, if necessary.
terminal (P1-69). Measure the duty cycle and
the frequency between terminals (P1-69) and STOP.
(P1-10). Wiggle the harness in the terminal
problem.

Wiggle the harness in the terminal box in
order to check for an intermittent problem.
291
i01755080 This troubleshooting procedure may generate

Analog Sensor Signal correcting the cause of the original diagnostic
code. Clear the diagnostic code after the problem
SMCS Code: 1901-038 is resolved.
S/N: BEN1-Up
S/N: 4ZS1-Up
Use this procedure to troubleshoot diagnostic

codes for open circuits or for short circuits for the
sensors of these parameters:

• Engine coolant temperature
The engine coolant temperature sensor does not
require +5 VDC from the Electronic Control Module
(ECM). The engine coolant temperature sensor is an
analog type of passive sensor. The sensor operates
without a voltage supply from the ECM.
The ECM can be configured for one of these types

of speed control:
• 0 to 5 V potentiometer
• 4 to 20 mA
The “DESIRED SPEED” potentiometer (if equipped)
must be supplied with +5 VDC from the ECM. If
the “DESIRED SPEED” potentiometer has a short
circuit or the potentiometer’s wiring has a short
circuit, a 262-03 or 262-04 diagnostic code may be
activated. There are no diagnostic codes for the
circuit of the “DESIRED SPEED” potentiometer.

poor connection or a problem in a wiring harness.
The next likely cause is a problem with a sensor.

292
g00897995
Illustration 128
293
Test Step 1. Inspect the Electrical • Terminal strip in the control panel (if equipped)
Note: For the following steps, refer to the ECM connector and for the P5 connector.
Troubleshooting, “Inspecting Electrical Connectors”. The proper torque is 6 ± 1 N·m (55 ± 9 lb in).
g00897495
Illustration 129
Terminal Box
(1) ECM connector J1/P1
(3) Connectors J3/P3 for the customer’s connector
(5) J5/P5 connectors for the harness from the sensors g00897505
Illustration 131
Left view
(7) Inlet air temperature sensor
g00861762
Illustration 130
g00897508
Illustration 132
A. Thoroughly inspect each of the following Front view
connectors:
• ECM J1/P1 connectors (10) Filtered engine oil pressure sensor
• J3/P3 customer connectors in the terminal box

• J5/P5 and J4/P4 connectors on the bottom of
the terminal box
294
Expected Result:

Results:


pinch points.

STOP.

A. Connect Cat ET to the service tool connector.
g00897510
Illustration 133 B. Switch the 16 amp circuit breaker for the ECM
Right view ON. Turn the engine control switch to the STOP
(11) Fuel temperature sensor position.
C. Clear any logged diagnostic codes.

ET. Wait at least 30 seconds so that any codes

to +batt

to ground
Expected Result:

g00898036
Illustration 134
Front view and top view Results:
(AA) Top view
(13) Engine coolant temperature sensor • No codes – There are no active codes. The +5 V
sensor voltage supply is operating correctly at
b. Inspect each electrical connection for the this time. Proceed to Test Step 3.
analog sensors. Check the harnesses and
wiring for abrasion and for pinch points from • Active code – There is an active “5 Volt Sensor DC
each of the analog sensors to the ECM. Power Supply” diagnostic code. This procedure
will not work when this type of code is active.
295
Repair: Refer to Troubleshooting, “+5V Sensor If the engine is running properly at this time,
Voltage Supply”. there may be an intermittent problem in the
harness that is causing the codes to be logged.
STOP. Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
Test Step 3. Check for Active Analog
Sensor Diagnostic Codes STOP.
A. Observe the “Active Diagnostic” screen on Cat • Active “open/short to +batt” (FMI 03) – There is
ET. Wait at least 30 seconds so that any codes an active “open/short to +batt” diagnostic code.
may become activated. Look for the codes that If you are troubleshooting the sensor for engine
are listed in Table 28: coolant temperature, proceed to Test Step 6.
Otherwise, proceed to Test Step 5.
Table 28
Analog Sensor Diagnostic Codes • Active “short to ground” (FMI 04) – There is an
active “short to ground” diagnostic code. Proceed
100-03 Engine Oil Pressure open/short to +batt to Test Step 4.
100-04 Engine Oil Pressure short to ground
Test Step 4. Create an Open Circuit for
101-03 Crankcase Pressure open/short to +batt the Sensor
101-04 Crankcase Pressure short to ground
110-03 Engine Coolant Temperature open/short to position. Switch the 16 amp circuit breaker for
+batt the ECM OFF.
110-04 Engine Coolant Temperature short to ground
B. Disconnect the sensor that has the “short to
172-03 Intake Manifold Air Temp open/short to +batt ground” diagnostic code.
172-04 Intake Manifold Air Temp short to ground
C. Turn the engine control switch to the STOP
174-03 Fuel Temperature open/short to +batt position.
174-04 Fuel Temperature short to ground
175-03 Engine Oil Temperature open/short to +batt ET. Allow a minimum of thirty seconds for any
175-04 Engine Oil Temperature short to ground codes to activate. Look for an active “open/short
to +batt” diagnostic code.
542-03 Unfiltered Engine Oil Pressure open/short to
+batt Expected Result:
542-04 Unfiltered Engine Oil Pressure short to ground
There is an active “open/short to +batt” diagnostic
code for the disconnected sensor.
B. If one of the above codes is active, identify the
type of diagnostic according to the condition: the Results:
diagnostic code is either “open/short to +batt”
(FMI 03) or “short to ground” (FMI 04). • Yes – Before the suspect sensor was
disconnected, there was an active “short to
Expected Result: ground” diagnostic code. After the suspect
sensor was disconnected, there was an active
None of the above codes are active. “open/short to +batt” diagnostic code.
Note: There are no diagnostic codes for the desired Repair: Reconnect the sensor. If the active “short
speed signal. to ground” diagnostic code recurs, replace the
original sensor.
Results:
Verify that the code does not activate when
• No active codes – None of the above codes are the new sensor is installed. Clear the logged
active. diagnostic code from the ECM.
Repair: If any of the above codes are logged STOP.
and the engine is not running properly, refer
to Troubleshooting, “Troubleshooting Without a
Diagnostic Code”.
296
• Not OK – Before the suspect sensor was Repair: Verify that the wiring and/or connectors
disconnected, there was an active “short to are OK. Repair any faulty wiring and/or
ground” diagnostic code. After the suspect connectors, when possible. Replace any
sensor was disconnected, the active “short to faulty wiring and/or connectors, if necessary.
ground” diagnostic code remained. If you are Refer to Troubleshooting, “Inspecting Electrical
troubleshooting the sensor for engine coolant Connectors”. Check for diagnostic codes again.
temperature, proceed to Test Step 6. Otherwise,
proceed to Test Step 5. STOP.
Test Step 5. Check the Supply Voltage at Test Step 6. Check the Pull-Up Voltage at
the Sensor Connector the Sensor
A. Verify that the suspect sensor is disconnected A. Verify that the suspect sensor’s connector is
from the engine harness. disconnected from the engine harness.
g00847511 g00847511
Harness connectors for the various sensors Harness connectors for the various sensors
(A) +5 volt supply (A) +5 volt supply
(B) Return (B) Return
(C) Signal (C) Signal
B. At the harness connector for the suspect sensor, B. At the harness connector for the suspect sensor,
measure the voltage between terminal “A” and measure the voltage between terminal “B” and
terminal “B”. terminal “C”.
The voltage between terminal “A” and terminal “B” The voltage between terminal “B” and terminal “C”
is 5.0 ± 0.5 VDC. is 6.5 ± 0.5 VDC.
Results: Results:
• OK – The voltage between terminal “A” and • OK – The voltage between terminal “B” and
terminal “B” is 5.0 ± 0.5 VDC. +5 V is present at terminal “C” is 6.5 ± 0.5 VDC. The pull-up voltage
the sensor connector. Proceed to Test Step 6. that is created by the ECM is present at the
sensor connector. The signal wire and the return
• Not OK – The voltage between terminal “A” and wire for the suspect sensor appear to be OK.
“B” is not 5.0 ± 0.5 VDC. The voltage is not Proceed to Test Step 9.
present at the sensor connector. The +5 V supply
voltage must be present at the sensor in order to • Not OK – The voltage between terminal “B” and
continue this procedure. The +5 V wiring problem terminal “C” is not 6.5 ± 0.5 VDC. Proceed to Test
may be inside the terminal box, or in an engine Step 7.
harness.
297
Test Step 7. Check the Pull-Up Voltage D. Fabricate a jumper wire with the appropriate
at the Terminal Box connectors on the ends. Insert one end of the
jumper wire into the open terminal of the P5
A. Turn the engine control switch to the OFF/RESET connector. Pull on the jumper wire in order to
position. Switch the 16 amp circuit breaker for verify proper installation of the terminal.
the ECM OFF.
E. Connect a multimeter lead to the end of the
B. Refer to Table 29. Determine the signal terminal jumper wire that is not inserted into the connector.
for the suspect sensor.
F. Insert a 7X-1710 Multimeter Probe into terminal
Table 29 59 of the P5 connector.
Sensor Signal Terminal
G. Connect the other multimeter lead to the probe.
Inlet air temperature P5-60
Engine coolant temperature P5-50 H. Switch the 16 amp circuit breaker for the ECM to
the ON position. Turn the engine control switch
Engine oil temperature P5-34 to the STOP position.
Unfiltered engine oil pressure P5-26
I. Measure the pull-up voltage.
Filtered engine oil pressure P5-16
Crankcase pressure P5-66 Expected Result:
Fuel temperature P5-38 The pull-up voltage for the suspect sensor at the
terminal box is 6.5 ± 0.5 VDC.
Results:
• OK – The pull-up voltage for the suspect sensor

at the terminal box is 6.5 ± 0.5 VDC. The pull-up
voltage that is created by the ECM is present at
terminal box P5 connector. There is a problem
with the engine harness.
Turn the engine control switch to the OFF/RESET

the ECM OFF.
Disconnect the multimeter leads.
Use a 151-6320 Wire Removal Tool to remove

the jumper wire from the terminal box’s connector.
g00898079 Reinstall the terminal that was removed from the

Illustration 137 ECM connector. Pull on the wire in order to verify
Bottom of terminal box proper installation of the terminal.
(P5-16) Filtered engine oil pressure
(P5-26) Unfiltered engine oil pressure Repair any faulty wiring and/or connectors, when
(P5-34) Engine oil temperature possible. Replace the harness, if necessary.
(P5-38) Fuel temperature
(P5-50) Engine coolant temperature
(P5-59) Analog return STOP.
(P5-60) Inlet air temperature
(P5-66) Crankcase pressure
• Not OK. – The pull-up voltage for the suspect
sensor at the terminal box is not 6.5 ± 0.5 VDC.
C. Use a 151-6320 Wire Removal Tool to remove
the signal terminal that is appropriate for the Repair: Perform the following procedure:
suspect sensor.
the ECM OFF.

298
Use a 151-6320 Wire Removal Tool to remove Expected Result:

The pull-up voltage for the suspect sensor at the
Reinstall the terminal that was removed from the ECM is 6.5 ± 0.5 VDC.
terminal box’s connector. Pull on the wire in order
to verify proper installation of the terminal. Results:
Proceed to Test Step 8. • OK – The pull-up voltage for the suspect sensor
at the ECM is 6.5 ± 0.5 VDC. The ECM is
Test Step 8. Check the Pull-Up Voltage producing a pull-up voltage that is valid. There
at the ECM is a problem with the signal wire between P1
and P5 inside the terminal box. There may be a
A. Verify that the Engine Control Switch is in the problem with a connector.
OFF/RESET position. Verify that the 16 amp
circuit breaker for the ECM is OFF. Repair: Perform the following procedure:

the ECM OFF.

the jumper wire from the P1 connector.
Reinstall the terminal that was removed from the

P1 connector. Pull on the wire in order to verify
proper installation of the terminal.
g00898103
Illustration 138 Repair any faulty wiring and/or connectors, when
Harness side of the P1 connector possible. Replace any wiring and/or connectors, if
(3) Analog return necessary. Refer to Troubleshooting, “Inspecting
(14) Inlet manifold air temperature Electrical Connectors”.
(15) Fuel temperature
(16) Desired engine speed
(17) Oil temperature
STOP.
(18) +5 V supply
(19) Unused ground for the ECM • Not OK. – The pull-up voltage for the suspect
(24) Filtered oil pressure sensor at the ECM is not 6.5 ± 0.5 VDC. Proceed
(25) Crankcase pressure to Test Step 10.
(26) Unfiltered oil pressure
(27) Engine coolant temperature
Test Step 9. Check the Sensor
the signal wire for the suspect sensor from the A. Temporarily connect a sensor that is known to be
P1 connector. good to the engine harness.
C. Use a jumper wire with the appropriate B. Switch the 16 amp circuit breaker for the ECM
connectors on the ends. Insert one end of the ON. Turn the engine control switch to the STOP
jumper wire into the open terminal of the P1 position.
connector. Connect a multimeter lead to the end
of the jumper wire. C. Observe the “Active Diagnostic” screen on Cat
ET. Allow a minimum of 30 seconds for any
D. Insert a 7X-1710 Multimeter Probe into terminal codes to activate.
3 on the harness side of the P1 connector.
Connect the other multimeter lead to the probe. Expected Result:
E. Switch the 16 amp circuit breaker for the ECM No diagnostic codes are activated.
position.
F. Measure the pull-up voltage at the ECM.

299
Results:
• OK – No diagnostic codes are activated when a

good sensor is temporarily installed. Connecting
a new sensor resolved the problem.
1. Reconnect the suspect sensor. Verify that the

“open/short to +batt” diagnostic code recurs.
2. Disconnect the suspect sensor. Verify that

the “open/short to +batt” diagnostic code is
deactivated.
g00867468
3. Connect the new connector. Verify that no Illustration 139
diagnostic codes are activated. Harness side of the P1 connector
(19) Ground
If these conditions are true, replace the faulty
sensor with the new sensor. For the proper E. Use a jumper wire that is the appropriate length
torque value for the new sensor, refer to the with the appropriate connectors on the ends.
engine’s Specifications. Install one end of the jumper wire into the terminal
for the signal wire that was removed from the
4. Clear all of the diagnostic codes. Verify that P1 connector. Install the other end of the jumper
the problem has been resolved. wire into terminal (19) of the P1 connector. This
will replace the sensor circuit with a short circuit.
STOP.
F. Switch the 16 amp circuit breaker for the ECM
• Not OK – The active “open/short to +batt” code ON. Turn the engine control switch to the STOP
remains. Connecting a new sensor did not resolve position.
the problem. Proceed to Test Step 10.
G. Observe the “Active Diagnostic” screen on Cat
Test Step 10. Check the Operation of the ET. Allow a minimum of 30 seconds for any
ECM codes to activate.
A. Verify that the signal wire for the suspect sensor An active “short to ground” diagnostic code is
has been removed from the P1 connector. generated.
B. Clear any existing diagnostic codes. Expected Result:
C. Observe the “Active Diagnostic” screen on Cat Active “open/short to +batt” and “short to ground”
ET. Allow a minimum of 30 seconds for any diagnostic codes are generated according to the
codes to activate. above steps.
An active “open/short to +batt” diagnostic code Results:

is generated for the sensor.
• OK – Active “open/short to +batt” and “short
D. Turn the engine control switch to the OFF/RESET to ground” diagnostic codes are generated
position. Switch the 16 amp circuit breaker for according to the above steps. The ECM is
the ECM to the OFF position. operating correctly. The initial diagnostic code
was probably caused by a poor electrical
connection.

the ECM OFF.

300
Reinstall the terminal that was removed from the The engine coolant temperature sensor does not
P1 connector. Pull on the wire in order to verify require +5 VDC from the Electronic Control Module
proper installation of the terminal. (ECM). The engine coolant temperature sensor is an
analog type of passive sensor. The sensor operates
Resume normal operation. without a voltage supply from the ECM.
STOP. The ECM can be configured for one of these types

of speed control:
• Not OK – No active “open/short to +batt” or “short
to ground” diagnostic codes were generated. The • 0 to 5 V potentiometer
ECM is not operating correctly.
• 4 to 20 mA
Perform this entire procedure again. If the problem The “DESIRED SPEED” potentiometer (if equipped)
is not resolved, perform the following steps: must be supplied with +5 VDC from the ECM. If
the “DESIRED SPEED” potentiometer has a short
Temporarily install a new ECM. Refer to circuit or the potentiometer’s wiring has a short
Troubleshooting, “Replacing the ECM”. circuit, a 262-03 or 262-04 diagnostic code may be
activated. There are no diagnostic codes for the
If the problem is resolved with the new ECM, circuit of the “DESIRED SPEED” potentiometer.
install the original ECM and verify that the problem
returns. If the new ECM operates correctly and The most likely causes of the diagnostic code are a
the original ECM does not operate correctly, poor connection or a problem in a wiring harness.
replace the ECM. Refer to Troubleshooting, The next likely cause is a problem with a sensor.
“Replacing the ECM”. The least likely cause is a problem with the ECM.
STOP. Logged diagnostic codes provide a historical

i01755506
Analog Sensor Signal This troubleshooting procedure may generate
SMCS Code: 1901-038 additional diagnostic codes. Keep your mind on
correcting the cause of the original diagnostic
S/N: BLB1-Up code. Clear the diagnostic code after the problem
is resolved.
S/N: BKE1-Up
Use this procedure to troubleshoot diagnostic

codes for open circuits or for short circuits for the
sensors of these parameters:

• Engine coolant temperature
301
g00898178
Illustration 140
302

g00848213
Illustration 141
Terminal Box g00867318
Illustration 142
(1) ECM connector J2/P2 The inlet air temperature sensor is installed in the inlet manifold
(2) ECM connector J1/P1 between the two cylinder heads on the right side of the engine.
(4) J6/P6 connectors for the harness from the sensors on the left (6) Inlet air temperature sensor
side of the engine
(5) J5/P5 connectors for the harness from the sensors on the right
side of the engine
A. Thoroughly inspect each of the following

connectors:
• J2/P2and J1/P1 ECM connectors

• J5/P5 and J6/P6 connectors on the terminal
box

6 ± 1 N·m (55 ± 9 lb in).
g00847085
Illustration 143
Right side view and top side view of the engine
(7) Engine coolant temperature sensor
303
g00847095 g00847097
Front view Rear view
(8) Unfiltered engine oil pressure (12) Fuel temperature sensor
(9) Engine oil temperature
(10) Filtered engine oil pressure b. Inspect each electrical connection for the
analog sensors. Check the harnesses and
wiring for abrasion and for pinch points from
each of the analog sensors to the ECM.
Expected Result:

Results:

g00867324 wiring do not have corrosion, abrasion, or pinch
Illustration 145
Right side view near the front of the engine with proper connections. Proceed to Test Step 2.
pinch points.

STOP.
304
Test Step 2. Check for Diagnostic Codes Table 30

Analog Sensor Diagnostic Codes
A. Connect Cat ET to the service tool connector.
100-03 Engine Oil Pressure open/short to +batt
B. Switch the 16 amp circuit breaker for the ECM 100-04 Engine Oil Pressure short to ground
position. 101-03 Crankcase Pressure open/short to +batt
101-04 Crankcase Pressure short to ground
C. Clear any logged diagnostic codes.
110-03 Engine Coolant Temperature open/short to
D. Observe the “Active Diagnostic” screen on Cat +batt
ET. Wait at least 30 seconds so that any codes 110-04 Engine Coolant Temperature short to ground
172-03 Intake Manifold Air Temp open/short to +batt
• 262-03 5 Volt Sensor DC Power Supply short 172-04 Intake Manifold Air Temp short to ground
to +batt
174-03 Fuel Temperature open/short to +batt
• 262-04 5 Volt Sensor DC Power Supply short 174-04 Fuel Temperature short to ground
to ground
175-03 Engine Oil Temperature open/short to +batt
Expected Result:
175-04 Engine Oil Temperature short to ground
The 262-03 code or the 262-04 code is not active. 542-03 Unfiltered Engine Oil Pressure open/short to
+batt
Results: 542-04 Unfiltered Engine Oil Pressure short to ground
• No codes – There are no active codes. The +5 V

sensor voltage supply is operating correctly at B. If one of the above codes is active, identify the
this time. Proceed to Test Step 3. type of diagnostic according to the condition: the
diagnostic code is either “open/short to +batt”
• Active code – There is an active “5 Volt Sensor DC (FMI 03) or “short to ground” (FMI 04).
Power Supply” diagnostic code. This procedure
will not work when this type of code is active. Expected Result:
Repair: Refer to Troubleshooting, “+5V Sensor None of the above codes are active.
Voltage Supply”.
Note: There are no diagnostic codes for the desired
STOP. speed signal.
Test Step 3. Check for Active Analog Results:

Sensor Diagnostic Codes
• No active codes – None of the above codes are
A. Observe the “Active Diagnostic” screen on Cat active.
may become activated. Look for the codes that Repair: If any of the above codes are logged
are listed in Table 30: and the engine is not running properly, refer
Diagnostic Code”.
If the engine is running properly at this time,

there may be an intermittent problem in the
harness that is causing the codes to be logged.
Connectors”.
STOP.
305
• Active “open/short to +batt” (FMI 03) – There is Test Step 5. Check the Supply Voltage at
an active “open/short to +batt” diagnostic code. the Sensor Connector
If you are troubleshooting the sensor for engine
coolant temperature, proceed to Test Step 6. A. Verify that the suspect sensor is disconnected
Otherwise, proceed to Test Step 5. from the engine harness.
• Active “short to ground” (FMI 04) – There is an

active “short to ground” diagnostic code. Proceed
to Test Step 4.
Test Step 4. Create an Open Circuit for

the Sensor
the ECM OFF.
B. Disconnect the sensor that has the “short to

ground” diagnostic code.
g00847511
C. Turn the engine control switch to the STOP Illustration 147
position. Harness connectors for the various sensors
(A) +5 volt supply
D. Observe the “Active Diagnostic” screen on Cat (B) Return
ET. Allow a minimum of thirty seconds for any (C) Signal
codes to activate. Look for an active “open/short
to +batt” diagnostic code. B. At the harness connector for the suspect sensor,
measure the voltage between terminal “A” and
Expected Result: terminal “B”.
There is an active “open/short to +batt” diagnostic Expected Result:

code for the disconnected sensor.
The voltage between terminal “A” and terminal “B”
Results: is 5.0 ± 0.5 VDC.
• Yes – Before the suspect sensor was Results:

disconnected, there was an active “short to
ground” diagnostic code. After the suspect • OK – The voltage between terminal “A” and
sensor was disconnected, there was an active terminal “B” is 5.0 ± 0.5 VDC. +5 V is present at
“open/short to +batt” diagnostic code. the sensor connector. Proceed to Test Step 6.
Repair: Reconnect the sensor. If the active “short • Not OK – The voltage between terminal “A” and
to ground” diagnostic code recurs, replace the “B” is not 5.0 ± 0.5 VDC. +5 V is not present at
original sensor. the sensor connector. The +5 V supply voltage
must be present at the sensor in order to continue
Verify that the code does not activate when this procedure. The +5 V wiring problem may be
the new sensor is installed. Clear the logged inside the terminal box, or in an engine harness.
diagnostic code from the ECM.
Repair: Verify that the wiring and/or connectors
STOP. are OK. Repair any faulty wiring and/or
connectors, when possible. Replace any
• Not OK – Before the suspect sensor was faulty wiring and/or connectors, if necessary.
disconnected, there was an active “short to Refer to Troubleshooting, “Inspecting Electrical
ground” diagnostic code. After the suspect Connectors”. Check for diagnostic codes again.
sensor was disconnected, the active “short to
ground” diagnostic code remained. If you are STOP.
troubleshooting the sensor for engine coolant
temperature, proceed to Test Step 6. Otherwise, Test Step 6. Check the Pull-Up Voltage at
proceed to Test Step 5. the Sensor
A. Verify that the suspect sensor’s connector is
disconnected from the engine harness.
306
Table 31
Sensor Signal Terminal
Inlet air temperature P5-60
Engine coolant temperature P5-42
Engine oil temperature P5-16
Unfiltered engine oil pressure P5-26
Filtered engine oil pressure P5-34
Crankcase pressure P5-50
Fuel temperature P6-56
g00847511
Illustration 148
Harness connectors for the various sensors
(A) +5 volt supply
(B) Return
(C) Signal
B. At the harness connector for the suspect sensor,

measure the voltage between terminal “B” and
terminal “C”.
Expected Result:
The voltage between terminal “B” and terminal “C”

is 6.5 ± 0.5 VDC.
Results:
• OK – The voltage between terminal “B” and

terminal “C” is 6.5 ± 0.5 VDC. The pull-up voltage
that is created by the ECM is present at the
sensor connector. The signal wire and the return g00867387
Illustration 149
wire for the suspect sensor appear to be OK. Bottom view of terminal box
(P5-16) Engine oil temperature
(P5-26) Unfiltered engine oil pressure
• Not OK – The voltage between terminal “B” and (P5-34) Filtered engine oil pressure
terminal “C” is not 6.5 ± 0.5 VDC. Proceed to Test (P5-42) Engine coolant temperature
Step 7. (P5-50) Crankcase pressure
(P5-59) Return
(P5-60) Inlet air temperature
Test Step 7. Check the Pull-Up Voltage (P6-56) Fuel temperature
at the Terminal Box
A. Turn the engine control switch to the OFF/RESET the signal terminal that is appropriate for the
position. Switch the 16 amp circuit breaker for suspect sensor.
the ECM OFF.
D. Fabricate a jumper wire with the appropriate
B. Refer to Table 31. Determine the signal terminal connectors on the ends. Insert one end of the
for the suspect sensor. jumper wire into the open terminal of the P5 or
P6 connector. Pull on the jumper wire in order to
verify proper installation of the terminal.
E. Connect a multimeter lead to the end of the

jumper wire that is not inserted into the connector.
F. Insert a 7X-1710 Multimeter Probe into terminal

59 of the P5 connector. Connect the other
multimeter lead to the probe.
307
G. Switch the 16 amp circuit breaker for the ECM to Test Step 8. Check the Pull-Up Voltage
the ON position. Turn the engine control switch at the ECM
A. Verify that the Engine Control Switch is in the
H. Measure the pull-up voltage. OFF/RESET position. Verify that the 16 amp
circuit breaker for the ECM is OFF.
Expected Result:
The pull-up voltage for the suspect sensor at the

terminal box is 6.5 ± 0.5 VDC.
Results:

at the terminal box is 6.5 ± 0.5 VDC. The pull-up
voltage that is created by the ECM is present at
with the right side engine harness or a harness
connector.
Repair: Perform the following procedure: g00898103

Illustration 150
Turn the engine control switch to the OFF/RESET Harness side of the P1 connector
position. Switch the 16 amp circuit breaker for (3) Analog return
the ECM OFF. (14) Inlet manifold air temperature
(15) Fuel temperature
Disconnect the multimeter leads. (17) Oil temperature
(18) +5 V supply
Use a 151-6320 Wire Removal Tool to remove (19) Unused ground for the ECM
the jumper wire from the terminal box’s connector. (24) Filtered oil pressure
(25) Crankcase pressure
Reinstall the terminal that was removed from the (27) Engine coolant temperature
ECM connector. Pull on the wire in order to verify
proper installation of the terminal. B. Use a 151-6320 Wire Removal Tool to remove
the signal wire for the suspect sensor from the
Repair any faulty wiring and/or connectors, when P1 connector.
C. Use a jumper wire with the appropriate
STOP. connectors on the ends. Insert one end of the
jumper wire into the open terminal of the P1
• Not OK. – The pull-up voltage for the suspect connector. Connect a multimeter lead to the end
sensor at the terminal box is not 6.5 ± 0.5 VDC. of the jumper wire.
Repair: Perform the following procedure: D. Insert a 7X-1710 Multimeter Probe into terminal
3 on the harness side of the P1 connector.
Turn the engine control switch to the OFF/RESET Connect the other multimeter lead to the probe.
the ECM OFF. E. Switch the 16 amp circuit breaker for the ECM
Disconnect the multimeter leads. position.
Use a 151-6320 Wire Removal Tool to remove F. Measure the pull-up voltage at the ECM.
Expected Result:
terminal box’s connector. Pull on the wire in order The pull-up voltage for the suspect sensor at the
to verify proper installation of the terminal. ECM is 6.5 ± 0.5 VDC.
308
Results: 1. Reconnect the suspect sensor. Verify that the

“open/short to +batt” diagnostic code recurs.
at the ECM is 6.5 ± 0.5 VDC. The ECM is 2. Disconnect the suspect sensor. Verify that
producing a pull-up voltage that is valid. There the “open/short to +batt” diagnostic code is
is a problem with the signal wire between P1 deactivated.
and P5 inside the terminal box. There may be a
problem with a connector. 3. Connect the new connector. Verify that no
diagnostic codes are activated.
If these conditions are true, replace the faulty
Turn the engine control switch to the OFF/RESET sensor with the new sensor. For the proper
position. Switch the 16 amp circuit breaker for torque value for the new sensor, refer to the
the ECM OFF. engine’s Specifications.
Disconnect the multimeter leads. 4. Clear all of the diagnostic codes. Verify that
the problem has been resolved.
the jumper wire from the P1 connector. STOP.
Reinstall the terminal that was removed from the • Not OK – The active “open/short to +batt” code
P1 connector. Pull on the wire in order to verify remains. Connecting a new sensor did not resolve
proper installation of the terminal. the problem. Proceed to Test Step 10.
Verify that the wiring and/or connectors are OK. Test Step 10. Check the Operation of the
Repair any faulty wiring and/or connectors, when ECM
possible. Replace any wiring and/or connectors, if
necessary. Refer to Troubleshooting, “Inspecting
Electrical Connectors”.
STOP.
• Not OK. – The pull-up voltage for the suspect

sensor at the ECM is not 6.5 ± 0.5 VDC. Proceed
to Test Step 10.

A. Temporarily connect a sensor that is known to be
good to the engine harness.
g00898103
B. Switch the 16 amp circuit breaker for the ECM Illustration 151
ON. Turn the engine control switch to the STOP Harness side of the P1 connector
position. (3) Analog return
(14) Inlet manifold air temperature
C. Observe the “Active Diagnostic” screen on Cat (15) Fuel temperature
ET. Allow a minimum of 30 seconds for any (17) Oil temperature
codes to activate. (18) +5 V supply
(19) Unused ground for the ECM
Expected Result: (24) Filtered oil pressure
(25) Crankcase pressure
No diagnostic codes are activated. (27) Engine coolant temperature
Results: A. Verify that the signal wire for the suspect sensor
has been removed from the P1 connector.
• OK – No diagnostic codes are activated when a
good sensor is temporarily installed. Connecting B. Clear any existing diagnostic codes.
a new sensor resolved the problem.
C. Observe the “Active Diagnostic” screen on Cat
Repair: Perform the following procedure: ET. Allow a minimum of 30 seconds for any
codes to activate.
309
An active “open/short to +batt” diagnostic code Turn the engine control switch to the OFF/RESET
is generated for the sensor. position. Switch the 16 amp circuit breaker for
the ECM OFF.
D. Turn the engine control switch to the OFF/RESET
position. Switch the 16 amp circuit breaker for Use a 151-6320 Wire Removal Tool to remove
the ECM to the OFF position. the jumper wire from the P1 connector.

P1 connector. Pull on the wire in order to verify
Resume normal operation.
STOP.
• Not OK – No active “open/short to +batt” or “short

to ground” diagnostic codes were generated. The
ECM is not operating correctly.

Perform this entire procedure again. If the problem
g00867468
Illustration 152 is not resolved, perform the following steps:
Harness side of the P1 connector
(19) Ground Temporarily install a new ECM. Refer to
E. Use a jumper wire that is the appropriate length
with the appropriate connectors on the ends. If the problem is resolved with the new ECM,
Install one end of the jumper wire into the terminal install the original ECM and verify that the problem
for the signal wire that was removed from the returns. If the new ECM operates correctly and
P1 connector. Install the other end of the jumper the original ECM does not operate correctly,
wire into terminal (19) of the P1 connector. This replace the ECM. Refer to Troubleshooting,
will replace the sensor circuit with a short circuit. “Replacing the ECM”.
F. Switch the 16 amp circuit breaker for the ECM STOP.

position. i01755982
G. Observe the “Active Diagnostic” screen on Cat Choke Actuator Solenoid

ET. Allow a minimum of 30 seconds for any
codes to activate. SMCS Code: 1901-038
An active “short to ground” diagnostic code is S/N: BEN1-Up

generated.
S/N: 4ZS1-Up
Expected Result:
Active “open/short to +batt” and “short to ground”
The Electronic Control Module (ECM) controls the
diagnostic codes are generated according to the
above steps. air choke actuator by adjusting current flow through
the actuator’s solenoid.
Results:
The diagnostic code is probably caused by a
problem in a harness or by a problem with an
• OK – Active “open/short to +batt” and “short electrical connector. The next likely cause is a
to ground” diagnostic codes are generated
problem inside the actuator solenoid. The least
according to the above steps. The ECM is
likely cause is a problem with the ECM.
operating correctly. The initial diagnostic code
was probably caused by a poor electrical
connection.
310

resolved.
g00898524
Illustration 153
Schematic of the circuit for the air choke actuator

Note: This step is important for troubleshooting a
problem with instability.
g00898559
Illustration 155
Left side view of the engine
(4) Air choke actuator
(5) Engine harness connectors for the air choke actuator
g00850164
Illustration 154

the ECM OFF. Illustration 156 g00850186

Troubleshooting, “Inspecting Electrical Connectors”. (P2-63) Air choke actuator’s circuit driver
(P2-64) Return
311

pinch points.

STOP.
Test Step 2. Check the Solenoid and

Harnesses for an Open Circuit
Illustration 157 the ECM OFF.
Harness side of the terminal box’s P6 connector
(P6-12) Return B. Disconnect the P2 connector from the ECM.
(P6-22) Air choke actuator’s circuit driver

connectors:

• J6/P6 connectors on the terminal box
• Engine harness’ connectors for the air choke
actuator

the ECM connector and for the P6 connector.
The proper torque is 6 ± 1 N·m (55 ± 9 lb in).
g00850190
Illustration 158
b. Perform a 45 N (10 lb) pull test on the wires ECM side of connector P2
that are associated with the circuit for the air (P2-63) Air choke actuator’s circuit driver
choke actuator. (P2-64) Return
c. Thoroughly inspect the engine harness C. Measure the resistance between terminals P2-63
connectors for the air choke actuator for and P2-64. During this measurement, wiggle the
moisture and for corrosion. Check the harness harnesses in order to check for an intermittent
and wiring for abrasion and for pinch points problem. Be sure to wiggle the harness near the
from the air choke actuator to the ECM. connectors.
All connectors, pins, and sockets are connected The resistance is between 5.0 and 20.6 ohms.
corrosion, abrasion, or pinch points. Results:
Results: • OK – The resistance is between 5.0 and 20.6

ohms. The solenoid and wiring appear to be OK.
• OK – All connectors, pins, and sockets are The return wire may have a short to ground.
connected properly. The connectors and the Proceed to Test Step 3.
points. The components are in good condition with • Not OK – The resistance is higher than 20.6
proper connections. If you are troubleshooting ohms. There is a problem with a connector and/or
a “525-05 open” diagnostic code, proceed to with the wiring for the solenoid or the solenoid
Test Step 2. If you are troubleshooting a “525-06 may have a problem. Proceed to Test Step 6.
short” diagnostic code, proceed to Test Step 8.
312
Test Step 3. Check All of the Return Test Step 4. Check the Return Wiring
Wiring for a Short to Ground Inside the Engine Harness for a Short to
Ground
A. Verify that connector P2 is disconnected from
the ECM.
g00898607
Illustration 160
(1) Ground strap for the ECM
g00852300
Illustration 159 (P6) Terminal box’s side of the engine harness’ connector
ECM side of connector P2 (P6-12) Return

(P2-64) Return A. Disconnect connector P6 from the terminal box.
B. Measure the resistance between the ground B. Measure the resistance between the ground
strap for the ECM and terminal P2-64. During strap for the ECM and terminal P6-12. During
this measurement, wiggle the harness in order this measurement, wiggle the harness in order
to check for an intermittent problem. Be sure to to check for an intermittent problem. Be sure to
wiggle the harness near the connectors. wiggle the harness near the connectors.
The resistance is greater than 20,000 ohms. The resistance is greater than 20,000 ohms.
Results: Results:
• OK – The resistance is greater than 20,000 ohms. • OK – The resistance is greater than 20,000
The return wire for the air choke actuator appears ohms. The return wire inside the engine harness
to be OK. Proceed to Test Step 12. appears to be OK. There is a problem with the
return wire inside the terminal box.
ohms. There is a problem with the return wire for Repair: Repair the wiring and/or the connector,
the air choke actuator. Proceed to Test Step 4. when possible. Replace the parts, if necessary.
STOP.

ohms. The return inside the engine harness may
have a problem or there may be a problem with
the solenoid. Proceed to Test Step 5.
313
Test Step 5. Check the Solenoid for an Repair: Replace the solenoid. Refer to Operation
Internal Short Circuit and Maintenance Manual, “Electrohydraulic
Actuator - Recondition”.
STOP.

and the Solenoid for an Open Circuit
g00898561
Illustration 162
Terminal box’s side of the engine harness P6 connector
(P6-12) Return
g00898553
Illustration 161 A. Disconnect the engine harness P6 connector
(AA) Solenoid’s connector from the terminal box.
(A) Air choke actuator’s circuit driver
(B) Return
B. Measure the resistance between terminals
P6-12 and P6-22. During this measurement,
A. Disconnect the engine harness connector from wiggle the harness in order to check for an
the air choke actuator’s solenoid. intermittent problem. Be sure to wiggle the
harness connectors.
B. Measure the resistance between terminal B on
the solenoid’s connector and the connector’s Expected Result:
shell.
The resistance is between 5.0 and 20.6 ohms.
Expected Result:
Results:

ohms. The engine harness and the solenoid
appear to be OK. The wiring inside the terminal
• OK – The resistance is greater than 20,000 ohms. box or the terminal box’s connectors may have
The solenoid does not have an internal short a problem.
circuit. The return wire inside the engine harness
has a short to ground. Repair: Repair the wiring and/or connectors,
when possible. Replace the wiring, if necessary.
Repair: Repair the engine harness or connectors,
when possible. Replace the harness, if necessary. STOP.
STOP.
• Not OK – The resistance is greater than 20.6
ohms. There is a problem with the engine harness
• Not OK – The resistance is less than 20,000 or with the solenoid. Proceed to Test Step 7.
ohms. The solenoid has an internal short circuit.
314
Open Circuit and Maintenance Manual, “Electrohydraulic
STOP.
Test Step 8. Check all of the Wiring and

the Solenoid for a Short Circuit
g00850190
Illustration 164
(P2-64) Return
A. Disconnect the P2 connector from the ECM.

g00898553 B. Measure the resistance between P2-63 and
Illustration 163
(AA) Solenoid’s connector P2-64. During this measurement, wiggle the
(A) Air choke actuator’s circuit driver harness in order to check for an intermittent
(B) Return problem. Be sure to wiggle the harness near the
connectors.
A. Disconnect the engine harness connector from
the air choke actuator’s solenoid. Expected Result:
B. Measure the resistance between terminals A and The resistance is between 5.0 and 20.6 ohms.
B on the solenoid’s connector.
Results:
Expected Result:
• OK – The resistance is between 5.0 and 20.6
The resistance is between 5.0 and 10.3 ohms. ohms. The solenoid and wiring do not have a
short circuit. Proceed to Test Step 11.
Results:
• Not OK – The resistance is less than 5.0 ohms.
• OK – The resistance of the solenoid is between There is a problem with a connector and/or with
5.0 and 10.3 ohms. The solenoid does not have the wiring or the solenoid has a problem. Proceed
an open circuit. There is an open circuit in the to Test Step 9.
engine harness.

when possible. Replace the harness, if necessary.
STOP.
• Not OK – The resistance of the solenoid is higher

than 10.3 ohms. The resistance of the solenoid is
incorrect. The solenoid has an open circuit.
315
Test Step 9. Check the Engine Harness Test Step 10. Check the Solenoid for a
and the Solenoid for a Short Circuit Short Circuit
g00898561
Illustration 165
(P6-12) Return
A. Disconnect the P6 connector from the terminal

box.
B. Measure the resistance between terminals P6-12

and P6-22. During this measurement, wiggle the
harness in order to check for an intermittent
problem. Be sure to wiggle the harness near the
connectors.
g00898553
Illustration 166
Expected Result: (AA) Solenoid’s connector
The resistance is between 5.0 and 20.6 ohms. (B) Return
Results: A. Disconnect the engine harness’ connector from

the air choke actuator’s solenoid.
ohms. The engine harness and the solenoid B. Measure the resistance between terminals A and
appear to be OK. The wiring inside the terminal B on the solenoid’s connector.
box has a problem.
Expected Result:
Repair: Repair the wiring and/or the connector,
when possible. Replace the harness, if necessary. The resistance is between 5.0 and 10.3 ohms.
STOP. Results:
• Not OK – The resistance is lower than 5.0 ohms. • OK – The resistance of the solenoid is between
There is a problem with the engine harness or 5.0 and 10.3 ohms. The solenoid does not have
with the solenoid. Proceed to Test Step 10. a problem. The engine harness appears to have
a short circuit.

STOP.
• Not OK – The resistance of the solenoid is lower

incorrect. The solenoid has a short circuit.
316
Repair: Replace the solenoid. Refer to Operation Results:

and Maintenance Manual, “Electrohydraulic
Actuator - Recondition”. • OK – When an open circuit was created, a
525-05 diagnostic code was generated. The ECM
STOP. is operating correctly. The problem appears to
be resolved. The initial diagnostic code was
Test Step 11. Create an Open Circuit and probably caused by a poor electrical connection.
Check the Operation of the ECM
A. Prevent fuel from entering the engine. Verify
that the gas supply to the engine is OFF. Turn the engine control switch to the OFF position.
Switch the 16 amp circuit breaker for the ECM
B. Verify that the engine control switch is in the OFF.
circuit breaker for the ECM is OFF. Reinstall the terminals that were removed from
connector P2. Pull on the wires in order to verify
proper installation of the terminals.
Reconnect all of the connectors. Verify that the

STOP.
• Not OK – When an open circuit was created, a

525-05 diagnostic code was not generated. The
ECM may have a problem.

g00850186
Illustration 167 following procedure:
(P2-63) Air choke actuator’s circuit driver Temporarily install a new ECM. Refer to
(P2-64) Return Troubleshooting, “Replacing the ECM”.
C. Use a 151-6320 Wire Removal Tool to remove If the problem is resolved with a new ECM, install
terminals P2-63 and P2-64. This will replace the the original ECM and verify that the problem
wiring for the air choke actuator with an open returns. If the new ECM operates correctly and
circuit. the original ECM does not operate correctly,
replace the original ECM. Follow the instructions
D. Switch the 16 amp circuit breaker for the ECM in Troubleshooting, “Replacing the ECM”.
ON.
STOP.
E. If a 525-05 diagnostic code and/or a 525-06
diagnostic code is logged, clear the code. Test Step 12. Create a Short Circuit and
F. Turn the engine control switch to the START
position and crank the engine. Allow a minimum A. Prevent fuel from entering the engine. Verify
of 30 seconds for the generation of any codes. that the gas supply to the engine is OFF.
Then turn the engine control switch to the STOP
position. B. Verify that the engine control switch is in the
G. Observe the “Active Diagnostic” screen on Cat circuit breaker for the ECM is OFF.
ET. Look for a 525-05 diagnostic code.
Expected Result:
A 525-05 diagnostic code is generated.

317
Remove the jumper wire from the P2 connector.
Reinstall the terminals that were removed from


STOP.
• Not OK – When the wiring for the air choke

actuator was replaced with a short circuit, a
525-06 diagnostic code was not generated by the
g00850186
ECM. The ECM may have a problem.
Illustration 168
Harness side of the ECM P2 connector Repair: It is unlikely that the ECM has failed.
(P2-63) Air choke actuator’s circuit driver Exit this procedure and perform this procedure
(P2-64) Return again. If the problem is not resolved, perform the
following procedure:
terminals P2-63 and P2-64. Temporarily install a new ECM. Refer to
D. Fabricate a jumper wire of the appropriate length
with the appropriate connectors. Insert one end If the problem is resolved with a new ECM, install
of the jumper wire into the open terminals P2-63 the original ECM and verify that the problem
and P2-64. Verify that the sockets are contacting returns. If the new ECM operates correctly and
the pins. This will replace the wiring for the air the original ECM does not operate correctly,
choke actuator with a short circuit. replace the original ECM. Follow the instructions
in Troubleshooting, “Replacing the ECM”.
E. Switch the 16 amp circuit breaker for the ECM
ON. STOP.
F. If a 525-05 diagnostic code and/or a 525-06

diagnostic code is logged, clear the code. i01756886
G. Turn the engine control switch to the START

Choke Actuator Solenoid
position and crank the engine. Allow a minimum
SMCS Code: 1901-038
of 30 seconds for the generation of any codes.
Then turn the engine control switch to the STOP S/N: BLB1-Up
position.
S/N: BKE1-Up
H. Observe the “Active Diagnostic” screen on Cat
ET. Look for a 525-06 diagnostic code. System Operation Description:
Expected Result: The Electronic Control Module (ECM) controls the

air choke actuator by adjusting current flow through
A 525-06 diagnostic code is generated. the actuator’s solenoid.
Results: The diagnostic code is probably caused by a

short circuit in a harness or by a problem with an
• OK – When the wiring for the air choke actuator electrical connector. The next likely cause is a short
was replaced with a short circuit, a 525-06 circuit inside the actuator solenoid. The least likely
diagnostic code was generated by the ECM. The cause is a problem with the ECM.
ECM is operating correctly. The problem appears
to be resolved. The initial diagnostic code was Logged diagnostic codes provide a historical
probably caused by a poor electrical connection. record. Before you begin this procedure, use the
Repair: Perform the following procedure: the logged codes to a file.
Turn the engine control switch to the OFF position.

OFF.
318

resolved.
g00899897
Illustration 169
Schematic of the circuit for the air choke actuator

g00866896
Illustration 171
(4) Air choke actuator
(5) Engine harness connectors for the air choke actuator
g00850164
Illustration 170
(2) J6/P6 connectors for the left engine harness

the ECM OFF.

319
Expected Result:

Results:

points. The components are in good condition with
proper connections. If you are troubleshooting a
525-05 diagnostic code, proceed to Test Step 2.
g00850186
If you are troubleshooting a 525-06 diagnostic
Illustration 172 code, proceed to Test Step 8.
(P2-63) Air choke actuator’s circuit driver • Not OK – At least one of the connectors, pins, or
(P2-64) Return sockets is not connected properly. At least one
pinch points.

STOP.

the ECM OFF.
g00850188
Illustration 173 B. Disconnect the P2 connector from the ECM.
(P6-44) Return

connectors:

• Engine harness’ connectors for the air choke
actuator

g00850190
the ECM connector and for the P6 connector. Illustration 174
The proper torque is 6 ± 1 N·m (55 ± 9 lb in). ECM side of connector P2
b. Perform a 45 N (10 lb) pull test on the four (P2-64) Return
the air choke actuator. C. Measure the resistance between terminals P2-63
c. Thoroughly inspect the engine harness harnesses in order to check for an intermittent
connectors for the air choke actuator for problem. Be sure to wiggle the harness near the
moisture and for corrosion. Check the harness connectors.
and wiring for abrasion and for pinch points
from the air choke actuator to the ECM.
320
The resistance is between 5.0 and 20.6 ohms. • OK – The resistance is greater than 20,000 ohms.
The return wire for the air choke actuator appears
Results: to be OK. Proceed to Test Step 12.
• OK – The resistance is between 5.0 and 20.6 • Not OK – The resistance measurement is less
ohms. The solenoid and wiring appear to be OK. than 20,000 ohms. There is a problem with the
The low side wire may have a short to ground or return wire for the air choke actuator. Proceed to
the ECM may have a problem. Proceed to Test Test Step 4.
Step 3.
Test Step 4. Check the Return Wiring
• Not OK – The resistance is higher than 20.6 Inside the Engine Harness for a Short to
ohms. There is a problem with a connector and/or Ground
with the wiring for the solenoid or the solenoid
may have a problem. Proceed to Test Step 6.
Test Step 3. Check All of the Return

Wiring for a Short to Ground
the ECM.
g00852362
Illustration 176
(P6) Terminal box’s side of the engine harness’ connector
(P6-44) Return
A. Disconnect connector P6 from the terminal box.
B. Measure the resistance between the ground

g00852300 strap for the ECM and terminal P6-44. During
Illustration 175
ECM side of connector P2 this measurement, wiggle the harness in order
to check for an intermittent problem. Be sure to
(P2-64) Return wiggle the harness near the connectors.
B. Measure the resistance between the ground Expected Result:

strap for the ECM and terminal P2-64. During
this measurement, wiggle the harness in order The resistance is greater than 20,000 ohms.
to check for an intermittent problem. Be sure to
wiggle the harness near the connectors. Results:
Expected Result: • OK – The resistance is greater than 20,000

ohms. The return wire inside the engine harness
The resistance is greater than 20,000 ohms. appears to be OK. There is a problem with the
321
Repair: Repair the wiring and/or the connector, Repair: Repair the engine harness or connectors,
when possible. Replace the parts, if necessary. when possible. Replace the harness, if necessary.
STOP. STOP.
• Not OK – The resistance is less than 20,000 • Not OK – The resistance is less than 20,000
ohms. The return wire inside the engine harness ohms. The solenoid has an internal short circuit.
may have a problem or there may be a problem
with the solenoid. Proceed to Test Step 5. Repair: Replace the solenoid. Refer to Operation
Test Step 5. Check the Solenoid for an Actuator - Recondition”.
Internal Short Circuit
.
STOP.

g00852315
Illustration 178
(P6-44) Return
A. Disconnect the engine harness connector P6

g00850485
from the terminal box.
Illustration 177
(1) Solenoid for the air choke actuator B. Measure the resistance between terminals
(B) Return P6-44 and P6-45. During this measurement,
(Shell) Shell for the connector
wiggle the harness in order to check for an
intermittent problem. Be sure to wiggle the
A. Disconnect the engine harness connector P527 harness connectors.
from the air choke actuator’s solenoid.
Expected Result:
B. Measure the resistance between terminal B and
the connector’s shell. The resistance is between 5.0 and 20.6 ohms.
Results: appear to be OK. The wiring inside the terminal
box or the terminal box’s connectors may have
• OK – The resistance is greater than 20,000 ohms. a problem.
The solenoid does not have an internal short
circuit. The return wire inside the engine harness Repair: Repair the wiring and/or connectors,
has a short to ground. when possible. Replace the wiring, if necessary.
STOP.
322
• Not OK – The resistance is greater than 20.6 • Not OK – The resistance of the solenoid is higher
ohms. There is a problem with the engine harness than 10.3 ohms. The resistance of the solenoid is
or with the solenoid. Proceed to Test Step 7. incorrect. The solenoid has an open circuit.
STOP.

g00850190
Illustration 180
(P2-64) Return

g00850456 B. Measure the resistance between P2-63 and
Illustration 179
(1) Solenoid on the air choke actuator P2-64. During this measurement, wiggle the
(B) Return harness in order to check for an intermittent
(A) Air choke actuator’s circuit driver problem. Be sure to wiggle the harness near the
connectors.
A. Disconnect the engine harness connector from
the air choke actuator’s solenoid. Expected Result:
B. Measure the resistance between terminals B and The resistance is between 5.0 and 20.6 ohms.
A on the solenoid’s connector.
Results:
Expected Result:
Results:
engine harness.

STOP.
323
g00852315
Illustration 181
(P6-44) Return

box.

connectors.
g00850456
Illustration 182
Expected Result: (1) Solenoid on the air choke actuator
The resistance is between 5.0 and 20.6 ohms. (B) Return
Results: A. Disconnect the engine harness’ connector from

the air choke actuator’s solenoid.
ohms. The engine harness and the solenoid B. Measure the resistance between terminals B and
appear to be OK. The wiring inside the terminal A on the solenoid’s connector.
box has a problem. There may be a problem with
a connector. Expected Result:
Repair: Repair the wiring and/or the connector, The resistance is between 5.0 and 10.3 ohms.
Results:
STOP.
• OK – The resistance of the solenoid is between
• Not OK – The resistance is lower than 5.0 ohms. 5.0 and 10.3 ohms. The solenoid does not have
There is a problem with the engine harness or a problem. The engine harness appears to have
with the solenoid. Proceed to Test Step 10. a short circuit.

STOP.

324

Actuator - Recondition”. • OK – When an open circuit was created, a
STOP. is operating correctly. The problem appears to

STOP.


g00850186
(P2-63) Air choke actuator’s circuit driver Temporarily install a new ECM. Refer to
wiring for the air choke actuator with an open returns. If the new ECM operates correctly and
circuit. the original ECM does not operate correctly,
D. Switch the 16 amp circuit breaker for the ECM in Troubleshooting, “Replacing the ECM”.
ON.
STOP.
diagnostic code is logged, clear the code. Test Step 12. Create a Short Circuit and
position and crank the engine. Allow a minimum A. Prevent fuel from entering the engine. Verify
of 30 seconds for the generation of any codes. that the gas supply to the engine is OFF.
position. B. Verify that the engine control switch is in the
G. Observe the “Active Diagnostic” screen on Cat circuit breaker for the ECM is OFF.
Expected Result:

325


STOP.
• Not OK – When the wiring for the air choke

525-06 diagnostic code was not generated by the
g00850186
ECM. The ECM may have a problem.
Illustration 184
(P2-63) Air choke actuator’s circuit driver Exit this procedure and perform this procedure
(P2-64) Return again. If the problem is not resolved, perform the
D. Fabricate a jumper wire of the appropriate length
with the appropriate connectors. Insert one end If the problem is resolved with a new ECM, install
of the jumper wire into the open terminals P2-63 the original ECM and verify that the problem
the pins. This will replace the wiring for the air the original ECM does not operate correctly,
choke actuator with a short circuit. replace the original ECM. Follow the instructions
ON. STOP.


Combustion Sensor
SMCS Code: 1901-038
Then turn the engine control switch to the STOP S/N: BEN1-Up
position.
S/N: 4ZS1-Up
Expected Result: Each cylinder has a combustion sensor that is

positioned on the edge of the cylinder. When the
A 525-06 diagnostic code is generated. engine control switch is in the STOP position, in
the START position, or in the AUTO position, the
Results: Integrated Combustion Sensing Module (ICSM)
provides +80 VDC to the combustion sensors.
• OK – When the wiring for the air choke actuator
was replaced with a short circuit, a 525-06 When the flame front reaches the sensor, the
diagnostic code was generated by the ECM. The sensor briefly outputs a low voltage signal that
ECM is operating correctly. The problem appears is approximately −80 millivolts. The sensor’s low
to be resolved. The initial diagnostic code was voltage signal is detected by the ICSM. The ICSM
probably caused by a poor electrical connection. measures the length of time from the all cylinders
firing signal to the combustion sensor’s signal. The
Repair: Perform the following procedure: ICSM determines the combustion burn time for the
cylinder.
OFF.
326
Each combustion sensor has a single terminal that

is connected to a signal wire. The signal wire from
each sensor is shielded.
Use this procedure to troubleshoot the system

only when there is an active noisy diagnostic code
or an active short circuit diagnostic code that is
associated with a combustion sensor.
A noisy diagnostic code indicates that the signal

from the sensor is noisy or connected to the wrong
cylinder.
Note: If the harness from the sensor is not routed to

the proper connector, the combustion burn time will
be incorrect. False misfire will be indicated.
The short to ground diagnostic code indicates that

the sensor’s signal has a short circuit or the signal
is below the acceptable range.


resolved.
g00898228
Illustration 185
Schematic for the circuit of the combustion sensors for the six cylinder engine
327
g00898229
Illustration 186
Schematic for the circuit of the combustion sensors for the eight cylinder engine

position. Switch OFF the 16 amp circuit breaker
for the Electronic Control Module (ECM).

g00858362
Illustration 187
(1) ICSM
(2) Connectors for the combustion sensors
328
Table 32
Cylinders and Corresponding Connectors
on the ICSM
Cylinder Connectors on the ICSM
1 R3
2 R2
3 R1
4 L1
5 L2
6 L3
For an eight cylinder engine, refer to Table 33 for

the proper connections:
Table 33
Cylinders and Corresponding Connectors
on the ICSM
1 R4
2 R3
3 R2
g00858414
Illustration 188 4 R1
Section view of a cylinder head with a combustion sensor
5 L1
(3) Harness connector
(4) Extension 6 L2
(5) Sensor
7 L3
B. Thoroughly inspect the suspect connector (2) at
the ICSM for corrosion or moisture. 8 L4
C. Thoroughly inspect the suspect connector (3) for Expected Result:

corrosion or moisture.
D. Thoroughly check the suspect harness for properly. The connectors and the wiring do not have
abrasion and for pinch points from the sensor corrosion, abrasion, or pinch points. The sensors
to the ICSM. are connected to the correct connector on the ICSM.
E. Verify that the suspect harness has the proper Results:
length in order to reach from the sensor to the
ICSM.
F. Verify that the suspect harness is connected to wiring do not have corrosion, abrasion, or pinch
the correct connector on the ICSM. points. The components are in good condition with
For a six cylinder engine, refer to Table 32 for noisy diagnostic code, proceed to Test Step 2. If
the proper connections: you are troubleshooting a diagnostic code for a
short circuit, proceed to Test Step 4.

pinch points. The components are not in good
condition and/or at least one of the connections
is improper.
329
Repair: Perform the necessary repairs and/or Results:

• No -02 code – Before the suspect harness was
STOP. replaced, there was a -02 diagnostic code. After
the suspect harness was replaced, there was
Test Step 2. Replace the Harness no -02 diagnostic code. The suspect harness is
faulty.
Repair: Completely install the new harness onto

the engine. Resume normal operation.
STOP.
• Active -02 code – Before the harness was

replaced, there was a -02 diagnostic code. After
the harness was replaced, the -02 diagnostic
code remained.

breaker for the ECM OFF. Remove the new
harness and install the original harness.
Test Step 3. Inspect the Extension and

the Combustion Sensor
A. Inspect the combustion sensor and clean the
sensor, if necessary. Refer to Operation and
Maintenance Manual, “Combustion Sensor -
Clean/Inspect/Replace”.
B. Start the engine. Use Cat ET to place the engine

g00858679 in the prechamber calibration mode.
Illustration 189
(2) Seal C. Observe the “Active Diagnostics” screen on
(3) Connector Cat ET. The engine must be in the prechamber
calibration mode for at least 30 seconds in order
A. Temporarily exchange the suspect harness with for the -02 diagnostic code to become activated.
a harness that is known to be good. The new Look for an active -02 diagnostic code.
harness must be long enough to reach from
the sensor to the ICSM. Verify that seal (2) is Expected Result:
installed in connector (1) on the new harness.
Ensure that connectors (1) and (3) are clean, The -02 diagnostic code is not active.
dry, and properly connected. Do not install the
new harness onto the engine. Results:
B. Start the engine. Use Cat ET to place the engine • No -02 code – Before the sensor and extension
in the prechamber calibration mode. were serviced, there was a -02 diagnostic code.
After the sensor and extension were serviced,
C. Observe the “Active Diagnostics” screen on there was no -02 diagnostic code. Resume
Cat ET. The engine must be in the prechamber normal operation. STOP.
calibration mode for at least 30 seconds in order
for the -02 diagnostic code to become activated. • Active -02 code – Before the sensor and extension
Look for an active -02 diagnostic code. were serviced, there was a -02 diagnostic code.
After the sensor and extension were serviced, the
Expected Result: noisy diagnostic code remained. The ICSM may
have a problem.
The -02 code is not active.
330
Repair: It is unlikely that the ICSM has failed. C. Switch the 16 amp circuit breaker for the ECM
Exit this procedure and perform this procedure ON. Turn the engine control switch to the STOP
again. If the problem is not resolved, perform the position.
following steps:
D. Observe the “Active Diagnostics” screen on Cat
Temporarily install a new ICSM. Refer to ET. Wait at least 30 seconds so that any codes
Troubleshooting, “Replacing the ICSM”. may become activated. Look for an active -04
short circuit diagnostic code.
If the problem is resolved with a new ICSM,
install the original ICSM and verify that the Expected Result:
problem returns. If the new ICSM operates
correctly and the original ICSM does not operate The -04 diagnostic code is not active.
correctly, replace the original ICSM. Refer to
Troubleshooting, “Replacing the ICSM”. Results:
STOP. • No -04 code – Before the harness connector was

disconnected, there was a -04 diagnostic code.
Test Step 4. Disconnect the Combustion After the harness connector was disconnected,
Sensor there was no -04 diagnostic code. There is a
problem with the extension or with the sensor.
A. Verify that the engine control switch is in the
OFF/RESET position. Verify that the 16 amp Repair: Perform the following steps:
1. Thoroughly inspect harness connector (1)
and connector (3) for moisture. Inspect
O-ring seal (2) in the harness connector.
Refer to Operation and Maintenance Manual,
“Combustion Sensor - Clean/Inspect/Replace”.
2. Reconnect harness connector (1).
3. Switch the 16 amp circuit breaker for the ECM

position. Observe the “Active Diagnostics”
screen on Cat ET. Wait at least 30 seconds so
that any codes may become activated. Verify
that the problem is resolved.
STOP.

disconnected at the sensor there was a
-04 diagnostic code. After the harness was
disconnected the -04 diagnostic code remained.
There is a problem with the harness or with the
ICSM. Proceed to Test Step 5.
Test Step 5. Disconnect the Harness at

the ICSM
g00858679
Illustration 190 position. Switch the 16 amp circuit breaker for
Section view of a cylinder head with a combustion sensor the ECM OFF.
(2) Seal
(3) Connector
B. Disconnect harness connector (1) for the suspect

sensor.
331

position.

may become activated. Look for an active -04
code.
Expected Result:
The -04 diagnostic code is not active.
Results:
g00858905
Illustration 191
• No -04 code – Before the harness was
ICSM disconnected from the ICSM, there was a -04
(1) ICSM diagnostic code. Disconnecting the harness from
(2) Connector the ICSM cleared the -04 diagnostic code. The
harness is faulty.
B. Disconnect the suspect connector (2) from the
ICSM. Repair: Replace the harness. Verify that the
original condition is resolved.
For a six cylinder engine, refer to Table 34 for
the proper connections: STOP.
Table 34
Cylinders and Corresponding Connectors disconnected from the ICSM, there was a
on the ICSM -04 diagnostic code. After the harness was
disconnected from the ICSM, the -04 code
remained. The ICSM may have a problem.
1 R3
Repair: It is unlikely that the ICSM has failed.
2 R2
3 R1 again. If the problem is not resolved, perform the
following steps:
4 L1
5 L2 Temporarily install a new ICSM. Refer to
6 L3
For an eight cylinder engine, refer to Table 35 for install the original ICSM and verify that the
the proper connections: problem returns. If the new ICSM operates
correctly and the original ICSM does not operate
Table 35 correctly, replace the original ICSM. Refer to
Cylinders and Corresponding Connectors Troubleshooting, “Replacing the ICSM”.
on the ICSM
STOP.
1 R4
2 R3
3 R2
4 R1
5 L1
6 L2
7 L3
8 L4
332
i01755651
Combustion Sensor
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
Each cylinder has a combustion sensor that is

positioned on the edge of the cylinder. When the
engine control switch is in the STOP position, in
the START position, or in the AUTO position, the
provides +80 VDC to the combustion sensors.
When the flame front reaches the sensor, the

sensor briefly outputs a low voltage signal that
is approximately −80 millivolts. The sensor’s low
voltage signal is detected by the ICSM. The ICSM
measures the length of time from the all cylinders
firing signal to the combustion sensor’s signal. The
ICSM determines the combustion burn time for the
cylinder.
Each combustion sensor has a single terminal that

is connected to a signal wire. The signal wire from
each sensor is shielded.
Use this procedure to troubleshoot the system

only when there is an active noisy diagnostic code
or an active short circuit diagnostic code that is
associated with a combustion sensor.
A noisy diagnostic code indicates that the signal

from the sensor is noisy or connected to the wrong
cylinder.
Note: If the harness from the sensor is not routed to

the proper connector, the combustion burn time will
be incorrect. False misfire will be indicated.
The short to ground diagnostic code indicates that

the sensor’s signal has a short circuit or the signal
is below the acceptable range.


resolved.
333
g00865595
Illustration 192
Schematic for the circuit of the combustion sensors for the 12 cylinder engine
334
g00858406
Illustration 193
Schematic for the circuit of the combustion sensors for the 16 cylinder engine
335


Note: Illustration 194 shows one side of the engine.

The other side of the engine is similar.
g00858414
Illustration 195
(4) Extension
(5) Sensor
g00858362
Illustration 194 B. Thoroughly inspect the suspect connector (2) at
Left side of the engine the ICSM for corrosion and for moisture.
(1) ICSM
(2) Connectors for the combustion sensors C. Thoroughly inspect the suspect connector (3) for
corrosion and for moisture.
D. Thoroughly check the suspect harness for

abrasion and for pinch points from the sensor
to the ICSM.
E. Verify that the suspect harness has the proper

length in order to reach from the sensor to the
ICSM.
F. Verify that the suspect harness is connected to

the correct connector on the ICSM.
For a 12 cylinder engine, refer to Table 36 for

the proper connections:
336
Table 36 Expected Result:

Cylinder Connectors on Connectors on
the Left Side the Right Side All connectors, pins, and sockets are connected
ICSM ICSM properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points. The sensors
1 R3 are connected to the correct connector on the ICSM.
2 L3
Results:
3 R2
4 L2 • OK – All connectors, pins, and sockets are
5 R1 wiring do not have corrosion, abrasion, or pinch
6 L1 points. The components are in good condition with
7 L1 noisy diagnostic code, proceed to Test Step 2. If
8 R1 you are troubleshooting a diagnostic code for a
short circuit, proceed to Test Step 4.
9 L2
10 R2 • Not OK – At least one of the connectors, pins, or
11 L3 connector or wire has corrosion, abrasion, and/or
12 R3
pinch points. The components are not in good
condition and/or at least one of the connections
are improper.
For a 16 cylinder engine, refer to Table 37 for
the proper connections: Repair: Perform the necessary repairs and/or
Table 37
Cylinder Connectors on Connectors on STOP.
the Left Side the Right Side
ICSM ICSM
1 R4
2 L4
3 R3
4 L3
5 R2
6 L2
7 R1
8 L1
9 L1
10 R1
11 L2
12 R2
13 L3
14 R3
15 L4
16 R4
337
Test Step 2. Replace the Harness Repair: Completely install the new harness onto
the engine. Resume normal operation.
STOP.

the harness was replaced, the -02 diagnostic
code remained.

breaker for the ECM OFF. Remove the new
harness and install the original harness.
Test Step 3. Inspect the Extension and

the Combustion Sensor
A. Inspect the combustion sensor and clean the
sensor, if necessary. Refer to Operation and
Maintenance Manual, “Combustion Sensor -
Clean/Inspect/Replace”.
B. Start the engine. Use Cat ET to place the engine

in the prechamber calibration mode.
C. Observe the “Active Diagnostics” screen on

g00858679 Cat ET. The engine must be in the prechamber
Illustration 196
(1) Harness connector calibration mode for at least 30 seconds in order
(2) Seal for the -02 diagnostic code to become activated.
(3) Connector Look for an active -02 diagnostic code.
A. Temporarily exchange the suspect harness with Expected Result:

a harness that is known to be good. The new
harness must be long enough to reach from The -02 diagnostic code is not active.
the sensor to the ICSM. Verify that seal (2) is
installed in connector (1) on the new harness. Results:
Ensure that connectors (1) and (3) are clean,
dry, and properly connected. Do not install the • No -02 code – Before the sensor and extension
new harness onto the engine. were serviced, there was a -02 diagnostic code.
After the sensor and extension were serviced,
B. Start the engine. Use Cat ET to place the engine there was no -02 diagnostic code. Resume
in the prechamber calibration mode. normal operation. STOP.
C. Observe the “Active Diagnostics” screen on • Active -02 code – Before the sensor and extension
Cat ET. The engine must be in the prechamber were serviced, there was a -02 diagnostic code.
calibration mode for at least 30 seconds in order After the sensor and extension were serviced, the
for the -02 diagnostic code to become activated. noisy diagnostic code remained. The ICSM may
Look for an active -02 diagnostic code. have a problem.
Expected Result: Repair: It is unlikely that the ICSM has failed.

The -02 code is not active. again. If the problem is not resolved, perform the
following steps:
Results:
Temporarily install a new ICSM. Refer to
• No -02 code – Before the suspect harness was Troubleshooting, “Replacing the ICSM”.
the suspect harness was replaced, there was
no -02 diagnostic code. The suspect harness is
faulty.
338
If the problem is resolved with a new ICSM, Expected Result:

install the original ICSM and verify that the
problem returns. If the new ICSM operates The -04 diagnostic code is not active.
correctly, replace the original ICSM. Refer to Results:
• No -04 code – Before the harness connector was
STOP. disconnected, there was a -04 diagnostic code.
After the harness connector was disconnected,
Test Step 4. Disconnect the Combustion there was no -04 diagnostic code. There is a
Sensor problem with the extension or with the sensor.
A. Verify that the engine control switch is in the Repair: Perform the following steps:
circuit breaker for the ECM is OFF. 1. Thoroughly inspect harness connector (1)
and connector (3) for moisture. Inspect
O-ring seal (2) in the harness connector.
Refer to Operation and Maintenance Manual,
“Combustion Sensor - Clean/Inspect/Replace”.
2. Reconnect harness connector (1).

position. Observe the “Active Diagnostics”
screen on Cat ET. Wait at least 30 seconds so
that any codes may become activated. Verify
STOP.

disconnected at the sensor there was a
disconnected the -04 diagnostic code remained.
There is a problem with the harness or with the
ICSM. Proceed to Test Step 5.
Test Step 5. Disconnect the Harness at

the ICSM
g00858679
(2) Seal
(3) Connector
B. Disconnect harness connector (1) for the suspect

sensor.

position.

short circuit diagnostic code.
339
Table 39
Diagnostic Cylinder Connectors Connectors
Code on the Left on the Right
Side ICSM Side ICSM
1101-04 1 R4
1102-04 2 L4
1103-04 3 R3
1104-04 4 L3
1105-04 5 R2
1106-04 6 L2
1107-04 7 R1
g00858905
Illustration 198
1108-04 8 L1
ICSM
(1) ICSM 1109-04 9 L1
(2) Connector
1110-04 10 R1
B. Disconnect the suspect connector (2) from the 1111-04 11 L2
ICSM.
1112-04 12 R2
The connectors for the 12 cylinder engine are 1113-04 13 L3
identified in Table 38:
1114-04 14 R3
Table 38 1115-04 15 L4
Diagnostic Cylinder Connectors Connectors 1116-04 16 R4
Code on the Left on the Right
Side ICSM Side ICSM
1101-04 1 R3
1102-04 2 L3 position.
1103-04 3 R2
1104-04 4 L2 ET. Wait at least 30 seconds so that any codes
1105-04 5 R1
code.
1106-04 6 L1
Expected Result:
1107-04 7 L1
1108-04 8 R1 The -04 diagnostic code is not active.
1109-04 9 L2 Results:
1110-04 10 R2
1111-04 11 L3
• No -04 code – Before the harness was
disconnected from the ICSM, there was a -04
1112-04 12 R3 diagnostic code. Disconnecting the harness from
the ICSM cleared the -04 diagnostic code. The
harness is faulty.
The connectors for the 16 cylinder engine are
identified in Table 39: Repair: Replace the harness. Verify that the
original condition is resolved.
STOP.

disconnected from the ICSM, there was a
disconnected from the ICSM, the -04 code
remained. The ICSM may have a problem.
340
Repair: It is unlikely that the ICSM has failed. The 1043-08 diagnostic code is caused if the
Exit this procedure and perform this procedure number one cylinder firing signal and the all
again. If the problem is not resolved, perform the cylinders firing signal are connected to the opposite
following steps: terminals somewhere in the circuit.
Temporarily install a new ICSM. Refer to A -02, -03, and -04 diagnostic code is probably
Troubleshooting, “Replacing the ICSM”. caused by a problem with a harness connector
or with the wiring. The next likely cause is a faulty
If the problem is resolved with a new ICSM, electronic component.
problem returns. If the new ICSM operates Logged diagnostic codes provide a historical
correctly and the original ICSM does not operate record. Before you begin this procedure, use the
correctly, replace the original ICSM. Refer to Caterpillar Electronic Technician (Cat ET) to print
Troubleshooting, “Replacing the ICSM”. the logged codes to a file.
STOP. This troubleshooting procedure may generate

i01755668
Cylinder Firing Pulse resolved.
SMCS Code: 1901-038

S/N: BEN1-Up
S/N: 4ZS1-Up
Use this procedure to troubleshoot cylinder firing

signals that have diagnostic codes which are active
or easily repeated.
There are two different types of cylinder firing

signals. The number one cylinder firing signal
indicates that the Electronic Control Module (ECM)
is commanding the spark plug in the number
one cylinder to fire. The all cylinders firing signal
indicates that the ECM is commanding the spark
plug in each cylinder to fire. Each signal is
developed on a wire that connects the ECM to the
Integrated Combustion Sensing Module (ICSM).
The number one cylinder firing signal is created by

the ICSM and by the ECM. The modules maintain
the signal wire at +13 volts. The ECM pulls the
signal wire to ground potential whenever the
number one cylinder is commanded to fire. The
ECM maintains the wire at ground potential for g00898263
Illustration 199
approximately 200 microseconds. Schematic of the circuit for the cylinder firing signals
The all cylinders firing signal is also created by Test Step 1. Inspect the Electrical
the ICSM and by the ECM. The modules maintain Connectors and Wiring
the signal wire at +13 volts. The ECM pulls the
signal wire to ground potential whenever a spark A. Turn the engine control switch to the OFF/RESET
plug is commanded to fire. The ECM maintains position. Switch the 16 amp circuit breaker for
the wire at ground potential for approximately 300 the ECM OFF.
microseconds.
341
Results:

• Not OK – At least one of the connectors, pins,

or sockets is not connected properly. At least
one connector or wire has corrosion, abrasion,
and/or pinch points. The components are not in
good condition and/or at least one connection
is improper.
g00898264
Illustration 200 Repair: Perform the necessary repairs and/or
Terminal box replace parts, if necessary.
(2) 16 amp circuit breaker for the ECM STOP.
(3) J5/P5 connector for the engine harness
Test Step 2. Verify that the Diagnostic
Codes are Still Active
A. To prevent the engine from starting, shut the
main gas supply OFF.
B. Connect Cat ET to the service tool connector.

ON.
D. Crank the engine for ten seconds. Look for the

codes that are listed in Table 40:
g00898291
Table 40
Illustration 201
Diagnostic Codes for the Cylinder Firing Signal
(4) ICSM
(5) Engine harness connectors for the ICSM 1043-02 Cylinder #1 Firing Signal noisy
B. Thoroughly inspect the following connectors: 1043-03 Cylinder #1 Firing Signal open/short to +batt
1043-04 Cylinder #1 Firing Signal short to ground
• ECM J1/P1
1043-08 Cylinder #1 Firing Signal abnormal signal
• Terminal box’s J5/P5 1044-02 All Cylinder Firing Signal noisy
• Engine harness connectors for the ICSM 1044-03 All Cylinder Firing Signal open/short to +batt
1044-04 All Cylinder Firing Signal short to ground
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the
cylinder firing signals. Expected Result:
D. Check the harnesses and wiring for abrasion There are no active codes or logged codes.
and for pinch points from the connector for each
module to the terminal box. Results:
E. Check the wiring inside the terminal box for • OK - no codes – The problem seems to be
moisture, for abrasion, and for pinch points. resolved. There are no active codes or logged
codes. The cylinder firing signals are operating
Expected Result: correctly at this time.

342

caused by a poor electrical connection in one
of the harness connectors or terminals. Resume
normal operation.
STOP.
• Not OK - Active -02 Noisy – There is an active

diagnostic code for a noisy cylinder firing signal.
• Not OK - Active -03 Open – There is an active

code for a cylinder firing signal that has an open
circuit, or a short circuit to a positive voltage
source. Proceed to Test Step 3.
• Not OK - Active -04 Short – There is an active

code for a cylinder firing signal that has a short
to ground. Proceed to Test Step 6.
• Not OK - Active -08 Abnormal – A cylinder firing

signal is abnormal. Proceed to Test Step 3.

Wiring for an Open Circuit or a Short
Circuit to a Positive Voltage Source
g00898272
Illustration 203
(P1) ECM side of the connector for the ECM
(J5) Terminal box’s jack for the engine harness
(P1-49) All cylinders firing signal
(P1-58) Number one cylinder firing signal
(P1-69) -Battery
(J5-10) All cylinders firing signal
g00898264 (J5-20) Number one cylinder firing signal
Illustration 202 (J5-21) -Battery
Terminal box
(1) ECM J1/P1 connectors B. Disconnect connectors P1 and P5. This will
(2) 16 amp circuit breaker for the ECM isolate the wiring inside the terminal box.
(3) J5/P5 connector for the engine harness
C. Measure the resistance between the terminals
A. Turn the engine control switch to the OFF/RESET that are listed in Table 41. During each
position. Switch the 16 amp circuit breaker for measurement, wiggle the harness in order to
the ECM OFF. check for an intermittent problem. Be sure to
wiggle the harness near each of the connectors.
Table 41
P1-58 J5-20
P1-49 J5-10
343
The correct resistance measurements for Table Repair: Repair the harness or the connector, when
41 are less than 5 ohms. If the resistance possible. Replace the harness or the connector, if
measurements are incorrect, there is an open necessary.
circuit.
STOP.

for an Open Circuit or a Short Circuit to
a Positive Voltage Source
A. Connect the P5 connector to the terminal box.
B. Disconnect the engine harness connector from

the ICSM.
g00863864
Illustration 204
ECM side of connector P1
(P1-49) All cylinder firing signal
(P1-53) +Battery
D. Measure the resistance between the terminals

measurement, wiggle the harness in order
to check for an intermittent problem with the
harness. Be sure to wiggle the harness near g00898306
Illustration 205
each of the connectors. ECM side of connector P1
Table 42 (P1-49) All cylinder firing signal

Points for the Measurement of Resistance (P1-69) -Battery
Connector and Terminal Connector and Terminal C. Fabricate a jumper wire that is the appropriate
P1-53 P1-58 length with the appropriate terminals on the
ends. Connect the jumper wire between terminals
P1-49 P1-49 and P1-58.
The correct resistance measurements for

Table 42 are greater than 20,000 ohms. If the
resistance measurements are incorrect, there is
a short circuit to a positive voltage source.
Expected Result:
All of the resistance checks are within the

specifications.
Results:
• OK – All of the resistance checks are within the

specifications. The wires for the cylinder firing
signals inside the terminal box do not have an
open circuit or a short circuit to a positive voltage
• Not OK – At least one of the resistance checks

is not within the specifications. There is an open
circuit in the wiring inside the terminal box or
there is a short circuit to a positive voltage source.
There may be a problem with a connector.
344
g00863864
Illustration 207
(P1-53) +Battery
H. Measure the resistance between the terminals

harness. Be sure to wiggle the harness near
each of the connectors.
Illustration 206 g00898336 Table 43
Engine harness connector for the ICSM Points for the Measurement of Resistance
D. Measure the resistance between terminals E and
H on the engine harness connector for the ICSM. P1-53 P1-58
During the measurement, wiggle the harness in
P1-49
order to check for an intermittent problem with
the harness. Be sure to wiggle the harness near
the connector. The correct resistance measurements for Table
43 are greater than 20,000 ohms.
The correct resistance measurement is less than
5 ohms. Expected Result:
E. At the P1 connector, connect the jumper wire The resistance checks are within the specifications.
between terminals P1-49 and P1-69.
Results:
F. Measure the resistance between terminals B and
H on the engine harness connector for the ICSM. • OK – All of the resistance checks are within the
The correct resistance measurement is less than signals inside the engine harness do not have an
5 ohms. open circuit or a short circuit to a positive voltage
source. The wires for the cylinder firing signals
G. Remove the jumper wire from the P1 connector. are not switched. Proceed to Test Step 5.

circuit in the wiring inside the engine harness or
345
Repair: Repair the harness or the connector, when Test Step 6. Check for +13 V at the ECM
possible. Replace the harness or the connector, if
necessary.
STOP.

Code is still Active
B. Reconnect the P1 connector to the ECM.

Reconnect the engine harness connector to the
ICSM.

ON.

Table 44 g00863734
Illustration 208
1043-03 Cylinder #1 Firing Signal open/short to +batt (P1-49) All cylinder firing signal
1044-03 All Cylinder Firing Signal open/short to +batt (P1-69) -Battery
1043-08 Cylinder Firing Signal Abnormal
A. At the harness side of the P1 connector, insert
two 7X-1710 Multimeter Probes. Insert the first
Expected Result: probe into terminal 69. If you are troubleshooting
a problem with the signal for the number one
The codes that are listed in Table 44 are not active cylinder firing signal, insert the second probe
or logged. into terminal 58. If you are troubleshooting a
problem with the all cylinders firing signal, insert
Results: the second probe into terminal 49.
• No codes – The problem seems to be resolved. B. Connect a voltmeter to the probes and measure
The cylinder firing signals are operating correctly the voltage.
at this time.
Expected Result:
caused by a poor electrical connection in one The voltage at the P1 connector is 13 ± 3 VDC.
of the harness connectors or terminals. Resume
normal operation. Results:
STOP. • OK – The voltage at the P1 connector is 13 ± 3
VDC. The voltage appears to be OK. The ECM
• Active code – At least one of the diagnostic does not have an internal short circuit. Remove
codes is active. Proceed to Test Step 11. the probes from the P1 connector. Proceed to
Test Step 7.
• Not OK – The voltage at the P1 connector is

not 13 ± 3 VDC. The voltage is not within the
specification. The ICSM or the ECM may have a
problem. Do not remove the probe from terminal
69. Remove the probe from terminal 49 or terminal
58. Proceed to Test Step 8.
346
Test Step 7. Crank the Engine and Check

for Diagnostic Codes
B. Crank the engine for ten seconds. Look for the

codes that are listed in Table
Table 45
1043-02 Cylinder #1 Firing Signal noisy
1044-02 All Cylinder Firing Signal noisy
Expected Result:
g00863734
Illustration 209
None of the codes are active or logged. Harness side of the ECM P1 connector
Results: (P1-58) Number one cylinder firing signal
(P1-69) -Battery
• No codes – None of the codes are active or
logged. The problem seems to be resolved. The B. Use a 151-6320 Wire Removal Tool to remove
cylinder firing signals appear to be operating terminal 58 or 49 from ECM connector P1. If you
correctly at this time. are troubleshooting a problem with the number
one cylinder firing signal, remove terminal 58. If
Repair: The initial diagnostic code was probably you are troubleshooting a problem with the all
caused by a poor electrical connection. Resume cylinders firing signal, remove terminal 49.
normal operation.
C. Connect one voltmeter lead to the probe that
STOP. is inserted into terminal 69. Connect the other
voltmeter lead to the terminal that has been
• Code – At least one of the diagnostic codes is removed from P1.
active or logged. Proceed to Test Step 12.
D. Switch the 16 amp circuit breaker for the ECM
Test Step 8. Disconnect the ECM from the ON. Turn the engine control switch to the STOP
Circuit and Check for Voltage position.
A. Turn the engine control switch to the OFF/RESET E. Measure the voltage on the wire that was
position. Switch the 16 amp circuit breaker for removed from the P1 connector.
the ECM OFF.
Expected Result:
The voltage is 13 ± 3 VDC.
Results:
• OK – The voltage on the wire that was removed

from the ECM is 13 ± 3 VDC. The voltage appears
to be OK. When the ECM is connected to the
circuit, the voltage is not OK. There may be a

Perform the following steps:
347

breaker for the ECM OFF.
2. Remove the probe from terminal 69. Insert

terminal 49 or 58 into the P1 connector. Pull on
the wire in order to verify that the terminal is
fully inserted into the connector.

again. If the problem is not resolved, temporarily
install a new ECM. Refer to Troubleshooting,
“Replacing the ECM”.

STOP.
• Not OK – The voltage on the wire that was

removed from the ECM is not 13 ± 3 VDC. There
may be a problem with an ICSM. Proceed to Test
Step 9.
Test Step 9. Check the ICSM for a Short

Circuit.
OFF/RESET position.
g00857182
Illustration 210
Connector on the ICSM for the engine harness
B. Disconnect the engine harness connector from

the ICSM.
C. Measure the resistance between the terminals on

the ICSM that are listed in Table 46 according to
the corresponding diagnostic code:
Table 46
Diagnostic Code Terminals on the ICSM
1043-02 E and B
1043-04
1044-02 H and B
1044-04
Expected Result:
The resistance check is greater than 20,000 ohms.

348
Results:
• OK – The resistance check is greater than 20,000

ohms. The ICSM does not have a short circuit.
• Not OK – The resistance check is less than

20,000 ohms. There may be a problem with the
ICSM.

following steps:
Install a known good ICSM according to

If the problem is resolved with the new ICSM,

problem returns.
If the new ICSM operates correctly and the

original ICSM does not operate correctly, replace
the original ICSM. Refer to Troubleshooting,
“Replacing the ICSM”.
STOP.
g00898336
Illustration 211
Test Step 10. Check the Wiring for the Engine harness connector for the ICSM
ICSM
B. Measure the resistance between the terminals
A. Verify the status of the following connectors: on the engine harness connector that are listed
in Table 47:
• The engine harness is disconnected from the
ICSM. Table 47
Points for the Measurement of Resistance on the
• Connector P5 is connected to the junction box. Engine Harness Connector for the ICSM
Terminal Terminals on the Engine
• Connector P1 is disconnected from the ECM. Harness Connector for the ICSM
E A
B
D
H
J
K
M
N
H A
B
D
E
J
K
M
N
349
Expected Result:
All of the resistance checks are greater than 20,000

ohms.
Results:
• OK – All of the resistance checks are greater

than 20,000 ohms. The wiring for the modules
appears to be OK. Proceed to Test Step 12.
• Not OK – At least one of the resistance checks is

connector and/or with the wiring for the modules.

possible. Replace the connector and/or wiring, if
necessary.
STOP.
Test Step 11. Check the Modules for the Illustration 212 g00863334
Correct Configuration. Harness side of the ECM P1 connector
(P1-5) Ground
A. Use Cat ET to verify that the engine configuration (P1-49) All cylinder firing signal
is correct for the ECM and for the ICSM. The (P1-58) Number one cylinder firing signal
configuration must match the type of engine.
a. At the harness side of the P1 connector, insert
“G3606” is an example of a configuration. three 7X-1710 Multimeter Probes. Insert the
first probe into terminal 49. Insert the second
Expected Result: probe into terminal 58. Insert the third probe
into terminal 5.
The configuration of the modules matches the type
of engine. b. Connect one trace of the oscilloscope to the
probe on terminal 49. Connect the other trace
Results: of the oscilloscope to the probe on terminal
58.
• OK – The engine configuration is correct for both
modules. Proceed to Test Step 12. c. Use the probe that is connected to terminal 5
as a ground connection.
• Not OK – The engine configuration is not correct
for a module. B. Adjust the settings of the oscilloscope to
two volts for each vertical division and to ten
Repair: Change the configuration parameters milliseconds for each horizontal division.
to the correct values. Verify that the diagnostic
codes are no longer active. C. Start the engine and run the engine.
If the original diagnostic codes are still active,
proceed to Test Step 12.
Test Step 12. Use an Oscilloscope to

View the Cylinder Firing Signals
Note: This step is recommended.
A. Connect a dual trace oscilloscope by performing

the following steps:
350
g00863306
Illustration 213
Display for the oscilloscope
(1) All cylinder firing signal (2) Number one cylinder firing signal
D. Compare the display on the oscilloscope with

Illustration 213.
E. Adjust the oscilloscope for one millisecond for

each horizontal division.
351
g00863309
Illustration 214
(A) 300 microseconds ±100 microseconds (B) 200 microseconds ±100 microseconds
F. Compare the display on the oscilloscope with i01755878

Illustration 214.
Cylinder Firing Pulse
Expected Result:
SMCS Code: 1901-038
The signals are within the specification. S/N: BLB1-Up
• OK – The signals are within the specification. System Operation Description:

If a diagnostic code is still active, consult
with Caterpillar customer service for large gas Use this procedure to troubleshoot cylinder firing
engines. STOP. signals that have diagnostic codes which are active
or easily repeated.
• Not OK – The signals are not within the
specification. Consult with Caterpillar customer
service for large gas engines. STOP.
352
There are two different types of cylinder firing

signals. The number one cylinder firing signal
indicates that the Electronic Control Module (ECM)
is commanding the spark plug in the number
one cylinder to fire. The all cylinders firing signal
indicates that the ECM is commanding the spark
plug in each cylinder to fire. Each signal is
developed on a wire that connects the ECM to
the left and right integrated combustion sensing
modules.
The number one cylinder firing signal is created

by the Integrated Combustion Sensing Modules
(ICSM) and by the ECM. The modules maintain the
signal wire at +13 volts. The ECM pulls the signal
wire to ground potential whenever the number one
cylinder is commanded to fire. The ECM maintains
the wire at ground potential for approximately 200
microseconds.
The all cylinders firing signal is also created by the

integrated combustion sensing modules and by
the ECM. The modules maintain the signal wire at
+13 volts. The ECM pulls the signal wire to ground
potential whenever a spark plug is commanded to
fire. The ECM maintains the wire at ground potential
for approximately 300 microseconds.
The 1043-08 diagnostic code is caused if the

number one cylinder firing signal and the all
cylinders firing signal are connected to the opposite
terminals somewhere in the circuit.
A -02, -03, and -04 diagnostic code is probably

caused by a problem with a harness connector
or with the wiring. The next likely cause is a faulty
electronic component.


resolved.
353
g00855960
Illustration 215
Schematic of the circuit for the cylinder firing signals

the ECM OFF.

354
• ECM J1/P1
• Terminal box’s J5/P5
• Terminal box’s J6/P6
• Connectors J73/P73 for the left ICSM
• Connectors J83/P83 for the right ICSM
C. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the circuit for the
cylinder firing signals.
D. Check the harnesses and wiring for abrasion

and for pinch points from the connector for each
module to the terminal box.
E. Check the wiring inside the terminal box for

the following conditions: moisture, corrosion,
abrasion, and pinch points.
g00856128
Illustration 216
Terminal box
Expected Result:
(1) Ground strap
(2) ECM connectors J1/P1
(3) J6/P6 connectors for the harness from the left side of the engine properly. The connectors and the wiring do not have
(4) J5/P5 connectors for the harness from the right side of the corrosion, abrasion, or pinch points.
engine
(5) 16 amp circuit breaker for the ECM Results:
Note: Illustration 217 shows one side of the engine. • OK – All connectors, pins, and sockets are
The other side of the engine is similar. connected properly. The connectors and the

is improper.

STOP.

Codes are Still Active
g00856142
Illustration 217
Left side of the engine B. Connect Cat ET to the service tool connector.
(6) ICSM
(7) P73/J73 connectors for the ICSM C. Switch the 16 amp circuit breaker for the ECM
ON.
B. Thoroughly inspect the following connectors:
355
Table 48
1043-03 Cylinder #1 Firing Signal open/short to +batt
1044-03 All Cylinder Firing Signal open/short to +batt
Expected Result:
There are no active codes or logged codes.
Results:
• OK - No codes – The problem seems to be g00863809

resolved. There are no active codes or logged Illustration 218
codes. The cylinder firing signals are operating (1) P6 connector for the harness from the left side of the engine
correctly at this time. (2) P5 connector for the harness from the right side of the engine
caused by a poor electrical connection in one B. Disconnect connectors P1, P5, and P6. This will
of the harness connectors or terminals. Resume isolate the wiring inside the terminal box.
normal operation.
STOP.
• Not OK - Active -02 Noisy – There is an active

diagnostic code for a noisy cylinder firing signal.
• Not OK - Active -03 Open – There is an active

code for a cylinder firing signal that has an open
circuit or a short circuit to a positive voltage
• Not OK - Active -04 Short – There is an active

code for a cylinder firing signal that has a short
to ground. Proceed to Test Step 7.
• Not OK - Active -08 Abnormal – A cylinder firing

signal is abnormal. Proceed to Test Step 3.

Wiring for an Open Circuit or a Short
Circuit to a Positive Voltage Source
the ECM OFF.
356
The correct resistance measurements for Table

49 are less than 5 ohms. If the resistance
measurements are incorrect, there is an open
circuit.
g00863864
Illustration 220
(P1-53) +Battery
D. Measure the resistance between the terminals

Table 50
g00863859
Illustration 219 Connector and Terminal Connector and Terminal
ECM side of connector P1 and the connectors on the bottom of
the terminal box
P1-53 P1-58
(P1-49) All cylinders firing signal P1-49
(J6-9) All cylinders firing signal
(J6-19) Number one cylinder firing signal
(J5-9) All cylinders firing signal The correct resistance measurements for
(J5-19) Number one cylinder firing signal Table 50 are greater than 20,000 ohms. If the
resistance measurements are incorrect, there is
C. Measure the resistance between the terminals a short circuit to a positive voltage source.
measurement, wiggle the harness in order to Expected Result:
check for an intermittent problem. Be sure to
wiggle the harness near each of the connectors. All of the resistance checks are within the
specifications.
Table 49
Points for the Measurement of Resistance Results:
P1-58 J6-19 specifications. The wires for the cylinder firing
signals inside the terminal box do not have an
J5-19 open circuit or a short circuit to a positive voltage
P1-49 J6-9 source. Proceed to Test Step 4.
J5-9
357

circuit in the wiring inside the terminal box or
Repair: Repair the harness or the connector, when

necessary.
STOP.
Test Step 4. Check the Left Side Harness

for an Open Circuit or a Short Circuit to
This will add the left side harness to the circuit.
B. Disconnect connector P73 from the left ICSM.
g00898336
Illustration 222
Engine harness connector P73 for the left ICSM
D. Measure the resistance between terminals P73-E

and P73-H. During the measurement, wiggle the
g00898306
Illustration 221 harness near the P73 connector.
(P1-49) All cylinder firing signal The correct resistance measurement is less than
(P1-58) Number one cylinder firing signal 5 ohms.
(P1-69) -Battery
E. At the P1 connector, connect the jumper wire
C. Fabricate a jumper wire that is the appropriate between terminals P1-49 and P1-69.
length with the appropriate terminals on the
ends. Connect the jumper wire between terminals F. Measure the resistance between terminals P73-B
P1-49 and P1-58. and P73-H.
The correct resistance measurement is less than

5 ohms.
G. Remove the jumper wire from the P1 connector.

358

necessary.
STOP.
Test Step 5. Check the Right Side

Harness for an Open Circuit or a Short to
This will add the right side harness to the circuit.
B. Disconnect the engine harness connector P83

g00863864 from the right ICSM.
Illustration 223
(P1-53) +Battery

Table 51
g00898306
Illustration 224
P1-53 P1-58
P1-49 (P1-58) Number one cylinder firing signal
(P1-69) -Battery
The correct resistance measurements for Table C. Fabricate a jumper wire that is the appropriate
51 are greater than 20,000 ohms. length with the appropriate terminals on the
ends. Connect the jumper wire between terminals
Expected Result: P1-49 and P1-58.
The resistance checks are within the specifications.
Results:

signals inside the left harness do not have an
open circuit or a short circuit to a positive voltage
source. The wires for the cylinder firing signals
are not switched. Proceed to Test Step 5.

circuit in the wiring inside the left harness or there
is a short circuit to a positive voltage source.
359
g00863864
Illustration 226
(P1-53) +Battery

Illustration 225 g00898336 Table 52
Engine harness connector P83 for the right ICSM Points for the Measurement of Resistance
D. Measure the resistance between terminals P83-E
and P83-H. During the measurement, wiggle the P1-53 P1-58
P1-49
harness near the P83 connector.
The correct resistance measurements for Table
The correct resistance measurement is less than 52 are greater than 20,000 ohms.
5 ohms.
Expected Result:
E. At the P1 connector, connect the jumper wire
between terminals P1-49 and P1-69. The resistance checks are within the specifications.
F. Measure the resistance between terminals P83-B Results:

and P83-H.
The correct resistance measurement is less than specifications. The wiring inside the right harness
5 ohms. does not have an open circuit. The wiring inside
the right harness does not have a short circuit
G. Remove the jumper wire from the P1 connector. to a positive voltage source. The wires for the
cylinder firing signals are not switched. Connect
all of the connectors. Proceed to Test Step 6.

circuit in the wiring inside the left harness or there
is a short circuit to a positive voltage source.
360
Repair: Repair the harness or the connector, when Test Step 7. Check for +13 V at the ECM
necessary.
STOP.

Code is still Active
B. Reconnect connectors P1, P73, and P83.

ON.

Table 53
g00863734
1043-03 Cylinder #1 Firing Signal open/short to +batt Illustration 227
1044-03 All Cylinder Firing Signal open/short to +batt
1043-08 Cylinder Firing Signal Abnormal (P1-58) Number one cylinder firing signal
(P1-69) -Battery
Expected Result: A. At the harness side of the P1 connector, insert

two 7X-1710 Multimeter Probes. Insert the first
The codes that are listed in Table 53 are not active probe into terminal 69. If you are troubleshooting
or logged. a problem with the signal for the number one
cylinder firing signal, insert the second probe
Results: into terminal 58. If you are troubleshooting a
problem with the all cylinders firing signal, insert
• No codes – The problem seems to be resolved. the second probe into terminal 49.
The cylinder firing signals are operating correctly
at this time. B. Connect a voltmeter to the probes and measure
the voltage.
caused by a poor electrical connection in one Expected Result:
of the harness connectors. Resume normal
operation. The voltage at the P1 connector is 13 ± 3 VDC.
STOP. Results:
• Active code – At least one of the diagnostic • OK – The voltage at the P1 connector is 13 ± 3
codes is active. Proceed to Test Step 13. VDC. The voltage appears to be OK. The ECM
does not have an internal short circuit. Remove
the probes from the P1 connector. Proceed to
Test Step 8.
• Not OK – The voltage at the P1 connector is

not 13 ± 3 VDC. The voltage is not within the
specification. An ICSM may have a problem, or
the ECM may be faulty. Do not remove the probe
in terminal 69. Remove the probe from terminal
49 or from terminal 58. Proceed to Test Step 9.
361
Test Step 8. Crank the Engine and Check

for Diagnostic Codes
B. Crank the engine for ten seconds. Look for the

codes that are listed in Table 54.
Table 54
Expected Result:
g00863734
Illustration 228
None of the codes are active or logged. Harness side of the ECM P1 connector
Results: (P1-58) Number one cylinder firing signal
(P1-69) -Battery
• No codes – None of the codes are active or
logged. The problem seems to be resolved. The B. Use a 151-6320 Wire Removal Tool to remove
cylinder firing signals appear to be operating terminal 58 or 49 from ECM connector P1. If you
correctly at this time. are troubleshooting a problem with the number
one cylinder firing signal, remove terminal 58. If
Repair: The initial diagnostic code was probably you are troubleshooting a problem with the all
caused by a poor electrical connection. Resume cylinders firing signal, remove terminal 49.
normal operation.
C. Connect one voltmeter lead to the probe that
STOP. is inserted into terminal 69. Connect the other
voltmeter lead to the terminal that has been
• Code – At least one of the diagnostic codes is removed from P1.
active or logged. Proceed to Test Step 14.
Test Step 9. Disconnect the ECM from the ON. Turn the engine control switch to the STOP
Circuit and Check for Voltage position.
A. Turn the engine control switch to the OFF/RESET E. Measure the voltage on the wire that was
position. Switch the 16 amp circuit breaker for removed from the P1 connector.
the ECM OFF.
Expected Result:
The voltage is 13 ± 3 VDC.
Results:
• OK – The voltage on the wire that was removed

from the ECM is 13 ± 3 VDC. The voltage appears
to be OK. When the ECM is connected to the
circuit, the voltage is not OK. There may be a

Perform the following steps:
362

2. Remove the probe from terminal 69. Insert

terminal 49 or 58 into the P1 connector. Pull on
the wire in order to verify that the terminal is
fully inserted into the connector.


STOP.
• Not OK – The voltage on the wire that was

removed from the ECM is not 13 ± 3 VDC. There
may be a problem with an ICSM. Proceed to Test
Step 10.
Test Step 10. Check the Left Side ICSM

for a Short Circuit.
OFF/RESET position.
g00857182
Illustration 229
Connector J73 on the left side ICSM
B. Disconnect the engine harness P73 connector

from the J73 connector on the left ICSM.
C. Measure the resistance between the terminals

that are listed in Table 55 according to the
corresponding diagnostic code:
Table 55
Diagnostic Code Terminals
1043-02 J73-E and J73-B
1043-04
1044-02 J73-H and J73-B
1044-04
Expected Result:

363
Results: Test Step 11. Check the Right Side ICSM

for a Short Circuit.
ohms. The left ICSM does not have a short circuit.

ICSM.

following steps:


problem returns.

STOP.
g00863765
Illustration 230
Connector J83 on the right side ICSM
A. Disconnect the engine harness P83 connector

from the J83 connector on the right ICSM.

that are listed in Table 56 according to the
corresponding diagnostic code:
Table 56
Diagnostic Code Terminals
1043-02 J83-E and J83-B
1043-04
1044-02 J83-H and J83-B
1044-04
Expected Result:

364
Results:

ohms. The right ICSM does not have a short
circuit. Proceed to Test Step 12.

right side ICSM.

following steps:


problem returns.

STOP.
g00898336
Illustration 231
Test Step 12. Check the Wiring for the Engine harness connector P83 for the right side ICSM
ICSM
A. Verify the status of the following connectors: that are listed in Table 57 for the right side
engine harness connector P83:
• Connector P73 is connected to the left side
ICSM. Table 57
P83 Points for the Measurement of Resistance
• Connector P83 is disconnected from the right
side ICSM. Terminal Connector and Terminals
P83-E P83-A
• Connector P5 is connected to the junction box. P83-B
P83-D
• Connector P6 is connected to the junction box. P83-H
P83-J
• Connector P1 is disconnected from the ECM. P83-K
P83-M
P83-N
P83-H P83-A
P83-B
P83-D
P83-E
P83-J
P83-K
P83-M
P83-N
Expected Result:
All of the resistance checks are greater than 20,000

ohms.
365
Results:
• OK – All of the resistance checks are greater

than 20,000 ohms. The wiring for the modules
• Not OK – At least one of the resistance checks is

connector and/or with the wiring for the modules.

possible. Replace the connector and/or wiring, if
necessary.
STOP.
Test Step 13. Check the Modules for the

Correct Configuration.
A. Use Cat ET to verify that the engine configuration
is correct for both of the integrated combustion
sensing modules and for the ECM. The Illustration 232 g00863334
configurations must be identical and the Harness side of the ECM P1 connector
configurations must match the type of engine.
(P1-5) Ground
“G3612 Vee” is an example of a configuration. (P1-58) Number one cylinder firing signal
Expected Result: a. At the harness side of the P1 connector, insert

three 7X-1710 Multimeter Probes. Insert the
Each module has the correct configuration that first probe into terminal 49. Insert the second
matches the type of engine. probe into terminal 58. Insert the third probe
into terminal 5.
Results:
b. Connect one trace of the oscilloscope to the
• OK – The engine configuration is correct for each probe on terminal 49. Connect the other trace
module. Proceed to Test Step 14. of the oscilloscope to the probe on terminal
58.
• Not OK – The engine configuration is not correct
for a module. c. Use the probe that is connected to terminal 5
as a ground connection.
Repair: Change the configuration parameters
to the correct values. Verify that the diagnostic B. Adjust the settings of the oscilloscope to
codes are no longer active. two volts for each vertical division, and ten
milliseconds for each horizontal division.
If the original diagnostic codes are still active,
proceed to Test Step 14. C. Start the engine and run the engine.
Test Step 14. Use an Oscilloscope to
View the Cylinder Firing Signals
Note: This step is recommended.
A. Connect a dual trace oscilloscope by performing

the following steps:
366
g00863306
Illustration 233
(1) All cylinder firing signal (2) Number one cylinder firing signal
D. Compare the display on the oscilloscope with

Illustration 233.
E. Adjust the oscilloscope for one millisecond for

each horizontal division.
367
g00863309
Illustration 234
(A) 300 microseconds ±100 microseconds (B) 200 microseconds ±100 microseconds
F. Compare the display on the oscilloscope with

Illustration 234.
Expected Result:
The signals are within the specification.
Results:
• OK – The signals are within the specification.

If a diagnostic code is still active, consult
with Caterpillar customer service for large gas
engines. STOP.
• Not OK – The signals are not within the

specification. Consult with Caterpillar customer
service for large gas engines. STOP.
368
i01756922 Logged diagnostic codes provide a historical

record. Before you begin this procedure, use Cat
Desired Speed Input (4 - 20 ET to print the logged codes to a file.
mA)
SMCS Code: 1901-038 additional diagnostic codes. Keep your mind on
System Operation Description: Clear the diagnostic codes after the problem is
resolved.
Note: For this troubleshooting procedure,
the “Desired Speed Input” configuration
parameter must be set to “4-20 mA Input” in the
“Service/Configuration” screen of the Caterpillar
Electronic Technician (Cat ET). The selection of this
setting requires a 4 to 20 mA signal for regulation
of the desired engine speed. If the “Desired Speed
Input” is set to “0-5 VDC Input”, do not use this
procedure to troubleshoot the circuit.
When the desired speed input is correspondingly

configured, the Electronic Control Module (ECM)
controls the engine speed according to the 4 to 20
mA current.
The value of the current corresponds to a range

of desired engine speeds between minimum high
idle and maximum high idle. The “Minimum Engine
High Idle Speed” and the “Maximum Engine High
Idle Speed” are set with the “Service/Configuration”
screen of Cat ET. For more information, refer
g00854357
to Systems Operation/Testing and Adjusting, Illustration 235
“Electronic Control System Parameters”. Schematic of the 4 to 20 mA desired speed input
When the “Idle/Rated” switch is in the Rated Test Step 1. Inspect the Electrical
position, a current value of 4.0 mA corresponds Connectors and Wiring
to the programmed “Minimum Engine High Idle
Speed”. A current value of 20.0 mA corresponds
to “Maximum Engine High Idle Speed”. Current
values within this range will vary the desired engine
speed in a linear fashion between “Minimum Engine
High Idle Speed” and “Maximum Engine High Idle
Speed”.
The ECM will generate a diagnostic code in

response to current outside of the range of 4 to 20
mA.
Current values that are greater than 22.0 mA will

activate the “524-03 Desired Engine Speed Sensor
short to +batt” diagnostic code. Current values
that are less than 2.0 mA will activate the “524-04 Illustration 236 g00854386
Desired Engine Speed Sensor short to ground” (1) ECM J1/P1 connectors
diagnostic code. (2) 16 amp circuit breaker for the ECM
(3) 70-pin customer connector J3
The most likely causes of the diagnostic code (4) Terminal box’s 47-pin connector for the control panel (if
are a poor connection or a problem in a wiring equipped)
harness. The next likely cause is a problem with
a component. The least likely cause is a problem A. Turn the engine control switch to the OFF/RESET
with the ECM. position. Switch the 16 amp circuit breaker for
the ECM OFF.
369

g00862834
Illustration 237
Inside of the control panel
(5) Terminal strip
B. Thoroughly inspect the following components:

• 70-pin customer connectors J3/P3 (if
equipped)
g00856110
Illustration 238
• Terminal box’s 47-pin connectors J4/P4 for the
control panel (if equipped) Harness side of the ECM P1 connector
(36) + Signal
(37) − Signal
• Terminal strip in the control panel (if equipped)
• Wiring and the connections between the b. Perform a 45 N (10 lb) pull test on each of
terminal box and the device that supplies the the wires that are associated with the 4 to 20
4 to 20 mA signal mA circuit.
a. Check the torque of the Allen head screw for c. Inspect the terminal strip in the control panel
the ECM J1/P1 connector and for the 70-pin (if equipped) for the following conditions:
J3/P3 customer connectors. The proper loose wires, frayed wires, foreign objects, and
torque is 6 ± 1 N·m (55 ± 9 lb in). corrosion.
d. Check the harness and wiring for abrasion

and for pinch points between the device that
supplies the 4 to 20 mA signal and the ECM.
Expected Result:

370
Results:

wiring do not have corrosion, abrasion, or
pinch points. The components are in good
condition with proper connections. If you are
troubleshooting a “524-03 Desired Engine Speed
Sensor short to +batt” diagnostic code, proceed
to Test Step 2. If you are troubleshooting a
“524-04 Desired Engine Speed Sensor short to
ground” diagnostic code, proceed to Test Step 4.

or sockets is not connected properly. At least g00862700
one connector or wire has corrosion, abrasion, Illustration 240
and/or pinch points. The components are not in ECM J1 connector
good condition and/or at least one connection (J1-70) Keyswitch +Battery
is improper.
E. Use an ohmmeter to measure the resistance
Repair: Perform the necessary repairs and/or between terminals P1-36 and J1-70.
Expected Result:
STOP.
Test Step 2. Check for a Short Circuit to
the +Battery Side at the ECM P1 Terminal Results:
36
• Yes – The resistance is greater than 20,000
A. Verify that the engine control switch is in the ohms. The wiring from terminal P1-36 is not
OFF/RESET position and the 16 amp circuit shorted to the +Battery side. Do not reconnect
breaker for the ECM OFF. any connectors. Proceed to Test Step 3.
B. Make sure that there is no electrical power to the • No – The resistance is less than 20,000 ohms.
device that provides the 4 to 20 mA signal. There is a problem with a connection and/or with
the wiring from terminal P1-36.
C. Remove the two wires (“+” and “-”) for the 4 to
20 mA signal from the device that supplies the Repair: The problem may be between the ECM
4 to 20 mA signal. Tape the leads in order to P1 connector and the J3 or J4 connector.
ensure that the leads do not contact any object. Alternatively, the problem may be between the
P3 or P4 connector and the device that provides
D. Disconnect the ECM P1 connector. the 4 to 20 mA signal.
Repair the connection and/or the wire, when

possible. Replace parts, if necessary. Verify that
the problem is resolved.
STOP.
Test Step 3. Check for a Short to Ground

at the ECM P1 Terminal 37
OFF/RESET position and the 16 amp circuit
g00870622
B. Make sure that the leads of the wires for the 4 to
Illustration 239 20 mA signal do not contact any object.
(P1-36) + Signal
371
Repair: The problem may be between the ECM

P1 connector and the J3 or J4 connector.
Alternatively, the problem may be between the
J3 or J4 connector and the device that provides
the 4 to 20 mA signal.
Locate the wire with the short circuit and replace

the wire. Verify that the problem is resolved.
STOP.

the +Battery Side at the ECM P1 Terminal
37
g00856589
Illustration 241
(1) ECM P1 connector OFF/RESET position and the 16 amp circuit
(2) Ground strap
B. Make sure that there is no electrical power to the

device that provides the 4 to 20 mA signal.
C. Remove the two wires (“+” and “-”) for the 4 to

20 mA signal from the device that supplies the
4 to 20 mA signal. Tape the leads in order to
ensure that the leads do not contact any object.
D. Disconnect the ECM P1 connector.
g00856119
Illustration 242
(P1-37) − Signal
C. Use an ohmmeter to measure the resistance

between terminal P1-37 and the ECM ground
strap.
Expected Result:
g00856119
The resistance is greater than 20,000 ohms. Illustration 243
Results: (P1-37) − Signal
• Yes – The resistance is greater than 20,000 ohms.

The wiring from terminal P1-37 appears to be ok.
Repair: Reconnect the ECM P1 connector.

Reconnect the two wires (“+” and “-”) for the 4 to
20 mA signal to the device that supplies the 4 to
20 mA signal.
• No – The resistance for at least one of the

measurements is less than 20,000 ohms. There
is a problem with a connection and/or with the
wiring that is connected to P1-37.
372
g00862700 g00856589
ECM J1 connector (1) ECM P1 connector
(2) Ground strap
E. Use an ohmmeter to measure the resistance

between terminals P1-37 and J1-70.
Expected Result:
Results:

ohms. The wiring from terminal P1-37 is not
shorted to the +Battery side. Do not reconnect
any connectors. Proceed to Test Step 5.
g00856119
Illustration 246
• No – The resistance is less than 20,000 ohms.
There is a problem with a connection and/or with ECM side of the P1 connector
the wiring from terminal P1-37. (P1-36) + Signal
Repair: The problem may be between the ECM C. Use an ohmmeter to measure the resistance
P1 connector and the J3 or J4 connector. between terminal P1-36 and the ECM ground
Alternatively, the problem may be between the strap.
the 4 to 20 mA signal. Expected Result:
Repair the connection and/or the wire, when The resistance is greater than 20,000 ohms.
possible. Replace parts, if necessary. Verify that
the problem is resolved. Results:
STOP. • Yes – The resistance is greater than 20,000

ohms. The wiring from terminal P1-36 appears
Test Step 5. Check for a Short Circuit to to be OK. Do not reconnect any connectors.
Ground at the ECM P1 Terminal 36 Proceed to Test Step 6.
A. Verify that the engine control switch is in the • No – The resistance is less than 20,000 ohms.
OFF/RESET position and the 16 amp circuit There is a problem with a connection and/or with
breaker for the ECM OFF. the wiring from terminal P1-36.
B. Make sure that the ends of the wires for the 4 to Repair: The problem may be between the ECM
20 mA signal do not contact any object. P1 connector and the J3 or J4 connector.
Alternatively, the problem may be between the
the 4 to 20 mA signal.
373
Repair the connection and/or the wire, when Repair the connection and/or the wire, when
possible. Replace parts, if necessary. Verify that possible. Replace parts, if necessary. Verify that
the problem is resolved. the problem is resolved.
STOP. STOP.
Test Step 6. Check for an Open Circuit Test Step 7. Check the Device that
Provides the 4 to 20 mA Signal
A. Install a jumper wire between the two wires (“+”
and “-”) that were removed from the device that Measure the 4 to 20 mA signal according to the
supplies the 4 to 20 mA signal. literature that is provided by the OEM of the device
that provides the 4 to 20 mA signal. Verify that the
correct signal is provided to the ECM.
g00870629
Illustration 247
(P1-36) + Signal
(P1-37) − Signal
B. Use an ohmmeter to measure the resistance

between terminals P1-36 and P1-37 on the ECM
side of the P1 connector.
Expected Result:
The resistance is less than 5 ohms.
Results:
g00856110
• OK – The resistance is less than 5 ohms. The Illustration 248
circuit is not open. Harness side of the P1 connector
(P1-36) + Signal
Repair: Remove the jumper wire. Reconnect the (P1-37) − Signal
two wires (“+” and “-”) for the 4 to 20 mA signal
to the device that supplies the 4 to 20 mA signal. Verify the correct 4 to 20 mA signal at terminals
Reconnect the ECM P1 connector. P1-36 and P1-37.
Proceed to Test Step 7. Expected Result:
• Not OK – The resistance is greater than 5 ohms. The correct 4 to 20 mA signal is provided to the
There is a problem with a connector and/or with ECM.
the wiring from the P1 connector.
Results:
Repair: The problem may be between the ECM
P1 connector and the J3 or J4 connector. • Yes – The correct 4 to 20 mA signal is provided
Alternatively, the problem may be between the to the ECM. However, the ECM is not responding
P3 or P4 connector and the device that provides correctly to the signal. There may be a problem
the 4 to 20 mA signal. with the ECM.
374
Repair: It is unlikely that the ECM is faulty. Exit The ECM can retard timing by as few as three
this procedure and perform this procedure again. degrees for light detonation levels. The timing can
If the problem is not resolved, replace the ECM be retarded up to six degrees for severe detonation.
according to Troubleshooting, “Replacing the For most applications, the minimum allowable actual
ECM”. Verify that the problem is resolved. timing is ten degrees Before Top Center (BTC). A
proportional strategy is used for advancing the
STOP. timing after the timing has been retarded. The rate
of advance is based upon the level of detonation.
• No – The ECM is not receiving the correct 4 to The rate is faster for lighter detonation. The fastest
20 mA signal. There is probably a problem with rate of advance is one degree per minute.
the device that provides the 4 to 20 mA.
The ECM will diagnose the detonation sensor’s
Repair: Service the device that provides the 4 to signal for a short circuit to the −Battery side, for
20 mA according to the literature that is provided a short circuit to the +Battery side, and for an
by the OEM of the device. Verify that the problem open circuit. To avoid detecting vibrations that are
is resolved. not related to detonation, the ECM only monitors
a detonation sensor when one of the sensor’s
STOP. cylinders is between top center and 40 degrees
after top center.
i01756931
An input from a detonation sensor that is diagnosed
Detonation Sensors by the ECM as “short to ground” may actually
indicate an open circuit.
SMCS Code: 1559-038
The ECM also supports event codes when the levels
S/N: BEN1-Up of detonation warrant a reaction from the ECM. If the
timing has been retarded by the maximum amount
S/N: 4ZS1-Up and the level of detonation remains high, the ECM
will shut down the engine.
Detonation sensors are located on the upper record. Before you begin this procedure, use the
cylinder block between every two cylinders. Caterpillar Electronic Technician (Cat ET) to print
Each sensor monitors two adjacent cylinders. For the logged codes to a file.
example, one sensor monitors cylinders 1 and 2.
The Electronic Control Module (ECM) supplies 8 poor connection or a problem in a wiring harness.
VDC in order to power the sensors. The detonation The next likely cause is a problem with a sensor.
sensors provide electrical signals to the ECM The least likely cause is a problem with the ECM.
that indicate mechanical engine vibrations. Each
sensor outputs an electrical signal that is filtered The troubleshooting procedure may generate
and the signal is amplified. The frequency of the additional diagnostic codes. Keep your mind on
signal corresponds to the mechanical frequency correcting the cause of the original diagnostic code.
of the vibrations. The amplitude of the signal is Clear the diagnostic codes after the problem is
proportional to the intensity of the vibrations. resolved.
The ECM monitors the signals in order to determine
the presence and the severity of the detonation. The
ECM retards the timing in order to limit detonation
levels. The timing may be retarded for a single
cylinder or for all of the cylinders, if necessary. If
retardation of the timing does not sufficiently limit
the detonation, the engine is shut down.
375
g00898655
Illustration 249
Schematic for the detonation sensors
The wiring for the detonation sensors is routed through a rail on the side of the engine. Each detonation sensor has a 3-pin connector that is
connected to a receptacle on the rail.
The rail has a 6-pin connector for a wiring harness that connects the detonation sensors to the terminal box.

g00898665
Illustration 251
(4) Rail
Illustration 250
g00897591 (5) 6-pin connectors for the engine harness
(6) 3-pin connectors on the rail for the detonation sensor
(1) ECM J2/P2 connectors (7) Detonation sensor
(3) Terminal box’s J5/P5 connectors for the engine harness
B. Thoroughly inspect the following connectors:
position. Switch the 16 amp circuit breaker for • ECM J2/P2 connectors
the ECM OFF.
• The suspect detonation sensor’s connectors
Troubleshooting, “Inspecting Electrical Connectors”. • Terminal box’s J5/P5 connectors
376
• 6-pin connectors on the rail • “41-04 8 Volt DC Supply short to ground”

• 3-pin connectors from the detonation sensors Expected Result:
to the rail
Neither of the “8 Volt DC Supply” diagnostic codes
a. Check the torque of the Allen head screws for are active.
the ECM P2 connector and for the terminal
box’s P5 connector. The proper torque is Results:
6 ± 1 N·m (55 ± 9 lb in).
• OK – Neither of the “8 Volt DC Supply” diagnostic
b. Perform a 45 N (10 lb) pull test on each of the codes are active. Proceed to Test Step 3.
the detonation sensor. Refer to the schematic. • Not OK – At least one of the “8 Volt DC Supply”
diagnostic codes is active.
and for pinch points from the suspect Repair: The “8 Volt DC Supply” diagnostic code
detonation sensor to the ECM. must be resolved before you can proceed with
this functional test.
d. Make sure that the detonation sensors are
properly installed according to the torque in Exit this procedure and refer to Troubleshooting,
Specifications, “Detonation Sensors”. “+8V Sensor Voltage Supply”.
Expected Result: If necessary, return to this functional test in order

to troubleshoot the detonation sensor after the
All connectors, pins, and sockets are connected “8 Volt DC Supply” diagnostic code has been
properly. The connectors and the wiring do not have resolved.
STOP.
Results:
Test Step 3. Check for Active Diagnostic
• OK – All connectors, pins, and sockets are Codes for the Detonation Sensors
wiring do not have corrosion, abrasion, or pinch Note: The run relay and the crank terminate relay
points. The components are in good condition must be energized before a diagnostic code for a
with proper connections. Proceed to Test Step 2. detonation sensor can be generated. Therefore, the
engine must be running. The engine will shut down
• Not OK – At least one of the connectors, pins, soon after the diagnostic code is activated.
one connector or wire has corrosion, abrasion, A. Start the engine and run the engine.
good condition and/or at least one connection B. Allow a minimum of 30 seconds for any
is improper. diagnostic codes to become active. Observe the
“Active Diagnostic” screen of Cat ET and look for
Repair: Perform the necessary repairs and/or the diagnostic codes that are listed in Table 58:
STOP.

for the +8 V Sensor Supply
position.
B. Observe the “Active Diagnostic” screen of Cat

may become activated. Look for these diagnostic
codes:
• “41-03 8 Volt DC Supply short to +batt”

377
Table 58 Test Step 4. Verify the Presence of the

Code Description Cylinders Supply Voltage to the Sensor
1501-03 Cylinder #1 Detonation A. Turn the engine control switch to the OFF/RESET
Sensor short to +batt position. Switch the 16 amp circuit breaker for
1 and 2
1501-04 Cylinder #1 Detonation the ECM OFF.
1503-03 Cylinder #3 Detonation
Sensor short to +batt
3 and 4
5 and 6
7 and 8
g00857709
Sensor short to ground Illustration 252
(AA) View of the rail’s receptacle for the sensor’s connector
(A) +8 V supply
Note: A “short to ground” diagnostic code can (B) Return
indicate either an actual short to ground or an open (C) Signal
circuit.
B. Disconnect the suspect sensor’s 3-pin connector
Expected Result: from the rail.
None of the above diagnostic codes are active. C. Switch the 16 amp circuit breaker for the ECM
Results: position.
• OK (No active codes) – None of the above codes D. Measure the voltage between terminals A and B
are active at this time. The problem seems to on the rail’s receptacle for the sensor’s connector.
be resolved. The original diagnostic code was
probably caused by a poor electrical connection Expected Result:
in one of the harness connectors.
The voltage is between 7.6 VDC and 8.4 VDC.
Repair: If any of the above codes are logged
and the engine is not running properly, refer Results:
Diagnostic Code”. • OK – The voltage is between 7.6 VDC and 8.4
VDC. The correct voltage is available to the
If any of the above codes are logged and the sensor. Do not reconnect the sensor. Proceed to
engine is running properly, there may be an Test Step 5.
intermittent problem in a connector or a wiring
harness. Refer to Troubleshooting, “Inspecting • Not OK – The voltage is not between 7.6 VDC
Electrical Connectors”. and 8.4 VDC. The correct voltage is not available
to the sensor. There is probably an open circuit in
STOP. the +8 volt supply or in the return for the sensor.
• Not OK (Active Code) – A “short to +batt” or Repair: The open circuit may be caused by a
“short to ground” diagnostic code was activated. poor electrical connection or by a wiring problem
between the ECM and the connector for the
Repair: Note the diagnostic code and note the sensor.
location of the suspect detonation sensor.
If only one detonation sensor has an “04 short to
Proceed to Test Step 4. ground” diagnostic code, the open circuit for the
+8 volt supply is in the rail. Repair the electrical
378
If more than one detonation sensor has an 5. Turn the engine control switch to the
“04 short to ground” diagnostic code, use the OFF/RESET position. Switch the 16 amp circuit
following procedure to locate the open circuit for breaker for the ECM OFF.
the +8 volt supply:
6. Disconnect the engine harness P5 connector
1. Turn the engine control switch to the from the terminal box.
breaker for the ECM OFF. 7. Switch the 16 amp circuit breaker for the ECM
ON. Turn the engine control switch to the
STOP position.
g00857795
Illustration 253
(1) 6-pin connectors for the engine harness
2. Disconnect the 6-pin connector from the rail.

STOP position.
g00898671
Illustration 255
Bottom view of the terminal box
(J5) Terminal box’s connector for the engine harness
(J5-56) Return
(J5-57) +8 V supply
8. Measure the voltage between terminals J5-56

and J5-57.
If the voltage is between 7.6 VDC and 8.4 VDC,

the wiring in the terminal box is OK. The open
circuit is in the engine harness. Repair the
electrical connection and/or the wiring, when
g00858454
Illustration 254
If the voltage is not between 7.6 VDC and 8.4
6-pin connector on the engine harness
VDC, the open circuit is in the terminal box
between the ECM J2 connector and the engine
4. Use a voltmeter to measure the voltage
harness connector on the terminal box.
between terminals “A” and “B” on the engine
harness’ 6-pin connector.
Repair the electrical connection and/or the wiring,
when possible. Replace the components, if
If the voltage is between 7.6 VDC and 8.4
necessary.
VDC, the open circuit is in the rail. Repair the
electrical connection and/or the wiring, when STOP.
possible. Replace the rail, if necessary.

VDC, the open circuit may be in the engine
harness. Proceed to the next Step.
379
Test Step 5. Measure the Voltage of the Test Step 6. Measure the Voltage of the
Signal Wire at the Rail Suspect Signal Terminal at the ECM
A. Ensure that the 16 amp circuit breaker for the A. Turn the engine control switch to the OFF/RESET
ECM is ON and that the engine control is in the position. Switch the 16 amp circuit breaker for
STOP position. the ECM OFF.
g00857709
Illustration 256
(A) +8 V supply
(B) Return
(C) Signal
B. Measure the voltage between terminals B and

C on the rail’s receptacle for the sensor’s
connector.
Expected Result:

g00898674
Illustration 257
Results:
(P2-36) Signal for cylinders 1 and 2
• Yes – The voltage is between 0.4 VDC and 0.6 (P2-37) Signal for cylinders 3 and 4
VDC. (P2-38) Signal for cylinders 5 and 6
Repair: Reconnect the suspect sensor. Start the (P2-54) Return
engine again and check for the diagnostic code.
If the diagnostic code recurs, replace the the suspect signal wire from the ECM P2
detonation sensor with a known good detonation connector.
sensor. Tighten the detonation sensor according
to Specifications, “Detonation Sensor”. Verify that C. Install one end of jumper wire with the
the problem is resolved. appropriate connectors on the ends into the
terminal for the suspect signal wire. Leave the
STOP. other end of the jumper wire unconnected. Pull
on the jumper wire in order to verify that the
• No – The voltage is not between 0.4 VDC and 0.6 jumper wire is properly connected.
VDC. If the voltage is less than 0.4 VDC, there
is probably a short to ground or an open circuit D. Insert a lead of a 7X-1710 Multimeter Probe into
between the rail’s connector for the detonation the terminal for the corresponding return wire.
sensor and the ECM. If the voltage is greater than
4.8 VDC, there is probably a short circuit to a E. Connect the leads of a voltmeter to the 7X-1710
+Battery source between the rail’s connector for Multimeter Probe and to the loose end of the
the detonation sensor and the ECM. jumper wire.
Repair: F. Switch the 16 amp circuit breaker for the ECM

Proceed to Test Step 6. position.
380
G. Use the voltmeter to measure the voltage.
Expected Result:
Results:
• Yes – The voltage is between 0.4 VDC and 0.6

VDC. The ECM is OK. There is a problem with a
connection and/or with the wiring between the
ECM and the rail’s connector for the detonation
sensor. If you suspect that there is a short circuit
to a +Battery source, proceed to test Step 7. If
you suspect that there is an open circuit, proceed
to Test Step 8. If you suspect that there is a short
to ground, proceed to Test Step 9.
• No – The voltage is not between 0.4 VDC and 0.6

VDC. There is a problem with the ECM.


the jumper wire from ECM P2 connector. Reinstall
the original signal wire into the P2 connector. Pull
g00898674
on the wire in order to verify that the terminal is Illustration 258
secure. Harness side of the ECM P2 connector
Replace the ECM according to Troubleshooting, (P2-37) Signal for cylinders 3 and 4
“Replacing the ECM”. (P2-38) Signal for cylinders 5 and 6
(P2-54) Return
STOP.
C. Insert the lead of a 7X-1710 Multimeter Probe
Test Step 7. Monitor the Voltage and into the terminal for the suspect sensor’s signal
Isolate the Short Circuit wire in the harness side of the ECM P2 connector.
A. Turn the engine control switch to the OFF/RESET D. Verify that the voltmeter is properly connected
position. Switch the 16 amp circuit breaker for to the leads of the 7X-1710 Multimeter Probes.
the ECM OFF. Switch the 16 amp circuit breaker for the ECM
B. Use a 151-6320 Wire Removal Tool to remove position.
the jumper wire from the ECM P2 connector.
Reinstall the removed suspect signal wire into E. Measure the voltage.
the terminal. Pull on the wire in order to verify
proper installation. Because a short circuit to a +Battery source is
suspected, the expected voltage is greater than
4.8 VDC.
F. Turn the engine control switch to the OFF/RESET

the ECM OFF.
381
L. Switch the 16 amp circuit breaker for the ECM

position.
M. Use the voltmeter to measure the voltage again.

Compare the voltage to the previously noted
voltage.
Expected Result:
Before the harness was disconnected, the voltage

was greater than 4.8 VDC. After the harness was
disconnected, the voltage was between 0.4 VDC
and 0.6 VDC.
g00857795
Illustration 259 Results:
(1) 6-pin connectors
• Yes – Before the harness was disconnected,
G. Disconnect the engine harness’ 6-pin connector the voltage was greater than 4.8 VDC. After the
from the rail. harness was disconnected, the voltage was
between 0.4 VDC and 0.6 VDC. There is a
H. Switch the 16 amp circuit breaker for the ECM problem in the engine harness.
position. Repair: The problem is probably caused by a
poor electrical connection and/or by a wiring
I. Use the voltmeter to measure the voltage again. problem in the harness.
Compare the voltage to the previously noted
voltage. Turn the engine control switch to the OFF/RESET
position. Switch the 16 amp circuit breaker for the
If the voltage is between 0.4 VDC and 0.6 VDC, ECM OFF. Repair the harness, when possible.
there is a short circuit in the rail on the suspect Replace the harness, if necessary.
sensor’s side of the engine. Repair the electrical
connection and/or the wiring, when possible. STOP.
• No – Before the harness was disconnected,
If the voltage is still greater than 4.8 VDC, the rail the voltage was greater than 4.8 VDC. After the
is probably OK. Continue with this procedure. harness was disconnected, the voltage was still
greater than 4.8 VDC. There is a problem in the
terminal box.

breaker for the ECM OFF. Repair the connector
and/or wiring, when possible. Replace the
connector and/or wiring, if necessary.
STOP.
g00897591
Illustration 260
J. Turn the engine control switch to the OFF/RESET

the ECM OFF.
K. Disconnect the P5 connector from the terminal

box.
382

for a Short Circuit to Ground
g00858454
Illustration 263
g00897591
Illustration 261

the ECM OFF.

the suspect signal wire into connector P2. Pull
on the wire in order to verify that the terminal is
secure.
g00858460
Illustration 264
Ground strap for the Integrated Combustion Sensing Module
(ICSM)
D. Measure the resistance between the ground

strap for the ICSM and the terminal for the
suspect signal wire on the engine harness’ 6-pin
connector.
The terminals on the 6-pin connectors for the

detonation sensors are identified in Table 59.
Table 59
Illustration 262 g00898665 Terminals on the 6-Pin Connectors for the

Detonation Sensors’ Signal Wires
(4) Rail
(5) 6-pin connectors for the engine harness Terminal Cylinders
(7) Detonation sensor C Cylinders 1 and 2
D Cylinders 3 and 4
C. Disconnect the engine harness’ 6-pin connector
from the rail. E Cylinders 5 and 6
F Cylinders 7 and 8
If the resistance is greater than 20,000 ohms,

the signal wire from the engine harness to the
ECM is OK. The signal wire is probably shorted
to ground in the rail.
383
Verify that the short circuit is in the rail.

Reconnect the engine harness’ 6-pin connector
to the rail’s receptacle. Measure the resistance
between the ground strap for the ICSM and the
terminal for the suspect signal wire on the rail’s
3-pin connector for the detonation sensor. If the
resistance is less than 5 ohms, the short circuit is
in the rail. The short circuit is caused by a poor
electrical connection and/or by a wiring problem
in the rail. Repair the connector and/or the wiring,
when possible. Replace the rail, if necessary.
If the resistance is less than 5 ohms, the short

circuit is probably in the engine harness or the
terminal box. Continue with this procedure.
E. Ensure that the engine control switch is in the

OFF/RESET position. Ensure that the 16 amp
g00898719
Illustration 266
(J5) Connector for the engine harness
G. Measure the resistance between the ground

strap for the ECM and the terminal for the
suspect signal wire on connector J5.
Expected Result:
g00898679
Illustration 265
(8) Ground strap for the ECM The resistance is greater than 20,000 ohms.
(3) J5/P5 connectors for the right side engine harness
Results:
F. Disconnect the P5 connector from the terminal
box. • Yes – The resistance is greater than 20,000 ohms.
The signal wire from the terminal box’s connector
to the ECM is OK. The signal wire is probably
shorted to ground in the engine harness.
Repair: Verify that the short circuit is in the engine

harness. Reconnect the engine harness to the
terminal box. Measure the resistance between the
ground strap for the ICSM and the terminal for
the suspect signal wire on the engine harness’
6-pin connector for the detonation sensors. If the
in the engine harness.
The short circuit is caused by a poor electrical

connection or by a wiring problem in the harness.
Repair the connector and/or the wiring, when
STOP.
• No – The resistance is less than 5 ohms. The

short circuit is in the terminal box.
384
Repair: The short circuit is caused by a poor D. Use a jumper wire with the appropriate terminals
electrical connection or by a wiring problem in on the ends. Install the jumper wire onto the
the terminal box. Repair the connector and/or terminals for the suspect signal wire and the
the wiring, when possible. Replace the wiring, if voltage supply wire on the rail’s 3-pin connector
necessary. for the detonation sensor.
STOP.
Test Step 9. Isolate the Open Circuit
g00858654
Illustration 269
6-pin connector on the rail
E. Measure the resistance between the terminals for

g00897591
Illustration 267 the suspect signal wire and the voltage supply
(1) ECM J2/P2 connectors on the rail’s 6-pin connector.
(3) Terminal box’s J5/P5 connectors for the engine harness The terminals on the rail’s 6-pin connectors for
the detonation sensors are identified in Table 60.
position. Switch the 16 amp circuit breaker for Table 60
the ECM OFF. Terminals for the Voltage Supply Wires and Signal
Wires on the Rail’s 6-Pin Connectors
the jumper wire from the ECM P2 connector. Terminal Function
Reinstall the suspect signal wire into the P2 A +8 VDC
connector. Pull on the wire in order to verify that
the terminal is secure. C Signal for cylinders 1 and 2
D Signal for cylinders 3 and 4
E Signal for cylinders 5 and 6
F Signal for cylinders 7 and 8

there is an open circuit in the rail. The open
circuit is probably caused by a poor electrical
connection and/or by a broken wire. Repair the
If the resistance is less than 5 ohms, the rail is

OK. There is probably an open circuit between
g00898665
Illustration 268 the ECM and the rail. Proceed to the next Step.
(4) Rail
(5) 6-pin connectors for the engine harness
C. Disconnect the engine harness’ 6-pin connector

from the rail.
385
I. Measure the resistance between the

corresponding terminals for the suspect signal
wire and the voltage supply on the engine
harness connector for the terminal box.
The corresponding terminal box’s connectors are

identified in Table 61.
Table 61
Terminals on the Engine Harness Connectors
for the Detonation Sensors
Harness’ 6-Pin Corresponding Terminals
Connector Harness P5 Connector
Terminals
g00897591
Illustration 270
(2) 16 amp circuit breaker A + 8 VDC
(3) Terminal box’s J5/P5 connectors for the engine harness P5-57
C Signal for cylinders 1 and 2
F. Make sure that the engine control switch is in the P5-47
OFF/RESET position and that the 16 amp circuit
breaker for the ECM is OFF. D Signal for cylinders 3 and 4
P5-46
G. Disconnect the engine harness connector P5 E Signal for cylinders 5 and 6
from the terminal box. P5-45
F Signal for cylinders 7 and 8
P5-44
Expected Result:
Results:
• Yes – The resistance is less than 5 ohms. The

engine harness is OK. There is a problem with a
connector for the signal wire or the wire in the
terminal box is broken.
Repair: Repair the connector and/or the wire,

when possible. Replace the connector and/or the
wire, if necessary.
STOP.
Illustration 271 g00858710 • No – The resistance is greater than 5 ohms.

There is an open circuit in the engine harness.
Engine harness connectors
(AA) 6-pin connector for the detonation sensors Repair: The open circuit is probably caused by
(BB) Terminal box’s side of the P5 connector for the engine
harness a poor electrical connection and/or by broken
wire in the engine harness. Repair the connector
H. Install a jumper wire into the terminals for the and/or the wiring, when possible. Replace the
suspect signal wire and the voltage supply on engine harness, if necessary.
the engine harness’ 6-pin connector for the
detonation sensors. STOP.
The terminals for the 6-pin connectors are

identified in Table 61.
386
i01757172 The ECM also supports event codes when the levels
of detonation warrant a reaction from the ECM. If the
Detonation Sensors timing has been retarded by the maximum amount
and the level of detonation remains high, the ECM
SMCS Code: 1559-038 will shut down the engine.
S/N: BLB1-Up
S/N: BKE1-Up record. Before you begin this procedure, use the
System Operation Description: the logged codes to a file.
Detonation sensors are located on the upper The most likely causes of the diagnostic code are a
cylinder block between every two cylinders. poor connection or a problem in a wiring harness.
Each sensor monitors two adjacent cylinders. For The next likely cause is a problem with a sensor.
example, one sensor monitors cylinders 1 and 3. The least likely cause is a problem with the ECM.
The Electronic Control Module (ECM) supplies 8 The troubleshooting procedure may generate
VDC in order to power the sensors. The detonation additional diagnostic codes. Keep your mind on
sensors provide electrical signals to the ECM correcting the cause of the original diagnostic code.
that indicate mechanical engine vibrations. Each Clear the diagnostic codes after the problem is
sensor outputs an electrical signal that is filtered resolved.
and the signal is amplified. The frequency of the
signal corresponds to the mechanical frequency
of the vibrations. The amplitude of the signal is
proportional to the intensity of the vibrations.
The ECM monitors the signals in order to determine

the presence and the severity of the detonation. The
ECM retards the timing in order to limit detonation
levels. The timing may be retarded for a single
cylinder or for all of the cylinders, if necessary. If
retardation of the timing does not sufficiently limit
the detonation, the engine is shut down.
The ECM can retard timing by as few as three

degrees for light detonation levels. The timing can
be retarded up to six degrees for severe detonation.
For most applications, the minimum allowable actual
timing is ten degrees Before Top Center (BTC). A
proportional strategy is used for advancing the
timing after the timing has been retarded. The rate
of advance is based upon the level of detonation.
The rate is faster for lighter detonation. The fastest
rate of advance is one degree per minute.
The ECM will diagnose the detonation sensor’s

signal for a short circuit to the −Battery side, for
a short circuit to the +Battery side, and for an
open circuit. To avoid detecting vibrations that are
not related to detonation, the ECM only monitors
a detonation sensor when one of the sensor’s
cylinders is between top center and 40 degrees
after top center.
An input from a detonation sensor that is diagnosed

by the ECM as “short to ground” may actually
indicate an open circuit.
387
g00909130
Illustration 272
Schematic for the detonation sensors
The wiring for the detonation sensors is routed through rails on each side of the engine. Each detonation sensor has a 3-pin connector that is
connected to a receptacle on the rail.
Each rail has a 6-pin connector for a wiring harness that connects the detonation sensors to the terminal box.
388

g00855048
Illustration 275
g00854917
Illustration 273 (9) Rail on the left side of the engine
(1) ECM J2/P2 connectors (10) 6-pin connectors J676/P676 for the engine harness
(2) 16 amp circuit breaker (11) Connectors on the rail for the detonation sensor
(3) Terminal box’s J6/P6 connectors for the left side detonation (12) Detonation sensor
sensors
(4) Terminal box’s J5/P5 connectors for the right side detonation B. Thoroughly inspect the following connectors:
sensors
position. Switch the 16 amp circuit breaker for • The suspect detonation sensor’s connectors
the ECM OFF.
• For a diagnostic code on the right side of
Note: For the following steps, refer to the engine, inspect terminal box’s J5/P5
Troubleshooting, “Inspecting Electrical Connectors”. connectors and the 6-pin connectors
J675/P675 on the right side rail.
• For a diagnostic code on the left side of

the engine, inspect terminal box’s J6/P6
connectors and the 6-pin connectors
J676/P676 on the left side rail.
a. Check the torque of the Allen head screws for

box’s P5 or P6 connector. The proper torque
is 6 ± 1 N·m (55 ± 9 lb in).

g00855045
the detonation sensor. Refer to the schematic.
Illustration 274
Right side of the engine c. Check the harnesses and wiring for abrasion
(5) Rail on the right side of the engine and for pinch points from the suspect
(6) 6-pin connectors J675/P675 for the engine harness detonation sensor to the ECM.
(7) Connectors on the rail for the detonation sensor
d. Make sure that the detonation sensors are
properly installed according to the torque in
Specifications, “Detonation Sensors”.
Expected Result:

389
Results: Test Step 3. Check for Active Diagnostic

Codes for the Detonation Sensors
connected properly. The connectors and the Note: The run relay and the crank terminate relay
wiring do not have corrosion, abrasion, or pinch must be energized before a diagnostic code for a
points. The components are in good condition detonation sensor can be generated. Therefore, the
with proper connections. Proceed to Test Step 2. engine must be running. The engine will shut down
soon after the diagnostic code is activated.
or sockets is not connected properly. At least A. Start the engine and run the engine.
and/or pinch points. The components are not in B. Allow a minimum of 30 seconds for any
good condition and/or at least one connection diagnostic codes to become active. Observe the
is improper. “Active Diagnostic” screen of Cat ET and look for
the diagnostic codes that are listed in Table 62:
replace parts, if necessary. Table 62
Code Description Cylinders
STOP.
Test Step 2. Check for Diagnostic Codes Sensor short to +batt
1 and 3
for the +8 V Sensor Supply 1501-04 Cylinder #1 Detonation
ON. Turn the engine control switch to the STOP 1502-03 Cylinder #2 Detonation
position. 2 and 4
B. Observe the “Active Diagnostic” screen of Cat Sensor short to ground
ET. Wait at least 30 seconds so that any codes 1505-03 Cylinder #5 Detonation
may become activated. Look for these diagnostic Sensor short to +batt
codes: 5 and 7
• “41-03 8 Volt DC Supply short to +batt” Sensor short to ground
• “41-04 8 Volt DC Supply short to ground” Sensor short to +batt
6 and 8
Expected Result: 1506-04 Cylinder #6 Detonation
Neither of the “8 Volt DC Supply” diagnostic codes 1509-03 Cylinder #9 Detonation
are active. Sensor short to +batt
9 and 11
Results:
• OK – Neither of the “8 Volt DC Supply” diagnostic 1510-03 Cylinder #10 Detonation
codes are active. Proceed to Test Step 3. Sensor short to +batt
10 and 12
• Not OK – At least one of the “8 Volt DC Supply” Sensor short to ground
diagnostic codes is active.
Repair: The “8 Volt DC Supply” diagnostic code Sensor short to +batt
13 and 15
must be resolved before you can proceed with 1513-04 Cylinder #13 Detonation
this functional test. Sensor short to ground
Exit this procedure and refer to Troubleshooting, 1514-03 Cylinder #14 Detonation
“+8V Sensor Voltage Supply”. Sensor short to +batt
14 and 16
If necessary, return to this functional test in order Sensor short to ground
to troubleshoot the detonation sensor after the
“8 Volt DC Supply” diagnostic code has been
Note: A “short to ground” diagnostic code can
resolved.
indicate either an actual short to ground or an open
circuit.
STOP.
390
Expected Result: B. Disconnect the suspect sensor’s 3-pin connector

from the rail.
None of the above diagnostic codes are active.
Results: ON. Turn the engine control switch to the STOP
position.
• OK (No active codes) – None of the above codes
are active at this time. The problem seems to D. Measure the voltage between terminals (A)
be resolved. The original diagnostic code was and (B) on the rail’s receptacle for the sensor’s
probably caused by a poor electrical connection connector.
in one of the harness connectors.
Expected Result:
and the engine is not running properly, refer The voltage is between 7.6 VDC and 8.4 VDC.
Diagnostic Code”. Results:
If any of the above codes are logged and the • OK – The voltage is between 7.6 VDC and 8.4
engine is running properly, there may be an VDC. The correct voltage is available to the
intermittent problem in a connector or a wiring sensor. Do not reconnect the sensor. Proceed to
harness. Refer to Troubleshooting, “Inspecting Test Step 5.
Electrical Connectors”.
• Not OK – The voltage is not between 7.6 VDC
STOP. and 8.4 VDC. The correct voltage is not available
to the sensor. There is probably an open circuit in
• Not OK (Active Code) – A “short to +batt” or the +8 volt supply or in the return for the sensor.
“short to ground” diagnostic code was activated.
Repair: The open circuit may be caused by a
Repair: Note the diagnostic code and note the poor electrical connection or by a wiring problem
location of the suspect detonation sensor. between the ECM and the connector for the
sensor.
If only one detonation sensor has an “04 short to
Test Step 4. Verify the Presence of the ground” diagnostic code, the open circuit for the
Supply Voltage to the Sensor +8 volt supply is in the rail. Repair the electrical
A. Turn the engine control switch to the OFF/RESET Replace the rail, if necessary.
the ECM OFF. If more than one detonation sensor has an
“04 short to ground” diagnostic code, use the
following procedure to locate the open circuit for
the +8 volt supply:

g00857709
Illustration 276
(A) +8 V supply
(B) Return
(C) Signal
391
If the voltage is between 7.6 VDC and 8.4

VDC, the open circuit is in the rail. Repair the

VDC, the open circuit may be in the engine
harness. Proceed to the next Step.

6. Disconnect the appropriate harness from the

g00857795
terminal box.
Illustration 277
(1) 6-pin connectors J675/P675 for the right side engine harness If you are troubleshooting the sensors on
the right side of the engine, disconnect the
harness from the J5 connector.
If you are troubleshooting the sensors on the

left side of the engine, disconnect the harness
from the J6 connector.

STOP position.
g00857796
Illustration 278
(2) 6-pin connectors J676/P676 for the left side engine harness
2. Disconnect the 6-pin connector from the rail

on the suspect sensors’ side of the engine.

STOP position.
g00857845
Illustration 280
Bottom view of the terminal box
(J6) Terminal box’s connector for the harness on the left side of
the engine
(J6-54) Return
(J6-57) +8 V supply
(J5) Terminal box’s connector for the harness on the right side
of the engine
g00858454 (J5-31) +8 V supply
Illustration 279
(J5-23) Return
8. Measure the voltage between the terminals for

4. Use a voltmeter to measure the voltage
the detonation sensors’ supply and the return.
between terminals “A” and “B” on the engine
harness’ 6-pin connector.
392
If you are troubleshooting the sensors on the Results:

left side of the engine, measure the voltage
between terminals J6-54 and J6-57. • Yes – The voltage is between 0.4 VDC and 0.6
VDC.
If you are troubleshooting the sensors on the
right side of the engine, measure the voltage Repair: Reconnect the suspect sensor. Start the
between terminals J5-23 and J5-31. engine again and check for the diagnostic code.
If the voltage is between 7.6 VDC and 8.4 VDC, If the diagnostic code recurs, replace the
the open circuit is in the engine harness. Repair detonation sensor with a known good detonation
the electrical connection and/or the wiring, when sensor. Tighten the detonation sensor according
possible. Replace the harness, if necessary. to Specifications, “Detonation Sensor”. Verify that
VDC, the open circuit is in the terminal box STOP.
between the ECM J2 connector and the engine
harness connector on the terminal box. • No – The voltage is not between 0.4 VDC and 0.6
VDC. If the voltage is less than 0.4 VDC, there
Repair the electrical connection and/or the wiring, is probably a short to ground or an open circuit
when possible. Replace the components, if between the rail’s connector for the detonation
necessary. sensor and the ECM. If the voltage is greater than
4.8 VDC, there is probably a short circuit to a
STOP. +Battery source between the rail’s connector for
the detonation sensor and the ECM.
Test Step 5. Measure the Voltage of the
Signal Wire at the Rail Repair:
A. Ensure that the 16 amp circuit breaker for the Proceed to Test Step 6.
ECM is ON and that the engine control is in the
STOP position. Test Step 6. Measure the Voltage of the
Suspect Signal Terminal at the ECM
the ECM OFF.
g00857709
Illustration 281
(A) +8 V supply
(B) Return
(C) Signal
B. Measure the voltage between terminals B and

C on the rail’s receptacle for the sensor’s
connector.
Expected Result:

393
Expected Result:
Results:
• Yes – The voltage is between 0.4 VDC and 0.6

VDC. The ECM is OK. There is a problem with a
connection and/or with the wiring between the
ECM and the rail’s connector for the detonation
sensor. If you suspect that there is a short circuit
to a +Battery source, proceed to test Step 7. If
you suspect that there is an open circuit, proceed
to Test Step 8. If you suspect that there is a short
to ground, proceed to Test Step 9.
• No – The voltage is not between 0.4 VDC and 0.6

VDC. There is a problem with the ECM.


the original signal wire into the P2 connector. Pull
on the wire in order to verify that the terminal is
secure.
g00857753
Illustration 282
Harness side of the ECM P2 connector Replace the ECM according to Troubleshooting,
(P2-36) Signal for cylinders 1 and 3 “Replacing the ECM”.
(P2-38) Signal for cylinders 9 and 11 STOP.
(P2-54) Return (right side)
(P2-44) Signal for cylinders 2 and 4 Test Step 7. Monitor the Voltage and
(P2-45) Signal for cylinders 6 and 8 Isolate the Short Circuit
(P2-47) Signal for cylinders 14 and 16 A. Turn the engine control switch to the OFF/RESET
(P2-55) Return (left side)
the ECM OFF.
the suspect signal wire from ECM P2 connector.
the jumper wire from the ECM P2 connector.
C. Install one end of jumper wire with the
Reinstall the removed suspect signal wire into
appropriate connectors on the ends into the
the terminal. Pull on the wire in order to verify
terminal for the suspect signal wire. Leave the
proper installation.
other end of the jumper wire unconnected. Pull
on the jumper wire in order to verify that the
jumper wire is properly connected.
D. Insert a lead of a 7X-1710 Multimeter Probe into

the terminal for the corresponding return wire.
E. Connect the leads of a voltmeter to the 7X-1710

Multimeter Probe and to the loose end of the
jumper wire.

position.
G. Use the voltmeter to measure the voltage.

394
g00857795
Illustration 284
(1) 6-pin connectors J675/P675 on the rail for the right side
detonation sensors
g00857753
Illustration 283
(P2-38) Signal for cylinders 9 and 11 g00857796
(P2-39) Signal for cylinders 13 and 15 Illustration 285
(P2-54) Return (right side) (2) 6-pin connectors J676/P676 on the rail for the left side
(P2-44) Signal for cylinders 2 and 4 detonation sensors
(P2-47) Signal for cylinders 14 and 16 G. Disconnect the 6-pin connector from the rail on
(P2-55) Return (left side) the suspect sensor’s side of the engine.
C. Insert the lead of a 7X-1710 Multimeter Probe H. Switch the 16 amp circuit breaker for the ECM
into the terminal for the suspect sensor’s signal ON. Turn the engine control switch to the STOP
wire in the harness side of the ECM P2 connector. position.
D. Verify that the voltmeter is properly connected I. Use the voltmeter to measure the voltage again.
to the leads of the 7X-1710 Multimeter Probes. Compare the voltage to the previously noted
Switch the 16 amp circuit breaker for the ECM voltage.
position. If the voltage is between 0.4 VDC and 0.6 VDC,
there is a short circuit in the rail on the suspect
E. Measure the voltage. sensor’s side of the engine. Repair the electrical
Because a short circuit to a +Battery source is Replace the rail, if necessary.
suspected, the expected voltage is greater than
4.8 VDC. If the voltage is still greater than 4.8 VDC, the rail
is probably OK. Continue with this procedure.
F. Turn the engine control switch to the OFF/RESET
the ECM OFF.
395

ECM OFF. Repair the harness, when possible.
Replace the harness, if necessary.
STOP.
• No – Before the harness was disconnected,

the voltage was greater than 4.8 VDC. After the
harness was disconnected, the voltage was still
greater than 4.8 VDC. There is a problem in the
terminal box.

g00854917
Illustration 286 breaker for the ECM OFF. Repair the connector
(1) ECM J2/P2 connectors and/or wiring, when possible. Replace the
(2) 16 amp circuit breaker connector and/or wiring, if necessary.
(3) Terminal box’s J6/P6 connectors for the left side engine harness
(4) Terminal box’s J5/P5 connectors for the right side engine
harness STOP.
J. Turn the engine control switch to the OFF/RESET Test Step 8. Check the Engine Harness
position. Switch the 16 amp circuit breaker for for a Short Circuit to Ground
the ECM OFF.
K. Disconnect the appropriate harness from the

terminal box.
If you are troubleshooting a sensor on the right

side of the engine, disconnect the harness from
the J5 connector.
If you are troubleshooting a sensor on the left

side of the engine, disconnect the harness from
the J6 connector.
L. Switch the 16 amp circuit breaker for the ECM

ON. Turn the engine control switch to the STOP g00854917
position. Illustration 287
M. Use the voltmeter to measure the voltage again. (2) 16 amp circuit breaker
Compare the voltage to the previously noted (4) Terminal box’s J5/P5 connectors for the right side engine
voltage. harness
Expected Result: A. Turn the engine control switch to the OFF/RESET

Before the harness was disconnected, the voltage the ECM OFF.
was greater than 4.8 VDC. After the harness was
disconnected, the voltage was between 0.4 VDC B. Use a 151-6320 Wire Removal Tool to remove
and 0.6 VDC. the jumper wire from the ECM P2 connector.
Reinstall the suspect signal wire into the P2
Results: connector. Pull on the wire in order to verify that
the terminal is secure.
• Yes – Before the harness was disconnected,
the voltage was greater than 4.8 VDC. After the
harness was disconnected, the voltage was
between 0.4 VDC and 0.6 VDC. There is a
problem in the engine harness.
Repair: The problem is probably caused by a

poor electrical connection and/or by a wiring
problem in the harness.
396
g00855045 g00858454
Right side of the engine 6-pin connector on the engine harness
(5) Rail on the right side of the engine
(6) 6-pin connector J675/P675 for the detonation sensors
g00858460
Illustration 291
Ground strap for the Integrated Combustion Sensing Module
(ICSM)
g00855048
Illustration 289
D. Measure the resistance between the ground
Left side of the engine strap for the ICSM and the terminal for the
(9) Rail on the left side of the engine suspect signal wire on the engine harness’ 6-pin
(10) 6-pin connector J676/P676 for the detonation sensors connector.
The terminals on the 6-pin connectors for the
C. Disconnect the appropriate engine harness’ detonation sensors are identified in Table 63.
6-pin connector from the rail. Table 63
If you are troubleshooting a problem on the Terminals on the 6-Pin Connectors for the
right side of the engine, disconnect the P675 Detonation Sensors’ Signal Wires
connector. Terminal Right Side Harness Left Side Harness
P675 P676
If you are troubleshooting a problem on the
left side of the engine, disconnect the P676 C Cylinders 1 and 3 Cylinders 2 and 4
connector. D Cylinders 5 and 7 Cylinders 6 and 8
E Cylinders 9 and 11 Cylinders 10 and 12
F Cylinders 13 and 15 Cylinders 14 and 16

the signal wire from the engine harness to the
ECM is OK. The signal wire is probably shorted
to ground in the rail.
397
Verify that the short circuit is in the rail.

Reconnect the engine harness’ 6-pin connector
to the rail’s receptacle. Measure the resistance
between the ground strap for the ICSM and the
terminal for the suspect signal wire on the rail’s
3-pin connector for the detonation sensor. If the
in the rail. The short circuit is caused by a poor
electrical connection and/or by a wiring problem
in the rail. Repair the connector and/or the wiring,
when possible. Replace the rail, if necessary.
If the resistance is less than 5 ohms, the short

circuit is probably in the engine harness or the
terminal box. Continue with this procedure.
E. Ensure that the engine control switch is in the

OFF/RESET position. Ensure that the 16 amp
g00858514
Illustration 293
Connectors J6 and J5 on the bottom of the terminal box
(J6-63) Signal for cylinders 14 and 16
G. Measure the resistance between the ground

strap for the ECM and the terminal for the
Illustration 292
g00858507 suspect signal wire on connector J6 or J5.
(3) J6/P6 connectors for the left side engine harness
Expected Result:
(4) J5/P5 connectors for the right side engine harness
F. Disconnect the suspect engine harness from the
terminal box. Results:
If you are troubleshooting a problem on the right • Yes – The resistance is greater than 20,000 ohms.
side of the engine, disconnect the P5 connector. The signal wire from the terminal box’s connector
to the ECM is OK. The signal wire is probably
If you are troubleshooting a problem on the left shorted to ground in the engine harness.
side of the engine, disconnect the P6 connector.
Repair: Verify that the short circuit is in the engine
harness. Reconnect the engine harness to the
terminal box. Measure the resistance between the
ground strap for the ICSM and the terminal for
the suspect signal wire on the engine harness’
6-pin connector for the detonation sensors. If the
The short circuit is caused by a poor electrical

connection or by a wiring problem in the harness.
Repair the connector and/or the wiring, when
STOP.
398
• No – The resistance is less than 5 ohms. The

short circuit is in the terminal box.
Repair: The short circuit is caused by a poor

electrical connection or by a wiring problem in
the terminal box. Repair the connector and/or
the wiring, when possible. Replace the wiring, if
necessary.
STOP.
Test Step 9. Isolate the Open Circuit
g00855045
Illustration 295
(5) Rail on the right side of the engine
(6) 6-pin connectors J675/P675 for the detonation sensors
g00854917
Illustration 294
harness

g00855048
the ECM OFF. Illustration 296
B. Use a 151-6320 Wire Removal Tool to remove (9) Rail on the left side of the engine
the jumper wire from the ECM P2 connector. (10) 6-pin connectors J676/P676 for the detonation sensors
Reinstall the suspect signal wire into the P2 (11) 3-pin connectors on the rail for the detonation sensor
connector. Pull on the wire in order to verify that (12) Detonation sensor
the terminal is secure.
C. Disconnect the appropriate engine harness’
6-pin connector from the rail.
If you are troubleshooting a problem on the right

side of the engine, disconnect the J675/P675
connectors.
If you are troubleshooting a problem on the left

side of the engine, disconnect the J675/P675
connectors.
D. Use a jumper wire with the appropriate terminals

on the ends. Install the jumper wire onto the
terminals for the suspect signal wire and the
voltage supply wire on the rail’s 3-pin connector
for the detonation sensor.
399
g00858654 g00854917
6-pin connector on the rail (1) ECM J2/P2 connectors
E. Measure the resistance between the terminals for (3) Terminal box’s J6/P6 connectors for the left side engine harness
the suspect signal wire and the voltage supply harness
on the rail’s 6-pin connector.
F. Make sure that the engine control switch is in the
The terminals on the rail’s 6-pin connectors for OFF/RESET position and that the 16 amp circuit
the detonation sensors are identified in Table 64. breaker for the ECM is OFF.
Table 64
G. Disconnect the appropriate engine harness
Terminals for the Voltage Supply Wires and Signal connector from the terminal box.
Wires on the Rails’ 6-Pin Connectors
Terminal Right Side Harness Left Side Harness
If you are troubleshooting a problem on the right
J675 J676 side of the engine, disconnect the P5 connector.
A +8 VDC +8 VDC If you are troubleshooting a problem on the left

C Signal for cylinders Signal for cylinders side of the engine, disconnect the P6 connector.
1 and 3 2 and 4
D Signal for cylinders Signal for cylinders
5 and 7 6 and 8
E Signal for cylinders Signal for cylinders
9 and 11 10 and 12
F Signal for cylinders Signal for cylinders
13 and 15 14 and 16

there is an open circuit in the rail. The open
circuit is probably caused by a poor electrical
connection and/or by a broken wire. Repair the
If the resistance is less than 5 ohms, the rail is

OK. There is probably an open circuit between
the ECM and the rail. Proceed to the next Step.
g00858710
Illustration 299
Engine harness connectors
(AA) 6-pin connector for the detonation sensors
(BB) Connector for the terminal box
400
H. Install a jumper wire into the terminals for the Repair: The open circuit is probably caused by
suspect signal wire and the voltage supply on a poor electrical connection and/or by broken
the engine harness’ 6-pin connector for the wire in the engine harness. Repair the connector
detonation sensors. and/or the wiring, when possible. Replace the
engine harness, if necessary.
The terminals for the 6-pin connectors are
identified in Table 65. STOP.
I. Measure the resistance between the

i01757257
corresponding terminals for the suspect signal
wire and the voltage supply on the engine
harness connector for the terminal box.
ECM Output Circuit (Fuel
Control)
The corresponding terminal box’s connectors are
identified in Table 65. SMCS Code: 1901-038
Table 65 S/N: BEN1-Up

Terminals on the Engine Harness Connectors S/N: 4ZS1-Up
for the Detonation Sensors
Harness’ Corresponding Corresponding System Operation Description:
6-Pin Terminals Terminals
Connector Right Side Left Side Harness The Electronic Control Module (ECM) contains the
Terminals Harness P5 P6 Connector logic and the outputs that control the engine’s
Connector prelubrication, start-up, and shutdown. The
logic for starting and for stopping is customer
A + 8 VDC + 8 VDC
P5-31 P6-67 programmable. The logic responds to inputs from
the following components: engine control switch,
C Signal for cylinders Signal for cylinders emergency stop switch, remote start switch, data
1 and 3 2 and 4 link, and other inputs.
P5-38 P6-66
D Signal for cylinders Signal for cylinders The Gas Shutoff Valve (GSOV) is energize-to-run.
5 and 7 6 and 8 To enable fuel flow to the engine, the solenoid for
P5-30 P6-65 the GSOV must be energized. The ECM provides
+Battery voltage to the solenoid for the GSOV when
E Signal for cylinders Signal for cylinders
the logic determines that fuel is required for engine
9 and 11 10 and 12
P5-22 P6-64 operation. For engine shutdown, the ECM removes
the voltage from the GSOV. This stops the fuel flow.
F Signal for cylinders Signal for cylinders
13 and 15 14 and 16 Logged diagnostics provide a historical record.
P5-12 P6-63 Before you begin this procedure, use the Caterpillar
Electronic Technician (Cat ET) to print the logged
Expected Result: codes to a file.
The resistance is less than 5 ohms. The most likely causes of the diagnostic code are a
poor electrical connection or a problem in a wiring
Results: harness. The next likely cause is a problem with
the GSOV. The least likely cause is a problem with
• Yes – The resistance is less than 5 ohms. The the ECM.
engine harness is OK. There is a problem with a
connector for the signal wire or the wire in the The troubleshooting procedure may generate
terminal box is broken. additional diagnostic codes. Keep your mind on
Repair: Repair the connector and/or the wire, Clear the diagnostic codes after the problem is
when possible. Replace the connector and/or the resolved.
wire, if necessary.
STOP.
• No – The resistance is greater than 5 ohms.

There is an open circuit in the engine harness.
401
g00869732
Illustration 302
Terminal strip in the control panel
g00898820
Illustration 300
Schematic of the solenoid for the GSOV

g00869720
Illustration 303
(P2-11) Circuit driver for the gas shutoff valve’s solenoid
g00869702
Illustration 301 (P2-21) Return
(1) ECM P2 connectors
(3) Terminal box’s J6 connector for the engine harness
(4) 70-pin connector J3 (customer connector)
(5) Control panel’s 47-pin connector J4

ECM OFF. Switch the 6 amp circuit breaker OFF.

402
g00869896 g00898821
70-pin connector J3 (customer connector) Harness side of the terminal box P6 connector
(J3-60) Circuit driver for the gas shutoff valve’s solenoid (P6-69) Circuit driver for the gas shutoff valve’s solenoid
(P6-56) Return
g00869878
Illustration 306
Control panel’s 47-pin connector J4
(J4-m) Circuit driver for the gas shutoff valve’s solenoid
403

is improper.
Repair: Perform the necessary repairs, when

possible. Replace parts, if necessary.
STOP.
g00898825
Illustration 307 ON. Switch the 6 amp circuit breaker ON. Turn
Gas shutoff valve’s solenoid the engine control switch to the STOP position.
B. Thoroughly inspect the following connectors and Note: The “17-05 Fuel Shutoff Valve open circuit”
the wiring harnesses for the connectors: diagnostic code can only be detected when the
output for the gas shutoff valve’s solenoid is OFF.
• ECM J2/P2 connectors The output is OFF when the engine control switch is
in the STOP position and the engine is not running.
B. Wait for 30 seconds and use Cat ET to check for
• 70-pin connector J3 (customer connector) an active “17-05 Fuel Shutoff Valve open circuit”
diagnostic code.
• Control panel’s 47-pin connector J4
If there is an active “17-05 Fuel Shutoff Valve
• Terminal strip in the control panel (if equipped) open circuit” diagnostic code, proceed to the
“Results” for this Test Step. Otherwise, continue
• Connector for the gas shutoff valve’s solenoid this procedure.
a. Check the torque of the Allen head screw for C. Use Cat ET to check the logged diagnostic
the 70-pin connectors. The proper torque is codes. If there is a “17-06 Fuel Shutoff Valve
6 ± 1 N·m (55 ± 9 lb in). short to ground” or a “17-12 Fuel Shutoff Valve
malfunction” diagnostic code, clear the code.
wires that are associated with the gas shutoff D. To prevent the engine from starting, shut the gas
valve’s solenoid. supply OFF.
c. Check the harness and wiring for abrasion Note: To provide the output for the gas shutoff
and for pinch points from the ECM to the gas valve’s solenoid, the sequence for engine start-up
shutoff valve’s solenoid. must be initiated. Otherwise, a “17-06 Fuel Shutoff
Valve short to ground” or a “17-12 Fuel Shutoff Valve
d. Inspect the terminal strip in the control panel malfunction” diagnostic code cannot be generated.
(if equipped) for the following conditions:
loose wires, frayed wires, foreign material, Note: The ECM will not provide output for the gas
and corrosion. shutoff valve’s solenoid unless the prelube pressure
switch is closed. Make sure that the prelube
Expected Result: pressure switch is operating properly.
All connectors, pins, and sockets are connected E. Turn the engine control switch to the START
properly. The connectors and the wiring do not have position for at least 30 seconds. Then turn the
corrosion, abrasion, or pinch points. engine control switch to the STOP position.
Results: F. Use Cat ET to look for a logged “17-06 Fuel

Shutoff Valve short to ground” or a “17-12 Fuel
• OK – All connectors, pins, and sockets are Shutoff Valve malfunction” diagnostic code again.
404
Expected Result: Test Step 3. Check for a Short Circuit to

the +Battery Side
When the engine control switch was in the STOP
position, there was no active “17-05 Fuel Shutoff
Valve open circuit” diagnostic code.
After the engine was cranked, there was no logged Gaseous fuel is present. Personal Injury or Death
“17-06 Fuel Shutoff Valve short to ground” or “17-12 can result from an open flame or spark igniting the
Fuel Shutoff Valve malfunction” diagnostic code. gaseous fuel causing an explosion and/or fire. Al-
ways use a gas detector to determine the presence
Results: of gaseous fuel when maintaining and servicing.
Contact you local gas provider immediately for as-
• OK – No diagnostic codes were generated. sistance in the event of a leak.
The output for the gas shutoff valve’s solenoid
seems to be OK at this time. The initial diagnostic Note: Open sparks can be generated during this
code was probably caused by a poor electrical test.
connection.
A. Make sure that no combustible gas is present in
Repair: If there is an intermittent problem the surrounding atmosphere.
that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical B. Ensure that the engine control switch is in the
Connectors”. STOP position.
STOP.
• Not OK (“17-05 Fuel Shutoff Valve open circuit”

diagnostic code) – A “17-05 Fuel Shutoff Valve
open circuit” diagnostic code was activated. This
can be caused by an actual open circuit or by a
short circuit to the +Battery side. Proceed to Test
Step 3.
• Not OK (“17-06 Fuel Shutoff Valve short to ground”

diagnostic code) – After the engine was cranked,
a “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was generated. Proceed to Test
Step 8.
g00859796
Illustration 308
• Not OK (“17-12 Fuel Shutoff Valve malfunction” Typical connector for a solenoid
diagnostic code) – After the engine was cranked,
a “17-12 Fuel Shutoff Valve malfunction” C. Disconnect the connector from the gas shutoff
diagnostic code was generated. The ECM valve’s solenoid. Then reconnect the connector.
disabled the ignition. Listen for an audible click from the solenoid.
Repair: Turn the engine control switch to the If the ambient noise is too loud, touch the
OFF/RESET position. Switch the 16 amp circuit solenoid when the solenoid is reconnected in
breaker for the ECM OFF. order to feel the vibration. The solenoid will
vibrate when the solenoid is de-energized and
Replace the gas shutoff valve’s solenoid. energized.
STOP. Expected Result:
There is no audible click and/or vibration when the

solenoid is disconnected and reconnected. The
solenoid is not energized when the engine control
405
Results:
• OK – There is no audible click and/or vibration

when the solenoid is disconnected and
connected. There is no short circuit to the
+Battery side. There is an open circuit. Proceed
to Test Step 5.
• Not OK – There is an audible click and/or

vibration when the solenoid is disconnected and
connected. The solenoid is receiving power when
the engine control switch is in the STOP position.
There is probably a short circuit to the +Battery
side in a connector or a wiring harness. Proceed
to Test Step 4.
Test Step 4. Determine the Cause of the

Energized Solenoid
Gaseous fuel is present. Personal Injury or Death

can result from an open flame or spark igniting the
gaseous fuel causing an explosion and/or fire. Al-
of gaseous fuel when maintaining and servicing.
sistance in the event of a leak. g00898827
Illustration 309
Note: Open sparks can be generated during this (P6-69) Circuit driver for the gas shutoff valve’s solenoid
test.
A. Turn the engine control switch to the OFF/RESET terminal P6-69.
the ECM OFF. C. Switch the 16 amp circuit breaker for the ECM
position.
g00859796
Illustration 310
Typical connector for a solenoid
D. Disconnect the connector from the gas shutoff

valve’s solenoid. Then reconnect the connector.
Listen for an audible click from the solenoid.
406
If the ambient noise is too loud, touch the

solenoid when the solenoid is reconnected in
order to feel the vibration. The solenoid will
energized.
Expected Result:

solenoid is not energized when the circuit driver for
the solenoid is disconnected from the J6 connector.
Results:

reconnected. The solenoid is not energized when
the circuit driver for the solenoid is disconnected
Repair: Use the following procedure to determine

whether the circuit driver for the solenoid is faulty:

can result from an open flame or spark igniting the Illustration 311 g00869921
gaseous fuel causing an explosion and/or fire. Al- Harness side of the ECM P2 connector
sistance in the event of a leak. 3. Use a 151-6320 Wire Removal Tool to remove
terminal P2-11.
Note: Open sparks can be generated during this 4. Switch the 16 amp circuit breaker for the ECM
test. ON. Turn the engine control switch to the
STOP position.
OFF/RESET position. Switch the 16 amp circuit 5. Disconnect the connector from the gas
breaker for the ECM OFF. shutoff valve’s solenoid. Then reconnect the
connector. Listen for an audible click from the
2. Reinstall the removed wire into terminal P6-69. solenoid.
Pull on the wire in order to verify that the
terminal is properly installed. If the ambient noise is too loud, touch the
energized.
If the solenoid is energized, there is a problem

with a connector and/or with the wiring in the
terminal box. Repair the wiring and/or the
connector, when possible. Replace parts, if
necessary.
If the solenoid is not energized, there may be

a problem with the ECM. Continue with this
procedure.
407

7. Reinstall the terminal that was removed from

terminal P2-11. Pull on the wire in order to

STOP position.
9. Disconnect the connector from the gas

shutoff valve’s solenoid. Then reconnect the
connector. Listen for an audible click from the g00859796
solenoid. Illustration 312
solenoid when the solenoid is reconnected in C. Install a jumper wire with the appropriate
order to feel the vibration. The solenoid will connectors on the ends into terminals “A” and
vibrate when the solenoid is de-energized and “B” of the solenoid’s connector.
energized.
If the solenoid is not energized, there is an ON. Turn the engine control switch to the STOP
intermittent problem with a connector and/or position.
with the wiring. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. Note: The “17-05 Fuel Shutoff Valve open circuit”
diagnostic code can only be detected when the
If the solenoid is energized, there is a problem output for the gas shutoff valve’s solenoid is OFF.
with the ECM. Replace the ECM according to The output is OFF when the engine control switch is
Troubleshooting, “Replacing the ECM”. in the STOP position and the engine is not running.
STOP. E. Wait for 30 seconds and use the “Active

Diagnostic” screen of Cat ET to look for a “17-05
• Not OK – There is an audible click and/or Fuel Shutoff Valve open circuit” diagnostic code.
reconnected. The solenoid is energized when the Expected Result:
circuit driver for the solenoid is disconnected from
the terminal box J6 connector. There is a short A “17-05 Fuel Shutoff Valve open circuit” diagnostic
circuit to the +Battery side in the engine harness. code was not generated when the jumper wire was
installed.
Repair: Repair the connector and/or wiring in
the engine harness, when possible. Replace the Results:
• OK – A “17-05 Fuel Shutoff Valve open circuit”
STOP. diagnostic code was not generated when the
jumper wire was installed. The harness and
Test Step 5. Create a Short Circuit in the ECM are OK. There is a problem with the
order to Check for an Open Circuit solenoid.
A. Turn the engine control switch to the OFF/RESET Repair: Perform the following procedure:
the ECM OFF. 1. Turn the engine control switch to the
B. Disconnect the gas shutoff valve’s solenoid. breaker for the ECM OFF.
2. Remove the jumper wire from the solenoid’s

connector.
3. Verify that the solenoid’s connectors do not

have damage, moisture, or corrosion.
4. Make repairs, as needed.

408
If the problem is not resolved, replace the D. Install a jumper wire with the appropriate
solenoid. connectors on the ends into terminals P6-69 and
P6-56. Pull on the jumper wire in order to verify
STOP. proper installation.
• Not OK – A “17-05 Fuel Shutoff Valve open E. Switch the 16 amp circuit breaker for the ECM
circuit” diagnostic code was generated when the ON. Turn the engine control switch to the STOP
jumper wire was installed. There may be an open position.
circuit in the engine harness. Proceed to Test
Step 6. Note: The “17-05 Fuel Shutoff Valve open circuit”
Test Step 6. Check the Engine Harness output for the gas shutoff valve’s solenoid is OFF.
The output is OFF when the engine control switch is
A. Ensure that the engine control switch is in the in the STOP position and the engine is not running.
breaker for the ECM is OFF. F. Wait for 30 seconds and use Cat ET to check for
an active “17-05 Fuel Shutoff Valve open circuit”
B. Disconnect the P6 connector from the terminal diagnostic code.
box. Verify that the P6 and J6 connectors do
not have damage, moisture, or corrosion. Make Expected Result:
repairs, if necessary.
There is no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code.
Results:
• OK – When the jumper wire was installed, there

was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. There is a problem in
the engine harness.
Repair: Repair the engine harness, when possible.

Replace the engine harness, if necessary.
STOP.
• Not OK – When the jumper wire was installed, a

“17-05 Fuel Shutoff Valve open circuit” diagnostic
code was activated. The ECM did not detect
the jumper wire in the P6 connector. There is
a problem in the terminal box. Proceed to test
Step 7.
Test Step 7. Check the ECM

the ECM OFF.
g00898821 B. Use a 151-6320 Wire Removal Tool to remove
Illustration 313
Harness side of the terminal box P6 connector the jumper wire from the P6 connector.
(P6-56) Return C. Reinstall the terminals into P6-69 and P6-70.
Make sure that the terminals are installed into
C. Reconnect the P6 connector to the terminal box. the correct locations. Pull on the wires in order to
Use a 151-6320 Wire Removal Tool to remove verify proper installation of the terminals.
terminals P6-69 and P6-56. Label the terminals.
D. Disconnect the ECM J2/P2 connectors. Verify
that the connectors do not have damage,
moisture, or corrosion.
409
Make repairs, if necessary. Results:

circuit” diagnostic code. The ECM detects the
jumper wire at the P2 connector. However, the
ECM did not detect the jumper wire at the P6
connector. There is a problem between the ECM
P2 connector and the terminal box P6 connector.

2. Use a 151-6320 Wire Removal Tool to remove

3. Reinstall the terminals into P2-11 and P2-21.

the correct locations. Pull on the wires in order
to verify proper installation of the terminals.
4. Disconnect the ECM J2/P2 connectors. Verify

5. Thoroughly inspect the terminal box J6

g00869720 connector for the engine harness.
Illustration 314
6. Use an ohmmeter to measure the resistance
(P2-21) Return between the P2-11 terminal and the J6-70
terminal. Also, measure the resistance between
E. Use the 151-6320 Wire Removal Tool to remove the P2-21 terminal and the J6-57 terminal.
If the resistance is less than 5 ohms, the circuit
F. Reconnect the ECM J2/P2 connectors. has good continuity. Otherwise, there is an
open circuit.
G. Install the jumper wire into terminals P2-11 and
P2-21. Pull on the jumper wire in order to verify Make repairs, if necessary.
STOP.
H. Switch the 16 amp circuit breaker for the ECM
ON. Turn the engine control switch to the STOP • No – When the jumper wire was installed, a
position. “17-05 Fuel Shutoff Valve open circuit” diagnostic
code was activated. The ECM did not detect the
Note: The “17-05 Fuel Shutoff Valve open circuit” jumper wire. There is a problem with the ECM.
output for the gas shutoff valve’s solenoid is OFF. Repair: Perform the following procedure:
in the STOP position and the engine is not running. 1. Turn the engine control switch to the
I. Wait for 30 seconds and use the “Active breaker for the ECM OFF.
Diagnostic” screen of Cat ET to look for an
active “17-05 Fuel Shutoff Valve open circuit” 2. Use a 151-6320 Wire Removal Tool to remove
diagnostic code. the jumper wire from the P2 connector.
Expected Result: 3. Reinstall the terminals into P2-11 and P2-21.

There is no active “17-05 Fuel Shutoff Valve open the correct locations. Pull on the wires in order
circuit” diagnostic code. to verify proper installation of the terminals.
410
4. Replace the ECM according to Troubleshooting, 2. Inspect the solenoid’s connectors for damage
“Replacing the ECM”. Verify that the problem and/or for corrosion.
is resolved.
STOP.
If the problem is not resolved, replace the
Test Step 8. Create an Open Circuit in solenoid.
order to Check for a Short Circuit to
Ground STOP.
A. Turn the engine control switch to the OFF/RESET • Not OK – A “short to ground” diagnostic
position. code was generated when the solenoid was
disconnected. Proceed to Test Step 9.
B. Disconnect the gas shutoff valve’s solenoid.
Test Step 9. Create an Open Circuit at the
C. Turn the engine control switch to the STOP Terminal Box
position.
D. Use Cat ET to clear the logged “17-06 Fuel position. Switch the 16 amp circuit breaker for
Shutoff Valve short to ground” diagnostic code. the ECM OFF.
E. To prevent the engine from starting, shut OFF the

main gas supply.
Note: To provide the output for the gas shutoff

valve’s solenoid, the sequence for engine start-up
must be initiated. Otherwise, a “17-06 Fuel Shutoff
Valve short to ground” diagnostic code cannot be
generated.
Note: The ECM will not provide output for the gas
shutoff valve’s solenoid unless the prelube pressure
pressure switch is operating properly.

position for at least 30 seconds. Then turn the
engine control switch to the STOP position.
G. Use Cat ET to look for a logged “17-06 Fuel

Shutoff Valve short to ground” diagnostic code
again.
Expected Result:
A “17-06 Fuel Shutoff Valve short to ground” was

not generated.
g00898827
Results: Illustration 315
• OK – When the solenoid was connected, a “short (P6-69) Circuit driver for the gas shutoff valve’s solenoid
to ground” diagnostic code was generated. When
the solenoid was disconnected, no “short to B. Use a 151-6320 Wire Removal Tool to remove
ground” diagnostic code was generated. There terminal P6-69.
is a problem with the solenoid.
Repair: Perform the following procedure: ON. Turn the engine control switch to the STOP
position.
OFF/RESET position. Switch the 16 amp circuit D. Use Cat ET to clear the logged “17-06 Fuel
breaker for the ECM OFF. Shutoff Valve short to ground” diagnostic code.
411
E. To prevent the engine from starting, shut OFF the Test Step 10. Check the ECM
main gas supply.
Note: To provide the output for the gas shutoff position. Switch the 16 amp circuit breaker for
valve’s solenoid, the sequence for engine start-up the ECM OFF.
generated.


again.
Expected Result:

not generated.
Results:
• OK – A “17-06 Fuel Shutoff Valve short to ground”

diagnostic code was not generated when the
output to the solenoid was disconnected from the
g00869921
in the engine harness. Illustration 316
Repair: Perform the following procedure: (P2-11) Circuit driver for the gas shutoff valve’s solenoid
1. Turn the engine control switch to the B. Use the 151-6320 Wire Removal Tool to remove
OFF/RESET position. Switch the 16 amp circuit terminal P2-11.
2. Reinstall the terminal that was removed from ON. Turn the engine control switch to the STOP
P6-69. Pull on the wire in order to verify proper position.
installation of the terminal.
D. Use Cat ET to clear the logged “17-06 Fuel
3. Repair the harness, when possible. Replace Shutoff Valve short to ground” diagnostic code.
the harness, if necessary.
STOP. main gas supply.
• Not OK – A “17-06 Fuel Shutoff Valve short to Note: To provide the output for the gas shutoff
ground” diagnostic code was generated when valve’s solenoid, the sequence for engine start-up
the output to the solenoid was disconnected from must be initiated. Otherwise, a “17-06 Fuel Shutoff
the terminal box P6 connector. There is probably Valve short to ground” diagnostic code cannot be
a short circuit to ground in the terminal box. generated.
Repair: Reinstall the terminal that was removed Note: The ECM will not provide output for the gas
from P6-69. Pull on the wire in order to verify shutoff valve’s solenoid unless the prelube pressure
proper installation of the terminal. switch is closed. Make sure that the prelube
412
F. Turn the engine control switch to the START i01757340

engine control switch to the STOP position. ECM Output Circuit (Fuel
Control)
Shutoff Valve short to ground” diagnostic code SMCS Code: 1901-038
again.
S/N: BLB1-Up
Expected Result:
S/N: BKE1-Up
The “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was not generated. System Operation Description:
Results: The Electronic Control Module (ECM) contains the

logic and the outputs that control the engine’s
• OK – When the output to the solenoid was prelubrication, start-up, and shutdown. The
disconnected from the ECM P2 connector, logic for starting and for stopping is customer
the “17-06 Fuel Shutoff Valve short to ground” programmable. The logic responds to inputs from
diagnostic code was not generated. However, a the following components: engine control switch,
“short to ground” diagnostic code was generated emergency stop switch, remote start switch, data
when the output to the solenoid was disconnected link, and other inputs.
from the terminal box P6 connector. There is a
problem in the terminal box between the ECM The Gas Shutoff Valve (GSOV) is energize-to-run.
connector and the terminal box P6 connector. To enable fuel flow to the engine, the solenoid for
the GSOV must be energized. The ECM provides
Repair: Perform the following procedure: +Battery voltage to the solenoid for the GSOV when
the logic determines that fuel is required for engine
1. Turn the engine control switch to the operation. For engine shutdown, the ECM removes
OFF/RESET position. Switch the 16 amp circuit the voltage from the GSOV. This stops the fuel flow.
Logged diagnostics provide a historical record.
2. Reinstall the terminal that was removed from Before you begin this procedure, use the Caterpillar
P2-11. Pull on the wire in order to verify proper Electronic Technician (Cat ET) to print the logged
installation of the terminal. codes to a file.
3. Repair the harness, when possible. Replace The most likely causes of the diagnostic code are a
the harness, if necessary. poor electrical connection or a problem in a wiring
STOP. the GSOV. The least likely cause is a problem with
the ECM.
• Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when The troubleshooting procedure may generate
the output to the solenoid was disconnected from additional diagnostic codes. Keep your mind on
the ECM P2 connector. There seems to be a correcting the cause of the original diagnostic code.
problem with the ECM. Clear the diagnostic codes after the problem is
resolved.


P2-11. Pull on the wire in order to verify proper
3. Replace the ECM according to Troubleshooting,

“Replacing the ECM”. Verify that the problem
is resolved.
STOP.
413
g00869570 g00869720
Schematic of the solenoid for the GSOV Harness side of the ECM P2 connector
Test Step 1. Inspect the Electrical (P2-21) Return
g00869702
Illustration 318
(3) Terminal box’s J6 connector for the left engine harness


414
g00869726 g00869896
Harness side of the terminal box P6 connector 70-pin connector J3 (customer connector)
(P6-70) Circuit driver for the gas shutoff valve’s solenoid (J3-60) Circuit driver for the gas shutoff valve’s solenoid
(P6-57) Return
g00869878
Illustration 322
(J4-m) Circuit driver for the gas shutoff valve’s solenoid
415
d. Inspect the terminal strip in the control panel

loose wires, frayed wires, foreign material,
and corrosion.
Expected Result:

Results:

g00869732
Illustration 323 wiring do not have corrosion, abrasion, or pinch
Terminal strip in the control panel points. The components are in good condition

is improper.

STOP.
g00869737
Illustration 324
Gas shutoff valve’s solenoid A. Switch the 16 amp circuit breaker for the ECM
ON. Switch the 6 amp circuit breaker ON. Turn
B. Thoroughly inspect the following connectors and the engine control switch to the STOP position.
the wiring harnesses for the connectors:
Note: The “17-05 Fuel Shutoff Valve open circuit”
• ECM J2/P2 connectors diagnostic code can only be detected when the
output for the gas shutoff valve’s solenoid is OFF.
• Terminal box’s J6/P6 connectors The output is OFF when the engine control switch is
in the STOP position and the engine is not running.
• 70-pin connector J3 (customer connector)
B. Wait for 30 seconds and use Cat ET to check for
• Control panel’s 47-pin connector J4 an active “17-05 Fuel Shutoff Valve open circuit”
diagnostic code.
If there is an active “17-05 Fuel Shutoff Valve
• Connector for the gas shutoff valve’s solenoid open circuit” diagnostic code, proceed to the
a. Check the torque of the Allen head screw for this procedure.
the 70-pin connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in). C. Use Cat ET to check the logged diagnostic
codes. If there is a “17-06 Fuel Shutoff Valve
b. Perform a 45 N (10 lb) pull test on each of the short to ground” or a “17-12 Fuel Shutoff Valve
wires that are associated with the gas shutoff malfunction” diagnostic code, clear the code.
valve’s solenoid.
D. To prevent the engine from starting, shut the gas
c. Check the harness and wiring for abrasion supply OFF.
and for pinch points from the ECM to the gas
shutoff valve’s solenoid.
416
Note: To provide the output for the gas shutoff • Not OK (“17-12 Fuel Shutoff Valve malfunction”
valve’s solenoid, the sequence for engine start-up diagnostic code) – After the engine was cranked,
must be initiated. Otherwise, a “17-06 Fuel Shutoff a “17-12 Fuel Shutoff Valve malfunction”
Valve short to ground” or a “17-12 Fuel Shutoff Valve diagnostic code was generated. The ECM
malfunction” diagnostic code cannot be generated. disabled the ignition.
Note: The ECM will not provide output for the gas Repair: Turn the engine control switch to the
shutoff valve’s solenoid unless the prelube pressure OFF/RESET position. Switch the 16 amp circuit
switch is closed. Make sure that the prelube breaker for the ECM OFF.
Replace the gas shutoff valve’s solenoid.
E. Turn the engine control switch to the START
position for at least 30 seconds. Then turn the STOP.
F. Use Cat ET to look for a logged “17-06 Fuel the +Battery Side
Shutoff Valve short to ground” or a “17-12 Fuel
Shutoff Valve malfunction” diagnostic code again.
Expected Result:
When the engine control switch was in the STOP can result from an open flame or spark igniting the
position, there was no active “17-05 Fuel Shutoff gaseous fuel causing an explosion and/or fire. Al-
Valve open circuit” diagnostic code. ways use a gas detector to determine the presence
After the engine was cranked, there was no logged Contact you local gas provider immediately for as-
“17-06 Fuel Shutoff Valve short to ground” or “17-12 sistance in the event of a leak.
Fuel Shutoff Valve malfunction” diagnostic code.
Note: Open sparks can be generated during this
Results: test.
• OK – No diagnostic codes were generated. A. Make sure that no combustible gas is present in
The output for the gas shutoff valve’s solenoid the surrounding atmosphere.
seems to be OK at this time. The initial diagnostic
code was probably caused by a poor electrical B. Ensure that the engine control switch is in the
connection. STOP position.
Repair: If there is an intermittent problem
Connectors”.
STOP.
• Not OK (“17-05 Fuel Shutoff Valve open circuit”

diagnostic code) – A “17-05 Fuel Shutoff Valve
open circuit” diagnostic code was activated. This
can be caused by an actual open circuit or by a
short circuit to the +Battery side. Proceed to Test
Step 3.
g00859796
• Not OK (“17-06 Fuel Shutoff Valve short to ground” Illustration 325
diagnostic code) – After the engine was cranked, Typical connector for a solenoid
a “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was generated. Proceed to Test C. Disconnect the connector from the gas shutoff
Step 8. valve’s solenoid. Then reconnect the connector.
417

energized.
Expected Result:

Results:

to Test Step 5.

to Test Step 4.
g00869915
Illustration 326
Test Step 4. Determine the Cause of the Harness side of the terminal box P6 connector
Energized Solenoid (P6-70) Circuit driver for the gas shutoff valve’s solenoid

terminal P6-70.
position.
sistance in the event of a leak.

test.

the ECM OFF.
g00859796
Illustration 327
D. Disconnect the connector from the gas shutoff

valve’s solenoid. Then reconnect the connector.
418

energized.
Expected Result:

Results:



can result from an open flame or spark igniting the Illustration 328 g00869921
gaseous fuel causing an explosion and/or fire. Al- Harness side of the ECM P2 connector
sistance in the event of a leak. 3. Use a 151-6320 Wire Removal Tool to remove
terminal P2-11.
Note: Open sparks can be generated during this 4. Switch the 16 amp circuit breaker for the ECM
test. ON. Turn the engine control switch to the
STOP position.
OFF/RESET position. Switch the 16 amp circuit 5. Disconnect the connector from the gas
breaker for the ECM OFF. shutoff valve’s solenoid. Then reconnect the
2. Reinstall the removed wire into terminal P6-70. solenoid.
terminal is properly installed. If the ambient noise is too loud, touch the
energized.

necessary.

procedure.
419



STOP position.
9. Disconnect the connector from the gas

shutoff valve’s solenoid. Then reconnect the
energized.
“Inspecting Electrical Connectors”. Note: The “17-05 Fuel Shutoff Valve open circuit”
If the solenoid is energized, there is a problem output for the gas shutoff valve’s solenoid is OFF.
with the ECM. Replace the ECM according to The output is OFF when the engine control switch is
Troubleshooting, “Replacing the ECM”. in the STOP position and the engine is not running.
STOP. E. Wait for 30 seconds and use the “Active

• Not OK – There is an audible click and/or Fuel Shutoff Valve open circuit” diagnostic code.
reconnected. The solenoid is energized when the Expected Result:
circuit driver for the solenoid is disconnected from
the terminal box J6 connector. There is a short A “17-05 Fuel Shutoff Valve open circuit” diagnostic
circuit to the +Battery side in the engine harness. code was not generated when the jumper wire was
installed.
Repair: Repair the connector and/or wiring in
the engine harness, when possible. Replace the Results:
• OK – A “17-05 Fuel Shutoff Valve open circuit”
STOP. diagnostic code was not generated when the
Test Step 5. Create a Short Circuit in the ECM are OK. There is a problem with the
order to Check for an Open Circuit solenoid.
A. Turn the engine control switch to the OFF/RESET Repair: Perform the following procedure:
the ECM OFF. 1. Turn the engine control switch to the
B. Disconnect the gas shutoff valve’s solenoid. breaker for the ECM OFF.

connector.


420
If the problem is not resolved, replace the D. Install a jumper wire with the appropriate
solenoid. connectors on the ends into terminals P6-70 and
STOP. proper installation.
• Not OK – A “17-05 Fuel Shutoff Valve open E. Switch the 16 amp circuit breaker for the ECM
circuit” diagnostic code was generated when the ON. Turn the engine control switch to the STOP
jumper wire was installed. There may be an open position.
circuit in the engine harness. Proceed to Test
Step 6. Note: The “17-05 Fuel Shutoff Valve open circuit”
Test Step 6. Check the Engine Harness output for the gas shutoff valve’s solenoid is OFF.
A. Ensure that the engine control switch is in the in the STOP position and the engine is not running.
breaker for the ECM is OFF. F. Wait for 30 seconds and use Cat ET to check for
an active “17-05 Fuel Shutoff Valve open circuit”
B. Disconnect the P6 connector from the terminal diagnostic code.
not have damage, moisture, or corrosion. Make Expected Result:
There is no active “17-05 Fuel Shutoff Valve open
Results:

circuit” diagnostic code. There is a problem in
the engine harness.

STOP.

“17-05 Fuel Shutoff Valve open circuit” diagnostic
Step 7.

the ECM OFF.
g00869726 B. Use a 151-6320 Wire Removal Tool to remove
Illustration 330
Harness side of the terminal box P6 connector the jumper wire from the P6 connector.
(P2-57) Return C. Reinstall the terminals into P6-70 and P6-57.
C. Reconnect the P6 connector to the terminal box. the correct locations. Pull on the wires in order to
Use a 151-6320 Wire Removal Tool to remove verify proper installation of the terminals.
421
Make repairs, if necessary. Results:






g00869720 connector for the engine harness.
Illustration 331
6. Use an ohmmeter to measure the resistance
(P2-21) Return between the P2-11 terminal and the J6-70
terminal. Also, measure the resistance between
E. Use the 151-6320 Wire Removal Tool to remove the P2-21 terminal and the J6-57 terminal.
F. Reconnect the ECM J2/P2 connectors. has good continuity. Otherwise, there is an
open circuit.
G. Install the jumper wire into terminals P2-11 and
P2-21. Pull on the jumper wire in order to verify Make repairs, if necessary.
STOP.
H. Switch the 16 amp circuit breaker for the ECM
ON. Turn the engine control switch to the STOP • No – When the jumper wire was installed, a
position. “17-05 Fuel Shutoff Valve open circuit” diagnostic
Note: The “17-05 Fuel Shutoff Valve open circuit” jumper wire. There is a problem with the ECM.
output for the gas shutoff valve’s solenoid is OFF. Repair: Perform the following procedure:
in the STOP position and the engine is not running. 1. Turn the engine control switch to the
I. Wait for 30 seconds and use the “Active breaker for the ECM OFF.
Diagnostic” screen of Cat ET to look for an
active “17-05 Fuel Shutoff Valve open circuit” 2. Use a 151-6320 Wire Removal Tool to remove
diagnostic code. the jumper wire from the P2 connector.
Expected Result: 3. Reinstall the terminals into P2-11 and P2-21.

There is no active “17-05 Fuel Shutoff Valve open the correct locations. Pull on the wires in order
circuit” diagnostic code. to verify proper installation of the terminals.
422
4. Replace the ECM according to Troubleshooting, 2. Inspect the connections of the solenoid for
“Replacing the ECM”. Verify that the problem damage and/or for corrosion.
is resolved.
STOP.
Test Step 8. Create an Open Circuit in solenoid.
order to Check for a Short Circuit to
Ground STOP.
A. Turn the engine control switch to the OFF/RESET • Not OK – A “short to ground” diagnostic
position. code was generated when the solenoid was
disconnected. Proceed to Test Step 9.
B. Disconnect the gas shutoff valve’s solenoid.
C. Turn the engine control switch to the STOP Terminal Box
position.
D. Use Cat ET to clear the logged “17-06 Fuel position. Switch the 16 amp circuit breaker for
Shutoff Valve short to ground” diagnostic code. the ECM OFF.

main gas supply.
Note: To provide the output for the gas shutoff

valve’s solenoid, the sequence for engine start-up
generated.


again.
Expected Result:

not generated.
g00869915
Results: Illustration 332
• OK – When the solenoid was connected, a “short (P6-70) Circuit driver for the gas shutoff valve’s solenoid
the solenoid was disconnected, no “short to B. Use a 151-6320 Wire Removal Tool to remove
ground” diagnostic code was generated. There terminal P6-70.
is a problem with the solenoid.
position.
OFF/RESET position. Switch the 16 amp circuit D. Use Cat ET to clear the logged “17-06 Fuel
breaker for the ECM OFF. Shutoff Valve short to ground” diagnostic code.
423
E. To prevent the engine from starting, shut OFF the Test Step 10. Check the ECM
main gas supply.
Note: To provide the output for the gas shutoff position. Switch the 16 amp circuit breaker for
valve’s solenoid, the sequence for engine start-up the ECM OFF.
generated.


again.
Expected Result:

not generated.
Results:
• OK – A “17-06 Fuel Shutoff Valve short to ground”

g00869921
in the engine harness. Illustration 333
Repair: Perform the following procedure: (P2-11) Circuit driver for the gas shutoff valve’s solenoid
1. Turn the engine control switch to the B. Use the 151-6320 Wire Removal Tool to remove
OFF/RESET position. Switch the 16 amp circuit terminal P2-11.
2. Reinstall the terminal that was removed from ON. Turn the engine control switch to the STOP
P6-70. Pull on the wire in order to verify proper position.
D. Use Cat ET to clear the logged “17-06 Fuel
3. Repair the harness, when possible. Replace Shutoff Valve short to ground” diagnostic code.
STOP. main gas supply.
• Not OK – A “17-06 Fuel Shutoff Valve short to Note: To provide the output for the gas shutoff
ground” diagnostic code was generated when valve’s solenoid, the sequence for engine start-up
the output to the solenoid was disconnected from must be initiated. Otherwise, a “17-06 Fuel Shutoff
the terminal box P6 connector. There is probably Valve short to ground” diagnostic code cannot be
a short circuit to ground in the terminal box. generated.
Repair: Reinstall the terminal that was removed Note: The ECM will not provide output for the gas
from P6-70. Pull on the wire in order to verify shutoff valve’s solenoid unless the prelube pressure
proper installation of the terminal. switch is closed. Make sure that the prelube
424
F. Turn the engine control switch to the START i01757363

engine control switch to the STOP position. ECM Output Circuit
(Prelubrication Oil Pump)
Shutoff Valve short to ground” diagnostic code SMCS Code: 1901-038
again.
S/N: BEN1-Up
Expected Result:
S/N: 4ZS1-Up
The “17-06 Fuel Shutoff Valve short to ground”
diagnostic code was not generated. System Operation Description:
Results: The Electronic Control Module (ECM) contains the

• OK – When the output to the solenoid was prelubrication, start-up, and shutdown. The
disconnected from the ECM P2 connector, logic for starting and for stopping is customer
the “17-06 Fuel Shutoff Valve short to ground” programmable. The logic responds to inputs from
diagnostic code was not generated. However, a the following components: engine control switch,
“short to ground” diagnostic code was generated emergency stop switch, remote start switch, data
when the output to the solenoid was disconnected link, and other inputs.
from the terminal box P6 connector. There is a
problem in the terminal box between the ECM The prelube pump will not operate if the emergency
connector and the terminal box P6 connector. stop button is activated or if the engine speed is
greater than 0 rpm.
When the conditions permit operation and the logic
1. Turn the engine control switch to the determines that lubrication is required, the ECM
OFF/RESET position. Switch the 16 amp circuit provides +Battery voltage to the prelube pump’s
breaker for the ECM OFF. solenoid. After activation, the prelube pump will
operate until one of the following occurrences:
P2-11. Pull on the wire in order to verify proper • The prelube pressure switch closes.
• The programmable “Engine Pre-lube Time Out
3. Repair the harness, when possible. Replace Period” expires.
• The emergency stop button is pressed.
STOP.
The prelube pump can also be operated with
• Not OK – A “17-06 Fuel Shutoff Valve short to a manual switch. When the switch is closed, a
ground” diagnostic code was generated when +Battery signal is sent to the ECM. The ECM
the output to the solenoid was disconnected from provides +Battery voltage to the prelube pump’s
the ECM P2 connector. There seems to be a solenoid until the switch is released or until the
problem with the ECM. prelube pressure switch closes.
Repair: Perform the following procedure: The prelubrication system also operates after
shutdown. This ensures that the turbocharger has
1. Turn the engine control switch to the adequate lubrication during coastdown. When the
OFF/RESET position. Switch the 16 amp circuit engine reaches 0 rpm, the output for the prelube
breaker for the ECM OFF. pump will operate for three minutes.
2. Reinstall the terminal that was removed from When +Battery voltage is supplied to the prelube
P2-11. Pull on the wire in order to verify proper pump’s solenoid, the ECM also provides +Battery
installation of the terminal. voltage to the “Prelube Active” indicator in the
control panel (if equipped).
3. Replace the ECM according to Troubleshooting,
is resolved.
STOP.
425
Before you troubleshoot the prelubrication system,

make sure that the ECM is programmed properly.
The “Engine Pre-Lube Time Out Period” must
be programmed to a value between 30 and 300
seconds. Make sure that the hardware is installed:
prelube pump, solenoid for the pump, prelube
pressure switch, and manual prelube switch. Make
sure that the wiring is installed. Refer to the engine’s
electrical Schematic.
If Caterpillar did not supply the prelubrication

system, the prelubrication function and the E233 (3)
event code are disabled. The 338-05, 338-06, and
339-05 diagnostic codes are disabled.

Before you begin this procedure, use the Caterpillar
codes to a file.

harness. The next likely cause is a problem with the
prelube pump’s solenoid. The least likely cause is a

resolved.
g00898894
Illustration 334
Schematic for the prelube pump’s solenoid
426

g00899067
Illustration 335

ECM OFF. Switch the 6 amp circuit breaker OFF. g00870205
Illustration 337
Note: For the following steps, refer to Harness side of the ECM P2 connector
Troubleshooting, “Inspecting Electrical Connectors”. (P2-12) Return
(P2-22) Circuit driver for the prelube pump’s solenoid
g00870220
Illustration 336
Inside of the control panel (if equipped)
(8) “Manual Prelube” switch and “Prelube Active” indicator
(9) Terminal strip
427
g00898895 g00870215
Harness side of the terminal box P5 connector 70-pin connector J3 (customer connector)
(P5-12) Return (J3-58) Input signal for the manual prelube
(P5-13) Circuit driver for the prelube pump’s solenoid (J3-59) Circuit driver for the prelube pump’s solenoid
g00870225
Illustration 339
(J4-T) Input signal for the manual prelube
(J4-c) Circuit driver for the prelube pump’s solenoid
g00870226
Illustration 341
ECM connector P1
(P1-56) Input signal for the manual prelube
428
B. Thoroughly inspect the following connectors and Repair: Perform the necessary repairs, when
the wiring harnesses for the connectors: possible. Replace parts, if necessary.
• ECM J1/P1 connectors STOP.
• ECM J2/P2 connectors Test Step 2. Check for Diagnostic Codes

• Terminal box’s J5/P5 connectors A. Switch the 16 amp circuit breaker for the ECM
ON. Switch the 6 amp circuit breaker ON. Turn
• 70-pin connector J3 (customer connector) the engine control switch to the STOP position.
• Control panel’s 47-pin connector J4 Note: The “338-05 Prelube Relay open circuit”
• Terminal strip in the control panel (if equipped) ECM output for the prelube pump’s solenoid is OFF.
The output is normally OFF when the engine control
• “Manual Prelube” switch and “Prelube Active” switch is in the STOP position and when the prelube
indicator in the control panel (if equipped) pressure switch is closed.
• Connector for the prelube pump’s solenoid B. Wait for 30 seconds and use Cat ET to check for
an active “338-05 Prelube Relay open circuit”
a. Check the torque of the Allen head screw for diagnostic code.
6 ± 1 N·m (55 ± 9 lb in). If there is an active “338-05 Prelube Relay
open circuit” diagnostic code, proceed to the
b. Perform a 45 N (10 lb) pull test on each of “Results” for this Test Step. Otherwise, continue
the wires that are associated with the prelube this procedure.
pump’s solenoid.
C. Use Cat ET to check the logged diagnostic
c. Check the harness and wiring for abrasion codes. If there is a “338-06 Prelube Relay short
and for pinch points from the ECM to the to ground” diagnostic code, clear the code.
prelube pump’s solenoid.
Note: The “338-06 Prelube Relay short to ground”
d. Inspect the terminal strip in the control panel diagnostic code can only be detected when the
(if equipped) for the following conditions: ECM output for the prelube pump’s solenoid is ON.
loose wires, frayed wires, foreign material, The output is normally ON when the engine control
and corrosion. switch is in the START position and the prelube
pressure switch is open.
Expected Result:
D. Activate the manual prelube switch for at least
All connectors, pins, and sockets are connected 30 seconds. Then release the switch.
corrosion, abrasion, or pinch points. E. Use Cat ET to look for a logged “338-06 Prelube
Relay short to ground” diagnostic code again.
Results:
Expected Result:
connected properly. The connectors and the When the engine control switch was in the STOP
wiring do not have corrosion, abrasion, or pinch position, there was no active “338-05 Prelube Relay
points. The components are in good condition open circuit” diagnostic code.
After the manual prelube switch was operated,
• Not OK – At least one of the connectors, pins, there was no logged “338-06 Prelube Relay short to
or sockets is not connected properly. At least ground” diagnostic code.
and/or pinch points. The components are not in Results:
is improper. • OK – No diagnostic codes were generated. The
output for the prelube pump’s solenoid seems to
be OK at this time. The initial diagnostic code was
429
Repair: If there is an intermittent problem If the ambient noise is too loud, touch the
that is causing the codes to be logged, refer solenoid when the solenoid is reconnected in
to Troubleshooting, “Inspecting Electrical order to feel the vibration. The solenoid will
Connectors”. vibrate when the solenoid is de-energized and
energized.
STOP.
Expected Result:
• Not OK (“338-05 Prelube Relay open circuit”
diagnostic code) – A “338-05 Prelube Relay open There is no audible click and/or vibration when the
circuit” diagnostic code was activated. This can solenoid is disconnected and reconnected. The
be caused by an actual open circuit or by a short solenoid is not energized when the engine control
circuit to the +Battery side. Proceed to Test Step switch is in the STOP position.
3.
Results:
• Not OK (“338-06 Prelube Relay short to ground”
diagnostic code) – After the manual prelube • OK – There is no audible click and/or vibration
switch was operated, a “338-06 Prelube Relay when the solenoid is disconnected and
short to ground” diagnostic code was generated. connected. There is no short circuit to the
Proceed to Test Step 8. +Battery side. There is an open circuit. Proceed
to Test Step 5.
the +Battery Side • Not OK – There is an audible click and/or
Gaseous fuel is present. Personal Injury or Death side in a connector or a wiring harness. Proceed
can result from an open flame or spark igniting the to Test Step 4.
ways use a gas detector to determine the presence Test Step 4. Determine the Cause of the
of gaseous fuel when maintaining and servicing. Energized Solenoid

test.
the surrounding atmosphere.
B. Ensure that the engine control switch is in the
STOP position.

test.

the ECM OFF.
g00859796
Illustration 342
C. Disconnect the connector from the prelube

pump’s solenoid. Then reconnect the connector.
430

energized.
Expected Result:

Results:



Illustration 343 g00898898 can result from an open flame or spark igniting the
B. Use a 151-6320 Wire Removal Tool to remove sistance in the event of a leak.
terminal P5-13.
C. Switch the 16 amp circuit breaker for the ECM Note: Open sparks can be generated during this
ON. Turn the engine control switch to the STOP test.
position.
2. Reinstall the removed wire into terminal P5-13.

terminal is properly installed.
g00859796
Illustration 344
D. Disconnect the connector from the prelube

431


STOP position.
9. Disconnect the connector from the prelube

pump’s solenoid. Then reconnect the
solenoid.

energized.
If the solenoid is not energized, there is an

intermittent problem with a connector and/or

with the ECM. Replace the ECM according to
g00870243
Illustration 345 STOP.
(P2-12) Circuit driver for the prelube pump’s solenoid • Not OK – There is an audible click and/or
3. Use a 151-6320 Wire Removal Tool to remove reconnected. The solenoid is energized when the
terminal P2-12. circuit driver for the solenoid is disconnected from
the terminal box P5 connector. There is a short
4. Switch the 16 amp circuit breaker for the ECM circuit to the +Battery side in the engine harness.
STOP position. Repair: Repair the connector and/or wiring in
the engine harness, when possible. Replace the
5. Disconnect the connector from the prelube engine harness, if necessary.
connector. Listen for an audible click from the STOP.
solenoid.
Test Step 5. Create a Short Circuit in
If the ambient noise is too loud, touch the order to Check for an Open Circuit
order to feel the vibration. The solenoid will A. Turn the engine control switch to the OFF/RESET
vibrate when the solenoid is de-energized and position. Switch the 16 amp circuit breaker for
energized. the ECM OFF.
If the solenoid is energized, there is a problem B. Disconnect the prelube pump’s solenoid.
necessary.

procedure.

432


solenoid.
STOP.
• Not OK – A “338-05 Prelube Relay open circuit”

diagnostic code was generated when the jumper
wire was installed. There may be an open circuit
in the engine harness. Proceed to Test Step 6.
g00859796
Illustration 346 Test Step 6. Check the Engine Harness
A. Ensure that the engine control switch is in the
C. Install a jumper wire with the appropriate OFF/RESET position and that the 16 amp circuit
connectors on the ends into terminals “A” and breaker for the ECM is OFF.
“B” of the solenoid’s connector.
B. Disconnect the P5 connector from the terminal
D. Switch the 16 amp circuit breaker for the ECM box. Verify that the P5 and J5 connectors do
ON. Turn the engine control switch to the STOP not have damage, moisture, or corrosion. Make
position. repairs, if necessary.
Note: The “338-05 Prelube Relay open circuit”

ECM output for the prelube pump’s solenoid is OFF.
switch is in the STOP position and when the prelube
pressure switch is closed.
E. Wait for 30 seconds and use the “Active

Prelube Relay open circuit” diagnostic code.
Expected Result:
A “338-05 Prelube Relay open circuit” diagnostic

code was not generated when the jumper wire was
installed.
Results:
• OK – A “338-05 Prelube Relay open circuit”

the ECM are OK. There is a problem with the
solenoid.
1. Turn the engine control switch to the Illustration 347 g00898895

OFF/RESET position. Switch the 16 amp circuit Harness side of the terminal box P5 connector
(P5-12) Return
connector. C. Reconnect the P5 connector to the terminal box.
433
D. Install a jumper wire with the appropriate

connectors on the ends into terminals P5-12 and

position.

switch is in the STOP position and when the prelube
F. Wait for 30 seconds and use Cat ET to check for

diagnostic code.
Expected Result:
There is no active “338-05 Prelube Relay open

Results:
• OK – When the jumper wire was installed, there g00870205

was no active “338-05 Prelube Relay open circuit” Illustration 348
diagnostic code. There is a problem in the engine Harness side of the ECM P2 connector
harness. (P2-12) Return
Replace the engine harness, if necessary. E. Use the 151-6320 Wire Removal Tool to remove
STOP.
F. Reconnect the ECM J2/P2 connectors.
“338-05 Prelube Relay open circuit” diagnostic G. Install the jumper wire into terminals P2-12 and
code was activated. The ECM did not detect P2-22. Pull on the jumper wire in order to verify
the jumper wire in the P5 connector. There is proper installation.
Step 7. H. Switch the 16 amp circuit breaker for the ECM
Test Step 7. Check the ECM position.
A. Turn the engine control switch to the OFF/RESET Note: The “338-05 Prelube Relay open circuit”
position. Switch the 16 amp circuit breaker for diagnostic code can only be detected when the
the ECM OFF. ECM output for the prelube pump’s solenoid is OFF.
B. Use a 151-6320 Wire Removal Tool to remove switch is in the STOP position and when the prelube
the jumper wire from the P5 connector. pressure switch is closed.
C. Reinstall the terminals into P5-12 and P5-13. I. Wait for 30 seconds and use the “Active
Make sure that the terminals are installed into Diagnostic” screen of Cat ET to look for an active
the correct locations. Pull on the wires in order to “338-05 Prelube Relay open circuit” diagnostic
verify proper installation of the terminals. code.
D. Disconnect the ECM J2/P2 connectors. Verify Expected Result:

moisture, or corrosion. There is no active “338-05 Prelube Relay open
Make repairs, if necessary.
434
Results: 3. Reinstall the terminals into P2-12 and P2-22.

• OK – When the jumper wire was installed, there the correct locations. Pull on the wires in order
was no active “338-05 Prelube Relay open to verify proper installation of the terminals.
jumper wire at the P2 connector. However, the 4. Replace the ECM according to Troubleshooting,
ECM did not detect the jumper wire at the P5 “Replacing the ECM”. Verify that the problem
connector. There is a problem between the ECM is resolved.
STOP.
Test Step 8. Create an Open Circuit in
1. Turn the engine control switch to the order to Check for a Short Circuit to
OFF/RESET position. Switch the 16 amp circuit Ground
2. Use a 151-6320 Wire Removal Tool to remove position.
B. Disconnect the prelube pump’s solenoid.
Make sure that the terminals are installed into C. Turn the engine control switch to the STOP
the correct locations. Pull on the wires in order position.
D. Use Cat ET to clear the logged “338-06 Prelube
4. Disconnect the ECM J2/P2 connectors. Verify Relay short to ground” diagnostic code.
moisture, or corrosion. Note: The “338-06 Prelube Relay short to ground”
5. Thoroughly inspect the terminal box J5 ECM output for the prelube pump’s solenoid is ON.
connector for the engine harness. The output is normally ON when the engine control
switch is in the START position and the prelube
6. Use an ohmmeter to measure the resistance pressure switch is open.
between the P2-12 terminal and the J5-13
terminal. Also, measure the resistance between E. Activate the manual prelube switch for at least
the P2-22 terminal and the J5-12 terminal. 30 seconds. Then release the switch.
If the resistance is less than 5 ohms, the circuit F. Use Cat ET to look for a logged “338-06 Prelube
has good continuity. Otherwise, there is an Relay short to ground” diagnostic code again.
open circuit.
Expected Result:
STOP. there was no logged “338-06 Prelube Relay short to
• No – When the jumper wire was installed, a
“338-05 Prelube Relay open circuit” diagnostic Results:
jumper wire. There is a problem with the ECM. • OK – When the solenoid was connected, a “short
Repair: Perform the following procedure: the solenoid was disconnected, no “short to
ground” diagnostic code was generated. There
1. Turn the engine control switch to the is a problem with the solenoid.
breaker for the ECM OFF. Repair: Perform the following procedure:
2. Use a 151-6320 Wire Removal Tool to remove 1. Turn the engine control switch to the
the jumper wire from the P2 connector. OFF/RESET position. Switch the 16 amp circuit
2. Inspect the connections of the solenoid for

damage and/or for corrosion.
435
3. Make repairs, as needed. Note: The “338-06 Prelube Relay short to ground”
If the problem is not resolved, replace the ECM output for the prelube pump’s solenoid is ON.
solenoid. The output is normally ON when the engine control
STOP. pressure switch is open.
• Not OK – After the manual prelube switch was E. Activate the manual prelube switch for at least
operated, a “338-06 Prelube Relay short to 30 seconds. Then release the switch.
ground” diagnostic code was logged. Proceed
to Test Step 9. F. Use Cat ET to look for a logged “338-06 Prelube
Terminal Box Expected Result:
A. Turn the engine control switch to the OFF/RESET A “338-06 Prelube Relay short to ground” was not
position. Switch the 16 amp circuit breaker for generated.
the ECM OFF.
Results:
• OK – A “338-06 Prelube Relay short to ground”



3. Repair the harness, when possible. Replace

STOP.
• Not OK – A “338-06 Prelube Relay short to

ground” diagnostic code was generated when
the output to the solenoid was disconnected from
the terminal box P5 connector. There is probably
a short circuit to ground in the terminal box.
g00898898
Illustration 349
Harness side of the terminal box P5 connector Repair: Reinstall the terminal that was removed
(P5-13) Circuit driver for the prelube pump’s solenoid from P5-13. Pull on the wire in order to verify
terminal P5-13. Proceed to Test Step 10.
C. Switch the 16 amp circuit breaker for the ECM Test Step 10. Check the ECM
position. A. Turn the engine control switch to the OFF/RESET
D. Use Cat ET to clear the logged “338-06 Prelube the ECM OFF.
Relay short to ground” diagnostic code.
436
Results:
• OK – When the output to the solenoid was

disconnected from the ECM P2 connector, the
“338-06 Prelube Relay short to ground” diagnostic
code was not generated. However, a “short to
the terminal box P5 connector. There is a problem
in the terminal box between the ECM connector
and the terminal box P5 connector.



STOP.
g00870243
Illustration 350 ground” diagnostic code was generated when
Harness side of the ECM P2 connector the output to the solenoid was disconnected from
(P2-12) Circuit driver for the prelube pump’s solenoid the ECM P2 connector. There seems to be a
B. Use the 151-6320 Wire Removal Tool to remove
terminal P2-12. Repair: Perform the following procedure:
C. Switch the 16 amp circuit breaker for the ECM 1. Turn the engine control switch to the
ON. Turn the engine control switch to the STOP OFF/RESET position. Switch the 16 amp circuit
position. breaker for the ECM OFF.
D. Use Cat ET to clear the logged “338-06 Prelube 2. Reinstall the terminal that was removed from
Relay short to ground” diagnostic code. P2-12. Pull on the wire in order to verify proper
diagnostic code can only be detected when the 3. Replace the ECM according to Troubleshooting,
ECM output for the prelube pump’s solenoid is ON. “Replacing the ECM”. Verify that the problem
The output is normally ON when the engine control is resolved.
pressure switch is open. STOP.
E. Activate the manual prelube switch for at least

30 seconds. Then release the switch.
F. Use Cat ET to look for a logged “338-06 Prelube

Expected Result:
The “338-06 Prelube Relay short to ground”

diagnostic code was not generated.
437
i01757558 Before you troubleshoot the prelubrication system,

ECM Output Circuit The “Engine Pre-Lube Time Out Period” must
(Prelubrication Oil Pump) be programmed to a value between 30 and 300
SMCS Code: 1901-038 prelube pump, solenoid for the pump, prelube
S/N: BLB1-Up sure that the wiring is installed. Refer to the engine’s
S/N: BKE1-Up
System Operation Description: system, the prelubrication function and the E233 (3)
The Electronic Control Module (ECM) contains the 339-05 diagnostic codes are disabled.
prelubrication, start-up, and shutdown. The Logged diagnostics provide a historical record.
logic for starting and for stopping is customer Before you begin this procedure, use the Caterpillar
programmable. The logic responds to inputs from Electronic Technician (Cat ET) to print the logged
the following components: engine control switch, codes to a file.
emergency stop switch, remote start switch, data
link, and other inputs. The most likely causes of the diagnostic code are a
The prelube pump will not operate if the emergency harness. The next likely cause is a problem with the
stop button is activated or if the engine speed is prelube pump’s solenoid. The least likely cause is a
greater than 0 rpm. problem with the ECM.
When the conditions permit operation and the logic The troubleshooting procedure may generate
determines that lubrication is required, the ECM additional diagnostic codes. Keep your mind on
provides +Battery voltage to the prelube pump’s correcting the cause of the original diagnostic code.
solenoid. After activation, the prelube pump will Clear the diagnostic codes after the problem is
operate until one of the following occurrences: resolved.
• The prelube pressure switch closes.

• The programmable “Engine Pre-lube Time Out
Period” expires.

a manual switch. When the switch is closed, a
+Battery signal is sent to the ECM. The ECM
provides +Battery voltage to the prelube pump’s
solenoid until the switch is released or until the
prelube pressure switch closes.
The prelubrication system also operates after

adequate lubrication during coastdown. When the
engine reaches 0 rpm, the output for the prelube
pump will operate for three minutes.
When +Battery voltage is supplied to the prelube

pump’s solenoid, the ECM also provides +Battery
voltage to the “Prelube Active” indicator in the
control panel (if equipped).
438
g00870079
Illustration 351
Schematic for the prelube pump’s solenoid
Test Step 1. Inspect the Electrical Note: For the following steps, refer to
Connectors and Wiring Troubleshooting, “Inspecting Electrical Connectors”.
g00870200
Illustration 352

439
g00870205 g00870206
(P2-12) Return (P6-28) Return
(P2-22) Circuit driver for the prelube pump’s solenoid (P6-36) Circuit driver for the prelube pump’s solenoid
g00870220
Illustration 355
Inside of the control panel (if equipped)
(8) “Manual Prelube” switch and “Prelube Active” indicator
(9) Terminal strip
440
g00870225
Illustration 356
(J4-T) Input signal for the manual prelube
(J4-c) Circuit driver for the prelube pump’s solenoid
g00870226
Illustration 358
ECM connector P1
(P1-56) Input signal for the manual prelube
B. Thoroughly inspect the following connectors and


• 70-pin connector J3 (customer connector)
• Control panel’s 47-pin connector J4
g00870215
• “Manual Prelube” switch and “Prelube Active”
Illustration 357 indicator in the control panel (if equipped)
70-pin connector J3 (customer connector)
(J3-58) Input signal for the manual prelube • Connector for the prelube pump’s solenoid
(J3-59) Circuit driver for the prelube pump’s solenoid
6 ± 1 N·m (55 ± 9 lb in).

the wires that are associated with the prelube
pump’s solenoid.
441
c. Check the harness and wiring for abrasion Note: The “338-06 Prelube Relay short to ground”
and for pinch points from the ECM to the diagnostic code can only be detected when the
prelube pump’s solenoid. ECM output for the prelube pump’s solenoid is ON.
The output is normally ON when the engine control
d. Inspect the terminal strip in the control panel switch is in the START position and the prelube
(if equipped) for the following conditions: pressure switch is open.
loose wires, frayed wires, foreign material,
and corrosion. D. Activate the manual prelube switch for at least
Expected Result:
E. Use Cat ET to look for a logged “338-06 Prelube
All connectors, pins, and sockets are connected Relay short to ground” diagnostic code again.
corrosion, abrasion, or pinch points. Expected Result:
Results: When the engine control switch was in the STOP

position, there was no active “338-05 Prelube Relay
• OK – All connectors, pins, and sockets are open circuit” diagnostic code.
wiring do not have corrosion, abrasion, or pinch After the manual prelube switch was operated,
points. The components are in good condition there was no logged “338-06 Prelube Relay short to
with proper connections. Proceed to Test Step 2. ground” diagnostic code.
• Not OK – At least one of the connectors, pins, Results:

one connector or wire has corrosion, abrasion, • OK – No diagnostic codes were generated. The
and/or pinch points. The components are not in output for the prelube pump’s solenoid seems to
good condition and/or at least one connection be OK at this time. The initial diagnostic code was
is improper. probably caused by a poor electrical connection.
Repair: Perform the necessary repairs, when Repair: If there is an intermittent problem
possible. Replace parts, if necessary. that is causing the codes to be logged, refer
STOP. Connectors”.
A. Switch the 16 amp circuit breaker for the ECM • Not OK (“338-05 Prelube Relay open circuit”
ON. Switch the 6 amp circuit breaker ON. Turn diagnostic code) – A “338-05 Prelube Relay open
the engine control switch to the STOP position. circuit” diagnostic code was activated. This can
be caused by an actual open circuit or by a short
Note: The “338-05 Prelube Relay open circuit” circuit to the +Battery side. Proceed to Test Step
diagnostic code can only be detected when the 3.
The output is normally OFF when the engine control • Not OK (“338-06 Prelube Relay short to ground”
switch is in the STOP position and when the prelube diagnostic code) – After the manual prelube
pressure switch is closed. switch was operated, a “338-06 Prelube Relay
short to ground” diagnostic code was generated.
B. Wait for 30 seconds and use Cat ET to check for Proceed to Test Step 8.
diagnostic code. Test Step 3. Check for a Short Circuit to
the +Battery Side
If there is an active “338-05 Prelube Relay
this procedure.
C. Use Cat ET to check the logged diagnostic can result from an open flame or spark igniting the
codes. If there is a “338-06 Prelube Relay short gaseous fuel causing an explosion and/or fire. Al-
to ground” diagnostic code, clear the code. ways use a gas detector to determine the presence
442
Note: Open sparks can be generated during this Test Step 4. Determine the Cause of the
test. Energized Solenoid
the surrounding atmosphere.
B. Ensure that the engine control switch is in the Gaseous fuel is present. Personal Injury or Death
STOP position. can result from an open flame or spark igniting the

test.

the ECM OFF.
g00859796
Illustration 359
C. Disconnect the connector from the prelube


energized.
Expected Result:

Results:

g00870241
+Battery side. There is an open circuit. Proceed Illustration 360
to Test Step 5. Harness side of the terminal box P6 connector
vibration when the solenoid is disconnected and B. Use a 151-6320 Wire Removal Tool to remove
connected. The solenoid is receiving power when terminal P6-36.
There is probably a short circuit to the +Battery C. Switch the 16 amp circuit breaker for the ECM
side in a connector or a wiring harness. Proceed ON. Turn the engine control switch to the STOP
to Test Step 4. position.
443
2. Reinstall the removed wire into terminal P6-36.

terminal is properly installed.
g00859796
Illustration 361
D. Disconnect the connector from the prelube


energized.
Expected Result:

solenoid is disconnected and reconnected. The Illustration 362 g00870243
solenoid is not energized when the circuit driver for Harness side of the ECM P2 connector
Results:
terminal P2-12.
reconnected. The solenoid is not energized when 4. Switch the 16 amp circuit breaker for the ECM
the circuit driver for the solenoid is disconnected ON. Turn the engine control switch to the
from the J6 connector. STOP position.
Repair: Use the following procedure to determine 5. Disconnect the connector from the prelube
whether the circuit driver for the solenoid is faulty: pump’s solenoid. Then reconnect the
solenoid.

Gaseous fuel is present. Personal Injury or Death solenoid when the solenoid is reconnected in
can result from an open flame or spark igniting the order to feel the vibration. The solenoid will
gaseous fuel causing an explosion and/or fire. Al- vibrate when the solenoid is de-energized and
ways use a gas detector to determine the presence energized.
Contact you local gas provider immediately for as- If the solenoid is energized, there is a problem
sistance in the event of a leak. with a connector and/or with the wiring in the
Note: Open sparks can be generated during this necessary.
test.
1. Turn the engine control switch to the a problem with the ECM. Continue with this
OFF/RESET position. Switch the 16 amp circuit procedure.
444



STOP position.
9. Disconnect the connector from the prelube

energized.
“Inspecting Electrical Connectors”. Note: The “338-05 Prelube Relay open circuit”
If the solenoid is energized, there is a problem ECM output for the prelube pump’s solenoid is OFF.
with the ECM. Replace the ECM according to The output is normally OFF when the engine control
Troubleshooting, “Replacing the ECM”. switch is in the STOP position and when the prelube
STOP.
• Not OK – There is an audible click and/or Diagnostic” screen of Cat ET to look for a “338-05
vibration when the solenoid is disconnected and Prelube Relay open circuit” diagnostic code.
reconnected. The solenoid is energized when the
circuit driver for the solenoid is disconnected from Expected Result:
the terminal box P6 connector. There is a short
circuit to the +Battery side in the engine harness. A “338-05 Prelube Relay open circuit” diagnostic
Repair: Repair the connector and/or wiring in installed.
the engine harness, when possible. Replace the
engine harness, if necessary. Results:
STOP. • OK – A “338-05 Prelube Relay open circuit”

Test Step 5. Create a Short Circuit in jumper wire was installed. The harness and
order to Check for an Open Circuit the ECM are OK. There is a problem with the
solenoid.
position. Switch the 16 amp circuit breaker for Repair: Perform the following procedure:
the ECM OFF.
B. Disconnect the prelube pump’s solenoid. OFF/RESET position. Switch the 16 amp circuit

connector.
445
3. Verify that the solenoid’s connectors do not D. Install a jumper wire with the appropriate
have damage, moisture, or corrosion. connectors on the ends into terminals P6-28 and
4. Make repairs, as needed. proper installation.
If the problem is not resolved, replace the E. Switch the 16 amp circuit breaker for the ECM
solenoid. ON. Turn the engine control switch to the STOP
position.
STOP.
• Not OK – A “338-05 Prelube Relay open circuit” diagnostic code can only be detected when the
diagnostic code was generated when the jumper ECM output for the prelube pump’s solenoid is OFF.
wire was installed. There may be an open circuit The output is normally OFF when the engine control
in the engine harness. Proceed to Test Step 6. switch is in the STOP position and when the prelube
F. Wait for 30 seconds and use Cat ET to check for
A. Ensure that the engine control switch is in the an active “338-05 Prelube Relay open circuit”
OFF/RESET position and that the 16 amp circuit diagnostic code.
breaker for the ECM is OFF.
Expected Result:
box. Verify that the P6 and J6 connectors do There is no active “338-05 Prelube Relay open
not have damage, moisture, or corrosion. Make circuit” diagnostic code.
Results:

was no active “338-05 Prelube Relay open circuit”
diagnostic code. There is a problem in the engine
harness.

STOP.

“338-05 Prelube Relay open circuit” diagnostic
Step 7.

the ECM OFF.

g00870206 C. Reinstall the terminals into P6-28 and P6-36.
Illustration 364
Harness side of the terminal box P6 connector Make sure that the terminals are installed into
(P6-28) Return
the correct locations. Pull on the wires in order to
(P6-36) Circuit driver for the prelube pump’s solenoid verify proper installation of the terminals.
C. Reconnect the P6 connector to the terminal box. D. Disconnect the ECM J2/P2 connectors. Verify
Use a 151-6320 Wire Removal Tool to remove that the connectors do not have damage,
terminals P6-28 and P6-36. Label the terminals. moisture, or corrosion.

446
Expected Result:
There is no active “338-05 Prelube Relay open

Results:

was no active “338-05 Prelube Relay open



g00870205
Illustration 365
Harness side of the ECM P2 connector 4. Disconnect the ECM J2/P2 connectors. Verify
(P2-12) Return that the connectors do not have damage,
(P2-22) Circuit driver for the prelube pump’s solenoid moisture, or corrosion.
E. Use the 151-6320 Wire Removal Tool to remove 5. Thoroughly inspect the terminal box J6
terminals P2-12 and P2-22. Label the terminals. connector for the engine harness.
F. Reconnect the ECM J2/P2 connectors. 6. Use an ohmmeter to measure the resistance
G. Install the jumper wire into terminals P2-12 and terminal. Also, measure the resistance between
P2-22. Pull on the jumper wire in order to verify the P2-22 terminal and the J6-28 terminal.
H. Switch the 16 amp circuit breaker for the ECM has good continuity. Otherwise, there is an
ON. Turn the engine control switch to the STOP open circuit.
position.
diagnostic code can only be detected when the STOP.
The output is normally OFF when the engine control • No – When the jumper wire was installed, a
switch is in the STOP position and when the prelube “338-05 Prelube Relay open circuit” diagnostic
pressure switch is closed. code was activated. The ECM did not detect the
jumper wire. There is a problem with the ECM.
I. Wait for 30 seconds and use the “Active
Diagnostic” screen of Cat ET to look for an active Repair: Perform the following procedure:
“338-05 Prelube Relay open circuit” diagnostic
code. 1. Turn the engine control switch to the
447
2. Use a 151-6320 Wire Removal Tool to remove 2. Inspect the connections of the solenoid for
the jumper wire from the P2 connector. damage and/or for corrosion.
3. Reinstall the terminals into P2-12 and P2-22. 3. Make repairs, as needed.
the correct locations. Pull on the wires in order If the problem is not resolved, replace the
to verify proper installation of the terminals. solenoid.
4. Replace the ECM according to Troubleshooting, STOP.

is resolved. • Not OK – After the manual prelube switch was
operated, a “338-06 Prelube Relay short to
STOP. ground” diagnostic code was logged. Proceed
to Test Step 9.
Test Step 8. Create an Open Circuit in
order to Check for a Short Circuit to Test Step 9. Create an Open Circuit at the
Ground Terminal Box
A. Turn the engine control switch to the OFF/RESET A. Turn the engine control switch to the OFF/RESET
position. position. Switch the 16 amp circuit breaker for
the ECM OFF.
B. Disconnect the prelube pump’s solenoid.

position.
D. Use Cat ET to clear the logged “338-06 Prelube


ECM output for the prelube pump’s solenoid is ON.


Expected Result:

there was no logged “338-06 Prelube Relay short to
Results:
g00870241
Illustration 366
• OK – When the solenoid was connected, a “short Harness side of the terminal box P6 connector
to ground” diagnostic code was generated. When (P6-36) Circuit driver for the prelube pump’s solenoid
the solenoid was disconnected, no “short to
ground” diagnostic code was generated. There B. Use a 151-6320 Wire Removal Tool to remove
is a problem with the solenoid. terminal P6-36.
Repair: Perform the following procedure: C. Switch the 16 amp circuit breaker for the ECM
1. Turn the engine control switch to the position.
breaker for the ECM OFF. D. Use Cat ET to clear the logged “338-06 Prelube
448

ECM output for the prelube pump’s solenoid is ON.


Expected Result:
A “338-06 Prelube Relay short to ground” was not

generated.
Results:
• OK – A “338-06 Prelube Relay short to ground”


g00870243
1. Turn the engine control switch to the Illustration 367
OFF/RESET position. Switch the 16 amp circuit Harness side of the ECM P2 connector
breaker for the ECM OFF. (P2-12) Circuit driver for the prelube pump’s solenoid
2. Reinstall the terminal that was removed from B. Use the 151-6320 Wire Removal Tool to remove
P6-36. Pull on the wire in order to verify proper terminal P2-12.
3. Repair the harness, when possible. Replace ON. Turn the engine control switch to the STOP
the harness, if necessary. position.
STOP. D. Use Cat ET to clear the logged “338-06 Prelube
ground” diagnostic code was generated when Note: The “338-06 Prelube Relay short to ground”
the output to the solenoid was disconnected from diagnostic code can only be detected when the
the terminal box P6 connector. There is probably ECM output for the prelube pump’s solenoid is ON.
a short circuit to ground in the terminal box. The output is normally ON when the engine control
Repair: Reinstall the terminal that was removed pressure switch is open.
from P6-36. Pull on the wire in order to verify
proper installation of the terminal. E. Activate the manual prelube switch for at least
Test Step 10. Check the ECM Relay short to ground” diagnostic code again.
A. Turn the engine control switch to the OFF/RESET Expected Result:
the ECM OFF. The “338-06 Prelube Relay short to ground”
diagnostic code was not generated.
449
Results: i01757587
• OK – When the output to the solenoid was ECM Output Circuit (Starting
disconnected from the ECM P2 connector, the Motor)
“338-06 Prelube Relay short to ground” diagnostic
code was not generated. However, a “short to SMCS Code: 1901-038
the output to the solenoid was disconnected from S/N: BEN1-Up
in the terminal box between the ECM connector S/N: 4ZS1-Up
The Electronic Control Module (ECM) contains the
1. Turn the engine control switch to the logic and the outputs that control the engine’s
OFF/RESET position. Switch the 16 amp circuit prelubrication, start-up, and shutdown. The
breaker for the ECM OFF. logic for starting and for stopping is customer
programmable. The logic responds to inputs from
2. Reinstall the terminal that was removed from the following components: engine control switch,
P2-12. Pull on the wire in order to verify proper emergency stop switch, remote start switch, data
installation of the terminal. link, and other inputs.
3. Repair the harness, when possible. Replace The ECM supplies +Battery voltage to the starting
the harness, if necessary. motor’s solenoid when the logic determines that it
is necessary. The ECM removes the voltage when
STOP. the crank terminate relay is energized. The voltage
is also removed if the customer programmable
• Not OK – A “338-06 Prelube Relay short to “Overcrank Time” has expired.
the output to the solenoid was disconnected from Logged diagnostics provide a historical record.
the ECM P2 connector. There seems to be a Before you begin this procedure, use the Caterpillar
problem with the ECM. Electronic Technician (Cat ET) to print the logged
codes to a file.
1. Turn the engine control switch to the poor electrical connection or a problem in a wiring
OFF/RESET position. Switch the 16 amp circuit harness. The next likely cause is a problem with the
breaker for the ECM OFF. starting motor’s solenoid. The least likely cause is a
P2-12. Pull on the wire in order to verify proper The troubleshooting procedure may generate
installation of the terminal. additional diagnostic codes. Keep your mind on
3. Replace the ECM according to Troubleshooting, Clear the diagnostic codes after the problem is
“Replacing the ECM”. Verify that the problem resolved.
is resolved.
STOP.
450
g00898989
Illustration 368
Schematic for the starting motor’s solenoid

g00859811
Illustration 370
(P2-10) Circuit driver for the starting motor’s solenoid
(P2-20) Return
g00897591
Illustration 369
(3) Terminal box J5 connector for the engine harness

the ECM OFF.

451
Results:


is improper.

STOP.

position.
B. Wait for 30 seconds and use Cat ET to

check for an active “444-05 Start Relay open
g00898992
Illustration 371 circuit”diagnostic code.
(P5-22) Return If there is an active “444-05 Start Relay open
(P5-23) Circuit driver for the starting motor’s solenoid circuit” diagnostic code, proceed to the “Results”
for this Test Step. Otherwise, continue this
B. Thoroughly inspect the following connectors and procedure.
• ECM J2/P2 connectors codes. If there is a “444-06 Start Relay short to
ground” code, clear the code.
• Terminal box J5/P5 connectors
D. To prevent the engine from starting, shut the gas
• Connector to the starting motor’s solenoid supply OFF.
a. Check the torque of the Allen head screw for Note: To provide the output for the starting motor’s
the 70-pin connectors. The proper torque is solenoid, the sequence for engine start-up must be
6 ± 1 N·m (55 ± 9 lb in). initiated. Otherwise, a “444-06 Start Relay short to
ground” diagnostic code cannot be generated.
the wires that are associated with the starting E. Turn the engine control switch to the START
motor’s solenoid. position for at least 30 seconds. Then turn the
and for pinch points from the ECM to the F. Use Cat ET to look for a logged “444-06 Start
starting motor’s solenoid. Relay short to ground” diagnostic code again.
All connectors, pins, and sockets are connected When the engine control switch was in the STOP
properly. The connectors and the wiring do not have position, there was no active “444-05 Start Relay
corrosion, abrasion, or pinch points. open circuit” diagnostic code.
After the engine was cranked, there was no logged

“444-06 Start Relay short to ground” diagnostic
code.
452
Results:
• OK – No diagnostic codes were generated. The

output for the starting motor’s solenoid seems to
be OK at this time. The initial diagnostic code was
Repair: If there is an intermittent problem

Connectors”.
STOP.
• Not OK (“444-05 Start Relay open circuit” g00859796

diagnostic code) – A “444-05 Start Relay open Illustration 372
circuit” diagnostic code was activated. This can Typical connector for a solenoid
circuit to the +Battery side. Proceed to Test Step C. Disconnect the connector from the starting
3. motor’s solenoid. Then reconnect the connector.
• Not OK (“444-06 Start Relay short to ground”
diagnostic code) – After the engine was cranked, If the ambient noise is too loud, touch the
a “444-06 Start Relay short to ground” diagnostic solenoid when the solenoid is reconnected in
code was generated. Proceed to Test Step 8. order to feel the vibration. The solenoid will
Test Step 3. Check for a Short Circuit to energized.
the +Battery Side
Expected Result:

Gaseous fuel is present. Personal Injury or Death solenoid is not energized when the engine control
can result from an open flame or spark igniting the switch is in the STOP position.
ways use a gas detector to determine the presence Results:
Contact you local gas provider immediately for as- • OK – There is no audible click and/or vibration
sistance in the event of a leak. when the solenoid is disconnected and
Note: Open sparks can be generated during this +Battery side. There is an open circuit. Proceed
test. to Test Step 5.
A. Make sure that no combustible gas is present in • Not OK – There is an audible click and/or
the surrounding atmosphere. vibration when the solenoid is disconnected and
B. Ensure that the engine control switch is in the the engine control switch is in the STOP position.
STOP position. There is probably a short circuit to the +Battery
to Test Step 4.
453

Energized Solenoid

Note: Open sparks can be generated during this Illustration 374 g00859796
test.
position. Switch the 16 amp circuit breaker for D. Disconnect the connector from the starting
the ECM OFF. motor’s solenoid. Then reconnect the connector.

energized.
Expected Result:

Results:


g00898994
Illustration 373 Gaseous fuel is present. Personal Injury or Death
Harness side of the terminal box P5 connector can result from an open flame or spark igniting the
(P5-23) Circuit driver for the starting motor’s solenoid gaseous fuel causing an explosion and/or fire. Al-
B. Use a 151-6320 Wire Removal Tool to remove of gaseous fuel when maintaining and servicing.
terminal P5-23. Contact you local gas provider immediately for as-
position.
test.

454
2. Reinstall the removed wire into terminal 37 of If the solenoid is not energized, there may be
the terminal box J5 connector. Pull on the wire a problem with the ECM. Continue with this
in order to verify that the terminal is properly procedure.
installed.


STOP position.
9. Disconnect the connector from the starting

motor’s solenoid. Then reconnect the
solenoid.

energized.
If the solenoid is not energized, there is an

intermittent problem with a connector and/or
g00868867
Illustration 375 If the solenoid is energized, there is a problem
Harness side of the ECM P2 connector with the ECM. Replace the ECM according to
(P2-10) Circuit driver for the starting motor’s solenoid Troubleshooting, “Replacing the ECM”.
3. Use a 151-6320 Wire Removal Tool to remove STOP.

terminal P2-10.
4. Switch the 16 amp circuit breaker for the ECM vibration when the solenoid is disconnected and
ON. Turn the engine control switch to the reconnected. The solenoid is energized when the
STOP position. circuit driver for the solenoid is disconnected from
the terminal box J5 connector. There is a short
5. Disconnect the connector from the starting circuit to the +Battery side in the engine harness.
motor’s solenoid. Then reconnect the
connector. Listen for an audible click from the Repair: Repair the connector and/or wiring in
solenoid. the engine harness, when possible. Replace the
solenoid when the solenoid is reconnected in STOP.
vibrate when the solenoid is de-energized and Test Step 5. Create a Short Circuit in
energized. order to Check for an Open Circuit
If the solenoid is energized, there is a problem A. Turn the engine control switch to the OFF/RESET
with a connector and/or with the wiring in the position. Switch the 16 amp circuit breaker for
terminal box. Repair the wiring and/or the the ECM OFF.
necessary. B. Disconnect the starting motor’s solenoid.
455
• Not OK – A “444-05 Start Relay open circuit”

diagnostic code was generated when the jumper
wire was installed. There may be an open circuit

A. Ensure that the engine control switch is in the

not have damage, moisture, or corrosion. Make
g00859796
Illustration 376
C. Install a jumper wire with the appropriate

connectors on the ends into terminals “A” and

position.

Start Relay open circuit” diagnostic code.
Expected Result:
A “444-05 Start Relay open circuit” diagnostic

installed.
Results:
• OK – A “444-05 Start Relay open circuit”

the ECM are OK. There is a problem with the
solenoid.
g00898992
Illustration 377
Repair: Perform the following procedure: Harness side of the terminal box P5 connector
(P5-22) Return
1. Turn the engine control switch to the (P5-23) Circuit driver for the starting motor’s solenoid
breaker for the ECM OFF. C. Reconnect the P5 connector to the terminal box.
2. Remove the jumper wire from the solenoid’s terminals P5-22 and P5-23. Label the terminals.
connector.
3. Verify that the solenoid’s connectors do not connectors on the ends into terminals P5-22 and
have damage, moisture, or corrosion. P5-23. Pull on the jumper wire in order to verify
If the problem is not resolved, replace the ON. Turn the engine control switch to the STOP
solenoid. position.
STOP.
456
F. Wait for 30 seconds and use Cat ET to check

for an active “444-05 Start Relay open circuit”
diagnostic code.
Expected Result:
There is no active “444-05 Start Relay open circuit”

diagnostic code.
Results:

was no active “444-05 Start Relay open circuit”
diagnostic code. There is a problem in the engine
harness.

STOP.

“444-05 Start Relay open circuit” diagnostic code
was activated. The ECM did not detect the jumper
wire in the P5 connector. There is a problem in
the terminal box. Proceed to test Step 7.
Test Step 7. Check the ECM g00859811

Illustration 378
A. Turn the engine control switch to the OFF/RESET Harness side of the ECM P2 connector
position. Switch the 16 amp circuit breaker for (P2-10) Circuit driver for the starting motor’s solenoid
the ECM OFF. (P2-20) Return
B. Use a 151-6320 Wire Removal Tool to remove E. Use the 151-6320 Wire Removal Tool to remove
the jumper wire from the P5 connector. terminals P2-10 and P2-20. Label the terminals.
C. Reinstall the terminals into P5-22 and P5-23. F. Reconnect the ECM J2/P2 connectors.
the correct locations. Pull on the wires in order to G. Install the jumper wire into terminals P2-10 and
verify proper installation of the terminals. P2-20. Pull on the jumper wire in order to verify
that the connectors do not have damage, H. Switch the 16 amp circuit breaker for the ECM
moisture, or corrosion. ON. Turn the engine control switch to the STOP
position.
I. Wait for 30 seconds and use the “Active
Diagnostic” screen of Cat ET to look for an active
“444-05 Start Relay open circuit” diagnostic
code.
Expected Result:
There is no active “444-05” diagnostic code.

457
Results: 4. Replace the ECM according to Troubleshooting,

• OK – When the jumper wire was installed, is resolved.
there was no active “444-05 Start Relay open
circuit” diagnostic code. The ECM detects the STOP.
ECM did not detect the jumper wire at the P5 Test Step 8. Create an Open Circuit in
connector. There is a problem between the ECM order to Check for a Short Circuit to
P2 connector and the terminal box P5 connector. Ground
Repair: Perform the following procedure: A. Turn the engine control switch to the OFF/RESET
position.
OFF/RESET position. Switch the 16 amp circuit B. Disconnect the starting motor’s solenoid.
2. Use a 151-6320 Wire Removal Tool to remove position.
D. Use Cat ET to clear the logged “444-06 Start
3. Reinstall the terminals into P2-10 and P2-20. Relay short to ground” diagnostic code.
the correct locations. Pull on the wires in order E. To prevent the engine from starting, shut OFF the
to verify proper installation of the terminals. main gas supply.
4. Disconnect the ECM J2/P2 connectors. Verify Note: To provide the output for the starting motor’s
that the connectors do not have damage, solenoid, the sequence for engine start-up must be
moisture, or corrosion. initiated. Otherwise, a “444-06 Start Relay short to
connector for the engine harness. F. Turn the engine control switch to the START
6. Use an ohmmeter to measure the resistance engine control switch to the STOP position.
terminal. Also, measure the continuity between G. Use Cat ET to look for a logged “444-06 Start
the P2-20 terminal and the J5-22 terminal. Relay short to ground” diagnostic code again.
If the resistance is less than 5 ohms, the circuit Expected Result:

has good continuity. Otherwise, there is an
open circuit. A “444-06 Start Relay short to ground” was not
generated.
Results:
STOP.
• OK – When the solenoid was connected, a “short
• Not OK – When the jumper wire was installed, to ground” diagnostic code was generated. When
a “444-05 Start Relay open circuit” diagnostic the solenoid was disconnected, no “short to
code was activated. The ECM did not detect the ground” diagnostic code was generated. There
jumper wire. There is a problem with the ECM. is a problem with the solenoid.
Repair: Perform the following procedure: Repair: Perform the following procedure:
1. Turn the engine control switch to the 1. Turn the engine control switch to the
OFF/RESET position. Switch the 16 amp circuit OFF/RESET position. Switch the 16 amp circuit
breaker for the ECM OFF. breaker for the ECM OFF.
2. Use a 151-6320 Wire Removal Tool to remove 2. Inspect the connections of the solenoid for
the jumper wire from the P2 connector. damage and/or for corrosion.
3. Reinstall the terminals into P2-10 and P2-20. 3. Make repairs, as needed.
458
If the problem is not resolved, replace the Note: To provide the output for the starting motor’s
solenoid. solenoid, the sequence for engine start-up must be
initiated. Otherwise, a “444-06 Start Relay short to
STOP. ground” diagnostic code cannot be generated.
• Not OK – A “short to ground” diagnostic F. Turn the engine control switch to the START
code was generated when the solenoid was position for at least 30 seconds. Then turn the
disconnected. Proceed to Test Step 9. engine control switch to the STOP position.
Test Step 9. Create an Open Circuit at the G. Use Cat ET to look for a logged “444-06 Start
Terminal Box Relay short to ground” diagnostic code again.
A. Turn the engine control switch to the OFF/RESET Expected Result:

the ECM OFF. A “444-06 Start Relay short to ground” was not
generated.
Results:
• OK – A “444-06 Start Relay short to ground”


2. Reinstall the terminal that was removed into


STOP.
• Not OK – A “short to ground” diagnostic code

was generated when the output to the solenoid
was disconnected from the terminal box P5
g00898994
Illustration 379 connector. There is probably a short circuit to
Harness side of the terminal box P5 connector ground in the terminal box.
Repair: Reinstall the terminal that was removed
B. Use a 151-6320 Wire Removal Tool to remove into P5-23. Pull on the wire in order to verify
terminal P5-23. proper installation of the terminal.
C. Switch the 16 amp circuit breaker for the ECM Proceed to Test Step 10.
position. Test Step 10. Check the ECM
D. Use Cat ET to clear the logged “444-06 Start A. Turn the engine control switch to the OFF/RESET
Relay short to ground” diagnostic code. position. Switch the 16 amp circuit breaker for
the ECM OFF.
main gas supply.
459
Results:
• OK – When the output to the solenoid was

in the terminal box between the ECM connector



STOP.
g00868867
• Not OK – A “444-06 Start Relay short to ground”
Illustration 380 diagnostic code was generated when the output
Harness side of the ECM P2 connector to the solenoid was disconnected from the ECM
(P2-10) Circuit driver for the starting motor’s solenoid P2 connector. There seems to be a problem with
the ECM.
B. Use the 151-6320 Wire Removal Tool to remove
terminal P2-10. Repair: Perform the following procedure:
C. Switch the 16 amp circuit breaker for the ECM 1. Turn the engine control switch to the
ON. Turn the engine control switch to the STOP OFF/RESET position. Switch the 16 amp circuit
position. breaker for the ECM OFF.
D. Use Cat ET to clear the logged “444-06 Start 2. Reinstall the terminal that was removed into
Relay short to ground” diagnostic code. P2-10. Pull on the wire in order to verify proper
main gas supply. 3. Replace the ECM according to Troubleshooting,
Note: To provide the output for the starting motor’s is resolved.
solenoid, the sequence for engine start-up must be
initiated. Otherwise, a “444-06 Start Relay short to STOP.

G. Use Cat ET to look for a logged “444-06 Start

Expected Result:
The “444-06 Start Relay short to ground” diagnostic

code was not generated.
460
i01757773
ECM Output Circuit (Starting

Motor)
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
The Electronic Control Module (ECM) contains the

prelubrication, start-up, and shutdown. The
logic for starting and for stopping is customer
programmable. The logic responds to inputs from
the following components: engine control switch,
emergency stop switch, remote start switch, data
link, and other inputs.
g00855708
Illustration 381
The ECM supplies +Battery voltage to the starting
motor’s solenoid when the logic determines that it Schematic for the starting motor’s solenoid
is necessary. The ECM removes the voltage when
the crank terminate relay is energized. The voltage Test Step 1. Inspect the Electrical
is also removed if the customer programmable Connectors and Wiring
“Overcrank Time” has expired.

Before you begin this procedure, use the Caterpillar
codes to a file.

starting motor’s solenoid. The least likely cause is a

additional diagnostic codes. Keep your mind on g00868419
correcting the cause of the original diagnostic code. Illustration 382
Clear the diagnostic codes after the problem is (1) ECM J2/P2 connectors
resolved. (2) 16 amp circuit breaker
(3) Terminal box J6 connector for the left engine harness

the ECM OFF.

461
g00859811 g00859966
(P2-10) Circuit driver for the starting motor’s solenoid (P6-29) Return
(P2-20) Return (P6-37) Circuit driver for the starting motor’s solenoid
B. Thoroughly inspect the following connectors and


• Terminal box J6/P6 connectors
• Connector to the starting motor’s solenoid
6 ± 1 N·m (55 ± 9 lb in).

the wires that are associated with the starting
motor’s solenoid.

and for pinch points from the ECM to the
starting motor’s solenoid.
Expected Result:

462
Results: After the engine was cranked, there was no logged

• OK – All connectors, pins, and sockets are code.
wiring do not have corrosion, abrasion, or pinch Results:
with proper connections. Proceed to Test Step 2. • OK – No diagnostic codes were generated. The
output for the starting motor’s solenoid seems to
• Not OK – At least one of the connectors, pins, be OK at this time. The initial diagnostic code was
or sockets is not connected properly. At least probably caused by a poor electrical connection.
and/or pinch points. The components are not in Repair: If there is an intermittent problem
good condition and/or at least one connection that is causing the codes to be logged, refer
is improper. to Troubleshooting, “Inspecting Electrical
Connectors”.
possible. Replace parts, if necessary. STOP.
STOP. • Not OK (“444-05 Start Relay open circuit”

diagnostic code) – A “444-05 Start Relay open
Test Step 2. Check for Diagnostic Codes circuit” diagnostic code was activated. This can
A. Switch the 16 amp circuit breaker for the ECM circuit to the +Battery side. Proceed to Test Step
ON. Turn the engine control switch to the STOP 3.
position.
• Not OK (“444-06 Start Relay short to ground”
B. Wait for 30 seconds and use Cat ET to diagnostic code) – After the engine was cranked,
check for an active “444-05 Start Relay open a “444-06 Start Relay short to ground” diagnostic
circuit”diagnostic code. code was generated. Proceed to Test Step 8.
If there is an active “444-05 Start Relay open Test Step 3. Check for a Short Circuit to
circuit” diagnostic code, proceed to the “Results” the +Battery Side
for this Test Step. Otherwise, continue this
procedure.

codes. If there is a “444-06 Start Relay short to Gaseous fuel is present. Personal Injury or Death
ground” code, clear the code. can result from an open flame or spark igniting the
D. To prevent the engine from starting, shut the gas ways use a gas detector to determine the presence
supply OFF. of gaseous fuel when maintaining and servicing.
Note: To provide the output for the starting motor’s sistance in the event of a leak.
initiated. Otherwise, a “444-06 Start Relay short to Note: Open sparks can be generated during this
ground” diagnostic code cannot be generated. test.
E. Turn the engine control switch to the START A. Make sure that no combustible gas is present in
position for at least 30 seconds. Then turn the the surrounding atmosphere.
B. Ensure that the engine control switch is in the
F. Use Cat ET to look for a logged “444-06 Start STOP position.
Expected Result:
When the engine control switch was in the STOP

position, there was no active “444-05 Start Relay
open circuit” diagnostic code.
463

Energized Solenoid

Illustration 385 g00859796 Note: Open sparks can be generated during this
test.
C. Disconnect the connector from the starting position. Switch the 16 amp circuit breaker for
motor’s solenoid. Then reconnect the connector. the ECM OFF.

energized.
Expected Result:

Results:

to Test Step 5.

side in a connector or a wiring harness. Proceed Illustration 386
g00868932
to Test Step 4. Harness side of the terminal box P6 connector

terminal P6-37 from the harness side of the
terminal box P6 connector.

position.
464

2. Reinstall the removed wire into terminal (37) of

the terminal box J6 connector. Pull on the wire
in order to verify that the terminal is properly
installed.
g00859796
Illustration 387
D. Disconnect the connector from the starting

motor’s solenoid. Then reconnect the connector.

energized.
Expected Result:

Results:
g00868867
Illustration 388
• OK – There is no audible click and/or vibration Harness side of the ECM P2 connector
when the solenoid is disconnected and (P2-10) Circuit driver for the starting motor’s solenoid
the circuit driver for the solenoid is disconnected 3. Use a 151-6320 Wire Removal Tool to remove
from the J6 connector. terminal P2-10.
Repair: Use the following procedure to determine 4. Switch the 16 amp circuit breaker for the ECM
whether the circuit driver for the solenoid is faulty: ON. Turn the engine control switch to the
STOP position.

Gaseous fuel is present. Personal Injury or Death motor’s solenoid. Then reconnect the
can result from an open flame or spark igniting the connector. Listen for an audible click from the
gaseous fuel causing an explosion and/or fire. Al- solenoid.
of gaseous fuel when maintaining and servicing. If the ambient noise is too loud, touch the
Contact you local gas provider immediately for as- solenoid when the solenoid is reconnected in
sistance in the event of a leak. order to feel the vibration. The solenoid will
energized.
test.
465
If the solenoid is energized, there is a problem B. Disconnect the starting motor’s solenoid.
necessary.

procedure.


g00859796
installation of the terminal. Illustration 389
ON. Turn the engine control switch to the C. Install a jumper wire with the appropriate
STOP position. connectors on the ends into terminals “A” and
motor’s solenoid. Then reconnect the D. Switch the 16 amp circuit breaker for the ECM
connector. Listen for an audible click from the ON. Turn the engine control switch to the STOP
solenoid. position.
If the ambient noise is too loud, touch the E. Wait for 30 seconds and use the “Active
solenoid when the solenoid is reconnected in Diagnostic” screen of Cat ET to look for a “444-05
order to feel the vibration. The solenoid will Start Relay open circuit” diagnostic code.
energized. Expected Result:
If the solenoid is not energized, there is an A “444-05 Start Relay open circuit” diagnostic
intermittent problem with a connector and/or code was not generated when the jumper wire was
with the wiring. Refer to Troubleshooting, installed.
Results:
with the ECM. Replace the ECM according to • OK – A “444-05 Start Relay open circuit”
Troubleshooting, “Replacing the ECM”. diagnostic code was not generated when the
STOP. the ECM are OK. There is a problem with the
solenoid.
vibration when the solenoid is disconnected and Repair: Perform the following procedure:
reconnected. The solenoid is energized when the
circuit driver for the solenoid is disconnected from 1. Turn the engine control switch to the
the terminal box J6 connector. There is a short OFF/RESET position. Switch the 16 amp circuit
circuit to the +Battery side in the engine harness. breaker for the ECM OFF.
Repair: Repair the connector and/or wiring in 2. Remove the jumper wire from the solenoid’s
the engine harness, when possible. Replace the connector.
STOP. have damage, moisture, or corrosion.
Test Step 5. Create a Short Circuit in 4. Make repairs, as needed.

order to Check for an Open Circuit
A. Turn the engine control switch to the OFF/RESET solenoid.
the ECM OFF. STOP.
466
• Not OK – A “444-05 Start Relay open circuit” F. Wait for 30 seconds and use Cat ET to check
diagnostic code was generated when the jumper for an active “444-05 Start Relay open circuit”
wire was installed. There may be an open circuit diagnostic code.
Expected Result:
There is no active “444-05 Start Relay open circuit”
A. Ensure that the engine control switch is in the diagnostic code.
breaker for the ECM is OFF. Results:
B. Disconnect the P6 connector from the terminal • OK – When the jumper wire was installed, there
box. Verify that the P6 and J6 connectors do was no active “444-05 Start Relay open circuit”
not have damage, moisture, or corrosion. Make diagnostic code. There is a problem in the engine
repairs, if necessary. harness.

STOP.

“444-05 Start Relay open circuit” diagnostic code
was activated. The ECM did not detect the jumper
wire in the P6 connector. There is a problem in
the terminal box. Proceed to test Step 7.

the ECM OFF.

C. Reinstall the terminals into P6-29 and P6-37.

the correct locations. Pull on the wires in order to
verify proper installation of the terminals.

g00859966 moisture, or corrosion.
Illustration 390
(P6-29) Return
C. Reconnect the P6 connector to the terminal box.


connectors on the ends into terminals P6-29 and

position.
467
Results:
• OK – When the jumper wire was installed,

there was no active “444-05 Start Relay open




g00859811
Illustration 391 5. Thoroughly inspect the terminal box J6
Harness side of the ECM P2 connector connector for the engine harness.
(P2-20) Return 6. Use an ohmmeter to measure the resistance
E. Use the 151-6320 Wire Removal Tool to remove terminal. Also, measure the continuity between
terminals P2-10 and P2-20. Label the terminals. the P2-20 terminal and the J6-29 terminal.
F. Reconnect the ECM J2/P2 connectors. If the resistance is less than 5 ohms, the circuit
has good continuity. Otherwise, there is an
G. Install the jumper wire into terminals P2-10 and open circuit.
proper installation. Make repairs, if necessary.
H. Switch the 16 amp circuit breaker for the ECM STOP.

position. • Not OK – When the jumper wire was installed,
a “444-05 Start Relay open circuit” diagnostic
I. Wait for 30 seconds and use the “Active code was activated. The ECM did not detect the
Diagnostic” screen of Cat ET to look for an active jumper wire. There is a problem with the ECM.
“444-05 Start Relay open circuit” diagnostic
code. Repair: Perform the following procedure:
Expected Result: 1. Turn the engine control switch to the

There is no active “444-05” diagnostic code. breaker for the ECM OFF.


468
4. Replace the ECM according to Troubleshooting, If the problem is not resolved, replace the
“Replacing the ECM”. Verify that the problem solenoid.
is resolved.
STOP.
STOP.
• Not OK – A “short to ground” diagnostic
Test Step 8. Create an Open Circuit in code was generated when the solenoid was
order to Check for a Short Circuit to disconnected. Proceed to Test Step 9.
Ground
A. Turn the engine control switch to the OFF/RESET Terminal Box
position.
B. Disconnect the starting motor’s solenoid. position. Switch the 16 amp circuit breaker for
the ECM OFF.
position.


main gas supply.
Note: To provide the output for the starting motor’s



Expected Result:
A “444-06 Start Relay short to ground” was not

generated.
Results:
g00868932
• OK – When the solenoid was connected, a “short Illustration 392
to ground” diagnostic code was generated. When Harness side of the terminal box P6 connector
the solenoid was disconnected, no “short to (P6-37) Circuit driver for the starting motor’s solenoid
ground” diagnostic code was generated. There
is a problem with the solenoid. B. Use a 151-6320 Wire Removal Tool to remove
terminal P6-37.
1. Turn the engine control switch to the ON. Turn the engine control switch to the STOP
OFF/RESET position. Switch the 16 amp circuit position.
2. Verify that the solenoid’s connectors do not Relay short to ground” diagnostic code.
have damage and/or corrosion.
3. Make repairs, as needed. main gas supply.
469



Expected Result:
A “444-06 Start Relay short to ground” was not

generated.
Results:
• OK – A “444-06 Start Relay short to ground”


g00868867
OFF/RESET position. Switch the 16 amp circuit Illustration 393
breaker for the ECM OFF. Harness side of the ECM P2 connector
P6-37. Pull on the wire in order to verify proper B. Use the 151-6320 Wire Removal Tool to remove
installation of the terminal. terminal P2-10.
3. Repair the harness, when possible. Replace C. Switch the 16 amp circuit breaker for the ECM
the harness, if necessary. ON. Turn the engine control switch to the STOP
position.
STOP.
• Not OK – A “short to ground” diagnostic code Relay short to ground” diagnostic code.
was generated when the output to the solenoid
was disconnected from the terminal box P6 E. To prevent the engine from starting, shut OFF the
connector. There is probably a short circuit to main gas supply.
ground in the terminal box.
Repair: Reinstall the terminal that was removed solenoid, the sequence for engine start-up must be
into P6-37. Pull on the wire in order to verify initiated. Otherwise, a “444-06 Start Relay short to
proper installation of the terminal. ground” diagnostic code cannot be generated.
Proceed to Test Step 10. F. Turn the engine control switch to the START
Test Step 10. Check the ECM engine control switch to the STOP position.
A. Turn the engine control switch to the OFF/RESET G. Use Cat ET to look for a logged “444-06 Start
position. Switch the 16 amp circuit breaker for Relay short to ground” diagnostic code again.
the ECM OFF.
Expected Result:
The “444-06 Start Relay short to ground” diagnostic

code was not generated.
470
Results: i01757794
• OK – When the output to the solenoid was ECM Status Indicator Output
“444-06 Start Relay short to ground” diagnostic SMCS Code: 1901-038
ground” diagnostic code was generated when System Operation Description:
the terminal box P6 connector. There is a problem The Electronic Control Module (ECM) has four
in the terminal box between the ECM connector outputs in order to indicate the status of engine
and the terminal box P6 connector. operation: “Run Relay”, “Crank Terminate”, “Active
Alarm”, and “Engine Failure”. These outputs can be
Repair: Perform the following procedure: used to energize indicator lamps or the outputs can
be used to interface with other controls.
OFF/RESET position. Switch the 16 amp circuit When the output is OFF, the circuit is open. The
breaker for the ECM OFF. output provides a maximum current of 0.3 amperes
to the ECM. The ECM grounds the current to the
2. Reinstall the terminal that was removed into -Battery side in order to activate the appropriate
P2-10. Pull on the wire in order to verify proper output.
If any of the outputs have a short circuit to the
3. Repair the harness, when possible. Replace +Battery side or excessive current, a diagnostic
the harness, if necessary. code is generated.
STOP. “Run Relay” – This output indicates that the engine

is in the “Run” status. The engine will start soon or
• Not OK – A “444-06 Start Relay short to ground” the engine is running.
diagnostic code was generated when the output
to the solenoid was disconnected from the ECM “Crank Terminate” – This output indicates that the
P2 connector. There seems to be a problem with engine rpm is greater than the programmed engine
the ECM. speed that is required for disengagement of the
starting motor.
“Active Alarm” – This is the alarm output. This output
1. Turn the engine control switch to the indicates that the ECM has detected an electrical
OFF/RESET position. Switch the 16 amp circuit problem or an abnormal operating condition.
“Engine Failure” – This is the shutdown output.
2. Reinstall the terminal that was removed into This output indicates that a potentially damaging
P2-10. Pull on the wire in order to verify proper operating condition was detected by the ECM. The
installation of the terminal. ECM has shut down the engine.
3. Replace the ECM according to Troubleshooting, A “323-03 Shutdown Lamp short to +batt” or
“Replacing the ECM”. Verify that the problem “324-03 Warning Lamp short to +batt” diagnostic
is resolved. code can only be generated if a shutdown condition
or an alarm condition is active. Failure to correct
STOP. these serious conditions can result in engine
damage.
Use the Caterpillar Electronic Technician (Cat ET)

to determine the event code or the diagnostic
code that corresponds to the 323-03 or 324-03
diagnostic code. Troubleshoot that event code
or that diagnostic code before you troubleshoot
the 323-03 or 324-03 diagnostic code. Refer to
Troubleshooting, “Troubleshooting with an Event
Code” or Troubleshooting, “Troubleshooting with a
Diagnostic Code”.
471
The most likely causes of a diagnostic code for a

status indicator is a poor electrical connection or a
problem in a wiring harness. The next likely cause
is a problem with an indicator. The least likely cause
is a problem with the ECM.

ET to print the logged codes to a file.

resolved.
g00899121
Illustration 394
Schematic for the status indicators
472

g00856552
Illustration 395
(4) Customer connector J3
(5) Connector J4 for the optional control panel

position. Switch circuit breakers (1) and (2) OFF.
Note: Some indicators may obtain the status of the

engine via a data link. If all of the status indicators Illustration 397 g00857399
are not directly controlled by the ECM, do not
Location of the output wires for the status indicators on the harness
proceed with this test. side of the P2 connector
(10) Ground strap
(P2-28) “Run Relay”
(P2-29) “Crank Terminate”
(P2-30) “Engine Failure”
(P2-31) “Active Alarm”
g00856682
Illustration 396
Inside of the control panel
(6) “Engine Failure” indicator
(7) “Active Alarm” indicator
(8) “Engine On” indicator
(9) Terminal strip
B. Check the wiring of the equipment in order to

determine if the indicators for the engine status
are present. Determine whether the circuit for
the status indicators is directly controlled by the
ECM.

473
C. Thoroughly inspect the ECM J2/P2 connectors.

Inspect the customer connectors (J3) and (P3)
(if equipped). Inspect connectors (J4) and (P4)
for the control panel (if equipped). Inspect the
wiring and the connections for the circuit of the
status indicators.

6 N·m (55 lb in).

the status indicators.
Note: These outputs do not provide enough current

for illumination of standard incandescent lights. If a
lamp is burned out, replace the lamp with the lamp
that is specified in the engine’s Parts Manual.
c. Inspect the wiring and the receptacles for the

Illustration 398 g00863317 status indicators.
Terminal box’s side of the 47-pin connector (P4)
d. Check the harness and wiring for abrasion
(P4-C) “Crank Terminate”
(P4-H) “Active Alarm”
and for pinch points from the status indicators
(P4-P) “Engine Failure” to the ECM.
(P4-Z) “Run Relay”
e. Inspect the terminal strip in the control panel
loose wires, frayed wires, foreign objects, and
corrosion.
Expected Result:

Results:


is improper.

g00857008
Illustration 399
Customer connector J3 STOP.
(J3-7) Crank terminate
(J3-8) Active alarm Test Step 2. Check for Diagnostic Codes
(J3-9) Engine failure
(J3-19) Run relay A. Switch the 16 amp circuit breaker for the ECM
ON.
474
B. Attempt to start the engine and observe the Repair: The 323-03 and 324-03 diagnostic codes
status indicators. Allow a minimum of 30 seconds can only be activated when the corresponding
for any diagnostic codes to activate. Use the indicator is activated. There may still be a
“Active Diagnostic” screen on Cat ET to look for problem with the output for the alarm indicator
the codes that are listed in Table 66: or the shutdown indicator. The alarm and/or the
shutdown must be activated.
Table 66
Diagnostic Codes and Descriptions with Allow the engine operation to continue. Proceed
Corresponding ECM Outputs to Test Step 3.
Code Description ECM Output
• Not OK (Active 323-03 or 324-03 Diagnostic
323-03 Shutdown Lamp short to “Engine Failure” Code) – There is an active “323-03 Shutdown
+batt Lamp short to +batt” or “324-03 Warning Lamp
short to +batt”. There must be a shutdown
324-03 Warning Lamp short to “Active Alarm” condition before a 323-03 diagnostic code
+batt
can be generated. There must be an alarm
443-03 Crank Terminate Relay “Crank condition before a 324-03 diagnostic code can be
short to +batt Terminate” generated. Both of these conditions are serious.
445-03 Run Relay short to +batt “Run Relay”
Repair: Use Cat ET to determine the event code
or the diagnostic code that corresponds to the
Expected Result: 323-03 or 324-03 diagnostic code. Troubleshoot
that event code or that diagnostic code
There are no active diagnostic codes. The “Engine before you troubleshoot the 323-03 or 324-03
On” indicator and the “Crank Terminate” indicator (if diagnostic code. Refer to Troubleshooting,
equipped) illuminated normally. The “Active Alarm” “Troubleshooting with an Event Code” or
indicator and the “Engine Failure” indicator did not Troubleshooting, “Troubleshooting with a
illuminate. Diagnostic Code”.
Results: Exit this procedure. After you have resolved the

condition, return to this procedure in order to
• Yes (Original 443-03 or 445-03 Diagnostic Code) – troubleshoot the 323-03 and/or 324-03 diagnostic
The original diagnostic code was “443-03 Crank code, if necessary.
Terminate Relay short to +batt” or “445-03 Run
Relay short to +batt”. When the engine was STOP.
started, the “Engine On” indicator and the “Crank
Terminate” indicator (if equipped) illuminated • Not OK (Active 443-03 or 445-03 Diagnostic
normally. The “Active Alarm” indicator and the Code) – When the engine was started, the
“Engine Failure” indicator did not illuminate. There “Engine On” indicator and/or the “Crank
are no active diagnostic codes. Terminate” indicator (if equipped) did not
illuminate normally. The “Active Alarm” indicator
Repair: The outputs for the status indicators seem and the “Engine Failure” indicator did not
to be operating correctly at this time. The original illuminate. A 443-03 or 445-03 diagnostic code
diagnostic code was probably caused by a poor was activated. There is a problem with the
electrical connection. output for the “Engine On” indicator and/or with
the “Crank Terminate” indicator (if equipped).
If there is an intermittent problem that is causing Proceed to Test Step 4.
the codes to be logged, refer to Troubleshooting,
“Inspecting Electrical Connectors”. Test Step 3. Check for Proper Operation
of the Status Indicators for the Alarm and
STOP. Shutdown
• Yes (Original 323-03 or 324-03 Diagnostic Code) – Allow the engine operation to continue for this
The original diagnostic code was “323-03 procedure.
Shutdown Lamp short to +batt” or “324-03
Warning Lamp short to +batt”. When the engine
was started, the “Engine On” indicator and
the “Crank Terminate” indicator (if equipped)
illuminated normally. The “Active Alarm” indicator
and the “Engine Failure” indicator did not
illuminate. There are no active diagnostic codes.
475
Results:
• OK – The indicators, diagnostic codes, and

shutdown were activated according to the
“Expected Result”. The outputs for the status
indicators seem to be operating correctly at this
time. The original problem seems to be resolved.
Repair: The original diagnostic code was probably

caused by a poor electrical connection.
If there is an intermittent problem that is causing

the codes to be logged, refer to Troubleshooting,
STOP.
• Not OK – The “Active Alarm” indicator and/or

the “Engine Faiure” indicator did not illuminate
normally when the sensors were disconnected. A
“323-03 Shutdown Lamp short to +batt” and/or a
“324-03 Warning Lamp short to +batt” diagnostic
code was generated. There is a problem with the
output for the status indicators. The “542-03” and
the “100-03” diagnostic codes were generated.
The engine was shut down. Proceed to Test Step
4.
g00856957
Illustration 400
A. During engine operation, disconnect connector

(1) for the unfiltered oil pressure sensor. Observe
the “Active Alarm” indicator on the control panel
(if equipped). Wait for 30 seconds and use Cat
ET to check for active diagnostic codes.
If you are only troubleshooting a “324-03 Warning

Lamp short to +batt”, proceed to the “Expected
Result”.
Note: When the filtered engine oil pressure sensor

is disconnected, the engine will shut down.
B. Disconnect connector (2) for the filtered engine

oil pressure sensor. Observe the “Engine Failure”
indicator on the control panel (if equipped). Wait
for 30 seconds and use Cat ET to check for
active diagnostic codes.
Expected Result:
The “Active Alarm” indicator illuminated and a

“542-03 Unfiltered Engine Oil Pressure open/short
to +batt” diagnostic code was activated when
the unfiltered engine oil pressure sensor is
disconnected.
The “Engine Failure” indicator illuminated and a

“100-03 Engine Oil Pressure open/short to +batt”
diagnostic code was activated when the filtered
engine oil pressure sensor is disconnected. The
engine was shut down.
476
Test Step 4. Measure the Voltage of

the Suspect Indicator at the ECM P2
Connector
g00863378
Illustration 402
Terminal strip in the control panel
(14) “Engine On”
(15) “Crank Terminate”
(16) “Active Alarm”
(17) “Engine Failure”
G. Disconnect the suspect control wire from the

terminal strip in the control panel (if equipped).
Disconnect the wire from the indicator’s side of
the terminal strip.
If the customer has equipment for the status

indicators, disconnect the output wire of the
suspect indicator.
g00871059 Tape the end of the disconnected wire in order

Illustration 401
to ensure that the wire is isolated.
side of the P2 connector
H. Switch circuit breakers (1) and (2) ON. Turn the
(1) 16 amp circuit breaker engine control switch to the STOP position.
(3) Ground strap
(P2-28) “Run Relay” I. Note the voltage that is displayed on the
(P2-29) “Crank Terminate” voltmeter.
(P2-30) “Engine Failure”
(P2-31) “Active Alarm”
Expected Result:
A. Turn the engine control switch to the OFF/RESET Before the suspect indicator was disconnected,
position. Switch circuit breakers (1) and (2) OFF. voltage was displayed on the voltmeter. After the
suspect indicator was disconnected, the voltmeter
B. Insert a 7X-1710 Multimeter Probe into the displayed approximately zero volts.
suspect control terminal in the ECM P2 connector.
Results:
C. Connect the other lead of the 7X-1710
Multimeter Probe to the positive lead of a
voltmeter. Connect the voltmeter’s negative lead
• Yes – Before the suspect indicator was
disconnected from the terminal strip, voltage was
to ground strap (3). displayed on the voltmeter. After the suspect
indicator was disconnected, the voltmeter
D. Switch circuit breakers (1) and (2) ON. Turn the displayed approximately zero volts. There is a
engine control switch to the STOP position. problem in the control panel (if equipped) or in
the customer’s panel.
E. Note the voltage that is displayed on the
voltmeter. Repair: The problem could be caused by one
of the following conditions: poor electrical
F. Turn the engine control switch to the OFF/RESET connection, damaged wire, and damaged
position. Switch circuit breakers (1) and (2) OFF. component in the panel.
477
Turn the engine control switch to the OFF/RESET The voltage is approximately zero. – After
position. Switch circuit breakers (1) and (2) OFF. customer connector (P3) was disconnected,
the reading on the voltmeter was approximately
Thoroughly inspect all of the wiring and the zero. There is a problem with a connection
connectors in the panel. Refer to Troubleshooting, and/or the wiring between customer connector
“Inspecting Electrical Connectors”. (P3) and the indicator in the customer’s
panel. Turn the engine control switch to the
If you suspect that the indicator has an internal OFF/RESET position. Switch circuit breakers
short circuit, switch a known good indicator for (2) and (3) OFF. Repair the connection and/or
the suspect indicator. Test the indicator. Verify that the wiring, when possible. Replace parts, if
the problem is resolved. necessary. Stop
Make the necessary repairs, when possible. The voltage remained. – After customer
Replace parts, if necessary. connector (P3) was disconnected, voltage was
still displayed on the voltmeter. Proceed to the
STOP. next Step.
• No – Before the suspect indicator was 3. Turn the engine control switch to the
disconnected from the terminal strip, voltage was OFF/RESET position. Switch circuit breakers
displayed on the voltmeter. After the suspect (2) and (3) OFF. Disconnect connector (P4) (if
indicator was disconnected, the voltage was equipped) from terminal box’s connector (J4).
still displayed on the voltmeter. The problem is
between the indicator’s terminal strip and the 4. Switch circuit breakers (2) and (3) ON. Turn
ECM. the engine control switch to the STOP position.
Observe the reading on the voltmeter.
Repair: Do not disconnect the voltmeter. Perform
the following procedure: Results
The voltage is approximately zero. – After

connector (P4) was disconnected, the reading
on the voltmeter was approximately zero.
There is a problem with a connection and/or
with the wiring between connector (P4) and
the terminal strip in the control panel. Turn
the engine control switch to the OFF/RESET
position. Switch circuit breakers (2) and (3)
OFF. Repair the connection and/or the wiring,
when possible. Replace parts, if necessary.
Stop
The voltage remained. – After customer

connector (P4) was disconnected, voltage was
g00856552
Illustration 403 still displayed on the voltmeter. Continue with
(1) ECM J2/P2 connectors this procedure.
(3) 6 amp circuit breaker 5. Turn the engine control switch to the
(4) Customer connector J3
(5) Connector J4 for the optional control panel
OFF/RESET position. Switch circuit breakers
(2) and (3) OFF. Remove the 7X-1710
1. Turn the engine control switch to the Multimeter Probe from the suspect control
OFF/RESET position. Switch circuit breakers terminal in the ECM P2 connector.
(2) and (3) OFF. Disconnect customer
connector (P3) (if equipped) from terminal
box’s connector (J3).
2. Switch circuit breakers (2) and (3) ON. Turn

the engine control switch to the STOP position.
Observe the reading on the voltmeter.
Results
478
The voltage is approximately zero. – After

the suspect terminal was removed from
connector (P2), the reading on the voltmeter
was approximately zero. There is a problem
with a connection and/or with the wiring in
the terminal box. Turn the engine control
switch to the OFF/RESET position. Switch
circuit breakers (2) and (3) OFF. Repair the
Replace parts, if necessary. Stop
The voltage remained. – After the suspect

terminal was removed from connector (P2),
voltage was still displayed on the voltmeter.
There is a problem with the ECM. Replace the
ECM according to Troubleshooting, “Replacing
the ECM”. Verify that the problem is resolved.
STOP.
i01757894
Electrical Power Supply

SMCS Code: 1401-038
S/N: BEN1-Up
g00863371
Illustration 404 S/N: 4ZS1-Up
side of the P2 connector System Operation Description:
(3) 6 amp circuit breaker Electrical power is supplied to the Electronic Control
(6) Ground strap Module (ECM), to the Integrated Combustion
(P2-28) “Run Relay” Sensing Module (ICSM), and to the air/fuel pressure
(P2-29) “Crank Terminate”
(P2-30) “Engine Failure” module. The cause of an intermittent power supply
(P2-31) “Active Alarm” can occur on either the positive side or on the
negative side of the power supply.
6. Use a 151-6320 Wire Removal Tool to
remove the suspect terminal from the ECM P2 The 24 VDC power supply for the ECM can be
connector. Tape the terminal in order to isolate provided by a battery or by an electrical power
the terminal. supply. The minimum requirement for the power
supply is 22 VDC at 16 amperes. The 24 VDC
7. Insert the 7X-1710 Multimeter Probe into power supply can be connected to the terminal box
the suspect control terminal in the ECM P2 or to the control panel. Route the power supply
connector. Use the voltmeter to measure the through a dedicated fuse or through a dedicated
voltage between the suspect terminal in the circuit breaker.
ECM and ground strap (6). Switch circuit
breakers (2) and (3) ON. Turn the engine The ECM input at terminal 70 of the P1 connector
control switch to the STOP position. Observe (“Switched +Battery”) receives battery voltage
the reading on the voltmeter. from the engine control switch when the switch is
in the START position, in the STOP position, or in
Results the AUTO position. When the ECM detects battery
voltage at this input, the ECM will power up. When
battery voltage is removed from this input, the ECM
will power down after the engine has shut down.
479
The “168-02” diagnostic code indicates that the

voltage of the power supply is intermittent or low
while the engine is running. If the supply voltage
drops to zero and stays at zero, the ECM will not
log this code. The engine will shut down.

ECM has detected a problem with the circuit for
the engine control switch.

This procedure may generate additional diagnostic

codes. Keep your mind on correcting the cause of
the original diagnostic code. Clear the diagnostic
codes after the problem is resolved.
480
g00899416
Illustration 405
Schematic for the electrical power source
The 24 VDC power supply is connected to the terminal box.
481
g00899420
Illustration 406
The 24 VDC power supply is connected to the control panel.
482

the ECM OFF.

g00868008
Illustration 408
a. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the electrical
power supply:
• Unswitched +Battery terminals 52, 53, 55,

and 57
• −Battery terminals 63, 65, 67, and 69

• Switched +Battery terminal 70
b. Check the harness and wiring for abrasion
g00868000 and for pinch points from the power supply to
Illustration 407 the ECM and from the engine control switch
(1) J1/P1 connectors for the ECM to the ECM.
Expected Result:
B. Disconnect the J1/P1 connectors. Verify that the
connectorsdo not have damage, corrosion, or All connectors, pins, and sockets are connected
moisture. Reconnect the connectors. Tighten properly. The connectors and the wiring do not have
the Allen head screw to a torque of 6 ± 1 N·m corrosion, abrasion, or pinch points.
(55 ± 9 lb in).
Results:
C. Thoroughly inspect the following connections:
• Connectors for the circuit breaker connected properly. The connectors and the
• Connectors for the 24 VDC power supply points. The components are in good condition
• Connectors for the engine control switch
is improper.
483
Repair: Perform the necessary repairs and/or E. Measure the power supply voltage at the P1
replace parts, if necessary. Ensure that all of the connector. During the measurement, wiggle the
seals are properly installed. Make sure that the harness in order to check for an intermittent
connectors are properly fastened. Verify that the problem. Be sure to wiggle the harness near
repair has eliminated the problem. each of the connections.
Test Step 2. Check the Voltage at the The voltage that is measured at the terminals for the
Power Supply and at the ECM power supply is at least 22 VDC. The voltage that
is measured at the P1 connector is within 2 VDC of
A. Make sure that the engine will not crank during the voltage that was measured at the terminals for
this procedure. Make sure that the pressurized the power supply. The voltage measurements are
air supply is OFF. Make sure that the air is constant.
purged from the system.
Results:
Note: If a power supply is used instead of batteries,
the minimum voltage for the power supply is 22 • OK – The ECM is receiving the correct voltage at
VDC at 16 amperes. the P1 connector.
B. Measure the voltage at the terminals for the Repair: Perform the following procedure:
power supply. Record the voltage.
OFF.
Remove the probes from connector P1.
• Not OK – The ECM is not receiving the correct

voltage at the P1 connector.

OFF.
2. Remove the probes from connector P1.
3. Use a voltmeter to check the wiring. Refer to

the appropriate schematic for the electrical
system. Locate the source of the voltage drop.
STOP.
Test Step 3. Check the Engine Control

Switch
g00867982 A. Make sure that the engine will not crank during
Illustration 409
Harness side of ECM P1 connector this procedure. Make sure that the pressurized
air supply is OFF. Make sure that the air is
C. Insert two 7X-1710 Multimeter Probes into the purged from the system.
harness side of the P1 connector. Insert the first
probe into terminal 52. Insert the second probe B. Connect Cat ET to the service tool connector.
into terminal 63. Connect a multimeter to the
probes. C. Switch the 16 amp circuit breaker for the ECM
ON.
ON.
484
Note: An “E225 Engine Overcrank” and/or an “E233

Low Engine Prelube Pressure” event code may
be generated during this step. After you have
completed this step, clear the events from the
“Logged Events” screen of Cat ET.

ET and turn the engine control switch to the
STOP position, to the START position, and to
the AUTO position. Look for an active “336-02
Incorrect ECS Switch inputs” diagnostic code.
Repeat this step several times.
Expected Result:
A “336-02 Incorrect ECS Switch inputs” diagnostic

code was not activated when the engine control
switch was turned to the STOP position, the START
position, and the AUTO position.
Results:
• OK – A “336-02 Incorrect ECS Switch inputs”

diagnostic code was not activated. The inputs
to the engine control switch are correct. The
problem seems to be resolved.
Repair: The problem may be intermittent.

g00868154
Refer to Troubleshooting, “Inspecting Electrical Illustration 410
Connectors”. Harness side of ECM P1 connector
STOP. C. Insert two 7X-1710 Multimeter Probes into the

harness side of the P1 connector. Insert the first
• Not OK – A “336-02 Incorrect ECS Switch inputs” probe into terminal 31. Insert the second probe
diagnostic code was activated. The ECM has into terminal 61. Connect a multimeter to the
detected an invalid pattern for the input to the probes.
engine control switch. Proceed to Test Step 4.
Test Step 4. Check the Circuit of the ON.
Engine Control Switch
Note: An “E225 Engine Overcrank” and/or an “E233
A. Make sure that the engine will not crank during Low Engine Prelube Pressure” event code may be
this procedure. Make sure that the pressurized generated during the test. After you have completed
air supply is OFF. Make sure that the air is the test, clear the events from the “Logged Events”
purged from the system. screen of Cat ET.
B. Turn the engine control switch to the OFF/RESET Note: During these measurements, wiggle the
position. Switch the 16 amp circuit breaker for harness in order to check for an intermittent
the ECM OFF. problem. Be sure to wiggle the harness near each
of the connections.
E. Turn the engine control switch to the STOP

position and measure the voltage between
terminal 31 and terminal 61 of the P1 connector.
The correct voltage measurement is less than
one volt.
F. Remove the probe from terminal 61 and insert

the probe into terminal 62.
485
G. Turn the engine control switch to the START • Not OK – The P1 connector does not have the
position and measure the voltage between correct voltage.
The correct voltage measurement is less than Repair: Perform the following steps:
one volt.
H. Remove the probe from terminal 62 and insert OFF/RESET position. Switch the 16 amp circuit
the probe into terminal 64. breaker for the ECM OFF.
I. Turn the engine control switch to the AUTO 2. Disconnect the wires for the STOP, START, and
position and measure the voltage between AUTO positions from the engine control switch.
The correct voltage measurement is less than 3. Use an ohmmeter to check the contacts for
one volt. the switch. Turn the switch to each position in
order to check the contacts.
J. Remove the probe from terminal 31 and insert the
probe into terminal 69. Remove the probe from 4. If the engine control switch is faulty, replace
terminal 64 and insert the probe into terminal 70. the switch. If the problem is not resolved,
repair the harness, when possible. Replace
K. Turn the engine control switch to the STOP the harness, if necessary.
terminal 69 and terminal 70 of the P1 connector. STOP.
The correct voltage measurement is at least 20
VDC.
i01758299
L. Turn the engine control switch to the START

Electrical Power Supply
terminal 69 and terminal 70 of the P1 connector. SMCS Code: 1401-038
The correct voltage measurement is at least +20
VDC. S/N: BLB1-Up
M. Turn the engine control switch to the AUTO S/N: BKE1-Up

terminal 69 and terminal 70 of the P1 connector. System Operation Description:
VDC. Electrical power is supplied to the Electronic Control
Module (ECM), to the Integrated Combustion
Expected Result: Sensing Module (ICSM), and to the air/fuel pressure
module. The cause of an intermittent power supply
The voltage checks are within the specifications. can occur on either the positive side or on the
negative side of the power supply.
Results:
The 24 VDC power supply for the ECM can be
• OK – The voltage checks are within the provided by a battery or by an electrical power
specifications. Remove the probes from the P1 supply. The minimum requirement for the power
connector. Start the engine and run the engine. supply is 22 VDC at 16 amperes. The 24 VDC
If the original problem is not resolved, the ECM power supply can be connected to the terminal box
may have a problem. or to the control panel. Route the power supply
through a dedicated fuse or through a dedicated
Repair: It is unlikely that the ECM has failed. circuit breaker.
Perform the following procedure:
The ECM input at terminal 70 of the P1 connector
Temporarily install a new ECM. Refer to (“Switched +Battery”) receives battery voltage
Troubleshooting, “Replacing the ECM”. from the engine control switch when the switch is
in the START position, in the STOP position, or in
If the problem is resolved with the new ECM, the AUTO position. When the ECM detects battery
install the original ECM and verify that the problem voltage at this input, the ECM will power up. When
returns. If the new ECM operates correctly and battery voltage is removed from this input, the ECM
the original ECM does not operate correctly, will power down after the engine has shut down.
replace the ECM. Refer to Troubleshooting,
STOP.
486

voltage of the power supply is intermittent or low
while the engine is running. If the supply voltage
drops to zero and stays at zero, the ECM will not
log this code. The engine will shut down.

ECM has detected a problem with the circuit for
the engine control switch.

This procedure may generate additional diagnostic

codes. Keep your mind on correcting the cause of
the original diagnostic code. Clear the diagnostic
codes after the problem is resolved.
487
g00899506
Illustration 411
The 24 VDC power supply is connected to the terminal box.
488
g00899509
Illustration 412
The 24 VDC power supply is connected to the control panel.
489

the ECM OFF.

g00868008
Illustration 414
a. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the electrical
power supply:
• Unswitched +Battery terminals 52, 53, 55,

and 57
• −Battery terminals 63, 65, 67, and 69

• Switched +Battery terminal 70
b. Check the harness and wiring for abrasion
g00868000 and for pinch points from the power supply to
Illustration 413 the ECM and from the engine control switch
(1) J1/P1 connectors for the ECM to the ECM.
Expected Result:
B. Disconnect the J1/P1 connectors. Verify that the
connectorsdo not have damage, corrosion, or All connectors, pins, and sockets are connected
moisture. Reconnect the connectors. Tighten properly. The connectors and the wiring do not have
the Allen head screw to a torque of 6 ± 1 N·m corrosion, abrasion, or pinch points.
(55 ± 9 lb in).
Results:
C. Thoroughly inspect the following connections:
• Connectors for the circuit breaker connected properly. The connectors and the
• Connectors for the 24 VDC power supply points. The components are in good condition
• Connectors for the engine control switch
is improper.

replace parts, if necessary. Ensure that all of the
seals are properly installed. Make sure that the
connectors are properly fastened. Verify that the
repair has eliminated the problem.
STOP.
490
Test Step 2. Check the Voltage at the Expected Result:

Power Supply and at the ECM
The voltage that is measured at the terminals for the
A. Make sure that the engine will not crank during power supply is at least 22 VDC. The voltage that
this procedure. Make sure that the pressurized is measured at the P1 connector is within 2 VDC of
air supply is OFF. Make sure that the air is the voltage that was measured at the terminals for
purged from the system. the power supply. The voltage measurements are
constant.
Note: If a power supply is used instead of batteries,
the minimum voltage for the power supply is 22 Results:
VDC at 16 amperes.
• OK – The ECM is receiving the correct voltage at
B. Measure the voltage at the terminals for the the P1 connector.
power supply. Record the voltage.

OFF.
Remove the probes from connector P1.
• Not OK – The ECM is not receiving the correct

voltage at the P1 connector.

OFF.
3. Use a voltmeter to check the wiring. Refer to

the appropriate schematic for the electrical
system. Locate the source of the voltage drop.
STOP.
Test Step 3. Check the Engine Control

Illustration 415
g00867982 Switch
Harness side of ECM P1 connector
A. Make sure that the engine will not crank during
C. Insert two 7X-1710 Multimeter Probes into the this procedure. Make sure that the pressurized
harness side of the P1 connector. Insert the first air supply is OFF. Make sure that the air is
probe into terminal 52. Insert the second probe purged from the system.
probes. B. Connect Cat ET to the service tool connector.
D. Switch the 16 amp circuit breaker for the ECM C. Switch the 16 amp circuit breaker for the ECM
ON. ON.
E. Measure the power supply voltage at the P1 Note: An “E225 Engine Overcrank” and/or an “E233
connector. During the measurement, wiggle the Low Engine Prelube Pressure” event code may
harness in order to check for an intermittent be generated during this step. After you have
problem. Be sure to wiggle the harness near completed this step, clear the events from the
each of the connections. “Logged Events” screen of Cat ET.
491

ET and turn the engine control switch to the
STOP position, to the START position, and to
the AUTO position. Look for an active “336-02
Incorrect ECS Switch inputs” diagnostic code.
Repeat this step several times.
Expected Result:
A “336-02 Incorrect ECS Switch inputs” diagnostic

code was not activated when the engine control
switch was turned to the STOP position, the START
position, and the AUTO position.
Results:
• OK – A “336-02 Incorrect ECS Switch inputs”

diagnostic code was not activated. The inputs
to the engine control switch are correct. The
problem seems to be resolved.
Repair: The problem may be intermittent.

Connectors”.
STOP.
• Not OK – A “336-02 Incorrect ECS Switch inputs” g00868154

diagnostic code was activated. The ECM has Illustration 416
detected an invalid pattern for the input to the Harness side of ECM P1 connector
engine control switch. Proceed to Test Step 4.
C. Insert two 7X-1710 Multimeter Probes into the
Test Step 4. Check the Circuit of the harness side of the P1 connector. Insert the first
Engine Control Switch probe into terminal 31. Insert the second probe
A. Make sure that the engine will not crank during probes.
this procedure. Make sure that the pressurized
air supply is OFF. Make sure that the air is D. Switch the 16 amp circuit breaker for the ECM
purged from the system. ON.
B. Turn the engine control switch to the OFF/RESET Note: An “E225 Engine Overcrank” and/or an “E233
position. Switch the 16 amp circuit breaker for Low Engine Prelube Pressure” event code may be
the ECM OFF. generated during the test. After you have completed
the test, clear the events from the “Logged Events”
screen of Cat ET.
Note: During these measurements, wiggle the

problem. Be sure to wiggle the harness near each
of the connections.
E. Turn the engine control switch to the STOP

The correct voltage measurement is less than

one volt.
F. Remove the probe from terminal 61 and insert

492
G. Turn the engine control switch to the START If the problem is resolved with the new ECM,
position and measure the voltage between install the original ECM and verify that the problem
terminal 31 and terminal 62 of the P1 connector. returns. If the new ECM operates correctly and
the original ECM does not operate correctly,
The correct voltage measurement is less than replace the ECM. Refer to Troubleshooting,
one volt. “Replacing the ECM”.
H. Remove the probe from terminal 62 and insert STOP.

• Not OK – The P1 connector does not have the
I. Turn the engine control switch to the AUTO correct voltage.
terminal 31 and terminal 64 of the P1 connector. Repair: Perform the following steps:
The correct voltage measurement is less than 1. Turn the engine control switch to the
one volt. OFF/RESET position. Switch the 16 amp circuit
J. Remove the probe from terminal 31 and insert the
probe into terminal 69. Remove the probe from 2. Disconnect the wires for the STOP, START, and
terminal 64 and insert the probe into terminal 70. AUTO positions from the engine control switch.
K. Turn the engine control switch to the STOP 3. Use an ohmmeter to check the contacts for
position and measure the voltage between the switch. Turn the switch to each position in
terminal 69 and terminal 70 of the P1 connector. order to check the contacts.
The correct voltage measurement is at least 20 4. If the engine control switch is faulty, replace
VDC. the switch. If the problem is not resolved,
repair the harness, when possible. Replace
L. Turn the engine control switch to the START the harness, if necessary.
terminal 69 and terminal 70 of the P1 connector. STOP.

VDC.
M. Turn the engine control switch to the AUTO


VDC.
Expected Result:
The voltage checks are within the specifications.
Results:
• OK – The voltage checks are within the

specifications. Remove the probes from the P1
connector. Start the engine and run the engine.
If the original problem is not resolved, the ECM
may have a problem.


493
i01829105 The speed-timing wheel has a special tooth

pattern that indicates the position of the camshaft.
Engine Speed/Timing Sensor The speed-timing wheel has 36 teeth that are
evenly spaced and one extra tooth. The number
SMCS Code: 1912-038 one cylinder is at the top center position on the
compression stroke when the centerline of the first
S/N: BEN1-Up
tooth after the extra tooth aligns with the centerline
S/N: 4ZS1-Up of the sensor. All 37 teeth pass the sensor during
one revolution of the camshaft or two revolutions of
System Operation Description: the crankshaft.
With the information from the engine speed/timing

sensor, the ECM is able to calculate the positions of
the pistons in the cylinders. The ECM determines
the desired ignition timing according to the engine
speed and to the load. If detonation is detected in
any of the cylinders, the ECM retards the timing
of the affected cylinders. The ECM sends voltage
pulses to the ignition transformers for firing the
spark plugs according to the desired timing.
If the ECM detects a problem with the engine

speed/timing sensor’s signal, the ECM will shut
down the engine. If there is a problem with the
engine speed/timing sensor’s signal during start-up,
the ECM will not initiate the ignition. The engine will
not start. The corresponding diagnostic code is
generated.
If the engine speed/timing sensor is replaced,

the sensor does not require calibration and the
g00933282 speed-timing wheel does not require adjustment.
Illustration 417
Position of the speed-timing wheel with the number one cylinder at The most likely causes of the diagnostic code are a
the top center position on the compression stroke poor electrical connection or a problem in a wiring
(1) Speed-timing wheel harness. The next likely cause is a problem with the
(2) Engine speed/timing sensor engine speed/timing sensor. The least likely cause
(3) Extra tooth
The engine speed/timing sensor provides
information about engine speed and about the
position of the crankshaft to the Electronic Control
Module (ECM). The sensor monitors the rotation of
a speed-timing wheel. The passive sensor has a
coil around a permanent magnet which generates
voltage as the teeth of the speed-timing wheel pass
through the magnetic field. The speed-timing wheel
is installed on the rear of the camshaft.
resolved.
The engine speed/timing sensor generates a signal
that matches the pattern of the speed-timing
wheel’s teeth. The ECM monitors the speed of the
signal pulses in order to determine the engine rpm.
494
g00899617
Illustration 418
Schematic for the circuit of the engine speed/timing sensor
The ECM is connected to the engine speed/timing sensor via the J6/P6 connectors on the terminal box.

g00933284
Illustration 420
Connectors for the engine speed/timing sensor
g00843978
Illustration 419
(1) ECM J1/P1 connectors B. Thoroughly inspect the ECM J1/P1 connectors,
(2) 16 amp circuit breaker for the ECM the terminal box J6/P6 connectors, and the
(3) J6/P6 connectors for the engine harness connectors for the engine speed/timing sensor.


g00899618
Illustration 421
(P6-47) Shield
(P6-57) − Signal
(P6-70) + Signal
495
g00850524
Illustration 422
Harness side of the ECM P1 connector g00850545
Illustration 423
(P1-32) + Signal Engine speed/timing sensor
(P1-33) − Signal
(P1-51) Shield (1) Terminal for the - signal
(2) Terminal for the + signal
(3) Bracket
a. Perform a 45 N (10 lb) pull test on each of the (4) Integral connector on the sensor
wires that are associated with the circuit for (5) O-ring seal
the engine speed/timing sensor. (6) Sensor
b. Check the torque of the Allen head screw for

box’s P6 connector. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

and for pinch points from the engine
speed/timing sensor to the ECM.
Expected Result:

corrosion, abrasion, or pinch points. g00933286
Illustration 424
Results: (4) Integral connector on the sensor
(7) Cover
• OK – All connectors, pins, and sockets are A. Disconnect the engine harness from connector
wiring do not have corrosion, abrasion, or pinch (4). Remove the bolt from bracket (3) and remove
points. The components are in good condition sensor (6) and the bracket as a unit.
B. Inspect the sensor for damage. Inspect O-ring
seal (5). If the O-ring seal is damaged, obtain a
• Not OK – At least one of the connectors, pins, new O-ring seal for assembly.
and/or pinch points. The components are not in C. Clean the tip of the sensor, the sensor’s mounting
good condition and/or at least one connection flange and the counterbore for the sensor in the
is improper. rear housing.
Repair: Perform the necessary repairs and/or D. Use an ohmmeter to measure the resistance
replace parts, if necessary. between terminals (1) and (2) in connector (4).
STOP.
496
c. Make sure that the connector on the engine

harness is in good condition. Connect the
engine harness to the sensor’s connector.
Make sure that the mating of the connection
is secure.
2. Verify that the condition is resolved.
STOP.
• Not OK – The sensor and/or the speed-timing

wheel’s teeth are damaged.
Repair: Obtain a new sensor and/or a new

g00933287
speed-timing wheel. Perform the following
Illustration 425 procedure:
(8) Speed-timing wheel
1. Install the sensor:
E. Remove cover (7) and inspect speed-timing
wheel (8) for damage. a. Lubricate the sensor’s O-ring seal with
clean engine oil.
Expected Result:
b. Install the sensor into the counterbore in the
The sensor appears to be in good condition. rear housing. Make sure that the sensor is
properly seated and that the bracket is flush
The resistance between terminals (1) and (2) is with the mounting surface. Use the bolt to
between 75 and 230 ohms. secure the bracket to the rear housing.
Note: At a temperature of 25 C (77 F), the c. Make sure that the connector on the engine
resistance is between 110 and 200 ohms. harness is in good condition. Connect the
The speed-timing wheel is in good condition. Make sure that the mating of the connection
is secure.
Results:
2. Install the speed-timing wheel.
• OK – The sensor appears to be in good condition.
The resistance is within the specifications. The a. Install the timing pin into the camshaft
speed-timing wheel is in good condition. There according to the instructions in Systems
may be a problem with a connector and/or with Operation/Testing and Adjusting, “Engine
the wiring in the engine harness. Install the cover. Timing Procedures”.
Reconnect the sensor to the engine harness. Do
not install the sensor yet. Proceed to Test Step 3. b. Orient one of the camshaft drive gear’s
1/2-13 threaded holes to the 12 o’clock
• Not OK – The sensor is damaged and/or the position. The four 1/2-13 threaded holes
sensor’s resistance is not within the specifications. form a diamond pattern.
Repair: Obtain a new sensor. Perform the

a. Lubricate the sensor’s O-ring seal with

clean engine oil.

rear housing. Make sure that the sensor is
with the mounting surface. Use the bolt to
secure the bracket to the rear housing.
497
g00933288 g00899620
Rear view and section view Terminal box’s side of the P6 connector
(1) Spacer (P6-47) Shield
(2) Speed-timing wheel (P6-57) − Signal
(3) Direction of the camshaft’s rotation (P6-70) + Signal
(4) Extra tooth
(5) Bolt
and P6-70 on the terminal box’s side of the
c. Install spacer (1) and speed-timing wheel connector.
(2). Orient extra tooth (4) near the sensor.
Loosely install four bolts (5) in order to C. Wiggle the engine harness as you measure the
enable speed-timing wheel to be moved. resistance in order to check for an intermittent
d. Rotate the speed-timing wheel in the harness near the sensor’s connector.
direction of the camshaft’s rotation (3) until
the first tooth after the extra tooth is aligned Expected Result:
with the centerline of the sensor.
The resistance is between 75 and 230 ohms.
e. Tighten the four bolts.
Note: At a temperature of 25 C (77 F), the
f. Install the cover for the speed-timing wheel. resistance is between 110 and 200 ohms.
3. Verify that the condition is resolved. Results:
STOP.
• OK – The resistance is within the specifications.
The circuit between the P6 connector and the
Test Step 3. Measure the Sensor’s sensor seems to be OK. There may be a problem
Resistance from the Terminal Box P6 with a connection and/or with the wiring in the
Connector terminal box. Reconnect the P6 connector to the
J6 connector on the terminal box. Proceed to Test
A. Disconnect the terminal box P6 connector. Step 4.
• Not OK – The resistance is not within the

specifications. There is a problem with a
connection and/or with the wiring in the engine
connector for the engine speed/timing sensor.
Repair: Repair the connector(s) and/or the wiring,

when possible. Replace the engine harness, if
necessary.
STOP.
Test Step 4. Measure the Sensor’s

Resistance from the ECM P1 Connector
A. Disconnect the ECM P1 connector.
498
Test Step 5. Verify the Engine Operation

A. Install the sensor:
a. Lubricate the sensor’s O-ring seal with clean

engine oil.


g00850802
Illustration 428 engine harness to the sensor’s connector.
ECM side of the P1 connector Make sure that the mating of the connection
(P1-32) + Signal is secure.
(P1-33) - Signal
(P1-51) Shield Note: It is possible that a diagnostic code is
generated for the engine speed/timing sensor
B. Measure the resistance between terminals P1-32 only when the engine runs at normal operating
and P1-33 on the ECM side of the connector. temperature.
C. Wiggle the wiring harness as you measure the B. Start the engine. Run the engine at normal
resistance in order to check for an intermittent operating temperature.
problem with the harness.
Expected Result:
Expected Result:
The engine operates normally.
Results:
resistance is between 110 and 200 ohms. • OK – The engine operates normally. The initial
diagnostic code was probably caused by a
Results: poor electrical connection in one of the harness
connectors. Resume normal operation. STOP.
The sensor, the engine harness, and the wiring • Not OK (No Start-Up) – The engine did not
in the terminal box seem to be OK. However, it operate normally. The engine did not start. A
is possible that there is still a problem with the 190-02 or 190-08 diagnostic code was activated.
sensor. Reconnect the ECM P1 connector to the Proceed to Test Step 6.
ECM J1 connector. Proceed to Test Step 5.
• Not OK (Shutdown After Warm-Up) – The engine
• Not OK – The resistance is not within the was shut down after normal operating temperature
specifications. The resistance through the engine was achieved. A 190-02 or 190-08 diagnostic
harness and through the sensor was OK. When code was activated. Proceed to Test Step 6.
the resistance through the wiring harness in
the terminal box was added, the result was not Test Step 6. Switch the Sensor
correct. There is a problem with a connector or
with the wiring between the P1 connector and A. Make sure that the engine control switch is in the
the J6 connector. OFF/RESET position and that the 16 amp circuit
when possible. Replace the connector(s) and/or B. Remove the original engine speed/timing sensor.
the wiring, if necessary. Install an engine speed/timing sensor that is
known to be good. Use the following procedure:
STOP.
engine oil.
499
b. Install the sensor into the counterbore in the Repair: It is unlikely that the ECM has failed.
rear housing. Make sure that the sensor is Exit this procedure and perform this procedure
properly seated and that the bracket is flush again. If the condition is not resolved, install a
with the mounting surface. Use the bolt to known good ECM according to Troubleshooting,
secure the bracket to the rear housing. “Replacing the ECM”. Verify that the problem is
resolved.
harness is in good condition. Connect the STOP.
i01758517
is secure.

Engine Speed/Timing Sensor
to the ON position. SMCS Code: 1912-038
D. Prepare to use the “Status - Gas Engine Group S/N: BLB1-Up
1” screen of Cat ET for observation of the engine
speed. S/N: BKE1-Up
E. Shut OFF the main fuel supply to the engine. System Operation Description:
F. Observe the status of the engine speed and turn

the engine control switch to the START position.
G. After the engine speed stabilizes at the normal

cranking speed, turn the engine control switch
H. Use the “Diagnostics” screen of Cat ET to check

for active diagnostic codes.
Expected Result:
When the engine control switch was turned to the

START position, the engine speed accelerated from
“0” rpm to an approximate speed of “60” rpm. The
engine speed gradually increased to the normal
cranking speed. When the engine control switch
was turned to the STOP position, the engine speed
returned to “0” rpm when the crankshaft stopped
rotating.
g00850136
Illustration 429
No 190-02 or 190-08 diagnostic code was activated.
Position of the speed-timing wheel with the number one cylinder at
the top center position on the compression stroke
Results:
• OK – The correct engine speed was displayed. (3) Extra tooth
The ECM is receiving a good signal from the
engine speed/timing sensor. No 190-02 or 190-08 The engine speed/timing sensor provides
diagnostic code was activated. Switching the information about engine speed and about the
sensor resolved the problem. Resume normal position of the crankshaft to the Electronic Control
operation. STOP. Module (ECM). The sensor monitors the rotation of
a speed-timing wheel. The passive sensor has a
• Not OK – The correct engine speed was not coil around a permanent magnet which generates
displayed. A 190-02 or 190-08 diagnostic code voltage as the teeth of the speed-timing wheel pass
was activated. The wiring and the sensor are through the magnetic field. The speed-timing wheel
apparently OK. There may be a problem with the is installed on the rear of the right camshaft.
ECM.
The engine speed/timing sensor generates a signal
that matches the pattern of the speed-timing
wheel’s teeth. The ECM monitors the speed of the
signal pulses in order to determine the engine rpm.
500
The speed-timing wheel has a special tooth

pattern that indicates the position of the camshaft.
The speed-timing wheel has 36 teeth that are
evenly spaced and one extra tooth. The number
one cylinder is at the top center position on the
compression stroke when the centerline of the first
tooth after the extra tooth aligns with the centerline
of the sensor. All 37 teeth pass the sensor during
one revolution of the camshaft or two revolutions of
the crankshaft.
With the information from the engine speed/timing

sensor, the ECM is able to calculate the positions of
the pistons in the cylinders. The ECM determines
the desired ignition timing according to the engine
speed and to the load. If detonation is detected in
any of the cylinders, the ECM retards the timing
of the affected cylinders. The ECM sends voltage
pulses to the ignition transformers for firing the
spark plugs according to the desired timing.
If the ECM detects a problem with the engine

speed/timing sensor’s signal, the ECM will shut
down the engine. If there is a problem with the
engine speed/timing sensor’s signal during start-up,
the ECM will not initiate the ignition. The engine will
not start. The corresponding diagnostic code is
generated.
If the engine speed/timing sensor is replaced,

the sensor does not require calibration and the
speed-timing wheel does not require adjustment.

engine speed/timing sensor. The least likely cause


resolved.
501
g00850348
Illustration 430
Schematic for the circuit of the engine speed/timing sensor
The ECM is connected to the engine speed/timing sensor via the J6/P6 connectors on the terminal box.

g00850522
Illustration 432
Connectors for the engine speed/timing sensor
g00843978
Illustration 431
(1) ECM J1/P1 connectors B. Thoroughly inspect the ECM J1/P1 connectors,
(2) 16 amp circuit breaker for the ECM the terminal box J6/P6 connectors, and the
(3) J6/P6 connectors for the left engine harness connectors for the engine speed/timing sensor.


g00850527
Illustration 433
(P6-13) Shield
(P6-23) − Signal
(P6-31) + Signal
502
g00850524
Illustration 434
Harness side of the ECM P1 connector g00850545
Illustration 435
(P1-32) + Signal Engine speed/timing sensor
(P1-33) − Signal
(P1-51) Shield (1) Terminal for the - signal
(2) Terminal for the + signal
(3) Bracket
a. Perform a 45 N (10 lb) pull test on each of the (4) Integral connector on the sensor
wires that are associated with the circuit for (5) O-ring seal
the engine speed/timing sensor. (6) Sensor
b. Check the torque of the Allen head screw for

the ECM P1 connector and the terminal box’s
P6 connector. The proper torque is 6 ± 1 N·m
(55 ± 9 lb in).

and for pinch points from the engine
speed/timing sensor to the ECM.
Expected Result:

corrosion, abrasion, or pinch points. g00862402
Illustration 436
Results: Engine speed/timing sensor
(4) Integral connector on the sensor
• OK – All connectors, pins, and sockets are (7) Cover
wiring do not have corrosion, abrasion, or pinch A. Disconnect the engine harness from connector
points. The components are in good condition (4). Remove the bolt from bracket (3) and remove
with proper connections. Proceed to Test Step 2. sensor (6) and the bracket as a unit.
• Not OK – At least one of the connectors, pins, B. Inspect the sensor for damage. Inspect O-ring
or sockets is not connected properly. At least seal (5). If the O-ring seal is damaged, obtain a
one connector or wire has corrosion, abrasion, new O-ring seal for assembly.
good condition and/or at least one connection C. Clean the tip of the sensor, the sensor’s mounting
is improper. flange and the counterbore for the sensor in the
rear housing.
replace parts, if necessary. D. Use an ohmmeter to measure the resistance
between terminals (1) and (2) in connector (4).
STOP.
503

is secure.
2. Verify that the condition is resolved.
STOP.
• Not OK – The sensor and/or the speed-timing

wheel’s teeth are damaged.
Repair: Obtain a new sensor and/or a new

g00862412
speed-timing wheel. Perform the following
Illustration 437 procedure:
E. Remove cover (7) and inspect speed-timing
wheel (8) for damage. a. Lubricate the sensor’s O-ring seal with
clean engine oil.
Expected Result:
The sensor appears to be in good condition. rear housing. Make sure that the sensor is
The resistance between terminals (1) and (2) is with the mounting surface. Use the bolt to
between 75 and 230 ohms. secure the bracket to the rear housing.
Note: At a temperature of 25 C (77 F), the c. Make sure that the connector on the engine
resistance is between 110 and 200 ohms. harness is in good condition. Connect the
The speed-timing wheel is in good condition. Make sure that the mating of the connection
is secure.
Results:
2. Install the speed-timing wheel.
• OK – The sensor appears to be in good condition.
The resistance is within the specifications. The a. Install the timing pin into the camshaft
speed-timing wheel is in good condition. There according to the instructions in Systems
may be a problem with a connector and/or with Operation/Testing and Adjusting, “Engine
the wiring in the engine harness. Install the cover. Timing Procedures”.
Reconnect the sensor to the engine harness. Do
not install the sensor yet. Proceed to Test Step 3. b. Orient one of the camshaft drive gear’s
1/2-13 threaded holes to the 12 o’clock
• Not OK – The sensor is damaged and/or the position. The four 1/2-13 threaded holes
sensor’s resistance is not within the specifications. form a diamond pattern.
Repair: Obtain a new sensor. Perform the

a. Lubricate the sensor’s O-ring seal with

clean engine oil.

504
g00862461 g00850816
Rear view and section view Terminal box’s side of the P6 connector
(1) Spacer (P6-13) Shield
(2) Speed-timing wheel (P6-23) - Signal
(3) Direction of the camshaft’s rotation (P6-31) + Signal
(4) Extra tooth
(5) Bolt
and P6-31 on the terminal box’s side of the
c. Install spacer (1) and speed-timing wheel connector.
(2). Orient extra tooth (4) near the sensor.
Loosely install four bolts (5) in order to C. Wiggle the engine harness as you measure the
enable speed-timing wheel to be moved. resistance in order to check for an intermittent
d. Rotate the speed-timing wheel in the harness near the sensor’s connector.
direction of the camshaft’s rotation (3) until
the first tooth after the extra tooth is aligned Expected Result:
with the centerline of the sensor.
e. Tighten the four bolts.
f. Install the cover for the speed-timing wheel. resistance is between 110 and 200 ohms.
3. Verify that the condition is resolved. Results:
STOP.
The circuit between the P6 connector and the
Test Step 3. Measure the Sensor’s sensor seems to be OK. There may be a problem
Resistance from the Terminal Box P6 with a connection and/or with the wiring in the
Connector terminal box. Reconnect the P6 connector to the
J6 connector on the terminal box. Proceed to Test
A. Disconnect the terminal box P6 connector. Step 4.
• Not OK – The resistance is not within the

specifications. There is a problem with a
connection and/or with the wiring in the engine
connector for the engine speed/timing sensor.

when possible. Replace the engine harness, if
necessary.
STOP.
505
Test Step 4. Measure the Sensor’s Test Step 5. Verify the Engine Operation
Resistance from the ECM P1 Connector
A. Install the sensor:
A. Disconnect the ECM P1 connector.
engine oil.


is secure.
g00850802
Illustration 440 Note: It is possible that a diagnostic code is
ECM side of the P1 connector generated for the engine speed/timing sensor
(P1-32) + Signal only when the engine runs at normal operating
(P1-33) - Signal temperature.
(P1-51) Shield
B. Start the engine. Run the engine at normal
B. Measure the resistance between terminals P1-32 operating temperature.
and P1-33 on the ECM side of the connector.
Expected Result:
C. Wiggle the wiring harness as you measure the
resistance in order to check for an intermittent The engine operates normally.
Results:
Expected Result:
• OK – The engine operates normally. The initial
The resistance is between 75 and 230 ohms. diagnostic code was probably caused by a
poor electrical connection in one of the harness
Note: At a temperature of 25 C (77 F), the connectors. Resume normal operation. STOP.
resistance is between 110 and 200 ohms.
• Not OK (No Start-Up) – The engine did not
Results: operate normally. The engine did not start. A
190-02 or 190-08 diagnostic code was activated.
• OK – The resistance is within the specifications. Proceed to Test Step 6.
The sensor, the engine harness, and the wiring
in the terminal box seem to be OK. However, it • Not OK (Shutdown After Warm-Up) – The engine
is possible that there is still a problem with the was shut down after normal operating temperature
sensor. Reconnect the ECM P1 connector to the was achieved. A 190-02 or 190-08 diagnostic
ECM J1 connector. Proceed to Test Step 5. code was activated. Proceed to Test Step 6.
• Not OK – The resistance is not within the Test Step 6. Switch the Sensor
specifications. The resistance through the engine
harness and through the sensor was OK. When A. Make sure that the engine control switch is in the
the resistance through the wiring harness in OFF/RESET position and that the 16 amp circuit
the terminal box was added, the result was not breaker for the ECM is OFF.
correct. There is a problem with a connector or
with the wiring between the P1 connector and B. Remove the original engine speed/timing sensor.
the J6 connector. Install an engine speed/timing sensor that is
known to be good. Use the following procedure:
when possible. Replace the connector(s) and/or a. Lubricate the sensor’s O-ring seal with clean
the wiring, if necessary. engine oil.
STOP.
506
b. Install the sensor into the counterbore in the Repair: It is unlikely that the ECM has failed.
rear housing. Make sure that the sensor is Exit this procedure and perform this procedure
properly seated and that the bracket is flush again. If the condition is not resolved, install a
with the mounting surface. Use the bolt to known good ECM according to Troubleshooting,
secure the bracket to the rear housing. “Replacing the ECM”. Verify that the problem is
resolved.
harness is in good condition. Connect the STOP.
i01758529
is secure.

Fuel Actuator Solenoid
to the ON position. SMCS Code: 1901-038
D. Prepare to use the “Status - Gas Engine Group S/N: BEN1-Up
1” screen of Cat ET for observation of the engine
speed. S/N: 4ZS1-Up
E. Shut OFF the main fuel supply to the engine. System Operation Description:
F. Observe the status of the engine speed and turn The Electronic Control Module (ECM) controls the
the engine control switch to the START position. fuel actuator by adjusting current flow through the
actuator’s solenoid.
G. After the engine speed stabilizes at the normal
cranking speed, turn the engine control switch The diagnostic code is probably caused by a
to the STOP position. short circuit in a harness or by a problem with an
electrical connector. The next likely cause is a short
H. Use the “Diagnostics” screen of Cat ET to check circuit inside the actuator solenoid. The least likely
for active diagnostic codes. cause is a problem with the ECM.
Expected Result: Logged diagnostic codes provide a historical

When the engine control switch was turned to the Caterpillar Electronic Technician (Cat ET) to print
START position, the engine speed accelerated from the logged codes to a file.
“0” rpm to an approximate speed of “60” rpm. The
engine speed gradually increased to the normal This troubleshooting procedure may generate
cranking speed. When the engine control switch additional diagnostic codes. Keep your mind on
was turned to the STOP position, the engine speed correcting the cause of the original diagnostic code.
returned to “0” rpm when the crankshaft stopped Clear the diagnostic codes after the problem is
rotating. resolved.
No 190-02 or 190-08 diagnostic code was activated.
Results:
• OK – The correct engine speed was displayed.

The ECM is receiving a good signal from the
engine speed/timing sensor. No 190-02 or 190-08
diagnostic code was activated. Switching the
sensor resolved the problem. Resume normal
operation. STOP.
• Not OK – The correct engine speed was not

displayed. A 190-02 or 190-08 diagnostic code
was activated. The wiring and the sensor are
apparently OK. There may be a problem with the
ECM.
507
g00899690
Illustration 441
Schematic of the circuit for the fuel actuator
The ECM is connected to the fuel actuator via the J6/P6 connectors on the terminal box.

g00849316
Illustration 443
(P2-6) Fuel actuator’s circuit driver
(P2-7) Return
g00850164
Illustration 442

the ECM to the OFF position. Illustration 444 g00899692

Troubleshooting, “Inspecting Electrical Connectors”. (P6-68) Fuel actuator’s circuit driver
(P6-55) Return
508
Results:

proper connections. If you are troubleshooting an
1844-05 diagnostic code, proceed to Test Step 2.
If you are troubleshooting an 1844-06 diagnostic
code, proceed to Test Step 8.

is improper.

Illustration 445 g00899691 STOP.

Fuel actuator
(AA) Solenoid’s connector
(A) Fuel actuator’s circuit driver
(B) Return
B. Thoroughly inspect each of the following position. Switch the 16 amp circuit breaker for
connectors: the ECM OFF.
• ECM J2/P2 connectors B. Disconnect the P2 connector from the ECM.

• Connectors for the fuel actuator
The proper torque is 6 N·m (53 lb in).
b. Perform a 45 N (10 lb) pull test on the wires

that are associated with the circuit for the fuel
actuator.
c. Thoroughly inspect the connectors for the fuel

actuator for moisture and for corrosion. Check g00849558
Illustration 446
the harness and wiring for abrasion and for
pinch points from the fuel actuator to the ECM. ECM side of connector P2
Expected Result: (P2-7) Return
All connectors, pins, and sockets are connected C. Measure the resistance between P2-6 and P2-7.
properly. The connectors and the wiring do not have During this measurement, wiggle the harnesses
corrosion, abrasion, or pinch points. in order to check for an intermittent problem.
Be sure to wiggle the harnesses near the
connectors.
Expected Result:

509
Results: • Not OK – The resistance is less than 20,000

ohms. There is a problem with the return wire for
• OK – The resistance is between 5.0 and 20.6 the fuel actuator. Proceed to Test Step 4.
The return wire may have a short to ground or the Test Step 4. Check the Return Wiring in
ECM may have a problem. Proceed to Test Step 3. the Engine Harness for a Short to Ground
• Not OK – The resistance is higher than 20.6 A. Disconnect connector P6 from the terminal box.
the wiring for the solenoid or the solenoid may
have a problem. Proceed to Test Step 6.

the ECM.
g00899694
Illustration 448
(P6-55) Return

this measurement, wiggle the harness in order
harness. Be sure to wiggle the harness near the
connector.
Expected Result:

g00868352
Illustration 447
Results:
(1) Ground strap for the ECM • OK – The resistance is greater than 20,000
(P2-7) Return
appears to be OK. There is a problem with the
B. Measure the resistance between the ground return wire inside the terminal box.
this measurement, wiggle the harnesses in Repair: Repair the wiring and/or the connector
order to check for an intermittent problem. Be in the terminal box, when possible. Replace the
sure to wiggle the harnesses near each of the parts, if necessary.
connectors.
STOP.
Expected Result:

ohms. There is a problem with the return wire
inside the engine harness or there may be a
Results: problem with the solenoid. Proceed to Test Step 5.
The return wire for the fuel actuator appears to be
OK. Proceed to Test Step 12.
510
Test Step 5. Check the Solenoid for an Test Step 6. Check the Engine Harness
Internal Short Circuit and the Solenoid for an Open Circuit
g00899694
Illustration 450
(P6-55) Return
A. Disconnect the engine harness P6 connector

g00899691 from the terminal box.
Illustration 449
Fuel actuator
(AA) Solenoid’s connector
(A) Fuel actuator’s circuit driver and P6-68. During this measurement, wiggle the
(B) Return harness in order to check for an intermittent
A. Disconnect the connector from the fuel actuator’s connectors.
solenoid.
Expected Result:
B. Measure the resistance between terminal (B) and
the connector’s shell. The resistance is between 5.0 and 20.6 ohms.
The resistance is greater than 20,000 ohms. • OK – The resistance is between 5.0 and 20.6
Results: appear to be OK. The wiring inside the terminal
• OK – The resistance is greater than 20,000 ohms. a problem.
circuit. The return wire inside the engine harness Repair: Repair the wiring and/or connectors,
has a short to ground. when possible. Replace the wiring, if necessary.
Repair: Repair the engine harness or connectors, STOP.

STOP. ohms. There is a problem with the engine harness
or with the solenoid. Proceed to Test Step 7.
Repair: Replace the solenoid. Refer to Operation

STOP.
511
Test Step 7. Check the Solenoid for an Test Step 8. Check all of the Wiring and
Open Circuit the Solenoid for a Short Circuit
g00849558
Illustration 452
(P2-7) Return

g00899691
Illustration 451
Fuel actuator and P2-6. During this measurement, wiggle the
(AA) Solenoid’s connector harnesses in order to check for an intermittent
(A) Fuel actuator’s circuit driver problem. Be sure to wiggle the harnesses near
(B) Return
A. Disconnect the connector from the fuel actuator’s Expected Result:
solenoid.
B. Measure the resistance between terminals A and
B on the solenoid’s connector. Results:
Expected Result:
ohms. The solenoid and wiring do not have a
The resistance is between 5.0 and 10.3 ohms. short circuit. Proceed to Test Step 11.
Results:
There is a problem with a connector and/or the
• OK – The resistance of the solenoid is between wiring or the solenoid has a problem. Proceed
5.0 and 10.3 ohms. The solenoid does not have to Test Step 9.
an open circuit. There is an open circuit in the
engine harness.

STOP.


STOP.
512
g00899694
Illustration 453
(P6-55) Return

box. Illustration 454 g00899691
Fuel actuator
and P6-68. During this measurement, wiggle the (AA) Solenoid’s connector
(A) Fuel actuator’s circuit driver
harness in order to check for an intermittent (B) Return
connectors. A. Disconnect the connector from the fuel actuator’s
solenoid.
Expected Result:
The resistance is between 5.0 and 20.6 ohms. B on the solenoid’s connector.
Results: Expected Result:
• OK – The resistance is between 5.0 and 20.6 The resistance is between 5.0 and 10.3 ohms.
appear to be OK. The wiring inside the terminal Results:
box has a problem.
Repair: Repair the wiring and/or the connectors,

5.0 and 10.3 ohms. The solenoid does not have
when possible. Replace the harness, if necessary. a problem. The engine harness appears to have
a short circuit.
STOP.
• Not OK – The resistance is lower than 5.0 ohms. when possible. Replace the harness, if necessary.
There is a problem with the engine harness or
with the solenoid. Proceed to Test Step 10. STOP.


STOP.
513
Test Step 11. Create an Open Circuit and Turn the engine control switch to the OFF position.
Check the Operation of the ECM Switch the 16 amp circuit breaker for the ECM
OFF.
that the gas supply to the engine is OFF. Reinstall the terminals that were removed from
B. Verify that the engine control switch is in the proper installation of the terminals.
circuit breaker for the ECM is OFF. Reconnect all of the connectors. Verify that the
STOP.



g00849316
Illustration 455
Harness side of the ECM P2 connector If the problem is resolved with a new ECM, install
(P2-6) Fuel actuator’s circuit driver the original ECM and verify that the problem
(P2-7) Return returns. If the new ECM operates correctly and
C. Use a 151-6320 Wire Removal Tool to remove replace the original ECM. Follow the instructions
terminals P2-6 and P2-7. This will replace the in Troubleshooting, “Replacing the ECM”.
wiring for the fuel actuator with an open circuit.
STOP.
ON. Test Step 12. Create a Short Circuit and
E. If an 1844-05 and/or 1844-06 diagnostic code is
logged, clear the code. A. Prevent fuel from entering the engine. Verify
that the gas supply to the engine is OFF.
position and crank the engine. Allow a minimum B. Verify that the engine control switch is in the
of 30 seconds for the generation of any codes. OFF/RESET position. Verify that the 16 amp
Then turn the engine control switch to the STOP circuit breaker for the ECM is OFF.
position.

ET. Look for an 1844-05 diagnostic code.
Expected Result:
An 1844-05 diagnostic code is generated.
Results:
• OK – When an open circuit was created, an

1844-05 diagnostic code was generated. The
to be resolved. The initial diagnostic code was g00849316
probably caused by a poor electrical connection. Illustration 456
Repair: Perform the following procedure: (P2-6) Fuel actuator’s circuit driver
(P2-7) Return
514
C. Use a 151-6320 Wire Removal Tool to remove Repair: It is unlikely that the ECM has failed.
terminals P2-6 and P2-7. Exit this procedure and perform this procedure
D. Fabricate a jumper wire of the appropriate length following procedure:
with the appropriate connectors. Install the ends
of the jumper wire into the open terminals P2-6 Temporarily install a new ECM. Refer to
and P2-7. Verify that the sockets are contacting Troubleshooting, “Replacing the ECM”.
the pins. This will replace the wiring for the fuel
actuator with a short circuit. If the problem is resolved with a new ECM, install
the original ECM and verify that the problem
E. Switch the 16 amp circuit breaker for the ECM returns. If the new ECM operates correctly and
ON. the original ECM does not operate correctly,
F. If an 1844-05 and/or 1844-06 diagnostic code is in Troubleshooting, “Replacing the ECM”.
logged, clear the code.
STOP.
i01758844
position.
Fuel Actuator Solenoid
SMCS Code: 1901-038
ET. Look for a 1844-06 diagnostic code. S/N: BLB1-Up
Expected Result: S/N: BKE1-Up
An 1844-06 diagnostic code is generated. System Operation Description:
Results: The Electronic Control Module (ECM) controls the

fuel actuator by adjusting current flow through the
• OK – When the wiring for the fuel actuator actuator’s solenoid.
was replaced with a short circuit, an 1844-06
diagnostic code was generated by the ECM. The The diagnostic code is probably caused by a
ECM is operating correctly. The problem appears short circuit in a harness or by a problem with an
to be resolved. The initial diagnostic code was electrical connector. The next likely cause is a short
probably caused by a poor electrical connection. circuit inside the actuator solenoid. The least likely
cause is a problem with the ECM.
Turn the engine control switch to the OFF position. record. Before you begin this procedure, use the
Switch the 16 amp circuit breaker for the ECM Caterpillar Electronic Technician (Cat ET) to print
OFF. the logged codes to a file.
Remove the jumper wire from the P2 connector. This troubleshooting procedure may generate
Reinstall the terminals that were removed from correcting the cause of the original diagnostic code.
connector P2. Pull on the wires in order to verify Clear the diagnostic codes after the problem is
proper installation of the terminals. resolved.

STOP.
• Not OK – When the wiring for the fuel actuator is

replaced with a short circuit, a 1844-06 diagnostic
code is not generated by the ECM. The ECM
may have a problem.
515
g00899915
Illustration 457
Schematic of the circuit for the fuel actuator
The ECM is connected to the fuel actuator via the J5/P5 connectors on the terminal box.

g00849316
Illustration 459
(P2-7) Return
g00849037
Illustration 458
(2) J5/P5 connectors for the harness from the right side of the
engine

position. Switch the 16 amp circuit breaker for g00849319
Illustration 460
Note: For the following steps, refer to (P5-57) Return
Troubleshooting, “Inspecting Electrical Connectors”. (P5-70) Fuel actuator’s circuit driver
516
Results:

wiring do not have corrosion, abrasion, or
pinch points. The components are in good
condition with proper connections. If you are
troubleshooting a 23-05 diagnostic code, proceed
to Test Step 2. If you are troubleshooting a 23-06
diagnostic code, proceed to Test Step 8.

is improper.

STOP.

g00849064
Fuel actuator
(4) Fuel actuator B. Disconnect connector P2 from the ECM.
(5) Solenoid’s connector

connectors:

• (J5/P5) connectors on the terminal box
• Connectors for the fuel actuator
the ECM connector and the P5 connector. The
proper torque is 6 N·m (53 lb in).
g00849558
b. Perform a 45 N (10 lb) pull test on the wires Illustration 462
that are associated with the circuit for the fuel ECM side of connector P2
actuator. (P2-6) Fuel actuator’s circuit driver
(P2-7) Return
c. Thoroughly inspect the connectors for the fuel
actuator for moisture and for corrosion. Check C. Measure the resistance between P2-6 and P2-7.
the harness and wiring for abrasion and for During this measurement, wiggle the harnesses
pinch points from the fuel actuator to the ECM. in order to check for an intermittent problem.
Be sure to wiggle the harnesses near the
Expected Result: connectors.
All connectors, pins, and sockets are connected Expected Result:

corrosion, abrasion, or pinch points. The resistance is between 5.0 and 20.6 ohms.
517

• OK – The resistance is between 5.0 and 20.6 the fuel actuator. Proceed to Test Step 4.
The return wire may have a short to ground or the Test Step 4. Check the Return Wiring
ECM may have a problem. Proceed to Test Step 3. inside the Engine Harness for a Short to
Ground
• Not OK – The resistance is higher than 20.6
ohms. There is a problem with a connector and/or A. Disconnect connector P5 from the terminal box.

A. Verify that harness connector P2 is disconnected
from the ECM.
g00868364
Illustration 464
(1) Ground Strap for the ECM
(P5-57) Return

g00868352
this measurement, wiggle the harnesses in
Illustration 463 order to check for an intermittent problem. Be
ECM side of connector P2 sure to wiggle the harnesses near each of the
(1) Ground strap for the ECM connectors.
(P2-7) Return
Expected Result:
strap for the ECM and terminal P2-7. During The resistance is greater than 20,000 ohms.
this measurement, wiggle the harnesses in
order to check for an intermittent problem. Be Results:
sure to wiggle the harnesses near each of the
connectors. • OK – The resistance is greater than 20,000
Expected Result: appears to be OK. There is a problem with the
Repair: Repair the wiring and/or the connector
Results: in the terminal box, when possible. Replace the
The return wire for the fuel actuator appears to be STOP.
OK. Proceed to Test Step 12.
518
• Not OK – The resistance is less than 20,000 Repair: Repair the engine harness or connectors,
ohms. There is a problem with the return wire when possible. Replace the harness, if necessary.
inside the engine harness or there may be a
problem with the solenoid. Proceed to Test Step 5. STOP.
Test Step 5. Check the Solenoid for an • Not OK – The resistance is less than 20,000
Internal Short Circuit ohms. The solenoid has an internal short circuit.

STOP.

g00852133
Illustration 466
(P5-57) Return
g00868369
Illustration 465
(1) Solenoid for the fuel actuator A. Disconnect connector P5 from the terminal box.
(2) Solenoid connector
(B) Return
(Shell) Shell for the connector
B. Measure the resistance between P5 terminal (57)
and terminal (70). During this measurement,
A. Disconnect the connector from the fuel actuator’s wiggle the harnesses in order to check for an
solenoid. intermittent problem. Be sure to wiggle the
B. Measure the resistance between terminal (B) and
the connector’s shell. Expected Result:
Expected Result: The resistance is between 5.0 and 20.6 ohms.
The resistance is greater than 20,000 ohms. Results:

• OK – The resistance is greater than 20,000 ohms. box or the terminal box’s connectors may have
circuit. The return wire inside the engine harness a problem.
has a short to ground.
Repair: Repair the wiring and/or connectors,
STOP.
519
• Not OK – The resistance is greater than 20.6 • Not OK – The resistance of the solenoid is higher
ohms. There is a problem with the engine harness than 10.3 ohms. The resistance of the solenoid is
or with the solenoid. Proceed to Test Step 7. incorrect. The solenoid has an open circuit.
STOP.

g00849558
Illustration 468
(P2-7) Return

g00849459 B. Measure the resistance between terminals P2-6
Illustration 467
(1) Solenoid on the fuel actuator and P2-7. During this measurement, wiggle the
(B) Return harnesses in order to check for an intermittent
(A) Fuel actuator’s circuit driver problem. Be sure to wiggle the harnesses near
A. Disconnect the connector from the fuel actuator’s
solenoid. Expected Result:
B. Measure the resistance between terminals A and The resistance is between 5.0 and 20.6 ohms.
B on the solenoid’s connector.
Results:
Expected Result:
Results:
engine harness.

STOP.
520
g00852133
Illustration 469
(P5-57) Return

box.

and terminal P5-70. During this measurement,
wiggle the harness in order to check for an
intermittent problem. Be sure to wiggle the
harness near the connectors.
g00849459
Illustration 470
Expected Result: (1) Solenoid on the fuel actuator
(2) J525 connector on the solenoid
The resistance is between 5.0 and 20.6 ohms. (J525-B) Return
(J525-A) Fuel actuator’s circuit driver
Results:
A. Disconnect the connector from the fuel actuator’s
solenoid.
appear to be OK. The wiring inside the terminal B. Measure the resistance between terminals A and
box has a problem. B on the solenoid’s connector.
Repair: Repair the wiring and/or the connector, Expected Result:

STOP.
Results:
• Not OK – The resistance is lower than 5.0 ohms.
There is a problem with the engine harness or • OK – The resistance of the solenoid is between
with the solenoid. Proceed to Test Step 10. 5.0 and 10.3 ohms. The solenoid does not have
a problem. The engine harness appears to have
a short circuit.

STOP.

521

Actuator - Recondition”. • OK – When an open circuit was created, an
1844-05 diagnostic code was generated. The
STOP. ECM is operating correctly. The problem appears

STOP.


g00849316
(P2-6) Fuel actuator’s circuit driver Temporarily install a new ECM. Refer to
wiring for the fuel actuator with an open circuit. returns. If the new ECM operates correctly and
D. Switch the 16 amp circuit breaker for the ECM replace the original ECM. Follow the instructions
ON. in Troubleshooting, “Replacing the ECM”.
E. If an 1844-05 and/or 1844-06 diagnostic code is STOP.

Test Step 12. Create a Short Circuit and
F. Turn the engine control switch to the START Check the Operation of the ECM
of 30 seconds for the generation of any codes. A. Prevent fuel from entering the engine. Verify
Then turn the engine control switch to the STOP that the gas supply to the engine is OFF.
position.
B. Verify that the engine control switch is in the
G. Observe the “Active Diagnostic” screen on Cat OFF/RESET position. Verify that the 16 amp
ET. Look for a 1844-05 diagnostic code. circuit breaker for the ECM is OFF.
Expected Result:

522

OFF.


STOP.
g00849316
Illustration 472
• Not OK – When the wiring for the fuel actuator is
Harness side of the ECM P2 connector replaced with a short circuit, a 1844-06 diagnostic
(P2-6) Fuel actuator’s circuit driver code is not generated by the ECM. The ECM
(P2-7) Return may have a problem.
C. Use a 151-6320 Wire Removal Tool to remove Repair: It is unlikely that the ECM has failed.
terminals P2-6 and P2-7. Exit this procedure and perform this procedure
D. Fabricate a jumper wire of the appropriate length following procedure:
with the appropriate connectors. Install the ends
of the jumper wire into the open terminals P2-6 Temporarily install a new ECM. Refer to
and P2-7. Verify that the sockets are contacting Troubleshooting, “Replacing the ECM”.
the pins. This will replace the wiring for the fuel
actuator with a short circuit. If the problem is resolved with a new ECM, install
E. Switch the 16 amp circuit breaker for the ECM returns. If the new ECM operates correctly and
ON. the original ECM does not operate correctly,
F. If an 1844-05 and/or 1844-06 diagnostic code is in Troubleshooting, “Replacing the ECM”.
STOP.
of 30 seconds for the generation of any codes. i01758921
position.
Ignition Transformers Primary
Circuit
ET. Look for a 1844-06 diagnostic code. SMCS Code: 1561-038
Expected Result: S/N: BEN1-Up

S/N: 4ZS1-Up
Results:
The Electronic Control Module (ECM) has internal
• OK – When the wiring for the fuel actuator circuit drivers for the transformers. The circuit
was replaced with a short circuit, an 1844-06
drivers send a signal of +108 volts to the high
diagnostic code was generated by the ECM. The
side of the ignition transformers’ primary circuits.
The transformers deliver high voltage (8000 to
37,000 volts) to the spark plugs. The ignition wiring
is continuous from the ECM P2 connector to the
connectors for the transformers. The ignition wiring
is routed through a rail on the side of the engine.
523
A single problem with a primary circuit will generate Table 67

one diagnostic code or multiple codes. 6 Cylinder Engine
Diagnostic Conditions and the Combinations
Circuit Driver’s Side of Cylinders that are Affected
Internally, the ECM has an individual circuit driver Condition Cylinders

for each transformer. These circuits are wired Circuit driver’s side open Only one cylinder is
individually from the ECM J2/P2 connectors to each affected.
transformer. If any cylinder’s circuit driver’s side has Circuit driver’s side
a problem, only that cylinder is affected. Short to +Battery
Circuit driver’s side
Return Side Short to ground
The current for the return to ground is limited to a Return side open
single transformer. This means that a return short Return side short to ground
circuit to the −Battery side or an open circuit will
affect only one cylinder. Return side 1, 2, and 3
Short to +Battery
4, 5, and 6
The ECM has internal returns for the transformers.
These returns consist of groups of terminals that are
Table 68
connected via diodes inside the ECM. This means
that a return short circuit to the +Battery side will 8 Cylinder Engine
simultaneously affect all of the cylinders that are Diagnostic Conditions and the Combinations
grouped. of Cylinders that are Affected
Condition Cylinders
Recommendation
Circuit driver’s side open Only one cylinder is
If multiple diagnostic codes are active for the affected.
primary ignition, troubleshoot the affected circuits Short to +Battery
one at a time in order to find the root cause.
For the combinations of cylinders that can be Short to ground
affected in 6 cylinder engines, refer to Table 67. Return side open
Illustration 473 is a schematic that includes the
internal circuitry for a 6 cylinder engine’s ECM. Return side short to ground
Return side 1, 2, 7, and 8
For the combinations of cylinders that can be Short to +Battery
affected in 8 cylinder engines, refer to Table 68. 3, 4, 5, and 6
internal circuitry for an 8 cylinder engine’s ECM.


an ignition transformer. The least likely cause is a
524
g00900158
Illustration 473
Schematic of a 6 cylinder engine’s ignition system
525
g00900159
Illustration 474
Schematic of an 8 cylinder engine’s ignition system
B. Thoroughly inspect the ECM J2/P2 connectors.

the ECM P2 connector. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

of the ignition system.
The terminals for G3606 Engines are identified

in Illustration 476.

g00861708
Illustration 475 in Illustration 477.
(1) ECM P2 connector

the ECM OFF.
526
g00900410 g00861683
Harness side of the ECM P2 connector (G3606 Engine) (3) Typical connectors for ignition transformers
(4) Rail
(P2-1) Number 1 transformer’s circuit driver
(P2-2) Number 1 transformer’s return
(P2-24) Number 2 transformer’s circuit driver c. Check the ignition harness and wiring for
(P2-25) Number 2 transformer’s return abrasion and for pinch points from the
transformer’s connector to the rail and check
(P2-26) Number 4 transformer’s circuit driver from the rail to the ECM.
(P2-3) Number 5 transformer’s circuit driver Expected Result:
(P2-17) Number 6 transformer’s return All connectors, pins, and sockets are connected
Results:


Illustration 477 g00900411 good condition and/or at least one connection
Harness side of the ECM P2 connector (G3608 Engine)
is improper.
(P2-14) Number 2 transformer’s circuit driver replace parts, if necessary. Ensure that all of the
(P2-15) Number 2 transformer’s return seals are properly installed. Make sure that the
(P2-26) Number 3 transformer’s circuit driver connections are properly fastened. Verify that the
(P2-27) Number 3 transformer’s return repair has eliminated the problem.
(P2-16) Number 5 transformer’s circuit driver If the condition is not resolved, proceed to Test
(P2-17) Number 5 transformer’s return Step 2.
(P2-33) Number 7 transformer’s return for the Primary Circuit
(P2-25) Number 8 transformer’s return A. Connect Cat ET to the service tool connector
breaker for the ECM ON.
527
B. Attempt to start the engine and use Cat ET to Test Step 3. Check the Primary Circuit
determine if the following codes are active or and the Secondary Circuit
logged:
• 301-05 Ignition Transformer Primary #1 open

circuit through 316-05 Ignition Transformer
Primary #16 open circuit
• 301-06 Ignition Transformer Primary #1 short

through 316-06 Ignition Transformer Primary
#16 short
Note: If a diagnostic code for the primary circuit is

logged but not currently active, attempt to repeat
the condition that generated the code. Run the
engine to full operating temperature.
Expected Result:
Results:
• No (Active “open circuit”) – There is an open

primary circuit. Proceed to Test Step 3.
• No (Active “short”) – There is a short primary

• Yes (Logged only) – None of the above diagnostic

codes are active. The original diagnostic code g00900790
Illustration 479
was probably caused by a poor electrical Schematic for the primary circuit and for the secondary circuit
connection. There may be an intermittent problem
with the ignition wiring.
Repair: Make sure that the connectors and

the wiring are in good condition. Inspect the There is a strong electrical shock hazard when the
connectors for damage and/or for corrosion. crankshaft is rotating.
Make sure that the connections are secure.
Refer to Troubleshooting, “Inspecting Electrical Do not touch the wires that are associated with
Connectors”. the ignition system when the engine is cranking
or when the engine is running.
STOP.
the ECM OFF.
B. Disconnect the transformer. Visually inspect

the connectors for dirt, for moisture, and for
corrosion. Make sure that the pins and sockets
are not loose.
C. Remove the transformer.

528
g00861770 g00863850
Section view of an ignition transformer and front view of the Resistance versus temperature
transformer’s connector
(Y) Resistance in ohms
(1) Mounting flange (X) Temperature in degrees Celsius (degrees Fahrenheit)
(2) Terminal for the spark plug’s extension
(A) Transformer’s circuit driver c. Measure the resistance of the secondary
(B) Transformer’s return
(C) Unused circuit. Set the multimeter to the 40,000
ohm scale. Measure the resistance between
D. Use a multimeter to check the primary circuit mounting flange (1) and terminal (2) for the
and the secondary circuits. spark plug’s extension.
Expected Result:
For the primary circuit, one of the voltage

g00754013 measurements is approximately 0.450 VDC. The
Illustration 481
other voltage measurement is an open circuit.
Symbol for a diode
For the secondary circuit, the resistance between
a. Measure the primary circuit by checking the mounting flange and the terminal for the spark
the voltage of the blocking diode. Set the plug’s extension is within the acceptable tolerance.
multimeter to the diode scale. Connect the
multimeter leads to the terminals (A) and (B) Results:
of the transformer’s connector. The polarity
of the leads is not important. Measure the • Not OK – At least one of the measurements is
voltage between the terminals. Record the incorrect. There is a problem with the transformer.
measurement.
Repair: Replace the transformer.
b. Reverse the polarity of the probe and measure
the voltage between terminals (A) and (B) STOP.
again. Record the measurement.
• OK – Both of the measurements are correct.
Note: The resistance of the secondary coil will vary
with the temperature. Illustration 482 demonstrates Repair: Perform the following steps:
the relationship between the secondary coil’s
resistance and the temperature. A reading that is 1. Switch the suspect transformer with a
within ± 1000 ohms is acceptable. For example, if transformer from a different cylinder that is
the transformer’s temperature is 60 C (140 F), the known to be good. Install the transformers.
correct resistance is 22,000 ± 1000 ohms.
2. Reset the control system. Clear any logged
codes.
3. Restart the engine. Operate the engine. Check

for a recurrence of the problem.
If the problem stays with the suspect transformer,

replace the transformer.
529
If the problem stays with the suspect cylinder, D. Use a 151-6320 Wire Removal Tool to remove
continue to troubleshoot the problem according the suspect circuit driver and return terminals
to the type of original diagnostic code. from the ECM P2 connector. Label the wires.
If the original diagnostic code is a “05 open The terminals for G3606 Engines are identified
circuit”, proceed to Test Step 4. If the original in Illustration 485.
diagnostic code is a “06 short”, proceed to Test
Step 5. The terminals for G3608 Engines are identified
Test Step 4. Check the Ignition Harness
for an Open Circuit
the ECM OFF.
g00900410
Illustration 485
g00861936 (P2-14) Number 3 transformer’s circuit driver
Illustration 483
Typical harness connectors for the transformers (P2-26) Number 4 transformer’s circuit driver
B. Disconnect the suspect ignition harness from (P2-3) Number 5 transformer’s circuit driver
the transformer. Inspect the connectors of the (P2-16) Number 6 transformer’s circuit driver
harness and of the transformer for damage (P2-17) Number 6 transformer’s return
and/or for corrosion.
g00861968
Illustration 484
Ignition harness’ connector for the transformer
(A) Transformer’s circuit driver
(C) Unused

connectors onto terminals (A) and (B) of the
suspect ignition harness’ connector for the
transformer.
530
Repair: The problem is caused by a poor

electrical connection and/or a broken wire in the
ignition harness. Repair the connection and/or
the wiring, when possible. Replace the ignition
harness, if necessary.
STOP.

for a Short Circuit
the ECM OFF.
g00900411
Illustration 486
(P2-24) Number 8 transformer’s circuit driver g00861936
Illustration 487
Typical harness connectors for the transformers
E. Use an ohmmeter to measure the resistance of
the suspect terminals that were removed from B. Disconnect the suspect ignition harness from
the ECM P2 connector. the transformer. Inspect the connectors of the
harness and of the transformer for damage
Expected Result: and/or for corrosion.
The resistance is less than 5 ohms. C. Use a 151-6320 Wire Removal Tool to remove
the suspect circuit driver and return terminals
Results: from the ECM P2 connector. Label the wires.
• Yes – The resistance is less than 5 ohms. The The terminals for G3606 Engines are identified
ignition harness is OK. There may be a problem in Illustration 488.
with the ECM.
Repair: It is unlikely that the ECM has failed. Exit in Illustration 489.
this procedure and perform this procedure again.
If the problem is not resolved, replace the ECM
STOP.

There is a problem in the ignition harness.
531
Expected Result:
Results:

ohms. The ignition harness is OK. There may be
a problem with the ECM.
Repair: It is unlikely that the ECM has failed. Exit

g00900410
Illustration 488
Harness side of the ECM P2 connector (G3606 Engine) STOP.
(P2-2) Number 1 transformer’s return • No – The resistance is less than 20,000 ohms.
(P2-24) Number 2 transformer’s circuit driver There is a problem in the ignition harness.
(P2-15) Number 3 transformer’s return Repair: There is a poor electrical connection
(P2-26) Number 4 transformer’s circuit driver and/or a wiring problem in the ignition harness.
(P2-27) Number 4 transformer’s return Repair the connection and/or the wiring, when
possible. Replace the ignition harness, if
(P2-16) Number 6 transformer’s circuit driver necessary.
STOP.
i01758978
Ignition Transformers Primary

Circuit
SMCS Code: 1561-038
S/N: BLB1-Up
S/N: BKE1-Up

g00900411
Illustration 489
The Electronic Control Module (ECM) has internal
Harness side of the ECM P2 connector (G3608 Engine) circuit drivers for the transformers. The circuit
(P2-1) Number 1 transformer’s circuit driver drivers send a signal of +108 volts to the high
(P2-2) Number 1 transformer’s return side of the ignition transformers’ primary circuits.
The transformers deliver high voltage (8000 to
(P2-26) Number 3 transformer’s circuit driver 37,000 volts) to the spark plugs. The ignition wiring
(P2-27) Number 3 transformer’s return is continuous from the ECM P2 connector to the
(P2-34) Number 4 transformer’s circuit driver connectors for the transformers. The ignition wiring
(P2-35) Number 4 transformer’s return for each bank of cylinders is routed through a rail
(P2-17) Number 5 transformer’s return on each side of the engine.
(P2-4) Number 6 transformer’s return A single problem with a primary circuit will generate
(P2-32) Number 7 transformer’s circuit driver one diagnostic code or multiple codes.
(P2-25) Number 8 transformer’s return Circuit Driver’s Side
D. Use an ohmmeter to measure the resistance of If any cylinder’s circuit driver’s side has an open
the suspect terminals that were removed from circuit, only that cylinder is affected.
the ECM P2 connector.
532
The pairs of cylinders that are opposite by 360 Table 69

degrees in the firing order reach Top Center 12 Cylinder Engine
simultaneously. These pairs of cylinders share the Diagnostic Conditions and the Combinations
same circuit driver inside the ECM. This means that of Cylinders that are Affected
a short circuit for any cylinder’s circuit driver’s side
will cause a short circuit for the cylinder that is Condition Cylinders
opposite by 360 degrees in the firing order. Circuit driver’s side open Only one cylinder is
affected.
Return Side Return side open
Return side short to ground
The current for the return to ground is limited to a
single transformer. This means that a return short Circuit driver’s side 1 and 11
circuit to the −Battery side will affect only one Short to +Battery
2 and 12
cylinder. Short to ground
3 and 9
The ECM has internal returns for the transformers. 4 and 10
These returns consist of groups of terminals that are
connected via diodes inside the ECM. This means 5 and 7
that a return short circuit to the +Battery side will 6 and 8
simultaneously affect all of the cylinders that are
grouped. Return side 1, 5, and 9
Short to +Battery
2, 6, and 10
Recommendation
3, 7, and 11
If multiple diagnostic codes are active for the
4, 8, and 12
primary ignition, troubleshoot the affected circuits
one at a time in order to find the root cause.
Table 70
For the combinations of cylinders that can be 16 Cylinder Engine
affected in 12 cylinder engines, refer to Table 69. Diagnostic Conditions and the Combinations
Illustration 490 is a schematic that includes the of Cylinders that are Affected
internal circuitry for a 12 cylinder engine’s ECM.
Condition Cylinders
For the combinations of cylinders that can be Circuit driver’s side open Only one cylinder is
affected in 16 cylinder engines, refer to Table 70. affected.
Return side open
internal circuitry for a 16 cylinder engine’s ECM. Return side short to ground
Logged diagnostic codes provide a historical Circuit driver’s side 1 and 15

Short to +Battery
record. Before you begin this procedure, use the Short to ground 2 and 16
the logged codes to a file. 3 and 13
4 and 14
poor electrical connection or a problem in a wiring 5 and 11
harness. The next likely cause is a problem with 6 and 12
an ignition transformer. The least likely cause is a
problem with the ECM. 7 and 9
8 and 10
Return side 1, 3, 5, and 9
Short to +Battery
2, 4, 6, and 10
7, 11, 13, and 15
8, 12, 14, and 16
533
g00900549
Illustration 490
534
g00900552
Illustration 491
535

g00861911
Illustration 493
Terminals for the ignition wiring on the harness side of the ECM
Illustration 492 g00861708 P2 connector (G3612 Engine)
(1) ECM P2 connector (P2-1) Number 1 transformer’s circuit driver

(2) 16 amp circuit breaker (P2-2) Number 1 transformer’s return
A. Turn the engine control switch to the OFF/RESET (P2-48) Number 3 transformer’s circuit driver
position. Switch the 16 amp circuit breaker for (P2-49) Number 3 transformer’s return
the ECM OFF. (P2-16) Number 4 transformer’s circuit driver
Note: For the following steps, refer to (P2-25) Number 5 transformer’s return
Troubleshooting, “Inspecting Electrical Connectors”. (P2-60) Number 6 transformer’s circuit driver
B. Thoroughly inspect the ECM J2/P2 connectors. (P2-58) Number 7 transformer’s circuit driver
a. Check the torque of the Allen head screw for (P2-27) Number 8 transformer’s return
the ECM P2 connector. The proper torque is (P2-14) Number 9 transformer’s circuit driver
6 ± 1 N·m (55 ± 9 lb in). (P2-15) Number 9 transformer’s return
b. Perform a 45 N (10 lb) pull test on each of (P2-40) Number 11 transformer’s circuit driver
the wires that are associated with the circuit (P2-41) Number 11 transformer’s return
of the ignition system. (P2-3) Number 12 transformer’s circuit driver

536
g00720097 g00861683
Terminals for the ignition wiring on the harness side of the ECM (3) Typical connectors for ignition transformers
P2 connector (G3616 Engine) (4) Rail
(P2-2) Number 1 transformer’s return c. Check the ignition harness and wiring for
(P2-3) Number 2 transformer’s circuit driver abrasion and for pinch points from the
transformer’s connector to the rail and check
(P2-25) Number 3 transformer’s return from the rail to the ECM.
(P2-27) Number 4 transformer’s return Expected Result:
(P2-16) Number 6 transformer’s circuit driver All connectors, pins, and sockets are connected
(P2-17) Number 6 transformer’s return properly. The connectors and the wiring do not have
(P2-5) Number 7 transformer’s circuit driver corrosion, abrasion, or pinch points.
Results:
(P2-33) Number 9 transformer’s return • OK – All connectors, pins, and sockets are
(P2-34) Number 10 transformer’s circuit driver connected properly. The connectors and the
(P2-35) Number 10 transformer’s return wiring do not have corrosion, abrasion, or pinch
(P2-49) Number 11 transformer’s return points. The components are in good condition
(P2-50) Number 12 transformer’s circuit driver with proper connections. Proceed to Test Step 2.
(P2-58) Number 13 transformer’s circuit driver • Not OK – At least one of the connectors, pins,
(P2-59) Number 13 transformer’s return or sockets is not connected properly. At least
(P2-61) Number 14 transformer’s return one connector or wire has corrosion, abrasion,
(P2-40) Number 15 transformer’s circuit driver and/or pinch points. The components are not in
(P2-41) Number 15 transformer’s return good condition and/or at least one connection
(P2-42) Number 16 transformer’s circuit driver is improper.
replace parts, if necessary. Ensure that all of the
seals are properly installed. Make sure that the
connections are properly fastened. Verify that the
repair has eliminated the problem.
If the condition is not resolved, proceed to Test

Step 2.

for the Primary Circuit
A. Connect Cat ET to the service tool connector
breaker for the ECM ON.
537
B. Attempt to start the engine and use Cat ET. Test Step 3. Check the Primary Circuit
Determine if the following codes are active or and the Secondary Circuit
logged:
• 301-05 Ignition Transformer Primary #1 open

circuit through 316-05 Ignition Transformer
Primary #16 open circuit
• 301-06 Ignition Transformer Primary #1 short

through 316-06 Ignition Transformer Primary
#16 short
Note: If a diagnostic code for the primary circuit is

logged but not currently active, attempt to repeat
the condition that generated the code. Run the
engine to full operating temperature.
Expected Result:
Results:
• No (Active “open circuit”) – There is an open

primary circuit. Proceed to Test Step 3.
• No (Active “short”) – There is a short primary

• Yes (Logged only) – None of the above diagnostic

codes are active. The original diagnostic code g00900790
Illustration 496
was probably caused by a poor electrical Schematic for the primary circuit and for the secondary circuit
connection. There may be an intermittent problem
with the ignition wiring.
Repair: Make sure that the connectors and

the wiring are in good condition. Inspect the There is a strong electrical shock hazard when the
connectors for damage and/or for corrosion. crankshaft is rotating.
Make sure that the connections are secure.
Refer to Troubleshooting, “Inspecting Electrical Do not touch the wires that are associated with
Connectors”. the ignition system when the engine is cranking
STOP.
the ECM OFF.
B. Disconnect the transformer. Ensure that the

connectors do not have dirt, moisture, or
corrosion. Make sure that the pins and sockets
are not loose.

538
g00861770 g00863850
Section view of an ignition transformer and front view of the Resistance versus temperature
(1) Mounting flange (X) Temperature in degrees Celsius (degree Fahrenheit)
(A) Transformer’s circuit driver c. Measure the resistance of the secondary
(C) Unused circuit. Set the multimeter to the 40,000
ohm scale. Measure the resistance between
D. Use a multimeter to check the primary circuit mounting flange (1) and terminal (2) for the
and the secondary circuits. spark plug’s extension.
Expected Result:
For the primary circuit, one of the voltage

g00754013 measurements is approximately 0.450 VDC. The
Illustration 498
other voltage measurement is an open circuit.
Symbol for a diode
For the secondary circuit, the resistance between
a. Measure the primary circuit by checking the mounting flange and the terminal for the spark
the voltage of the blocking diode. Set the plug’s extension is within the acceptable tolerance.
multimeter leads to the terminals (A) and (B) Results:
of the transformer’s connector. The polarity
of the leads is not important. Measure the • Not OK – At least one of the measurements is
voltage between the terminals. Record the incorrect. There is a problem with the transformer.
measurement.
the voltage between terminals (A) and (B) STOP.
again. Record the measurement.
Note: The resistance of the secondary coil will vary
with the temperature. Illustration 499 demonstrates Repair: Perform the following steps:
the relationship between the secondary coil’s
resistance and the temperature. A reading that is 1. Switch the suspect transformer with a
within ± 1000 ohms is acceptable. For example, if transformer from a different cylinder that is
the transformer’s temperature is 60 C (140 F), the known to be good. Install the transformers.
codes.


539
If the problem stays with the suspect cylinder, D. Use a 151-6320 Wire Removal Tool to remove
continue to troubleshoot the problem according the suspect circuit driver and return terminals
to the type of original diagnostic code. from the ECM P2 connector. Label the wires.
If the original diagnostic code is a “05 open The terminals for G3612 Engines are identified
circuit”, proceed to Test Step 4. If the original in Illustration 502.
diagnostic code is a “06 short”, proceed to Test
Step 5. The terminals for G3616 Engines are identified
for an Open Circuit
the ECM OFF.
g00861911
Illustration 502
P2 connector (G3612 Engine)
g00861936 (P2-43) Number 2 transformer’s return
Illustration 500
Typical harness connectors for the transformers (P2-49) Number 3 transformer’s return
B. Disconnect the suspect ignition harness from (P2-17) Number 4 transformer’s return
the transformer. Inspect the connectors of the (P2-25) Number 5 transformer’s return
harness and of the transformer for damage (P2-60) Number 6 transformer’s circuit driver
and/or for corrosion. (P2-61) Number 6 transformer’s return
g00861968
Illustration 501
Ignition harness’ connector for the transformer
(C) Unused

connectors onto terminals (A) and (B) of the
suspect ignition harness’ connector for the
transformer.
540
Repair: It is unlikely that the ECM has failed. Exit

STOP.

There is a problem in the ignition harness.
Repair: The problem is caused by a poor

electrical connection and/or a broken wire in the
ignition harness. Repair the connection and/or
g00720097
the wiring, when possible. Replace the ignition
Illustration 503 harness, if necessary.
P2 connector (G3616 Engine) STOP.
(P2-2) Number 1 transformer’s return Test Step 5. Check the Ignition Harness
(P2-4) Number 2 transformer’s return for a Short Circuit
(P2-25) Number 3 transformer’s return A. Turn the engine control switch to the OFF/RESET
(P2-26) Number 4 transformer’s circuit driver position. Switch the 16 amp circuit breaker for
(P2-14) Number 5 transformer’s circuit driver the ECM OFF.
(P2-60) Number 14 transformer’s circuit driver g00861936
(P2-61) Number 14 transformer’s return Illustration 504
(P2-40) Number 15 transformer’s circuit driver Typical harness connectors for the transformers
(P2-43) Number 16 transformer’s return B. Disconnect the suspect ignition harness from
the transformer. Inspect the connectors of the
E. Use an ohmmeter to measure the resistance of harness and of the transformer for damage
the suspect terminals that were removed from and/or for corrosion.
Expected Result: the suspect circuit driver and return terminals
from the ECM P2 connector. Label the wires.
Results: in Illustration 505.
• Yes – The resistance is less than 5 ohms. The The terminals for G3616 Engines are identified
ignition harness is OK. There may be a problem in Illustration 506.
with the ECM.
541
g00861911 g00720097
Terminals for the ignition wiring on the harness side of the ECM Terminals for the ignition wiring on the harness side of the ECM
P2 connector (G3612 Engine) P2 connector (G3616 Engine)
(P2-1) Number 1 transformer’s circuit driver (P2-1) Number 1 transformer’s circuit driver
(P2-2) Number 1 transformer’s return (P2-2) Number 1 transformer’s return
D. Use an ohmmeter to measure the resistance of

the suspect terminals that were removed from
Expected Result:
Results:

ohms. The ignition harness is OK. There may be
a problem with the ECM.
542
Repair: It is unlikely that the ECM has failed. Exit The secondary circuit of the transformer provides
this procedure and perform this procedure again. an initial 8,000 to 37,000 V to the spark plug via
If the problem is not resolved, replace the ECM the extension. This voltage ionizes the spark plug
according to Troubleshooting, “Replacing the gap. This voltage is then reduced to about 1000
ECM”. Verify that the problem is resolved. V. The total duration of the spark is approximately
400 µ seconds.
STOP.
The Electronic Control Module (ECM) can diagnose
• No – The resistance is less than 20,000 ohms. the primary circuit of the ignition transformers for
There is a problem in the ignition harness. open circuits and/or for short circuits. Secondary
open circuits and short circuits will not directly
Repair: There is a poor electrical connection shut down the engine. However, these conditions
and/or a wiring problem in the ignition harness. may lead to misfire which can cause lugging of
Repair the connection and/or the wiring, when the engine. Lugging of the engine can cause a
possible. Replace the ignition harness, if shutdown.
necessary.
Caterpillar spark plugs are high voltage devices
STOP. with internal resistors. The spark plugs operate at a
voltage that is greater than 5,000 volts.
i01760912
Most ignition systems are not affected by resistance
Ignition Transformers in the secondary circuit. If a measurement of the
resistance is desired, a megohmmeter must be
Secondary Circuit and Spark used. A low voltage multimeter will not provide a
reliable reading of the resistance because oxidation
Plugs of the spark plug’s internal components will affect
the readings of those meters.
SMCS Code: 1561-038
System Operation Description: Logged diagnostic codes provide a historical

The transformers are located on the covers for the
valve lifters. Each transformer is grounded to a the logged codes to a file.
cover via the transformer’s mounting flange. The
The most likely cause of the diagnostic code is a
transformers initiate combustion by providing high
voltage to the spark plugs. The positive output from problem with the spark plug. The next likely cause
the transformer’s secondary circuit is delivered to is a poor electrical connection or a problem with the
extension. The least likely cause is a problem with
the connection for the spark plug.
an ignition transformer.
Test Step 1. Check the Status Screen

of Cat ET for the Outputs of the
Transformers’ Secondary Circuits
the ECM OFF.
B. Connect Cat ET to the service tool connector on

the terminal box.

Illustration 507 g00863996 position.
Ignition transformer and spark plug
D. Use Cat ET to view the status screens that are
(1) Primary connection listed in Table 71:
(2) Mounting flange (ground)
(3) Ignition transformer
(4) Extension
(5) Secondary connection
(6) Spark plug
543
Table 71 • Not OK – At least one of the outputs displayed

Status Screens on Cat ET
a value of 0 percent or a value that is greater
than 90 percent. The ignition system components
Screen 1 Screen 2 require maintenance. Proceed to Test Step 2.
Group 8 Group 9
“Cylinder #1 Transformer “Cylinder #2 Transformer Test Step 2. Inspect the Transformer and
Secondary Output Voltage Secondary Output Voltage the Extension
Percentage” Percentage”
“Cylinder #3 Transformer “Cylinder #4 Transformer
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage” There is a strong electrical shock hazard when the
crankshaft is rotating.
Do not touch the wires that are associated with
the ignition system when the engine is cranking
“Cylinder #7 Transformer “Cylinder #8 Transformer or when the engine is running.
“Cylinder #9 Transformer “Cylinder #10 Transformer position. Switch the 16 amp circuit breaker for
Secondary Output Voltage Secondary Output Voltage the ECM OFF.
“Cylinder #11 Transformer “Cylinder #12 Transformer NOTICE
Secondary Output Voltage Secondary Output Voltage Pulling on the wiring harness may break the wires. Do
Percentage” Percentage” not pull on the wiring harness.
E. Start the engine. Apply the normal load at rated

g00864072
speed. Allow the engine to warm up to normal Illustration 508
operating temperature. (1) Ignition harness
(2) Transformer
F. Observe the value of the output for the secondary (3) Extension
(4) O-ring seal
circuit of each transformer.
Expected Result: B. Disconnect ignition harness (1) from the

transformer’s connector. Verify that the
The displayed value of the output for the secondary connectors do not have dirt, moisture, or
circuit of each transformer is between 1 and 90 corrosion. Make sure that the pins and sockets
percent. are not loose.
Results: C. Remove the four bolts in order to remove the

transformer (2) and extension (3) as a unit.
• OK – The displayed value of the output for D. Inspect the transformer’s body and the mounting
the secondary circuit of each transformer is
between 1 and 90 percent. The ignition system flange for corrosion and/or for damage.
components are operating properly.
E. Unscrew the extension from the transformer.
Repair: Investigate other possible root causes of Inspect the internal threads of the transformer
the problem. Troubleshoot the symptom. Refer and the external threads of the extension for
to Troubleshooting, “Troubleshooting Without A corrosion and/or for damage.
Diagnostic Code”.
F. Inspect the extension’s spark plug connector for
STOP. corrosion and/or for damage. Inspect O-ring seal
(4) inside the extension for damage.
544
G. Use an extra spark plug to check for a secure Note: A standard ohmmeter cannot be used for
connection between the extension and the spark measuring the resistance of a used spark plug.
plug.
a. Use the 142-5055 Insulation Testing Gp
Note: Punch through is caused by misfire in the (Electrical) to measure the resistance of
engine that does not generate a diagnostic code. the spark plug. Follow the warnings and
instructions that are provided with the tool.
H. Check the extension near the spacer for signs of
punch through (pin holes) and/or arcing. b. Connect the red lead of the tester to the
terminal post. Because the ground strap
NOTICE is close to the center electrode, you will
The extension can be scratched and damaged with a need to connect a smaller lead to the center
wire brush. Do not use a wire brush on the extension. electrode. Then connect the black lead of the
tester to the smaller lead.
I. Clean any deposits from the inside of the c. Use the tester’s “20 K ” scale.
extension. Use a 6V-7093 Brush with isopropyl
alcohol. Clean the internal threads of the Expected Result:
transformer and the external threads of the
extension. The spark plug is in good condition.
Expected Result: The resistance is less than 10,000 ohms.
The transformer and the extension are in good Results:

condition.
• OK – The spark plug is in good condition. The
Results: resistance is less than 10,000 ohms.
• OK – The transformer and the extension appear Repair: Install the spark plug according to
to be in good condition. Proceed to Test Step 3. Operation and Maintenance Manual, “Ignition
System Spark Plugs - Check/Adjust”.
• Not OK – An inspection found a problem with the
transformer and/or with the extension. Proceed to Test Step 4.
Repair: Repair the components, when possible. • Not OK – The spark plug is not in good
Replace the components, if necessary. condition and/or the resistance is not within the
specification.
Resume normal operation.
Repair: Discard the spark plug. Install a new
STOP. spark plug according to the instructions in
Operation and Maintenance Manual, “Ignition
Test Step 3. Check the Spark Plug System Spark Plugs - Check/Adjust”.
A. Make sure that the engine control switch is in the Reset the control system. Restart the engine.
OFF/RESET position and that the 16 amp circuit Clear the logged codes.
STOP.
B. Perform the following procedures according to
the instructions in Operation and Maintenance
Manual, “Ignition System Spark Plugs -
Check/Adjust”.
a. Remove the spark plug.
b. Inspect the spark plug.
c. Clean the spark plug.
C. Measure the spark plug’s resistance after the

spark plug has been cleaned.
545
Test Step 4. Check the Primary Circuit

and the Secondary Circuit
g00861770
Illustration 510
Section view of an ignition transformer and front view of the
(1) Mounting flange
(C) Unused
D. Use a multimeter to check the primary circuit

and the secondary circuits.
g00754013
Illustration 511
g00900790
Illustration 509
Symbol for a diode
Schematic for the primary circuit and for the secondary circuit
a. Measure the primary circuit by checking
the voltage of the blocking diode. Set the
There is a strong electrical shock hazard when the multimeter leads to the terminals (A) and (B)
crankshaft is rotating. of the transformer’s connector. The polarity
of the leads is not important. Measure the
Do not touch the wires that are associated with voltage between the terminals. Record the
the ignition system when the engine is cranking measurement.
the voltage between terminals (A) and (B)
A. Turn the engine control switch to the OFF/RESET again. Record the measurement.
the ECM OFF. Note: The resistance of the secondary coil will vary
with the temperature. Illustration 512 demonstrates
B. Disconnect the transformer. Visually inspect the relationship between the secondary coil’s
the connectors for dirt, for moisture, and for resistance and the temperature. A reading that is
corrosion. Make sure that the pins and sockets within ± 1000 ohms is acceptable. For example, if
are not loose. the transformer’s temperature is 60 C (140 F), the
546

If the problem stays with the suspect cylinder,

replace the spark plug according to Operation
and Maintenance Manual, “Ignition System Spark
Plugs - Check/Adjust”.
STOP.
i01746137
Inspecting Electrical
g00863850
Connectors
Illustration 512
Resistance versus temperature SMCS Code: 1901-038
(X) Temperature in degrees celsius (Degree Fahrenheit) System Operation Description:
c. Measure the resistance of the secondary Many of the troubleshooting procedures direct you
circuit. Set the multimeter to the 40,000 to a specific electrical connector. Use the following
ohm scale. Measure the resistance between test steps to help determine whether the connector
mounting flange (1) and terminal (2) for the is the cause of the problem. If a problem is found
spark plug’s extension. in a connector, repair the connector and verify that
the problem is corrected.
Expected Result:
Intermittent electrical problems are often caused
For the primary circuit, one of the voltage by poor connections. Always check for an active
measurements is approximately 0.450 VDC. The diagnostic code before you open any connection.
other voltage measurement is an open circuit. Immediately after you reconnect the connector,
check for codes again. Sometimes, simply
For the secondary circuit, the resistance between disconnecting a connector and then reconnecting
the mounting flange and the terminal for the spark the connector can solve a problem. If this occurs,
plug’s extension is within the acceptable tolerance. the following conditions are likely causes:
Results: • Loose terminals

• Not OK – At least one of the measurements is • Bent terminals
incorrect. There is a problem with the transformer.
• Improperly crimped terminals
• Improperly mated connectors
STOP.
• Moisture
• Corrosion
Repair: Perform the following Steps in order to
determine whether the transformer or the spark
plug has a problem:
1. Switch the suspect transformer with a

transformer from a different cylinder that is
known to be good. Install the transformers.

codes.

547
g00700045
Illustration 513
The MS Connectors have a metal housing. The pins

and the sockets are soldered to the electrical wires.
The solder connections are usually protected by
a chemical potting which prevents access to the
solder point.
g00700064
Illustration 514
Deutsch connectors have a plastic housing. The

pins and the sockets are crimped onto the electrical
wires. The connector has a locking mechanism
in order to hold the pins and the sockets. These
connectors are repairable without cutting the wires.
548
g00700442
Illustration 515
Use the following test steps in order to thoroughly Expected Result:

inspect the connectors and determine if the
connectors are the cause of the problem. All connectors are properly mated and free of
damage.
Test Step 1. Check the Connectors.
Results:
A. Always turn the engine control switch to the
OFF/RESET position before you inspect electrical • OK – Proceed to test step 2.
conductors. Switch the 16 amp circuit breaker
for the ECM OFF. • Not OK
B. For the MS connectors, make sure that the Repair: Repair the connectors and/or replace the
receptacle is turned fully in the clockwise connectors. Reconnect all of the connectors.
direction. Check that the threading is properly
aligned and securely mated. STOP.
C. For the Deutsch HD connectors, make sure Test Step 2. Check the Allen Head Screw
that the plug and the receptacle are aligned on the ECM Connector.
properly with the index markings. Make sure that
the receptacle is turned fully in the clockwise A. Ensure that the allen head screw is properly
direction. Verify that the receptacle is clicked tightened. Be careful not to overtighten the screw
into the locked position. Make sure that the two and break the screw.
halves cannot be pulled apart.
B. When you connect the 70-pin connector to the
D. For the Deutsch DT style, make sure that the Electronic Control Module (ECM), do not exceed
orange wedge is used in order to lock the pins. 6 ± 1 N·m (55 ± 9 lb in) of torque on the screw.
Check that the receptacle has clicked into the
locked position. Make sure that the two halves Expected Result:
cannot be pulled apart.
The ECM connector is secure and the allen head
screw is properly torqued.
549
Results: A. If there is an active diagnostic code that pertains

to the circuit, perform the following steps:
• OK – Proceed to Test Step 3.
• Not OK OFF/RESET position. Switch the 16 amp
circuit breaker for the ECM OFF.
Repair: Repair the connector or replace the
connector, as required. b. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector on the
Verify that the repair eliminates the problem. terminal box.
STOP. c. Switch the 16 amp circuit breaker for the ECM

Test Step 3. Perform a Pull Test on Each “STOP” position. Then start the engine. Run
Wire Connection. the engine under normal operating conditions.
A. Each terminal and each connector should easily d. Monitor the “Active Diagnostic Code” screen
withstand 45 N (10 lb) of pull and each wire on Cat ET while you pull on all harnesses and
should remain in the connector body. This test connectors for the circuit with the active code.
checks whether the wire was properly crimped
in the terminal and whether the terminal was If the harness is being pulled and the active
properly inserted into the connector. diagnostic code disappears, there is a
problem in the wiring or the connector.
B. The DT connectors use an orange wedge to lock
the terminals in place. Ensure that the orange B. If there are no active diagnostic codes that
wedge is not missing and that the orange wedge pertain to the circuit, perform the following test:
is installed properly on the DT connectors.
a. Run the engine under normal operating
Note: Terminals should ALWAYS be crimped onto conditions.
the wires by using a Crimp Tool. Do not solder
terminals. Use the 1U-5804 Crimp Tool. b. Monitor the “Display Status” screen on Cat
ET while you pull on all harnesses and
Expected Result: connectors for the circuit.
Each terminal and each connector easily withstands If the harness is being pulled and the reading
45 N (10 lb) of pull and each wire remains in the changes erratically, there is a problem in the
connector body. wiring or the connector.
Results: C. If there are no active diagnostic codes and there

are complaints about intermittent changes in
• OK – Proceed to Test Step 4. speed or power cutouts, perform the following
test:
• Not OK
a. Run the engine under normal operating
Repair: Repair the circuit. conditions.
Verify that the repair eliminates the problem. b. Listen for speed burps or power cutouts while
the wiring and/or the connectors are pulled.
STOP.
If the harness is being pulled and the engine
Test Step 4. Monitor the Electronic has a speed burp or a power cutout, there
Service Tool While the Wiring and the could be a problem in the wiring or the
Connectors Are Being Pulled. connector.
Expected Result:
The problem appears to be external to the

There is a strong electrical shock hazard when harnesses and connectors. Pulling on the harness
the crankshaft is rotating. Do not touch wires that and the connectors has no effect on the active
are associated with the ignition transformer circuit diagnostic code, component status, or engine
when the engine is cranking or running. performance.
550
Results: Test Step 6. Check the Connectors for

Moisture or Corrosion.
• Not OK
breaker for the ECM OFF. Repair the circuit.
Verify that the repair eliminates the problem.
STOP.
Test Step 5. Check Wires for Nicks or

Abrasion in the Insulation.
A. Turn the engine control switch to the “STOP”
position. Allow the engine to coast to a stop.
B. Turn the engine control switch to the

“OFF/RESET” position. Switch the 16 amp circuit
g00690571
Illustration 516
C. Carefully inspect each wire for signs of abrasion,
nicks, or cuts. A. Ensure that the connector seals and the white
sealing plugs are in place. If any of the seals or
The following areas are likely locations: plugs are missing, replace the seal or plug. If
necessary, replace the connector.
• Places with exposed insulation
• Points with wiring that rubs against the engine
• Places with wiring that rubs against a sharp
point
D. Check all of the hold down clamps for the

harness in order to verify that the harness is
properly clamped. Also, check all of the hold
down clamps in order to verify that the harness
is not compressed by the clamps. Pull back the
harness sleeves in order to check for flattening
of the wires by the clamps.
Expected Result:
The wires are free of abrasion, nicks, or cuts and

the harness is properly clamped.
Results:
g00690568
• OK – Proceed to Test Step 6. Illustration 517
• Not OK B. Check all of the wiring harnesses in order to

verify that the harness does not make a sharp
Repair: Repair the wires or replace the wires, as bend out of a connector. This will deform the
required. connector seal and this will create a path for the
entrance of moisture.
Verify that the repair eliminates the problem.
Thoroughly inspect ECM J1/P1 and J2/P2
STOP. connectors for evidence of moisture entry.
551
Note: It is normal to see some minor seal abrasion Test Step 7. Inspect the Connector
on the ECM connector seals. Minor seal abrasion Terminals.
will not allow the entry of moisture.
Verify that the terminals are not damaged. Verify that
If moisture or corrosion is evident in the connector, the terminals are properly aligned in the connector
the source of the moisture entry must be found and verify that the terminals are properly located in
and the source of the moisture entry must be the connector.
repaired. If the repair is not made, the problem will
recur. Simply drying the connector will not fix the Expected Result:
problem. The following list includes likely paths for
the entrance of moisture: The terminals are properly aligned and the terminals
appear undamaged.
• Missing seals or plugs
Results:
• Improperly installed seals or plugs
• Nicks in exposed insulation
• Not OK
• Improperly mated connectors
Repair: Repair the terminals and/or replace the
Moisture can also wick from one connector through terminals, as required.
the inside of a wire to the ECM connector. If
moisture is found in the ECM connector, thoroughly Verify that the repair eliminates the problem.
check all connectors and wires on the harness that
connects to the ECM. The ECM is not the source of STOP.
the moisture. Do not replace an ECM if moisture is
found in either ECM connector. Test Step 8. Check the Individual
Retention of the Pins and Sockets.
Note: If corrosion is evident on the pins, sockets or
the connector, use only denatured alcohol to remove
the corrosion. Use a cotton swab or a soft brush
to remove the corrosion. Do not use any cleaners
that contain 1,1,1 trichloro-ethylene because 1,1,1
trichloro-ethylene may damage the connector.
Expected Result:
All of the connectors are completely coupled and

all of the seals are completely inserted. The harness
and the wiring is free of corrosion, abrasion, and
pinch points.
Results:

• Not OK
Repair: Repair the circuit. Ensure that all of the
seals are properly in place and ensure that the Illustration 518 g00690572
connectors are completely coupled.
Note: This is especially important for intermittent
Verify that the repair eliminates the problem problems.
by running the engine for several minutes and
by checking again for moisture. If moisture A. One at a time, insert a new pin into each socket.
reappears, the moisture is wicking into the Make sure that the pin is properly gripped by
connector. Even if the moisture entry path is the socket.
repaired, it may be necessary to replace the
wires that have moisture. These wires may have B. One at a time, insert a new socket onto each pin.
moisture that is trapped inside the insulation. Make sure that the pin is properly gripped by the
Verify that the repair eliminates the problem. socket. Verify that the socket holds the pin when
the connector hangs freely.
STOP.
552
Expected Result: Information from an ICSM travels across the Cat

Data Link. The ICSM must be programmed in order
Each socket firmly grips each pin. to communicate across the Cat Data Link. The Cat
Data Link must be in good condition so that the
Results: ICSM can transmit the information. An ICSM may be
able to communicate with the Caterpillar Electronic
• OK – The pins and sockets mate properly. STOP. Technician (Cat ET) even though communication
with the Electronic Control Module (ECM) is not
• Not OK – The pins and sockets do not mate possible.
properly.
Repair: Repair any bad pins and sockets. problem with an electrical connector. The next likely
Replace the connectors, if necessary. Replace cause is a problem with the wiring. The least likely
the wiring, if necessary. cause is a problem with the ICSM.
Verify that the repair eliminates the problem. Logged diagnostic codes provide a historical
STOP. ET to print the logged codes to a file.

i01761101
Integrated Combustion correcting the cause of the original diagnostic code.
Sensing Module (ICSM) resolved.
SMCS Code: 1901-038

S/N: BEN1-Up
S/N: 4ZS1-Up
The ICSM monitors the combustion sensors and the

thermocouples. The ICSM performs calculations in
order to optimize the engine’s operation. The ICSM
broadcasts the following information:
• Fuel correction factor

• Actual combustion burn time for each cylinder
• Average combustion burn time for all of the
cylinders
• Actual exhaust port temperature of each cylinder

• Average exhaust port temperature for all of the
cylinders
• The temperature of the exhaust at the inlet and

at the outlet of the turbocharger
g00900898
Illustration 519
Schematic of the Cat Data Link wiring for the ICSM
553
Test Step 1. Inspect the Electrical D. Perform a 45 N (10 lb) pull test on each of the
Connectors and Wiring wires that are associated with the Cat Data Link
for the ICSM.
E. Check the harness and wiring for abrasion and

for pinch points from the ICSM to the terminal
box.
Expected Result:

Results:
g00900899
Illustration 520 connected properly. The connectors and the
Terminal box wiring do not have corrosion, abrasion, or pinch
(1) ECM J1/P1 connector
(2) 16 amp circuit breaker with proper connections. Proceed to Test Step 2.
(3) Service tool connector J7
(4) Terminal box J5/P5connectors for the engine harness • Not OK – At least one of the connectors, pins,
A. Turn the engine control switch to the OFF one connector or wire has corrosion, abrasion,
position. Switch the 16 amp circuit breaker for and/or pinch points. The components are not in
the ECM OFF. good condition and/or at least one connection
is improper.
Troubleshooting, “Inspecting Electrical Connectors”. Repair: Perform the necessary repairs and/or
STOP.

Code is Active
position.
B. The ECM must operate for at least five seconds

in order for these codes to become activated.
Use Cat ET to look for the codes that are listed
g00900900
in Table 72:
Illustration 521
Engine harness connector for the ICSM Table 72
Diagnostic Codes for the ICSM
connectors: 591-12 EEPROM Checksum Fault or ECM not
programmed
• ECM J1/P1 connectors 1040-09 ICSM #1 Not Communicating on Link
• Service tool connector J7

Expected Result:
• Terminal box J5/P5 connectors for the engine
harness There are no active codes.
• Engine harness connector for the ICSM Results:
C. Check the torque of the Allen head screw for the • No codes – The problem seems to be resolved.
ECM P1connector and for harness connector P5. There are no active codes. The modules appear
The proper torque is 6 ± 1 N·m (55 ± 9 lb in). to be operating correctly at this time.
554

caused by a poor electrical connection. Resume
normal operation.
STOP.
• 591-12 – The ICSM has a problem. The problem

may be resolved by programming the ICSM.
• 1040-09 – The ICSM is not communicating with

the ECM. Proceed to Test Step 3.
Test Step 3. Check the Cat Data Link for

Continuity
A. Turn the engine control to the OFF/RESET
the ECM OFF.
g00857920
Illustration 524
(1) ICSM
(2) Engine harness connector for the ICSM
C. Disconnect connector P1 and disconnect the

engine harness connector for the ICSM.
g00857875
Illustration 522
Service tool connector J7
B. Disconnect Cat ET from service tool connector

J7.
g00857942
Illustration 525
(P1-8) Cat Data Link +
(P1-9) Cat Data Link −
D. Fabricate a jumper wire that is the appropriate

length with the appropriate terminals on the ends.
Connect the jumper wire between terminals P1-8
and P1-9.
g00857873
Illustration 523
ECM P1 connector
555
G. Measure the resistance between the terminals

Table 73
P1-63 P1-8
P1-9
The correct resistances for the terminals in Table

73 are greater than 20,000 ohms.
Expected Result:
The resistance checks are within the specifications.
Results:

specifications. The wiring for the Cat Data Link
does not have an open circuit or a short circuit
g00900909 to ground.
Illustration 526
Engine harness connector for the ICSM Repair: Perform the following steps:
E. Measure the resistance between terminals J and 1. Verify that the ICSM is receiving the proper
N of the engine harness connector for the ICSM. supply voltage. Refer to Troubleshooting,
During the measurement, wiggle the harness “Electrical Power Supply”.
in order to check for an intermittent problem.
Be sure to wiggle the harness near each of the 2. If the ICSM is receiving the correct supply
connectors. voltage and the original diagnostic code is still
active, there may be a problem with the ICSM.
The correct resistance is less than 5 ohms. It is unlikely that the ICSM has failed. Exit this
procedure and perform this procedure again.
F. Remove the jumper wire from connector P1. If the problem is not resolved, perform the
Temporarily install a known good ICSM according

to Troubleshooting, “Replacing the ICSM”.

problem returns.

g00865258 STOP.
Illustration 527
ECM side of connector P1 • Not OK – At least one of the resistance checks
(P1-8) Cat Data Link + is not within the specifications. The wiring for
(P1-9) Cat Data Link − the Cat Data Link has an open circuit or a short
(P1-63) -Battery circuit to ground.
556
Repair: Repair the harness or the connector, when • Actual exhaust port temperature of each cylinder
necessary. • Average exhaust port temperature for each bank
of cylinders
STOP.
• The temperature of the exhaust at the inlet and at
Test Step 4. Program the ICSM the outlet of each turbocharger
Use Cat ET to flash the software for the ICSM. Refer Information from an ICSM travels across the Cat
to Troubleshooting, “Replacing the ICSM”. Verify Data Link. The ICSM must be programmed in order
that the problem is resolved. to communicate across the Cat Data Link. The Cat
Data Link must be in good condition so that the
Expected Result: ICSM can transmit the information. An ICSM may be
able to communicate with the Caterpillar Electronic
The 591-12 diagnostic code is not active. Technician (Cat ET) even though communication
with the Electronic Control Module (ECM) is not
Results: possible.
• No code – Before the ICSM was programmed, The diagnostic code is probably caused by a
there was a 591-12 diagnostic code. After the problem with an electrical connector. The next likely
ICSM was programmed, there was no 591-12 cause is a problem with the wiring. The least likely
diagnostic code. Resume normal operation. cause is a problem with the ICSM.
STOP.
• Active 591-12 diagnostic code. – Before the record. Before you begin this procedure, use Cat
ICSM was programmed, there was an active ET to print the logged codes to a file.
591-12 diagnostic code. After the ICSM was
programmed, there was an active 591-12 This troubleshooting procedure may generate
diagnostic code. The ICSM has failed. additional diagnostic codes. Keep your mind on
Repair: Replace the ICSM. Refer to Clear the diagnostic codes after the problem is
Troubleshooting, “Replacing the ICSM”. resolved.
STOP.
i01761102
Integrated Combustion
Sensing Module (ICSM)
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
The left side ICSM and the right side ICSM monitor
the combustion sensors and the thermocouples
for each bank. Each ICSM performs calculations
in order to optimize the engine’s operation. Each
ICSM broadcasts the following information:
• Fuel correction factor

• Actual combustion burn time for each cylinder
• Average combustion burn time for each bank of
cylinders
557
g00900973
Illustration 528
Schematic of the Cat Data Link for the ICSM
Test Step 1. Inspect the Electrical A. Turn the engine control switch to the OFF
Connectors and Wiring position. Switch the 16 amp circuit breaker for
the ECM OFF.

Note: Illustration 530 shows one side of the engine.

The other side is similar.
g00857755
Illustration 529
Terminal box
(2) Ground strap
(4) Service tool connector J7
(5) Connector J5 for the right engine harness
(6) Connector J6 for the left engine harness
558
Results:


is improper.

STOP.

Illustration 530 g00857762 Code is Active
(7) ICSM
(8) Connectors J73/P73 for the ICSM
position.
connectors: B. The ECM must operate for at least five seconds
in order for these codes to become activated.
Use Cat ET to look for the codes that are listed
• ECM J1/P1 connectors in Table 74:
• Service tool connector J7 Table 74
• Terminal box J5/P5 and J6/P6 connectors for Diagnostic Codes for the ICSM
the engine harnesses 253-02 Personality Module mismatch
• Connector J73/P73 for the left side ICSM 591-12 EEPROM Checksum Fault or ECM not
programmed
• Connector J83/P83 for the right side ICSM 1040-09 ICSM #1 (Right Side) Not Communicating
on Link
C. Check the torque of the Allen head screw for the
ECM P1connector and for harness connectors 1041-09 ICSM #2 (Left Side) Not Communicating
P5 and P6. The proper torque is 6 ± 1 N·m on Link
(55 ± 9 lb in).
Expected Result:
D. Perform a 45 N (10 lb) pull test on each of the
wires that are associated with the Cat Data Link There are no active codes.
for the ICSM.
Results:
E. Check the harness and wiring for abrasion and
pinch points from each ICSM to the terminal box. • No codes – The problem seems to be resolved.
There are no active codes. The modules appear
Expected Result: to be operating correctly at this time.
All connectors, pins, and sockets are connected Repair: The initial diagnostic code was probably
properly. The connectors and the wiring do not have caused by a poor electrical connection. Resume
corrosion, abrasion, or pinch points. normal operation.
STOP.
559
• 253-02 – The programming of both of the

Integrated Combustion Sensing Modules do not
match.
Repair: The programming of both of the Integrated

Combustion Sensing Modules must match. Use
Cat ET to flash the software from the ICSM that
is known to be good to the suspect ICSM. Refer
to Troubleshooting, “Replacing the ICSM”. Verify
STOP.
• 591-12 – An ICSM has a problem. The problem

may be resolved by programming the ICSM. g00857873
Proceed to Test Step 5. Illustration 532
ECM P1 connector
• 1040-09 – The right side ICSM is not
communicating with the ECM. Proceed to Test
Step 3.
• 1041-09 – The left side ICSM is not

communicating with the ECM. Proceed to Test
Step 4.
Test Step 3. Check the Right Side Cat

Data Link for Continuity
the ECM OFF.
g00857920
Illustration 533
(1) ICSM
(2) Connector P83 for the Cat Data Link
C. Disconnect connector P1 and P83.
g00857875
Illustration 531
B. Disconnect Cat ET from service tool connector

J7.
g00857942
Illustration 534
560

and P1-9.
g00865258
Illustration 536
(P1-63) -Battery

Table 75
g00857947
Illustration 535 P1-63 P1-8
Connector P83
P1-9
E. Measure the resistance between terminals P83-J
and P83-N. During the measurement, wiggle the The correct resistances for the terminals in Table
harness in order to check for an intermittent 75 are greater than 20,000 ohms.
problem. Be sure to wiggle the harness near
each of the connectors. Expected Result:
The correct resistance measurement is less than The resistance checks are within the specifications.
5 ohms.
Results:
F. Remove the jumper wire from connector P1.
to ground.
Repair: Perform the following steps:
1. Verify that the suspect ICSM is receiving

the proper supply voltage. Refer to
561
2. If the suspect ICSM is receiving the correct

supply voltage and the original diagnostic
code is still active, there may be a problem
with the ICSM. It is unlikely that the ICSM
has failed. Exit this procedure and perform
this procedure again. If the problem is not
resolved, perform the following procedure:

to Troubleshooting, “Replacing the ICSM”.

problem returns.
g00857873
If the new ICSM operates correctly and the Illustration 538
original ICSM does not operate correctly, replace ECM P1 connector
STOP.

is not within the specifications. The wiring for
the Cat Data Link has an open circuit or a short
circuit to ground. There may be a problem with a
connector.

necessary.
STOP.
Test Step 4. Check the Left Side Cat Data

Link for Continuity
position. Switch the 16 amp circuit breaker for g00865266
Illustration 539
the ECM OFF. Left side of the engine
(1) ICSM
(2) Connector P73 for the Cat Data Link
C. Disconnect connectors P1 and P73.
g00857875
Illustration 537
B. Disconnect Cat ET from connector J7.

g00857942
Illustration 540
562

and P1-9.
g00865258
Illustration 542
(P1-63) -Battery

Table 76
g00865288
Illustration 541 P1-63 P1-8
Connector P73
P1-9
E. Measure the resistance between terminals P73-J
and P73-N. During the measurement, wiggle the The correct resistances for the terminals in Table
harness in order to check for an intermittent 76 are greater than 20,000 ohms.
problem. Be sure to wiggle the harness near
each of the connectors. Expected Result:
The correct resistance is less than 5 ohms. The resistance checks are within the specifications.
F. Remove the jumper wire from connector P1. Results:

to ground.
Repair: Perform the following steps:
1. Verify that the suspect ICSM is receiving

the proper supply voltage. Refer to
563
2. If the suspect ICSM is receiving the correct Repair: Replace the ICSM. Refer to
supply voltage and the original diagnostic Troubleshooting, “Replacing the ICSM”.
code is still active, there may be a problem
with the ICSM. It is unlikely that the ICSM STOP.
has failed. Exit this procedure and perform
this procedure again. If the problem is not
i01761353
resolved, perform the following procedure:

Prelubrication System
to Troubleshooting, “Replacing the ICSM”. SMCS Code: 1319-038
If the problem is resolved with the new ICSM, S/N: BEN1-Up
install the original ICSM. Verify that the problem
returns. S/N: 4ZS1-Up
If the new ICSM operates correctly and the System Operation Description:
the original ICSM. Refer to Troubleshooting, The prelube pump will not operate if the emergency
“Replacing the ICSM”. stop button is activated or if the engine speed is
greater than 0 rpm.
STOP.
When the conditions permit operation and the
• Not OK – At least one of the resistance checks logic determines that lubrication is required, the
is not within the specifications. The wiring for Electronic Control Module (ECM) provides +Battery
the Cat Data Link has an open circuit or a short voltage to the prelube pump’s solenoid. After
circuit to ground. There may be a problem with a activation, the prelube pump will operate until one
connector. of the following occurrences:
Repair: Repair the harness or the connector, when • The prelube pressure switch closes.
necessary. • The programmable “Engine Pre-lube Time Out
Period” expires.
STOP.
Test Step 5. Program the ICSM
The ECM monitors the prelube pressure switch
The part numbers for the personality modules in in order to verify lubrication of the engine prior to
both of the Integrated Combustion Sensing Modules start-up. The pressure switch is normally open.
must match. Use Cat ET to flash the software from
the ICSM that is known to be good to the suspect Before start-up, the pressure switch closes when
ICSM. Refer to Troubleshooting, “Replacing the the prelube pump raises the engine oil pressure
ICSM”. Verify that the problem is resolved. to 9 ± 3 kPa (1.3 ± 0.4 psi). After the pressure
switch closes, the prelube pump operates for the
Expected Result: programmable “Engine Pre-Lube Time Out Period”.
The engine starting sequence continues.
The 591-12 diagnostic code is not active.
If the ECM does not detect closure of the pressure
Results: switch within the programmed period of time,
the ECM monitors the engine oil pressure sensor
• No code – Before the ICSM was programmed, in order to determine whether lubrication has
there was a 591-12 diagnostic code. After the occurred. If the prelubrication does not occur, an
ICSM was programmed, there was no 591-12 “E233 Low Engine Prelube Pressure” event code is
diagnostic code. Resume normal operation. generated. The starting sequence is terminated.
STOP.
At shutdown, the pressure switch opens when
• Active 591-12 diagnostic code. – Before the the engine oil pressure is reduced to 9 ± 3 kPa
ICSM was programmed, there was an active (1.3 ± 0.4 psi).
591-12 diagnostic code. After the ICSM was
programmed, there was an active 591-12 Note: To troubleshoot the circuit for the prelube
diagnostic code. The ICSM has failed. pump’s solenoid, refer to Troubleshooting, “ECM
Output Circuit (Prelubrication Oil Pump)”.
564



be programmed to a value between 30 and 300



poor electrical connection or a problem in a wiring Illustration 543 g00901025
Schematic of the prelubrication system
pressure switch. The least likely cause is a problem
with the ECM.
The troubleshooting procedure may generate Connectors and Wiring
resolved.
g00853863
Illustration 544
(3) Terminal box’s J5/P5 connectors
565
A. Turn the engine control switch to the OFF/RESET • Not OK – At least one of the connectors, pins,
position. Switch the 16 amp circuit breaker for or sockets is not connected properly. At least
the ECM OFF. one connector or wire has corrosion, abrasion,
is improper.

STOP.

position.
g00901028
Illustration 545 B. Observe the “Diagnostics” screen on Cat ET.
Location of the prelube pressure switch Determine whether the following diagnostic
codes are logged:
Troubleshooting, “Inspecting Electrical Connectors”. If there is an active “338-05 Prelube Relay
B. . Thoroughly inspect the following connectors: “Results” for this Test Step. Otherwise, continue
this procedure.
• ECM J1/P1
• 338-05 Pre-Lube Relay open circuit
• Terminal box J5/P5
• 338-06 Prelube Relay short to ground
• Connectors for the prelube pressure switch
• 339-05 Engine Prelube Pressure Switch open
a. Check the torque of the Allen head screw for circuit
connectors (P1) and (P5). The proper torque
is 6 ± 1 N·m (55 ± 9 lb in). Expected Result:
b. Perform a 45 N (10 lb) pull test on each of the None of the diagnostic codes are logged.
the prelube system. Results:
c. Check the harness and wiring for abrasion • OK (No Codes) – None of the codes are logged.
and for pinch points from the prelube pressure
switch to the ECM. Repair: The problem seems to be resolved.
If there is an intermittent problem, refer
Expected Result: to Troubleshooting, “Inspecting Electrical
Connectors”.
properly. The connectors and the wiring do not have STOP.
• Not OK (Logged 339-05) – There is a logged
Results: 339-05 diagnostic code. Proceed to Test Step 3.
• OK – All connectors, pins, and sockets are • Not OK (Logged 338-05 or 338-06) – There is a
connected properly. The connectors and the logged 338-05 or 338-06 diagnostic code.
points. The components are in good condition Repair: Refer to Troubleshooting, “ECM Output
with proper connections. Proceed to Test Step 2. Circuit (Prelubrication Oil Pump)”.
STOP.
566
Test Step 3. Check the Prelube Pressure F. Observe the pressure gauge. Look for a rise
Switch in the engine oil pressure. When the engine
oil pressure rises to 9 ± 3 kPa (1.3 ± 0.4 psi),
A. Turn the engine control switch to the OFF/RESET measure the resistance between terminals (A)
position. Switch the 16 amp circuit breaker for and (B) on the pressure switch’s connector.
the ECM OFF. Wiggle the switch’s harness as you measure the
resistance in order to check for an intermittent
G. Turn OFF the prelube pump.
Expected Result:
When the prelube pump was OFF, the resistance

was greater than 20,000 ohms. When the prelube
pump was ON and the engine oil pressure rose to
9 ± 3 kPa (1.3 ± 0.4 psi), the resistance was less
than 5 ohms.
Results:
g00901034
Illustration 546 • Yes – When the prelube pump was OFF, the
(AA) Connector for the prelube pressure switch resistance was greater than 20,000 ohms. When
(A) Switch input the prelube pump was ON and the engine oil
(B) Return
(C) Unused
pressure rose to 9 ± 3 kPa (1.3 ± 0.4 psi), the
resistance was less than 5 ohms. The pressure
B. Disconnect the prelube pressure switch from the switch is operating properly. There may be a
engine harness. Remove the prelube pressure problem in the engine harness.
switch from the cylinder block.
C. Install a tee that has 1/4-18 NPTF threads into OFF/RESET position. Switch the circuit breaker
the cylinder block’s port for the pressure switch. for the ECM OFF.
If a tee cannot be installed into the port, install a Remove the pressure switch and the pressure
flexible hose that has the appropriate fitting into gauge from the tee. Remove the tee from the
the port and attach the tee to the hose. cylinder block’s port. Install the pressure switch
into the cylinder block’s port. Tighten the pressure
Install the pressure switch into one side of the switch according to Specifications, “Prelube
tee. Attach a pressure gauge to the other side Pressure Switch”.
of the tee.
D. Connect an ohmmeter between terminals (A) and
(B) on the pressure switch’s connector. Measure • No – At least one of the resistance measurements
the resistance between terminals (A) and (B) is not correct. The contacts of the prelube
on the pressure switch’s connector. Wiggle the pressure switch are stuck in the closed position
switch’s harness as you measure the resistance or in the open position.
in order to check for an intermittent problem with
the harness. Repair: Turn the engine control switch to the
OFF/RESET position. Switch the circuit breaker
E. Switch the 16 amp circuit breaker for the ECM for the ECM OFF.
position. Manually operate the prelube pump. Remove the pressure switch and the pressure
Press the “Manual Prelube” switch on the control gauge from the tee. Remove the tee from the
panel (if equipped). Make sure that the prelube cylinder block’s port.
pump operates.
Install a new prelube pressure switch. Tighten
the pressure switch according to Specifications,
“Prelube Pressure Switch”. Connect the engine
harness to the switch.
STOP.
567
• No – The engine oil pressure did not rise to Expected Result:

9 ± 3 kPa (1.3 ± 0.4 psi) when the prelube pump
was ON. The engine oil is blocked from the The resistance is less than 5 ohms.
passages to the port for the pressure switch.
Results:
OFF/RESET position. Switch the circuit breaker • OK – The resistance is less than 5 ohms. The
for the ECM OFF. engine harness seems to be OK. There may be
a problem in the terminal box. Proceed to Test
Determine the cause of the obstruction in the Step 5.
passages for the engine oil. Make the necessary
repairs. • Not OK – The resistance is greater than 5 ohms.
There is a problem with a connection or with
STOP. the wiring in the engine harness between the
P5 connector and the connector for the prelube
Test Step 4. Check the Engine Harness pressure switch.
A. Make sure that the engine control switch is in the Repair: Repair the connector(s) and/or the wiring,
OFF/RESET position and that the 16 amp circuit when possible. Replace the harness, if necessary.
STOP.
Test Step 5. Check the Terminal Box

A. Make sure that the engine control switch is in the
g00901037
Illustration 547
(AA) Engine harness connector for the prelube pressure switch
(A) Switch input
(B) Return
(C) Unused
(BB) Terminal box’s side of the engine harness P5 connector
(P5-69) Return
(P5-70) Switch input
B. Disconnect the terminal box P5 connector.

terminals into terminals “A” and “B” of the engine
harness connector for the pressure switch.
D. Use an ohmmeter to measure the resistance

between terminals (P5-69) and (P5-70) on the
terminal box’s side of the connector. Wiggle the
engine harness as you measure the resistance
in order to check for an intermittent problem. Be
sure to wiggle the harness near the connectors.
568
Expected Result:
The continuity for both of the measurements is less

than 5 ohms.
Results:
• Yes – The continuity for both of the measurements

is less than 5 ohms. The prelube pressure switch,
the engine harness, and the wiring in the terminal
box seem to be OK. There may be a problem
with the ECM.

Reconnect the P1 connector to the ECM.
Reconnect the engine harness P5 connector to
the terminal box. Reconnect the prelube pressure
switch to the engine harness.

again. If the condition is not resolved, replace the
STOP.
• Not OK – The continuity for one or both of the

measurements is greater than 5 ohms. There is
a problem with a connector or with the wiring
between the P1 connector and the J5 connector.
Repair: Turn the engine control switch to the OFF

the ECM OFF. Repair the connector(s) and/or the
wiring, when possible. Replace the connector(s)
and/or the wiring, if necessary.
STOP.
i01761355
g00901039
Illustration 548
Prelubrication System
ECM side of the P1 connector and terminal box’s J5 connector for
the right engine harness
SMCS Code: 1319-038
(P1-31) Return S/N: BLB1-Up
(J5-69) Return
(J5-70) Switch input S/N: BKE1-Up
B. Disconnect the ECM P1 connector. System Operation Description:
C. Use an ohmmeter to measure the continuity The prelube pump will not operate if the emergency
between the terminals (P1-31) and (J5-69). stop button is activated or if the engine speed is
Wiggle the harness as you measure the continuity greater than 0 rpm.
in order to check for an intermittent problem.
When the conditions permit operation and the
D. Use an ohmmeter to measure the continuity logic determines that lubrication is required, the
between terminals (P1-30) and (J5-70). Wiggle Electronic Control Module (ECM) provides +Battery
the harness as you measure the continuity in voltage to the prelube pump’s solenoid. After
order to check for an intermittent problem. activation, the prelube pump will operate until one
of the following occurrences:
569
• The prelube pressure switch closes. Logged diagnostic codes provide a historical
• The programmable “Engine Pre-lube Time Out Caterpillar Electronic Technician (Cat ET) to print
Period” expires. the logged codes to a file.
• The emergency stop button is pressed. The most likely causes of the diagnostic code are a
The ECM monitors the prelube pressure switch harness. The next likely cause is a problem with the
in order to verify lubrication of the engine prior to pressure switch. The least likely cause is a problem
start-up. The pressure switch is normally open. with the ECM.
Before start-up, the pressure switch closes when The troubleshooting procedure may generate
the prelube pump raises the engine oil pressure additional diagnostic codes. Keep your mind on
to 9 ± 3 kPa (1.3 ± 0.4 psi). After the pressure correcting the cause of the original diagnostic code.
switch closes, the prelube pump operates for the Clear the diagnostic codes after the problem is
programmable “Engine Pre-Lube Time Out Period”. resolved.
The engine starting sequence continues.
If the ECM does not detect closure of the pressure

switch within the programmed period of time,
the ECM monitors the engine oil pressure sensor
in order to determine whether lubrication has
occurred. If the prelubrication does not occur, an
“E233 Low Engine Prelube Pressure” event code is
generated. The starting sequence is terminated.
At shutdown, the pressure switch opens when

the engine oil pressure is reduced to 9 ± 3 kPa
(1.3 ± 0.4 psi).
Note: To troubleshoot the circuit for the prelube

pump’s solenoid, refer to Troubleshooting, “ECM
Output Circuit (Prelubrication Oil Pump)”.



be programmed to a value between 30 and 300 Illustration 549 g00853659

570
Test Step 1. Inspect the Electrical c. Check the harness and wiring for abrasion
Connectors and Wiring and for pinch points from the prelube pressure
switch to the ECM.
Expected Result:

Results:

g00853863
Illustration 550
(1) ECM J1/P1 connectors • Not OK – At least one of the connectors, pins,
(2) 16 amp circuit breaker or sockets is not connected properly. At least
(3) Terminal box’s J5/P5 connectors one connector or wire has corrosion, abrasion,
A. Turn the engine control switch to the OFF/RESET good condition and/or at least one connection
position. Switch the 16 amp circuit breaker for is improper.
the ECM OFF.
STOP.

position.
B. Observe the “Diagnostics” screen on Cat ET.

Determine whether the following diagnostic
codes are logged:
g00853871
Illustration 551
If there is an active “338-05 Prelube Relay
Location of the prelube pressure switch open circuit” diagnostic code, proceed to the
Note: For the following steps, refer to this procedure.
• 338-05 Pre-Lube Relay open circuit
B. . Thoroughly inspect the following connectors:
• 338-06 Prelube Relay short to ground
• ECM J1/P1
• 339-05 Engine Prelube Pressure Switch open
• Terminal box J5/P5 circuit
• Connectors for the prelube pressure switch Expected Result:

a. Check the torque of the Allen head screw for None of the diagnostic codes are logged.
connectors (P1) and (P5). The proper torque
is 6 ± 1 N·m (55 ± 9 lb in). Results:
b. Perform a 45 N (10 lb) pull test on each of the • OK (No Codes) – None of the codes are logged.
the prelube system.
571
Repair: The problem seems to be resolved. D. Connect an ohmmeter between terminals (A) and
If there is an intermittent problem, refer (B) on the pressure switch’s connector. Measure
to Troubleshooting, “Inspecting Electrical the resistance between terminals (A) and (B)
Connectors”. on the pressure switch’s connector. Wiggle the
switch’s harness as you measure the resistance
STOP. in order to check for an intermittent problem with
the harness.
• Not OK (Logged 339-05) – There is a logged
339-05 diagnostic code. Proceed to Test Step 3. E. Switch the 16 amp circuit breaker for the ECM
• Not OK (Logged 338-05 or 338-06) – There is a position. Manually operate the prelube pump.
logged 338-05 or 338-06 diagnostic code. Press the “Manual Prelube” switch on the control
panel (if equipped). Make sure that the prelube
Repair: Refer to Troubleshooting, “ECM Output pump operates.
Circuit (Prelubrication Oil Pump)”.
F. Observe the pressure gauge. Look for a rise
STOP. in the engine oil pressure. When the engine
oil pressure rises to 9 ± 3 kPa (1.3 ± 0.4 psi),
Test Step 3. Check the Prelube Pressure measure the resistance between terminals (A)
Switch and (B) on the pressure switch’s connector.
Wiggle the switch’s harness as you measure the
A. Turn the engine control switch to the OFF/RESET resistance in order to check for an intermittent
position. Switch the 16 amp circuit breaker for problem with the harness.
the ECM OFF.
G. Turn OFF the prelube pump.
Expected Result:
When the prelube pump was OFF, the resistance

was greater than 20,000 ohms. When the prelube
pump was ON and the engine oil pressure rose to
9 ± 3 kPa (1.3 ± 0.4 psi), the resistance was less
than 5 ohms.
Results:
• Yes – When the prelube pump was OFF, the

resistance was greater than 20,000 ohms. When
g00854095
the prelube pump was ON and the engine oil
Illustration 552 pressure rose to 9 ± 3 kPa (1.3 ± 0.4 psi), the
(1) Prelube pressure switch resistance was less than 5 ohms. The pressure
(AA) Connector for the prelube pressure switch switch is operating properly. There may be a
(A) Switch input
(B) Return
problem in the engine harness.
(C) Unused
B. Disconnect the prelube pressure switch from the OFF/RESET position. Switch the circuit breaker
engine harness. Remove the prelube pressure for the ECM OFF.
switch from the cylinder block.
Remove the pressure switch and the pressure
C. Install a tee that has 1/4-18 NPTF threads into gauge from the tee. Remove the tee from the
the cylinder block’s port for the pressure switch. cylinder block’s port. Install the pressure switch
into the cylinder block’s port. Tighten the pressure
If a tee cannot be installed into the port, install a switch according to Specifications, “Prelube
flexible hose that has the appropriate fitting into Pressure Switch”.
the port and attach the tee to the hose.
Install the pressure switch into one side of the
tee. Attach a pressure gauge to the other side • No – At least one of the resistance measurements
of the tee. is not correct. The contacts of the prelube
pressure switch are stuck in the closed position
or in the open position.
572

OFF/RESET position. Switch the circuit breaker
for the ECM OFF.
Remove the pressure switch and the pressure

gauge from the tee. Remove the tee from the
cylinder block’s port.
Install a new prelube pressure switch. Tighten

the pressure switch according to Specifications,
“Prelube Pressure Switch”. Connect the engine
harness to the switch.
STOP.
• No – The engine oil pressure did not rise to

9 ± 3 kPa (1.3 ± 0.4 psi) when the prelube pump
was ON. The engine oil is blocked from the
passages to the port for the pressure switch.

OFF/RESET position. Switch the circuit breaker Illustration 553 g00854167
for the ECM OFF. (AA) Engine harness connector for the prelube pressure switch
(A) Switch input
Determine the cause of the obstruction in the (B) Return
passages for the engine oil. Make the necessary (C) Unused
repairs. (BB) Terminal box’s side of the engine harness P5 connector
(P5-56) Return
STOP.
B. Disconnect the terminal box P5 connector.
A. Make sure that the engine control switch is in the terminals into terminals “A” and “B” of the engine
OFF/RESET position and that the 16 amp circuit harness connector for the pressure switch.
D. Use an ohmmeter to measure the resistance
between terminals P5-56 and P5-69 on the
terminal box’s side of the connector. Wiggle the
engine harness as you measure the resistance
in order to check for an intermittent problem. Be
sure to wiggle the harness near the connectors.
Expected Result:
Results:
• OK – The resistance is less than 5 ohms. The

engine harness seems to be OK. There may be
a problem in the terminal box. Proceed to Test
Step 5.
• Not OK – The resistance is greater than 5 ohms.

There is a problem with a connection or with
the wiring in the engine harness between the
P5 connector and the connector for the prelube
pressure switch.
573
Repair: Repair the connector(s) and/or the wiring, C. Use an ohmmeter to measure the continuity
when possible. Replace the harness, if necessary. between the terminals P1-30 and J5-69. Wiggle
the harness as you measure the continuity in
STOP. order to check for an intermittent problem.
Test Step 5. Check the Terminal Box D. Use an ohmmeter to measure the continuity
between terminals P1-31 and J5-56. Wiggle the
A. Make sure that the engine control switch is in the harness as you measure the continuity in order
OFF/RESET position and that the 16 amp circuit to check for an intermittent problem.
Expected Result:
The continuity for both of the measurements is less

than 5 ohms.
Results:
• Yes – The continuity for both of the measurements

is less than 5 ohms. The prelube pressure switch,
the engine harness, and the wiring in the terminal
box seem to be OK. There may be a problem
with the ECM.

Reconnect the P1 connector to the ECM.
Reconnect the engine harness P5 connector to
the terminal box. Reconnect the prelube pressure
switch to the engine harness.

again. If the condition is not resolved, replace the
STOP.
• Not OK – The continuity for one or both of the

measurements is greater than 5 ohms. There is
a problem with a connector or with the wiring
between the P1 connector and the J5 connector.
Repair: Turn the engine control switch to the OFF

the ECM OFF. Repair the connector(s) and/or the
wiring, when possible. Replace the connector(s)
and/or the wiring, if necessary.
STOP.
i01761473
g00854193
Illustration 554 PWM Sensor
ECM side of the P1 connector and terminal box’s J5 connector for
the right engine harness SMCS Code: 1901-038
(P1-31) Return S/N: BEN1-Up
(J5-56) Return
(J5-69) Switch input S/N: 4ZS1-Up
B. Disconnect the ECM P1 connector. System Operation Description:
The engine coolant pressure sensor is a Pulse

Width Modulated sensor (PWM).
574
Pulse Width Modulation (PWM) – This is a digital Logged diagnostic codes provide a historical
signal. The frequency is constant: the widths of the record. Before you begin this procedure, use the
signal’s pulses are varied within a fixed interval Caterpillar Electronic Technician (Cat ET) to print
(frequency). The variable widths are also called a the logged codes to a file.
duty cycle. The variable widths enable the signal to
be interpreted as a range of values. This provides a This troubleshooting procedure may generate
more accurate status for a parameter than a signal additional diagnostic codes. Keep your mind on
that can only be ON or OFF. correcting the cause of the original diagnostic code.
resolved.
g00852792
Illustration 555
Sample duty cycles that are low, medium, and high.
Note: Excessive pressure can generate false “noisy

signal” diagnostic codes. If the actual engine
coolant pressure is greater than approximately
444 kPa (64 psi), a “109-08 Engine Coolant Outlet
Pressure Sensor noisy signal” diagnostic code will
be generated. Although there is not a problem with
the sensor, the code will be generated.
If a “109-08” diagnostic code is generated, measure

the absolute pressure with a pressure gauge before
you troubleshoot the sensor. If the pressure is
actually too high, reduce the pressure in order
to avoid the false diagnostic codes from being
activated.
The “109-03” diagnostic code is probably caused

by a problem with an electrical connector or with a
harness. The next likely cause is a problem with a
sensor. The least likely cause is a problem with the
575
g00901078
Illustration 556
Schematic of the circuit for the PWM sensor
The PWM sensor is connected to the ECM via the J5/P5 connectors on the terminal box.


g00901080
Illustration 558
Front and top views
(AA) Top view
(1) PWM sensor
(2) Engine harness connectors for the PWM sensor

connectors:
• J2/P2 connectors for the ECM

• Engine harness connectors for the sensor
g00844981
Illustration 557 the J2/P2 and J5/P5 connectors. The proper
(1) ECM connectors J2/P2 torque is 6 ± 1 N·m (55 ± 9 lb in).
576
Results:


is improper.
g00844989
Illustration 559 Repair: Perform the necessary repairs and/or
Harness side of the ECM P2 connector replace parts, if necessary.
(P2-65) +8 Volt supply
(P2-66) Return STOP.
(P2-68) Signal for the engine coolant pressure
Test Step 2. Check for Active “8 Volt DC
Supply” Diagnostic Codes
the terminal box. Switch the circuit breaker for
the ECM ON. Turn the engine control switch to
the STOP position.

ET. Allow a minimum of thirty seconds for any
codes to activate.
Look for a “41-03 8 Volt DC Supply short to

+batt” diagnostic code.
Expected Result:
There is no active “8 Volt DC Supply” diagnostic

code.
Results:
g00901081
Illustration 560
Harness side of the terminal box P5 connector • No code – There is no active “8 Volt DC Supply”
(P5-40) Shield
(P5-41) Return
(P5-42) Signal for the engine coolant pressure • Active code – There is an active “8 Volt DC
(P5-43) +8 Volt supply Supply” diagnostic code. This procedure will not
work when this type of code is active.
the wires that are associated with the circuit Repair: Refer to Troubleshooting, “+8 V Sensor
for the PWM sensor. Voltage Supply”.
c. Thoroughly check the harness and wiring for STOP.

abrasion and for pinch points from the sensor
to the ECM. Test Step 3. Check for Active Diagnostic
Codes for the PWM Sensor
Expected Result:
A. Turn on the “Active Diagnostic” screen on Cat
All connectors, pins, and sockets are connected ET. Determine if either of these diagnostic codes
properly. The connectors and the wiring do not have are active:
577
• 109-03 Coolant Outlet Pressure open/short to

+batt
• 109-08 Engine Coolant Outlet Pressure noisy

signal
Expected Result:
Neither of the codes are active.
Results:
• OK – Neither of the codes are active.

Repair: If any of the above codes are logged g00852837
and the engine is not running properly, refer Illustration 562
to Troubleshooting, “Troubleshooting Without a Engine harness connector for the engine coolant pressure sensor
Diagnostic Code”. (A) +8 V supply
(B) Return
If the engine is running properly at this time, (C) Signal
harness that is causing the codes to be logged. D. Measure the voltage between terminals “A” and
Refer to Troubleshooting, “Inspecting Electrical “B” on the engine harness connector for the
Connectors”. engine coolant pressure sensor.
• Not OK – At least one of the above diagnostic The voltage is 8.0 ± 0.8 VDC.
codes is active. Proceed to Test Step 4.
Results:
Test Step 4. Check the Supply Voltage at
the Sensor • OK – The voltage is within the specification. The
correct voltage is available to the sensor. Proceed
A. Turn the engine control switch to the OFF/RESET to Test Step 5.
the ECM OFF. • Not OK – The voltage is not within the
specification. The correct supply voltage is not
available to the sensor. There is probably an open
circuit or a short circuit in a harness between the
ECM and the sensor. Proceed to Test Step 9.
Test Step 5. Check the Pull-Up Voltage at

the Sensor
g00901278
Illustration 561
Front and top views
(AA) Top view
(1) Sensor
(2) Engine harness’ connectors for the sensor
B. Disconnect the engine harness connector from g00852837

the engine coolant pressure sensor. Illustration 563
Engine harness connector for the engine coolant pressure sensor
C. Switch the 16 amp circuit breaker for the ECM (A) +8 V supply
ON. Turn the engine control switch to the STOP (B) Return
position. (C) Signal
578
Measure the voltage between terminals “B” and “C” D. Turn the engine control switch to the STOP
on the engine harness connector for the engine position. Switch the 16 amp circuit breaker for
coolant pressure sensor. the ECM ON.
Expected Result: E. Measure the duty cycle and the frequency of the
sensor. Record the values.
The voltage is 8.0 ± 2.0 VDC.
Expected Result:
Results:
The frequency is between 400 and 600 Hz.
• OK – The voltage is within the specification. The
pull-up voltage that is created by the ECM is The duty cycle is between 5 and 95 percent.
present at the sensor connector. The signal wire
appears to be OK. Proceed to Test Step 6. Results:
• Not OK - Low voltage – The voltage is less than • OK – The frequency and the duty cycle are within
6.0 VDC. The signal wire may have an open circuit the specifications. The sensor is creating a valid
or a short to ground. Proceed to Test Step 10. signal.
• Not OK - High voltage – The voltage is above 10.0 Repair: Perform the following procedure:
VDC. The signal wire may have a short circuit to a
positive voltage source. Proceed to Test Step 14. 1. Turn the engine control switch to the
Test Step 6. Check the Sensor Signal at breaker for the ECM OFF.
the Sensor
2. Remove the adapter cable.
position. Switch the 16 amp circuit breaker for 3. Reconnect the sensor to the harness.
the ECM OFF.
B. Install an 8T-8726 Adapter Cable (3 Pin
Breakout) between the engine harness connector • Not OK – The sensor signal is not within the
and the engine coolant pressure sensor’s specifications. The sensor is receiving the correct
connector. supply voltage but the sensor is not producing
a valid signal.
1. Verify that the connectors for the engine

coolant pressure sensor do not have moisture
or corrosion. Refer to Troubleshooting,
2. Check the frequency and the duty cycle of the

sensor signal again.
3. If the frequency and the duty cycle of the

sensor signal are incorrect, disconnect the
g00852837
sensor. Connect a sensor that is known to be
Illustration 564 good. Do not install the new sensor into the
Engine harness connector for the engine coolant pressure sensor engine yet.
(A) +8 V supply
(B) Return 4. Switch the 16 amp circuit breaker for the ECM
(C) Signal ON. Turn the engine control switch to the
STOP position.
C. Use a multimeter that is capable of measuring
both the duty cycle and the frequency. Connect
the multimeter to terminal C (signal) and terminal
B (return) of the breakout t.
579
5. Check for an active diagnostic code for the Results:

PWM sensor. If the code is not active for the
new sensor, install the sensor into the engine. • OK – The frequency and the duty cycle of the
Clear any logged diagnostic codes. Verify that signal are within the specifications. The signal
the problem is resolved. that is developed by the sensor is present at the
terminal box. The engine harness appears to be
STOP. OK. There may be a problem with a connector or
with the harness inside the terminal box. Proceed
Test Step 7. Check the Sensor’s Signal to Test Step 8.
at the Terminal Box
• Not OK – The frequency or the duty cycle of the
signal are not within the specifications. The signal
that is developed by the sensor is not present at
the ECM. The signal wire in the engine harness
has a problem. There may be a problem with a
connector.

STOP.
Test Step 8. Check the Sensor’s Signal

at the ECM
the ECM OFF.
g00901127
Illustration 565
Harness side of connector P5
(P5-41) Return
(P5-42) Signal
A. Insert two 7X-1710 Multimeter Probes into the

harness side of the P5 connector. Insert one
probe into terminal P5-41. Insert the other probe
into terminal P5-42.
B. Connect a multimeter to the probes.

position.
D. Measure the frequency and the duty cycle of

the signal.
Expected Result:
The duty cycle is between 5 and 95 percent.

g00866171
Illustration 566
The frequency and the duty cycle are approximately
Harness side of ECM connector P2
equal to the values that were recorded for the
previous Test Step. (P2-66) Return
(P2-68) Signal
580
B. Insert two 7X-1710 Multimeter Probes into the • Not OK – The frequency or the duty cycle of the
harness side of the P2 connector. Insert one signal are not within the specifications. The signal
probe into terminal P2-68. Insert the other probe that is developed by the sensor is not present at
into terminal P2-66. the ECM. There is a problem with the harness
inside the terminal box. There may be a problem
C. Connect the multimeter leads to the probes. with a connector.
D. Switch the 16 amp circuit breaker for the ECM Repair: Repair the harness or the connector, when
ON. Turn the engine control switch to the STOP possible. Replace the harness, if necessary.
position.
STOP.
E. Measure the frequency and the duty cycle of
the signal. Test Step 9. Check the Sensor Supply
Voltage at the Terminal Box
Expected Result:
The frequency is between 400 and 600 Hz. position. Switch the 16 amp circuit breaker for
the ECM OFF.

equal to the values that were previously recorded.
Results:
• OK – The frequency and the duty cycle of the

signal are within the specifications. The signal
that is developed by the sensor is present at the
ECM. The connectors and the harness inside the
terminal box appear to be OK. There may be a


2. Remove the probes from connector P2. Illustration 567

g00901190

again. If the problem is not resolved, temporarily (P5-41) Return
(P5-43) +8 V supply
B. Insert two 7X-1710 Multimeter Probes into the
C. Connect the multimeter leads to the probes.
Clear any logged diagnostic codes. Verify that
position.
E. Measure the voltage on the terminals.
STOP.
Expected Result:

581
Results: C. Fabricate a jumper wire of the appropriate length

with the appropriate connectors on the ends.
• OK – The sensor voltage supply is present at Insert one end of the jumper wire into the open
the terminal box. The voltage supply was not terminal of P5-42. Pull on the jumper wire in order
available at the sensor. The engine harness to verify proper installation of the terminal.
appears to have a problem. There may be a
problem with a connector. D. Connect a multimeter lead to the end of the
Repair: Repair the engine harness or the
connector, when possible. Replace the harness, if E. Insert a 7X-1710 Multimeter Probe into terminal
necessary. P5-41. Connect the other multimeter lead to the
probe.
STOP.
• Not OK – The sensor voltage supply is not ON. Turn the engine control switch to the STOP
present at the terminal box. The harness inside position.
the terminal box appears to have a problem.
There may be a problem with a connector. G. Measure the voltage.
Repair: Repair the harness or the connector, when Expected Result:

STOP.
Results:
Test Step 10. Check the Pull-Up Voltage
at the Terminal Box • OK – The voltage is within the specification. The
pull-up voltage is present at the P5 connector.
A. Turn the engine control switch to the OFF/RESET The pull-up voltage was not present at the sensor.
position. Switch the 16 amp circuit breaker for The signal wire inside the engine harness has an
the ECM OFF. open circuit or a short to ground.

the ECM OFF.
Remove both of the multimeter probes from the

P5 connector.
Reinstall the terminal that was removed from

connector P5. Pull on the wire in order to verify
• Not OK – The voltage is not within the

specification. The pull-up voltage is not present
at the P5 connector. There may be a problem
with a connector or with the harness inside the
terminal box.
g00901127
Illustration 568
(P5-41) Return Turn the engine control switch to the OFF/RESET
(P5-42) Signal
the ECM OFF.
terminal P5-42.

582
Reinstall the terminal that was removed from F. Measure the pull-up voltage.
proper installation of the terminal. Expected Result:
Proceed to Test Step 11. The voltage is 8.0 ± 2.0 VDC.
Test Step 11. Measure the Pull-Up Voltage Results:

at the ECM
The pull-up voltage was not present at the P5
connector. The signal wire inside the terminal box
has an open circuit or a short to ground.

the ECM OFF.

the jumper wire from the ECM connector.


at the P2 connector. The ECM appears to have
a problem.
g00866263
Illustration 569 Repair: Perform the following procedure:
(P2-66) Signal Turn the engine control switch to the OFF/RESET
(P2-68) Return position. Switch the 16 amp circuit breaker for
the ECM OFF.
A. Use a 151-6320 Wire Removal Tool to remove
terminal P2-68. Disconnect the multimeter leads.
B. Fabricate a jumper wire of the appropriate length Use a 151-6320 Wire Removal Tool to remove
with the appropriate connectors on the ends. the jumper wire from the ECM connector.
Insert one end of the jumper wire into the open
terminal of P2-68. Pull on the jumper wire in order Reinstall the terminal that was removed from
to verify proper installation of the terminal. connector P2. Pull on the wire in order to verify
C. Connect a multimeter lead to the end of the
jumper wire that is not inserted into the connector. It is unlikely that the ECM has failed. Exit this
D. Insert a 7X-1710 Multimeter Probe into terminal the problem is not resolved, temporarily install a
P2-66. Connect the other multimeter lead to the new ECM. Refer to Troubleshooting, “Replacing
probe. the ECM”.

position.
583
If the problem is resolved with the new ECM, Repair: Repair the harness or the connector, when
install the original ECM and verify that the possible. Replace the harness, if necessary.
correctly and the original ECM does not operate STOP.
Troubleshooting, “Replacing the ECM”. • Not OK – The resistance is less than 20,000
ohms. The signal wire inside the terminal box
STOP. has a short to ground. There could be a problem
with a connector.
Test Step 12. Measure the Resistance of
the Signal Wire Inside the Terminal Box Repair: Repair the harness or the connector, when
STOP.
Test Step 13. Measure the Resistance

of the Signal Wire Inside the Engine
Harness
g00866283
Illustration 570
Terminal box and harness connector P2
(1) ECM ground strap
(2) Harness side of the P2 connector
(P2-68) Signal
A. Disconnect the P2 connector. g00901176

Illustration 571
B. Measure the resistance from the ECM ground Terminal box’s side of the P5 connector
strap to terminal P2-68. (1) ECM ground strap
(P5-42) Signal
Expected Result:
A. Verify that the P2 connector has been
The resistance is greater than 20,000 ohms. reconnected. Disconnect the P5 connector.
Results: B. Measure the resistance from the ECM ground

strap to terminal P5-42.
The signal wire inside the terminal box does not Expected Result:
have a short to ground. The signal wire inside the
terminal box has an open circuit. There may be a The resistance is greater than 20,000 ohms.
problem with a connector.
584
Results: C. Insert one end of a jumper wire into the open

terminal of P5-42 connector. Pull on the jumper
• OK – The resistance is greater than 20,000 ohms. wire in order to verify proper installation of the
The signal wire inside the engine harness does terminal.
not have a short to ground. The signal wire inside
the engine harness has an open circuit. There D. Connect a multimeter lead to the end of the
could be a problem with a connector. jumper wire that is not inserted into the connector.
Repair: Repair the harness or the connector, when E. Insert a 7X-1710 Multimeter Probe into terminal
possible. Replace the harness, if necessary. P5-41. Connect the other multimeter lead to the
probe.
STOP.
• Not OK – The resistance is less than 20,000 ON. Turn the engine control switch to the STOP
ohms. The signal wire inside the engine harness position.
has a short to ground. There could be a problem
with a connector. G. Measure the voltage.
Repair: Repair the harness or the connector, when Expected Result:

STOP.
Results:
at the Terminal Box • OK – The voltage is within the specification. The
A. Turn the engine control switch to the OFF/RESET The pull-up voltage was not present at the sensor.
position. Switch the 16 amp circuit breaker for The signal wire inside the engine harness has a
the ECM OFF. short circuit to a positive voltage source. There
could be a problem with a connector.

the ECM OFF.


Repair the harness or the connector, when

STOP.
g00901127
Illustration 572
(P5-41) Return at the P5 connector. There may be a problem
(P5-42) Signal
terminal box.
terminal P5-42.
585
Turn the engine control switch to the OFF/RESET D. Switch the 16 amp circuit breaker for the ECM
position. Switch the 16 amp circuit breaker for ON. Turn the engine control switch to the STOP
the ECM OFF. position.
Disconnect the multimeter leads. E. Measure the voltage.
Use a 151-6320 Wire Removal Tool to remove Expected Result:

connector P5. Pull on the wire in order to verify Results:
Proceed to Test Step 15. pull-up voltage is present at the P2 connector.
Test Step 15. Measure the Pull-Up Voltage connector. The signal wire inside the terminal box
at the ECM has a short circuit to a positive voltage source.

the ECM OFF.


Repair the terminal box’s harness or the

connector, when possible. Replace the terminal
box’s harness, if necessary.
STOP.

specification. The correct pull-up voltage is not
present at the P2 connector. The ECM appears
to have a problem.
g00866263
Illustration 573 Repair: Perform the following procedure:
(P2-66) Return Disconnect the multimeter leads.
(P2-68) Signal
A. Use a 151-6320 Wire Removal Tool to remove the jumper wire from the P2 connector.
terminal P2-68.
B. Insert one end of a jumper wire into the open connector P2. Pull on the wire in order to verify
terminal of P2-68. Pull on the jumper wire in proper installation of the terminal.
order to verify proper installation of the terminal.
Connect a multimeter lead to the end of the Turn the engine control switch to the OFF/RESET
jumper wire that is not inserted into the connector. position. Switch the 16 amp circuit breaker for
the ECM OFF.
C. Insert a 7X-1710 Multimeter Probe into terminal
P2-66. Connect the other multimeter lead to the
probe.
586

the problem is not resolved, temporarily install a
new ECM. Refer to Troubleshooting, “Replacing
the ECM”.

STOP.
i01761474
PWM Sensor
SMCS Code: 1901-038
S/N: BLB1-Up
S/N: BKE1-Up
The engine coolant pressure sensor is a Pulse

g00852792
Width Modulated sensor (PWM). Illustration 574
Sample duty cycles that are low, medium, and high.
Pulse Width Modulation (PWM) – This is a digital
signal. The frequency is constant: the widths of the Note: Excessive pressure can generate false “noisy
signal’s pulses are varied within a fixed interval signal” diagnostic codes. If the actual engine
(frequency). The variable widths are also called a coolant pressure is greater than approximately
duty cycle. The variable widths enable the signal to 444 kPa (64 psi), a “109-08 Engine Coolant Outlet
be interpreted as a range of values. This provides a Pressure Sensor noisy signal” diagnostic code will
more accurate status for a parameter than a signal be generated. Although there is not a problem with
that can only be ON or OFF. the sensor, the code will be generated.
If a “109-08” diagnostic code is generated, measure

the absolute pressure with a pressure gauge before
you troubleshoot the sensor. If the pressure is
actually too high, reduce the pressure in order
to avoid the false diagnostic codes from being
activated.
The “109-03” diagnostic code is probably caused

by a problem with an electrical connector or with a
harness. The next likely cause is a problem with a
sensor. The least likely cause is a problem with the

587

resolved.
g00901407
Illustration 575
Schematic of the circuit for the PWM sensor
The PWM sensor is connected to the ECM via the J5/P5 connector on the terminal box.


g00871201
Illustration 577
Right side and top view of the engine
(3) Engine coolant pressure sensor
(4) Engine harness connector for the engine coolant pressure
sensor

connectors:
g00844981
Illustration 576
• J2/P2 connectors for the ECM
(2) J5/P5 connectors for the harness on the right side of the engine
• Engine harness connectors for the sensor
588
a. Check the torque of the Allen head screw for Results:

the J2/P2 and J5/P5 connectors. The proper
torque is 6 ± 1 N·m (55 ± 9 lb in). • OK – All connectors, pins, and sockets are

is improper.

g00844989
Illustration 578 STOP.
(P2-65) +8 V supply Test Step 2. Check for Active “8 Volt DC
(P2-66) Return Supply” Diagnostic Codes
(P2-68) Signal for the engine coolant pressure
the terminal box. Switch the circuit breaker for
the ECM ON. Turn the engine control switch to
the STOP position.

ET. Allow a minimum of thirty seconds for any
codes to activate.
Look for a “41-03 8 Volt DC Supply short to

+batt” diagnostic code.
Expected Result:
g00844994
There is no active “8 Volt DC Supply” diagnostic
Illustration 579 code.
(P5-11) Shield Results:
(P5-21) Return
(P5-29) Signal for the engine coolant pressure • No code – There is no active “8 Volt DC Supply”
(P5-37) +8 V supply
• Active code – There is an active “8 Volt DC
Supply” diagnostic code. This procedure will not
for the PWM sensor. work when this type of code is active.
c. Thoroughly check the harness and wiring for Repair: Refer to Troubleshooting, “+8 V Sensor
abrasion and for pinch points from the sensor Voltage Supply”.
to the ECM.
STOP.
Expected Result:
Test Step 3. Check for Active Diagnostic
Codes for the PWM Sensor
A. Turn on the “Active Diagnostic” screen on Cat
ET. Determine if either of these diagnostic codes
are active:
589
• 109-03 Coolant Outlet Pressure open/short to B. Disconnect the engine harness connector from
+batt the engine coolant pressure sensor.
• 109-08 Engine Coolant Outlet Pressure noisy C. Switch the 16 amp circuit breaker for the ECM
signal ON. Turn the engine control switch to the STOP
position.
Expected Result:
Neither of the codes are active.
Results:
• OK – Neither of the codes are active.

and the engine is not running properly, refer
Diagnostic Code”.
If the engine is running properly at this time,

g00852837
harness that is causing the codes to be logged. Illustration 581
Refer to Troubleshooting, “Inspecting Electrical Engine harness connector for the engine coolant pressure sensor
Connectors”. (A) +8 V supply
(B) Return
STOP. (C) Signal
• Not OK – At least one of the above diagnostic D. Measure the voltage between terminals “A” and
codes is active. Proceed to Test Step 4. “B” on the engine harness connector for the
engine coolant pressure sensor.
Test Step 4. Check the Supply Voltage at
the Sensor Expected Result:
A. Turn the engine control switch to the OFF/RESET The voltage is 8.0 ± 0.8 VDC.
the ECM OFF. Results:

correct voltage is available to the sensor. Proceed
to Test Step 5.

specification. The correct supply voltage is not
available to the sensor. There is probably an open
circuit or a short circuit in a harness between the
ECM and the sensor. Proceed to Test Step 9.
g00845338
Illustration 580
Right side and top views
(AA) Top view
(1) Sensor
(2) Engine harness’ connectors for the sensor
590
Test Step 5. Check the Pull-Up Voltage at

the Sensor
g00852837
Illustration 583
Engine harness connector for the engine coolant pressure sensor
g00852837
Illustration 582 (A) +8 V supply
Engine harness connector for the engine coolant pressure sensor (B) Return
(C) Signal
(A) +8 V supply
(B) Return
(C) Signal C. Use a multimeter that is capable of measuring
both the duty cycle and the frequency. Connect
Measure the voltage between terminals “B” and “C” the multimeter to terminal C (signal) and terminal
on the engine harness connector for the engine B (return) of the breakout t.
coolant pressure sensor.
D. Turn the engine control switch to the STOP
Expected Result: position. Switch the 16 amp circuit breaker for
the ECM ON.
E. Measure the duty cycle and the frequency of the
Results: sensor. Record the values.
• OK – The voltage is within the specification. The Expected Result:

pull-up voltage that is created by the ECM is
present at the sensor connector. The signal wire The frequency is between 400 and 600 Hz.
• Not OK - Low voltage – The voltage is less than
6.0 VDC. The signal wire may have an open circuit Results:
or a short to ground. Proceed to Test Step 10.
• OK – The frequency and the duty cycle are within
• Not OK - High voltage – The voltage is above 10.0 the specifications. The sensor is creating a valid
VDC. The signal wire may have a short circuit to a signal.
positive voltage source. Proceed to Test Step 14.
Test Step 6. Check the Sensor Signal at
the Sensor 1. Turn the engine control switch to the
A. Turn the engine control switch to the OFF/RESET breaker for the ECM OFF.
the ECM OFF. 2. Remove the adapter cable.
B. Install an 8T-8726 Adapter Cable (3 Pin 3. Reconnect the sensor to the harness.
Breakout) between the engine harness connector
and the engine coolant pressure sensor’s Proceed to Test Step 7.
connector.
• Not OK – The sensor signal is not within the
specifications. The sensor is receiving the correct
supply voltage but the sensor is not producing
a valid signal.
591
Repair: Perform the following procedure: C. Switch the 16 amp circuit breaker for the ECM
1. Verify that the connectors for the engine position.
coolant pressure sensor do not have moisture
or corrosion. Refer to Troubleshooting, D. Measure the frequency and the duty cycle of
“Inspecting Electrical Connectors”. the signal.
2. Check the frequency and the duty cycle of the Expected Result:
sensor signal again.
3. If the frequency and the duty cycle of the
sensor signal are incorrect, disconnect the The duty cycle is between 5 and 95 percent.
sensor. Connect a sensor that is known to be
good. Do not install the new sensor into the The frequency and the duty cycle are approximately
engine yet. equal to the values that were recorded for the
previous Test Step.
ON. Turn the engine control switch to the Results:
STOP position.
5. Check for an active diagnostic code for the signal are within the specifications. The signal
PWM sensor. If the code is not active for the that is developed by the sensor is present at the
new sensor, install the sensor into the engine. terminal box. The engine harness appears to be
Clear any logged diagnostic codes. Verify that OK. There may be a problem with a connector or
the problem is resolved. with the harness inside the terminal box. Proceed
to Test Step 8.
STOP.
• Not OK – The frequency or the duty cycle of the
Test Step 7. Check the Sensor’s Signal signal are not within the specifications. The signal
at the Terminal Box that is developed by the sensor is not present at
the ECM. The signal wire in the engine harness
has a problem. There may be a problem with a
connector.

STOP.
Test Step 8. Check the Sensor’s Signal

at the ECM
the ECM OFF.
g00866149
Illustration 584
(P5-21) Return
(P5-29) Signal
A. Insert two 7X-1710 Multimeter Probes into the

B. Connect a multimeter to the probes.

592
Results:

signal are within the specifications. The signal
that is developed by the sensor is present at the
ECM. The connectors and the harness inside the
terminal box appear to be OK. There may be a




g00866171
Illustration 585 Troubleshooting, “Replacing the ECM”.
Harness side of ECM connector P2
(P2-66) Return Clear any logged diagnostic codes. Verify that
(P2-68) Signal the problem is resolved.
B. Insert two 7X-1710 Multimeter Probes into the STOP.

probe into terminal P2-68. Insert the other probe • Not OK – The frequency or the duty cycle of the
into terminal P2-66. signal are not within the specifications. The signal
that is developed by the sensor is not present at
C. Connect the multimeter leads to the probes. the ECM. There is a problem with the harness
inside the terminal box. There may be a problem
D. Switch the 16 amp circuit breaker for the ECM with a connector.
position. Repair: Repair the harness or the connector, when
E. Measure the frequency and the duty cycle of
the signal. STOP.
Expected Result: Test Step 9. Check the Sensor Supply

Voltage at the Terminal Box
The duty cycle is between 5 and 95 percent. position. Switch the 16 amp circuit breaker for
the ECM OFF.
equal to the values that were previously recorded.
593

STOP.

at the Terminal Box
the ECM OFF.
g00866184
Illustration 586
(P5-21) Return
(P5-37) +8 V supply
B. Insert two 7X-1710 Multimeter Probes into the

C. Connect the multimeter leads to the probes.

g00866221
Illustration 587
D. Switch the 16 amp circuit breaker for the ECM Harness side of connector P5
ON. Turn the engine control switch to the STOP (P5-21) Return
position. (P5-29) Signal
E. Measure the voltage on the terminals. B. Use a 151-6320 Wire Removal Tool to remove
terminal P5-29.
Expected Result:
C. Fabricate a jumper wire of the appropriate length
The voltage is 8.0 ± 0.8 VDC. with the appropriate connectors on the ends.
Insert one end of the jumper wire into the open
Results: terminal of P5-29. Pull on the jumper wire in order
to verify proper installation of the terminal.
• OK – The sensor voltage supply is present at
the terminal box. The voltage supply was not D. Connect a multimeter lead to the end of the
available at the sensor. The engine harness jumper wire that is not inserted into the connector.
appears to have a problem. There may be a
problem with a connector. E. Insert a 7X-1710 Multimeter Probe into terminal
Repair: Repair the engine harness or the probe.
connector, when possible. Replace the harness, if
necessary. F. Switch the 16 amp circuit breaker for the ECM
STOP. position.
• Not OK – The sensor voltage supply is not G. Measure the voltage.

present at the terminal box. The harness inside
the terminal box appears to have a problem. Expected Result:
594
Results: Test Step 11. Measure the Pull-Up Voltage

at the ECM
The pull-up voltage was not present at the sensor.
The signal wire inside the engine harness has an
open circuit or a short to ground.

the ECM OFF.
Remove both of the multimeter probes from the

P5 connector.


at the P5 connector. There may be a problem
terminal box.

g00866263
Illustration 588
Turn the engine control switch to the OFF/RESET Harness side of connector P2
position. Switch the 16 amp circuit breaker for (P2-66) Signal
the ECM OFF. (P2-68) Return
Disconnect the multimeter leads. A. Use a 151-6320 Wire Removal Tool to remove
terminal P2-68.
the jumper wire from the terminal box’s connector. B. Fabricate a jumper wire of the appropriate length
with the appropriate connectors on the ends.
Reinstall the terminal that was removed from Insert one end of the jumper wire into the open
connector P5. Pull on the wire in order to verify terminal of P2-68. Pull on the jumper wire in order
proper installation of the terminal. to verify proper installation of the terminal.
Proceed to Test Step 11. C. Connect a multimeter lead to the end of the
D. Insert a 7X-1710 Multimeter Probe into terminal

probe.

position.
F. Measure the pull-up voltage.
Expected Result:

595
Results: Test Step 12. Measure the Resistance of

the Signal Wire Inside the Terminal Box
connector. The ECM appears to be OK. The
signal wire inside the terminal box has an open
circuit or a short to ground.

the ECM OFF.



at the P2 connector. The ECM appears to have
a problem.
g00866283
Illustration 589
Repair: Perform the following procedure: Terminal box and harness connector P2
Turn the engine control switch to the OFF/RESET (2) Harness side of the P2 connector
position. Switch the 16 amp circuit breaker for (P2-68) Signal
the ECM OFF.
A. Disconnect the P2 connector.
B. Measure the resistance from the ECM ground
Use a 151-6320 Wire Removal Tool to remove strap to terminal P2-68.
Expected Result:
connector P2. Pull on the wire in order to verify The resistance is greater than 20,000 ohms.
Results:
procedure and perform this procedure again. If • OK – The resistance is greater than 20,000 ohms.
the problem is not resolved, temporarily install a The signal wire inside the terminal box does not
new ECM. Refer to Troubleshooting, “Replacing have a short to ground. The signal wire inside the
the ECM”. terminal box has an open circuit. There may be a
problem with a connector.
install the original ECM and verify that the Repair: Repair the harness or the connector, when
problem returns. If the new ECM operates possible. Replace the harness, if necessary.
correctly, replace the original ECM. Refer to STOP.
STOP. ohms. The signal wire inside the terminal box
has a short to ground. There could be a problem
with a connector.
596
Repair: Repair the harness or the connector, when Repair: Repair the harness or the connector, when
possible. Replace the harness, if necessary. possible. Replace the harness, if necessary.
STOP. STOP.
Test Step 13. Measure the Resistance • Not OK – The resistance is less than 20,000
of the Signal Wire Inside the Engine ohms. The signal wire inside the terminal box
Harness has a short to ground. There could be a problem
with a connector.
A. Verify that the P2 connector has been
reconnected. Disconnect the P5 connector. Repair: Repair the harness or the connector, when
STOP.

at the Terminal Box
the ECM OFF.
g00866324
Illustration 590
(2) Terminal box’s side of the P5 connector
(P5-29) Signal g00866221
Illustration 591
B. Measure the resistance from the ECM ground Harness side of connector P5
strap to terminal P5-29. (P5-21) Return
(P5-29) Signal
Expected Result:
The resistance is greater than 20,000 ohms. terminal P5-29.
Results: C. Insert one end of a jumper wire into the open

terminal of P5-29 connector. Pull on the jumper
• OK – The resistance is greater than 20,000 ohms. wire in order to verify proper installation of the
The signal wire inside the engine harness does terminal.
not have a short to ground. The signal wire inside
the engine harness has an open circuit. There D. Connect a multimeter lead to the end of the
could be a problem with a connector. jumper wire that is not inserted into the connector.
597
E. Insert a 7X-1710 Multimeter Probe into terminal Reinstall the terminal that was removed from
P5-21. Connect the other multimeter lead to the connector P5. Pull on the wire in order to verify
probe. proper installation of the terminal.
F. Switch the 16 amp circuit breaker for the ECM Proceed to Test Step 15.
position. Test Step 15. Measure the Pull-Up Voltage
at the ECM
G. Measure the voltage.
Expected Result:
Results:

The pull-up voltage was not present at the sensor.
The signal wire inside the engine harness has a
short circuit to a positive voltage source. There
could be a problem with a connector.

the ECM OFF.


g00866263
proper installation of the terminal. Illustration 592
Repair the harness or the connector, when (P2-66) Return
possible. Replace the harness, if necessary. (P2-68) Signal
STOP. A. Use a 151-6320 Wire Removal Tool to remove

terminal P2-68.
specification. The pull-up voltage is not present at B. Insert one end of a jumper wire into the open
the P5 connector. There may be a problem with a terminal of P2-68. Pull on the jumper wire in
connector or with the harness inside the terminal order to verify proper installation of the terminal.
box. The ECM may have a problem. Connect a multimeter lead to the end of the
C. Insert a 7X-1710 Multimeter Probe into terminal
Turn the engine control switch to the OFF/RESET P2-66. Connect the other multimeter lead to the
position. Switch the 16 amp circuit breaker for probe.
the ECM OFF.
Disconnect the multimeter leads. ON. Turn the engine control switch to the STOP
position.
the jumper wire from the terminal box’s connector. E. Measure the voltage.
Expected Result:

598
Results: If the problem is resolved with the new ECM,

• OK – The voltage is within the specification. The problem returns. If the new ECM operates
pull-up voltage is present at the P2 connector. correctly and the original ECM does not operate
The pull-up voltage was not present at the P5 correctly, replace the original ECM. Refer to
connector. The signal wire inside the terminal box Troubleshooting, “Replacing the ECM”.
has a short circuit to a positive voltage source.
There may be a problem with a connector. STOP.

i01762078

Thermocouple Test
the ECM OFF. SMCS Code: 7498-038
Disconnect the multimeter leads. S/N: BEN1-Up
Use a 151-6320 Wire Removal Tool to remove S/N: 4ZS1-Up

connector P2. Pull on the wire in order to verify Use this procedure to troubleshoot thermocouples
proper installation of the terminal. that have diagnostic codes which are active or
easily repeated.
Repair the terminal box’s harness or the
connector, when possible. Replace the terminal A thermocouple is installed into the exhaust port
box’s harness, if necessary. of each engine cylinder, into the inlet for the
turbocharger turbine, and into the outlet for the
STOP. turbocharger turbine.
• Not OK – The voltage is not within the The thermocouples do not require a supply voltage
specification. The incorrect pull-up voltage is from the Integrated Combustion Sensing Module
present at the P2 connector. The ECM appears (ICSM). Each thermocouple has two wires. Each
to have a problem. thermocouple develops a low voltage signal that is
detected by the ICSM.
A -03 diagnostic code may be caused by a
Disconnect the multimeter leads. thermocouple wire that has a short circuit to a high
voltage. A -03 diagnostic code may also occur if
Use a 151-6320 Wire Removal Tool to remove the thermocouple’s voltage is above an acceptable
the jumper wire from the P2 connector. range.
Reinstall the terminal that was removed from A -04 diagnostic code may be caused by a
connector P2. Pull on the wire in order to verify thermocouple wire that has a short circuit to a low
proper installation of the terminal. voltage. A -04 diagnostic code may also occur if
the thermocouple has a short to ground.
position. Switch the 16 amp circuit breaker for A -05 diagnostic code may be caused by a
the ECM OFF. thermocouple’s circuit that has a low current flow.
A -05 diagnostic code may also occur if there is
It is unlikely that the ECM has failed. Exit this an open circuit.
the problem is not resolved, temporarily install a A diagnostic code is probably caused by a problem
new ECM. Refer to Troubleshooting, “Replacing with a harness connector or by a wiring problem.
the ECM”. The next likely cause is a faulty thermocouple. The
least likely cause is a problem with the ICSM.

599

resolved.
g00901430
Illustration 593
Schematic for the circuit of the thermocouples for the 6 cylinder engine
g00901431
Illustration 594
600
Test Step 1. Inspect the Electrical B. Thoroughly inspect the following connectors for
Connectors and Wiring moisture, for corrosion, and for contamination:
A. Turn the engine control switch to the OFF/RESET • 20-pin connectors on the ICSM
for the Electronic Control Module (ECM). • Connectors for the thermocouple
Note: For the following steps, refer to C. Verify that all of the connectors are completely
Troubleshooting, “Inspecting Electrical Connectors”. connected. Verify that terminals in the suspect
thermocouple’s connector are completely
D. Check the harness and wiring for abrasion and

for pinch points from the suspect thermocouple
to the ICSM.
Expected Result:
All of the connectors do not have corrosion,

abrasion, or contamination. All of the connectors are
completely connected. The terminals in the suspect
thermocouple’s connector are completely inserted
into the connector. The harness and the wiring do
not have corrosion, abrasion, or pinch points.
Results:
• OK – The components are in good condition with

proper connections. Proceed to Test Step 2.
Illustration 595 g00853835 • Not OK – The components are not in good

condition and/or at least one connection is
(1) ICSM improper.
(2) 20-pin connector for the thermocouples

replace parts, if necessary. Verify that the repair
eliminates the problem.
STOP.

position.

may become activated. Look for the codes that
are listed in Table 77:
g00901432
Illustration 596
(3) Thermocouple for the outlet of the turbocharger turbine
(4) Thermocouple for the inlet of the turbocharger turbine
(5) Thermocouple for the exhaust port of a cylinder
601
Table 77 Test Step 3. Disconnect the Sensor in

Diagnostic Code Description Order to Create an Open Circuit
1490-03 “Right Turbo Turbine Out Temp A. Turn the engine control switch to the OFF/RESET
Sens short to +batt” position. Switch the 16 amp circuit breaker for
1490-04 “Right Turbo Turbine Out Temp the ECM OFF.
Sens short to ground”
B. Disconnect the thermocouple that has the short
1490-05 “Right Turbo Turbine Out Temp circuit diagnostic code.
Sens open circuit”
1491-03 “Right Turbo Turbine Out Temp C. Switch the 16 amp circuit breaker for the ECM
Sens short to +batt” ON. Turn the engine control switch to the STOP
position.
1491-04 “Right Turbo Turbine Out Temp
1491-05 “Right Turbo Turbine Out Temp ET. Wait at least 30 seconds so that any codes
Sens open circuit” may become activated.
1531-03 through “Cylinder #1 Exhaust Port Temp
1538-03 Sensor sort to +batt” through Expected Result:
“Cylinder #8 Exhaust Port Temp
Sensor sort to +batt” An open circuit diagnostic code was generated for
the suspect thermocouple.
1538-04 Sensor short to ground” through Results:
Sensor short to ground”
• OK – Before the suspect thermocouple was
1531-05 through “Cylinder #1 Exhaust Port Temp disconnected, there was an active “short circuit”
1538-05 Sensor open circuit” through diagnostic code. After the thermocouple was
“Cylinder #8 Exhaust Port Temp disconnected, there was an active “open circuit”
Sensor open circuit” diagnostic code.
Expected Result: Repair: Perform the following procedure:
None of the above codes are active. 1. Turn the engine control switch to the
Results: breaker for the ECM OFF.
• No active codes – The problem seems to be 2. Thoroughly inspect the thermocouple’s

resolved. There are no active codes. The connectors for moisture. Inspect the seals for
thermocouples are operating correctly at this time. the connectors.
Repair: The initial diagnostic code was probably 3. Reconnect the thermocouple to the harness.
of the harness connectors. Resume normal 4. Switch the 16 amp circuit breaker for the ECM
operation. ON. Turn the engine control switch to the
STOP position.
STOP.
5. Observe the “Active Diagnostic” screen on
• Active 03 “short to +batt” – There is an active Cat ET. Wait at least 30 seconds so that any
“short to +batt” diagnostic code. Proceed to Test codes may become activated. If the active
Step 3. “short circuit” diagnostic code recurs, the
thermocouple is the source of the problem.
• Active 04 “short to ground” – There is an active
“short to ground” diagnostic code. Proceed to 6. Turn the engine control switch to the
Test Step 3. OFF/RESET position. Switch the 16 amp circuit
• Active 05 “open circuit” – There is an active “open
circuit” diagnostic code. Proceed to Test Step 4. 7. Temporarily connect a new thermocouple to
the harness. Do not install the thermocouple
onto the engine.
602
8. Switch the 16 amp circuit breaker for the ECM C. Create a short circuit by inserting the jumper
ON. Turn the engine control switch to the wire into the harness connector for the suspect
STOP position. thermocouple. If the connector has two terminals,
insert one end of the jumper wire into each
9. Observe the “Active Diagnostic” screen on terminal. If the connector has three terminals,
Cat ET. Wait at least 30 seconds so that any insert one end of the jumper wire into terminal
codes may become activated. If the active “A” and insert the other end of the jumper wire
“short circuit” diagnostic code does not recur, into terminal “B”. The jumper wire must remain
replace the thermocouple. The correct torque connected in this manner for at least 30 seconds.
for a thermocouple is 12 ± 3 N·m (9 ± 2 lb ft).
Clear all of the logged diagnostic codes. Verify D. Remove the jumper wire from the engine
that the problem is resolved. harness. The jumper wire must be removed for
at least 30 seconds.
STOP.
Expected Result:
• Not OK – Before the suspect thermocouple was
disconnected, there was an active “short circuit” A “short circuit” diagnostic code becomes active
diagnostic code. After the thermocouple was when the jumper wire is connected to the engine
disconnected, the active “short circuit” diagnostic harness for 30 seconds. An “open circuit” diagnostic
code remained. Proceed to Test Step 5. code becomes active when the jumper wire is
removed from the engine harness for 30 seconds.
Test Step 4. Create a Short Circuit at the
Connector for the Thermocouple Results:
A. Switch the 16 amp circuit breaker for the ECM • OK – A “short circuit” diagnostic code becomes
ON. Turn the engine control switch to the STOP active when the jumper wire is connected. An
position. “open circuit” diagnostic code becomes active
when the jumper wire is removed. The engine
B. Fabricate a jumper wire with the appropriate harness and the ICSM appear to be functioning
terminals on each end. properly.
Note: Observe the “Active Diagnostic” screen on Repair: To verify that the thermocouple is faulty,
Cat ET before installing the jumper wire and after reconnect the suspect thermocouple for at least
installing the jumper wire. 30 seconds. If the “open circuit” diagnostic code
returns, replace the thermocouple. Tighten the
new thermocouple to 12 ± 3 N·m (9 ± 2 lb ft).
Verify that the new thermocouple does not create
a diagnostic code.
STOP.
• Not OK – A “short circuit” diagnostic code is not

active when the jumper wire is connected. The
“open circuit” diagnostic code remains active
at all times. The engine harness or the ICSM
appears to have a problem. Proceed to Test Step
5.
Test Step 5. Check the Operation of the

g00853960
Illustration 597 ICSM
Harness connectors for the thermocouples
(2) Negative wire for the turbocharger’s thermocouple A. Turn the engine control switch to the OFF/RESET
(1) Positive wire for the turbocharger’s thermocouple position. Switch the 16 amp circuit breaker for
(A) Negative wire for the exhaust port’s thermocouple the ECM OFF.
(B) Positive wire for the exhaust port’s thermocouple
(C) This terminal is not used.
603
Table 78
20-Pin Cylinder Number or Turbocharger
Connector
Terminal G3606 G3608
B + 1 1
C -
M + 2 2
N -
P + 3 3
D -
F + 4 4
E -
H + 5 5
G -
R + 6 6
g00854335
Illustration 598 Q -
(1) ICSM +
(2) 20-pin connector for the thermocouples V N/A 7
U -
B. Disconnect the 20-pin connector from the ICSM.
A + N/A 8
Thoroughly inspect connectors for moisture, for
corrosion, and for contamination. L -
Note: When the 20-pin connector is disconnected K + Inlet for the Inlet for the
from the ICSM, numerous “open circuit” codes Turbocharger Turbocharger
T -
Turbine Turbine
for the thermocouples will become active. Keep
your mind on the diagnostic code for the suspect J + Outlet for the Outlet for the
thermocouple. -
Turbocharger Turbocharger
S Turbine Turbine
position. Wait at least 30 seconds so that any
codes may become activated. “Open circuit”
diagnostic codes for the thermocouples should
activate. An “open circuit” diagnostic code
for the suspect thermocouple should also be
activated.

the ECM OFF.
E. Refer to Table 78 for the terminal locations.

Determine the positive terminal and the negative
terminal for the suspect thermocouple.
604
Results:
• OK – Active diagnostic codes are created

according to the above steps. The ICSM appears
to be working properly. There appears to be a
problem with the harness for the thermocouples.
Repair: Repair any faulty wiring and/or

connectors, when possible. Replace the harness,
if necessary. Clear any diagnostic codes. Verify
that the condition is resolved.
STOP.
• Not OK – Active diagnostic codes are not created

according to the above steps. The ICSM does not
respond properly when the 20-pin connector is
removed and when the jumper wire is connected.
The ICSM may have a problem.



g00901501
Illustration 599
STOP.
20-pin connector on the ICSM
F. Connect one end of a jumper wire to the i01762080

appropriate positive terminal on the module’s
20-pin connector. Connect the other end of the Thermocouple Test
jumper wire to the appropriate negative terminal.
SMCS Code: 7498-038
G. Switch the 16 amp circuit breaker for the ECM
S/N: BLB1-Up
position. Wait at least 30 seconds so that any S/N: BKE1-Up
codes may become activated. An active “short
circuit” diagnostic code for the suspect sensor System Operation Description:
should be activated.
Use this procedure to troubleshoot thermocouples
Expected Result: that have diagnostic codes which are active or
easily repeated.
An “open circuit” diagnostic code for the suspect
thermocouple is activated when the 20-pin A thermocouple is installed into the exhaust port
connector is disconnected from the ICSM. A “short of each engine cylinder, into the inlet for each
circuit” diagnostic code becomes active when the turbocharger turbine, and into the outlet for each
jumper wire is connected to the ICSM for at least turbocharger turbine.
30 seconds.
605
The thermocouples do not require a supply voltage

from the Integrated Combustion Sensing Module
(ICSM). Each thermocouple has two wires. Each
thermocouple develops a low voltage signal that is
detected by the ICSM.

thermocouple wire that has a short circuit to a high
the thermocouple’s voltage is above an acceptable
range.

thermocouple wire that has a short circuit to a low
the thermocouple has a short to ground.

thermocouple’s circuit that has a low current flow.
A -05 diagnostic code may also occur if there is
an open circuit.
A diagnostic code is probably caused by a problem

with a harness connector or by a wiring problem.
The next likely cause is a faulty thermocouple. The
least likely cause is a problem with the ICSM.


resolved.
606
g00866013
Illustration 600
607
g00853564
Illustration 601


Note: Illustrations 602 and 603 show one side of the

engine. The other side of the engine is similar.
608
g00853835
Illustration 602
(1) ICSM
(2) 20-pin connector P72 for the thermocouples
g00853840
Illustration 603
Right side view of the engine
(3) Thermocouple for the outlet of the turbocharger turbine
(4) Thermocouple for the inlet of the turbocharger turbine
(5) Thermocouple for the exhaust port of a cylinder
(6) Connector for the thermocouple for the turbocharger inlet
(7) Connector for the thermocouple for the turbocharger outlet
(8) Connector for the thermocouple for the exhaust port
(9) Thermocouple harness to the ICSM
B. Thoroughly inspect the following connectors for

moisture, for corrosion, and for contamination:
• 20-pin connectors on the integrated

combustion sensing modules
• Connectors for the thermocouple

C. Verify that all of the connectors are completely
connected. Verify that terminals in the suspect
thermocouple’s connector are completely
D. Check the harness and wiring for abrasion and

for pinch points from the suspect thermocouple
to the ICSM.
609
Expected Result: Table 79

Diagnostic Code Description
All of the connectors do not have moisture,
corrosion or contamination. All of the connectors are 1489-03 “Left Turbo Turbine Out Temp Sens
completely connected. The terminals in the suspect short to +batt”
thermocouple’s connector are completely inserted 1489-04 “Left Turbo Turbine Out Temp Sens
into the connector. The harness and wiring do not short to Ground”
have corrosion, abrasion or pinch points.
1489-05 “Left Turbo Turbine Out Temp Sens
Results: open circuit”
• OK – The components are in good condition with Sens short to +batt”
proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good
condition and/or at least one connection is 1490-05 “Right Turbo Turbine Out Temp
improper. Sens open circuit”
Repair: Perform the necessary repairs and/or Sens short to +batt”
replace parts, if necessary. Verify that the repair
eliminates the problem. 1491-04 “Right Turbo Turbine Out Temp
STOP. 1491-05 “Right Turbo Turbine Out Temp
Sens open circuit”
A. Switch the 16 amp circuit breaker for the ECM short to +batt”
ON. Turn the engine control switch to the STOP 1492-04 “Left Turbo Turbine Out Temp Sens
position. short to ground”
open circuit”
may become activated. Look for the codes that 1531-03 through “Cylinder #1 Exhaust Port Temp
are listed in Table 79: 1546-03 Sensor sort to +batt” through
Sensor sort to +batt”
1546-04 Sensor short to ground” through
Sensor short to ground”
1546-05 Sensor open circuit” through
Sensor open circuit”
Expected Result:
None of the above codes are active.
Results:
• No active codes – The problem seems to be

resolved. There are no active codes. The
thermocouples are operating correctly at this time.

of the harness connectors. Resume normal
operation.
STOP.
610
• Active 03 “short to +batt” – There is an active 5. Observe the “Active Diagnostic” screen on
“short to +batt” diagnostic code. Proceed to Test Cat ET. Wait at least 30 seconds so that any
Step 3. codes may become activated. If the active
“short circuit” diagnostic code recurs, the
• Active 04 “short to ground” – There is an active thermocouple is the source of the problem.
“short to ground” diagnostic code. Proceed to
Test Step 3. 6. Turn the engine control switch to the
• Active 05 “open circuit” – There is an active “open breaker for the ECM OFF.
circuit” diagnostic code. Proceed to Test Step 4.
7. Temporarily connect a new thermocouple to
Test Step 3. Disconnect the Sensor in the harness. Do not install the thermocouple
Order to Create an Open Circuit onto the engine.
A. Turn the engine control switch to the OFF/RESET 8. Switch the 16 amp circuit breaker for the ECM
position. Switch the 16 amp circuit breaker for ON. Turn the engine control switch to the
the ECM OFF. STOP position.
B. Disconnect the thermocouple that has the short 9. Observe the “Active Diagnostic” screen on
circuit diagnostic code. Cat ET. Wait at least 30 seconds so that any
codes may become activated. If the active
C. Switch the 16 amp circuit breaker for the ECM “short circuit” diagnostic code does not recur,
ON. Turn the engine control switch to the STOP replace the thermocouple. The correct torque
position. for a thermocouple is 12 ± 3 N·m (9 ± 2 lb ft).
Clear all of the logged diagnostic codes. Verify
D. Observe the “Active Diagnostic” screen on Cat that the problem is resolved.
may become activated. STOP.
Expected Result: • Not OK – Before the suspect thermocouple was

disconnected, there was an active “short circuit”
An open circuit diagnostic code was generated for diagnostic code. After the thermocouple was
the suspect thermocouple. disconnected, the active “short circuit” diagnostic
code remained. If the problem is on the left
Results: side of the engine, proceed to Test Step 5. If
the problem is on the right side of the engine,
• OK – Before the suspect thermocouple was proceed to Test Step 6.
disconnected, there was an active “short circuit”
diagnostic code. After the thermocouple was Test Step 4. Create a Short Circuit at the
disconnected, there was an active “open circuit” Connector for the Thermocouple
diagnostic code.
position.
OFF/RESET position. Switch the 16 amp circuit B. Fabricate a jumper wire with the appropriate
breaker for the ECM OFF. terminals on each end.
2. Thoroughly inspect the thermocouple’s Note: Observe the “Active Diagnostic” screen on
connectors for moisture. Inspect the seals for Cat ET before installing the jumper wire and after
the connectors. installing the jumper wire.
3. Reconnect the thermocouple to the harness.

STOP position.
611
• Not OK – A “short circuit” diagnostic code is not

active when the jumper wire is connected. The
“open circuit” diagnostic code remains active
at all times. The engine harness or the ICSM
appears to have a problem. If the problem is on
the left side of the engine, proceed to Test Step 5.
If the problem is on the right side of the engine,
proceed to Test Step 6.
Test Step 5. Check the Operation of the

Left Side ICSM
g00853960 the ECM OFF.
Illustration 604
Harness connectors for the thermocouples
(2) Negative wire for the turbocharger’s thermocouple
(1) Positive wire for the turbocharger’s thermocouple
(A) Negative wire for the exhaust port’s thermocouple
(B) Positive wire for the exhaust port’s thermocouple
(C) This terminal is not used.
C. Create a short circuit by inserting the jumper

wire into the harness connector for the suspect
thermocouple. If the connector has two terminals,
insert one end of the jumper wire into each
terminal. If the connector has three terminals,
insert one end of the jumper wire into terminal
“A” and insert the other end of the jumper wire
into terminal “B”. The jumper wire must remain
connected in this manner for at least 30 seconds.
D. Remove the jumper wire from the engine

harness. The jumper wire must be removed for
at least 30 seconds.
g00853835
Expected Result: Illustration 605
View of the center of the left side of the engine
A “short circuit” diagnostic code becomes active (1) ICSM
when the jumper wire is connected to the engine (2) 20-pin connector P72 for the thermocouples on the left side
harness for 30 seconds. An “open circuit” diagnostic of the engine
code becomes active when the jumper wire is
removed from the engine harness for 30 seconds. B. Disconnect connector (P72) from the ICSM.
Thoroughly inspect connectors P72 and J72 for
Results: moisture, for corrosion, and for contamination.
• OK – A “short circuit” diagnostic code becomes Note: When P72 is disconnected from the
active when the jumper wire is connected. An ICSM, numerous “open circuit” codes for the
“open circuit” diagnostic code becomes active thermocouples will become active. Keep your
when the jumper wire is removed. The engine mind on the diagnostic code for the suspect
harness and the ICSM appear to be functioning thermocouple.
properly.
Repair: To verify that the thermocouple is faulty, ON. Turn the engine control switch to the STOP
reconnect the suspect thermocouple for at least position.
30 seconds. If the “open circuit” diagnostic code
returns, replace the thermocouple. Tighten the Wait at least 30 seconds so that any codes may
new thermocouple to 12 ± 3 N·m (9 ± 2 lb ft). become activated. “Open circuit” diagnostic
Verify that the new thermocouple does not create codes for the thermocouples on the left side of
a diagnostic code. the engine should activate. An “open circuit”
diagnostic code for the suspect thermocouple
STOP. should also be activated.
612

the ECM OFF.

Table 80
Connector
Terminal G3612 G3616
J72 Left Bank Left Bank
B + 2 2
C -
M + 4 4
N -
P + 6 6
D -
F + 8 8
E -
H + 10 10
G -
R + 12 12
Q -
V + N/A 14
U -
g00854298
Illustration 606
A + N/A 16
20-pin connector J72 for the ICSM
L -
+ F. Connect one end of a jumper wire to the
K Inlet for the Inlet for the
Turbocharger Turbocharger appropriate positive terminal on connector J72.
T - Connect the other end of the jumper wire to the
Turbine Turbine
appropriate negative terminal.
J + Outlet for the Outlet for the
Turbocharger Turbocharger G. Switch the 16 amp circuit breaker for the ECM
S -
Turbine Turbine ON. Turn the engine control switch to the STOP
codes may become activated. A “short circuit”
diagnostic code for the suspect sensor should
be activated.
Expected Result:

thermocouple is activated when P72 is disconnected
from the ICSM. A “short circuit” diagnostic code
becomes active when the jumper wire is connected
for at least 30 seconds.
613
Results:
• OK – Active diagnostic codes are created

according to the above steps. The ICSM appears
to be working properly. There appears to be
a problem with the left side harness for the
thermocouples.
Repair: Repair any faulty wiring and/or connectors,

when possible. Replace any faulty wiring and/or
connectors, if necessary. Clear any diagnostic
codes. Verify that the condition is resolved.
STOP.

according to the above steps. The ICSM does
not respond properly when connector P72 is
Repair: It is unlikely that the ICSM has failed. Illustration 607 g00854335
Exit this procedure and perform this procedure View of the center of the right side of the engine
(1) ICSM
following procedure: (2) 20-pin connector P82 for the thermocouples on the right side
of the engine
Troubleshooting, “Replacing the ICSM”. B. Disconnect connector P82 from the ICSM.
Thoroughly inspect connectors P82 and J82 for
If the problem is resolved with a new ICSM, install moisture, for corrosion, and for contamination.
the original ICSM and verify that the problem
returns. If the new ICSM operates correctly and Note: When P82 is disconnected from the
the original ICSM does not work correctly, replace ICSM, numerous “open circuit” codes for the
the original ICSM. Refer to Troubleshooting, thermocouples will become active. Keep your
“Replacing the ICSM”. mind on the diagnostic code for the suspect
thermocouple.
STOP.
Test Step 6. Check the Operation of the ON. Turn the engine control switch to the STOP
Right Side ICSM position. Wait at least 30 seconds so that any
codes may become activated. “Open circuit”
A. Turn the engine control switch to the OFF/RESET diagnostic codes for the thermocouples on the
position. Switch the 16 amp circuit breaker for right side of the engine should activate. An
the ECM OFF. “open circuit” diagnostic code for the suspect
thermocouple should also be activated.

the ECM OFF.

614
Table 81
Connector
J82 G3612 G3616
Terminal Right Bank Right Bank
B + 1 1
C -
M + 3 3
N -
P + 5 5
D -
F + 7 7
E -
H + 9 9
G -
R + 11 11
Q -
V + N/A 13
U -
A + N/A 15
L -
K + Inlet for the Inlet for the

Turbocharger Turbocharger
T -
Turbine Turbine
J + Outlet for the Outlet for the
g00854356
Turbocharger Turbocharger Illustration 608
S -
Turbine Turbine 20-pin connector J82 on the ICSM
F. Connect one end of a jumper wire to the

appropriate positive terminal on connector J82.
Connect the other end of the jumper wire to the
appropriate negative terminal.
G. Switch the 16 amp circuit breaker for the ECM

codes may become activated. An active “short
circuit” diagnostic code for the suspect sensor
should be activated.
Expected Result:

thermocouple is activated when P82 is disconnected
from the ICSM. A “short circuit” diagnostic code
becomes active when the jumper wire is connected
for at least 30 seconds.
615
Results: Logged diagnostic codes provide a historical

• OK – Active diagnostic codes are created Caterpillar Electronic Technician (Cat ET) to print
according to the above steps. The ICSM appears the logged codes to a file.
to be working properly. There appears to be
a problem with the left side harness for the This troubleshooting procedure may generate
thermocouples. additional diagnostic codes. Keep your mind on
Repair: Repair any faulty wiring and/or Clear the diagnostic codes after the problem is
connectors, when possible. Replace the harness, resolved.
if necessary. Clear any diagnostic codes. Verify
that the condition is resolved.
STOP.

according to the above steps. The ICSM does
not respond properly when connector P82 is



STOP.
i01762278
Wastegate Solenoid
SMCS Code: 1057-038
S/N: BEN1-Up
S/N: 4ZS1-Up
The Electronic Control Module (ECM) controls the

wastegate actuator by adjusting the current flow
through the actuator’s solenoid.

short circuit in a harness or by a problem with an
electrical connector. The next likely cause is a short
circuit inside the actuator solenoid. The least likely
cause is a problem with the ECM.
616
g00901542
Illustration 609
Schematic of the circuit for the wastegate actuator

g00850664
Illustration 611
Harness side of the ECM connector P2
(P2-8) Wastegate actuator’s circuit driver
(P2-9) Return
g00850164
Illustration 610

the ECM OFF. Illustration 612
g00901555
Harness side of the terminal box’s connector P6

Troubleshooting, “Inspecting Electrical Connectors”. (P6-13) Return
617
Results:

proper connections. If you are troubleshooting
a “526-05 open” diagnostic code, proceed to
Test Step 2. If you are troubleshooting a “526-06

is improper.

Illustration 613 g00901549 STOP.

(AA) Engine harness connector for the wastegate actuator
B. Thoroughly inspect each of the following A. Turn the engine control switch to the OFF/RESET
connectors: position. Switch the 16 amp circuit breaker for
the ECM OFF.
B. Disconnect the P2 connector from the ECM.
• Engine harness’ connectors for the wastegate
actuator

box’s P6 connector. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

that are associated with the circuit for the
wastegate actuator.
c. Thoroughly inspect the wastegate actuator’s

engine harness connectors for moisture and Illustration 614 g00850667
for corrosion. Check the harness and wiring ECM side of connector P2
for abrasion and for pinch points from the
wastegate actuator to the ECM. (P2-9) Return
Expected Result: C. Measure the resistance between terminals P2-8

All connectors, pins, and sockets are connected harnesses in order to check for an intermittent
properly. The connectors and the wiring do not have problem. Be sure to wiggle the harnesses near
corrosion, abrasion, or pinch points. each of the connectors.
Expected Result:

618

• OK – The resistance is between 5.0 and 20.6 the wastegate actuator. Proceed to Test Step 4.
The return wire may have a short to ground. Test Step 4. Check the Return Wiring
Proceed to Test Step 3. Inside the Engine Harness for a Short to
Ground

the ECM.
g00901573
Illustration 616
Terminal box’s side of connector P6
(P6-13) Return

g00851601
Illustration 615 to check for an intermittent problem. Be sure to
ECM side of connector P2 wiggle the harness near the connectors.
(P2-9) Return Expected Result:
B. Measure the resistance between the ground The resistance is greater than 20,000 ohms.
strap for the ECM and P2-9. During this
measurement, wiggle the harnesses in order to Results:
wiggle the harness near the connectors. • OK – The resistance is greater than 20,000
Expected Result: appears to be OK. There is a problem with the
Results: when possible. Replace the parts, if necessary.
• OK – The resistance is greater than 20,000 STOP.

ohms. The return wire for the wastegate actuator
619
• Not OK – The resistance is less than 20,000 .

may have a problem or there may be a problem STOP.
with the solenoid. Proceed to Test Step 5.
Test Step 5. Check the Solenoid for an and the Solenoid for an Open Circuit
Internal Short Circuit
g00901571
Illustration 618
(P6-13) Return
Illustration 617 g00901549 B. Measure the resistance between terminals P6-13

Left side view of the engine and P6-23. During this measurement, wiggle the
(AA) Engine harness connector for the wastegate actuator
(A) Wastegate actuator’s circuit driver problem. Be sure to wiggle the harness near the
(B) Return connectors.
A. Disconnect the engine harness connector from Expected Result:

the wastegate actuator.
B. Measure the resistance between terminal B of the
solenoid’s connector and the connector’s shell. Results:
Expected Result: • OK – The resistance is between 5.0 and 20.6

The resistance is greater than 20,000 ohms. appear to be OK. The wiring inside the terminal
Results: a problem.
• OK – The resistance is greater than 20,000 ohms. Repair: Repair the wiring and/or connectors,
The solenoid does not have an internal short when possible. Replace the wiring, if necessary.
circuit. The return wire inside the engine harness
has a short to ground. STOP.
Repair: Repair the engine harness or connectors, • Not OK – The resistance is greater than 20.6
when possible. Replace the harness, if necessary. ohms. There is a problem with the engine harness
or with the solenoid. Proceed to Test Step 7.
STOP.


620
Test Step 7. Check the Solenoid for an Test Step 8. Check all of the Wiring and
Open Circuit the Solenoid for a Short Circuit
g00850667
Illustration 620
(P2-9) Return
A. Disconnect connector P2 from the ECM.

g00901549
Illustration 619
Left side view of the engine and P2-9. During this measurement, wiggle the
(AA) Engine harness connector for the wastegate actuator harness in order to check for an intermittent
(A) Wastegate actuator’s circuit driver problem. Be sure to wiggle the harness near the
(B) Return
connectors.
A. Disconnect the engine harness connector from Expected Result:
the wastegate actuator’s solenoid.
B on the solenoid’s connector. Results:
Expected Result:
The resistance is between 5.0 and 10.3 ohms. short circuit. Proceed to Test Step 11.
Results:
There is a problem with a connector and/or with
• OK – The resistance of the solenoid is between the wiring or the solenoid has a problem. Proceed
5.0 and 10.3 ohms. The solenoid does not have to Test Step 9.
engine harness.

STOP.


STOP.
621
g00901571
Illustration 621
(P6-13) Return
(P623) Wastegate actuator’s circuit driver

g00901549
Illustration 622
harness in order to check for an intermittent (AA) Engine harness connector for the wastegate actuator
(A) Wastegate actuator’s circuit driver
problem. Be sure to wiggle the harness near the (B) Return
connectors.
A. Disconnect the engine harness’ connector from
Expected Result: the wastegate actuator’s solenoid.
The resistance is between 5.0 and 20.6 ohms. B. Measure the resistance between terminals B and
Results:
Expected Result:
ohms. The engine harness and the solenoid The resistance is between 5.0 and 10.3 ohms.
box has a problem. Results:
5.0 and 10.3 ohms. The solenoid does not have
a problem. The engine harness appears to have
STOP. a short circuit.
• Not OK – The resistance is lower than 5.0 ohms. Repair: Repair the engine harness or connectors,
There is a problem with the engine harness or when possible. Replace the harness, if necessary.
with the solenoid. Proceed to Test Step 10.
STOP.

than 5.0 ohms. The solenoid has a short circuit.

STOP.
622
Test Step 11. Create an Open Circuit and Repair: Perform the following procedure:
A. Prevent fuel from entering the engine. Verify Switch the 16 amp circuit breaker for the ECM
that the gas supply to the engine is OFF. OFF.
B. Verify that the engine control switch is in the Reinstall the terminals that were removed from
OFF/RESET position. Verify that the 16 amp connector P2. Pull on the wires in order to verify
circuit breaker for the ECM is OFF. proper installation of the terminals.

STOP.


g00850664
Illustration 623 Temporarily install a new ECM. Refer to
Harness side of the ECM P2 connector Troubleshooting, “Replacing the ECM”.
(P2-9) Return If the problem is resolved with a new ECM, install
C. Use a 151-6320 Wire Removal Tool to remove returns. If the new ECM operates correctly and
terminals P2-8 and P2-9. This will replace the the original ECM does not operate correctly,
wiring for the wastegate actuator with an open replace the original ECM. Follow the instructions
circuit. in Troubleshooting, “Replacing the ECM”.
D. Switch the 16 amp circuit breaker for the ECM STOP.

ON.
E. If a 526-05 diagnostic code and/or a 526-06 Check the Operation of the ECM
diagnostic code is logged, clear the code.
F. Turn the engine control switch to the START that the gas supply to the engine is OFF.
of 30 seconds for the generation of any codes. B. Verify that the engine control switch is in the
Then turn the engine control switch to the STOP OFF/RESET position. Verify that the 16 amp
position. circuit breaker for the ECM is OFF.

Expected Result:
Results:
• OK – When an open circuit was created, a

is operating correctly. The problem appears to
623


STOP.
• Not OK – When the wiring for the wastegate

g00850664
Illustration 624
(8) Wastegate actuator’s circuit driver Exit this procedure and perform this procedure
(9) Return again. If the problem is not resolved, perform the
D. Fabricate a jumper wire of the appropriate
length with the appropriate connectors. Insert If the problem is resolved with a new ECM, install
the jumper wire into the open terminals P2-8 the original ECM and verify that the problem
the pins. This will replace the wiring for the the original ECM does not operate correctly,
wastegate actuator with a short circuit. replace the original ECM. Follow the instructions
ON. STOP.


Wastegate Solenoid
SMCS Code: 1057-038
Then turn the engine control switch to the STOP S/N: BLB1-Up
position.
S/N: BKE1-Up
Expected Result: The Electronic Control Module (ECM) controls the

wastegate actuator by adjusting the current flow
A 526-06 diagnostic code is generated. through the actuator’s solenoid.
Results: The diagnostic code is probably caused by a

problem with an electrical connector or with the
• OK – When the wiring for the wastegate actuator wiring. The next likely cause is a problem inside
was replaced with a short circuit, a 526-06 the actuator solenoid. The least likely cause is a
diagnostic code was generated. The ECM is problem with the ECM.
operating correctly. The problem appears to be
resolved. The initial diagnostic code was probably Logged diagnostic codes provide a historical
caused by a poor electrical connection. record. Before you begin this procedure, use the
Repair: Perform the following procedure: the logged codes to a file.

OFF.
624

resolved.
g00901760
Illustration 625
Schematic of the circuit for the wastegate actuator
The ECM is connected to the wastegate actuator via the J5/P5 connectors on the terminal box.

g00850664
Illustration 627
(P2-9) Return
g00849037
Illustration 626
(2) J5/P5 connectors for the harness from the left side of the engine

the ECM OFF.
625

The proper torque is 6 ± 1 N·m (55 ± 9 lb in).

that are associated with the circuit for the
wastegate actuator.
c. Thoroughly inspect the connectors for the

wastegate actuator for moisture and for
contamination. Check the harness and wiring
for abrasion and for pinch points from the
wastegate actuator to the ECM.
g00850666
Expected Result:
Illustration 628
Harness side of the terminal box’s P5 connector All connectors, pins, and sockets are connected
(P5-39) Return properly. The connectors and the wiring do not have
(P5-47) Wastegate actuator’s circuit driver corrosion, abrasion, or pinch points.
Results:

proper connections. If you are troubleshooting
a “526-05 open” diagnostic code, proceed to
Test Step 2. If you are troubleshooting a “526-06

is improper.

STOP.

g00850659
Illustration 629 position. Switch the 16 amp circuit breaker for
Left side view of the engine the ECM OFF.
(4) Wastegate actuator
(5) Connectors for the wastegate actuator B. Disconnect the P2 connector from the ECM.

connectors:

• Connectors for the wastegate actuator
626
g00850667
Illustration 630
(P2-9) Return
C. Measure the resistance between terminals P2-8

and P2-9. During this measurement, wiggle the Illustration 631 g00851601
problem. Be sure to wiggle the harnesses near
the connectors. (1) Ground strap for the ECM
(P2-9) Return
Expected Result:
The resistance is between 5.0 and 20.6 ohms. strap for the ECM and P2 terminal (9). During
Results: to check for an intermittent problem. Be sure to
wiggle the harness near the connectors.
• OK – The resistance is between 5.0 and 20.6 Expected Result:
The low side wire may have a short to ground.
Proceed to Test Step 3. The resistance is greater than 20,000 ohms.
Results:
with the wiring for the solenoid or the solenoid • OK – The resistance is greater than 20,000
may have a problem. Proceed to Test Step 6. ohms. The return wire for the wastegate actuator
Test Step 3. Check All of the Low Side
Wiring for a Short to Ground • Not OK – The resistance is less than 20,000
the wastegate actuator. Proceed to Test Step 4.
the ECM.
627
Test Step 4. Check the Return Wiring Test Step 5. Check the Solenoid for an
Inside the Engine Harness for a Short to Internal Short Circuit
Ground
g00868476
Illustration 632
(P5-39) Return
A. Disconnect connector P5 from the terminal box. Illustration 633 g00868482
(1) Solenoid for the wastegate actuator

B. Measure the resistance between the ground (2) Solenoid’s connector
strap for the ECM and terminal P5-39. During (B) Return
to check for an intermittent problem. Be sure to A. Disconnect the engine harness connector from
wiggle the harness near the connectors. the wastegate actuator.
Expected Result: B. Measure the resistance between terminal B of the

solenoid’s connector and the connector’s shell.
Expected Result:
Results:
• OK – The resistance is greater than 20,000
ohms. The return wire inside the engine harness Results:
appears to be OK. There is a problem with the
return wire inside the terminal box. • OK – The resistance is greater than 20,000 ohms.
Repair: Repair the harness and/or the connector, circuit. The return wire inside the engine harness
when possible. Replace the harness, if necessary. has a short to ground.
STOP. Repair: Repair the engine harness or connectors,

ohms. The low side wire inside the engine harness STOP.
may have a problem or there may be a problem
with the solenoid. Proceed to Test Step 5. • Not OK – The resistance is less than 20,000

628
. Test Step 7. Check the Solenoid for an

Open Circuit
STOP.

g00851590
Illustration 634
(P5-39) Return

g00850682
harness in order to check for an intermittent Illustration 635
problem. Be sure to wiggle the harness near the (1) Solenoid on the wastegate actuator
connectors. (2) Solenoid connector
(A) Wastegate actuator’s circuit driver
(B) Return
Expected Result:
The resistance is between 5.0 and 20.6 ohms. A. Disconnect the engine harness connector from
the wastegate actuator’s solenoid.
Results:
B. Measure the resistance between terminals B and
appear to be OK. The wiring inside the terminal Expected Result:
a problem. The resistance is between 5.0 and 10.3 ohms.
Repair: Repair the wiring and/or connectors, Results:

STOP. 5.0 and 10.3 ohms. The solenoid does not have
engine harness.
ohms. There is a problem with the engine harness
or with the solenoid. Proceed to Test Step 7. Repair: Repair the engine harness or connectors,
STOP.

629
Repair: Replace the solenoid. Refer to Operation Test Step 9. Check the Engine Harness
and Maintenance Manual, “Electrohydraulic and the Solenoid for a Short Circuit
STOP.

g00851590
Illustration 637
(P5-39) Return
g00850667
Illustration 636
ECM side of connector P2 B. Measure the resistance between harness
(P2-8) Wastegate actuator’s circuit driver terminals P5-39 and P5-47. During this
(P2-9) Return measurement, wiggle the harness in order to
A. Disconnect connector P2 from the ECM. wiggle the harnesses near the connectors.
B. Measure the resistance between terminals P2-8 Expected Result:

harness in order to check for an intermittent The resistance is between 5.0 and 20.6 ohms.
connectors. Results:
Expected Result: • OK – The resistance is between 5.0 and 20.6

The resistance is between 5.0 and 20.6 ohms. appear to be OK. The wiring inside the terminal
box has a problem.
Results:
• OK – The resistance is between 5.0 and 20.6 when possible. Replace the harness, if necessary.
short circuit. Proceed to Test Step 11. STOP.
• Not OK – The resistance is less than 5.0 ohms. • Not OK – The resistance is lower than 5.0 ohms.
There is a problem with a connector and/or with There is a problem with the engine harness or
the wiring or the solenoid has a problem. Proceed with the solenoid. Proceed to Test Step 10.
to Test Step 9.
630
Test Step 10. Check the Solenoid for a Repair: Replace the solenoid. Refer to Operation
Short Circuit and Maintenance Manual, “Electrohydraulic
STOP.
Test Step 11. Create an Open Circuit and


g00850682 g00850664
(1) Wastegate actuator’s solenoid Harness side of the ECM P2 connector
(2) Connector on the solenoid (P2-8) Wastegate actuator’s circuit driver
(A) Wastegate actuator’s circuit driver (P2-9) Return
(B) Return
A. Disconnect the engine harness’ connector from terminals P2-8 and P2-9. This will replace the
the wastegate actuator’s solenoid. wiring for the wastegate actuator with an open
circuit.
B on the solenoid’s connector. D. Switch the 16 amp circuit breaker for the ECM
ON.
Expected Result:
The resistance is between 5.0 and 10.3 ohms. diagnostic code is logged, clear the code.
Results: F. Turn the engine control switch to the START
• OK – The resistance of the solenoid is between of 30 seconds for the generation of any codes.
5.0 and 10.3 ohms. The solenoid does not have Then turn the engine control switch to the STOP
a problem. The engine harness appears to have position.
a short circuit.
Repair: Repair the engine harness or connectors, ET. Look for a 526-05 diagnostic code.
Expected Result:
STOP.
than 5.0 ohms. The solenoid has a short circuit.
631
Results:
• OK – When an open circuit was created, a

is operating correctly. The problem appears to

OFF.
Reinstall the terminals that were removed from g00850664

connector P2. Pull on the wires in order to verify Illustration 640
proper installation of the terminals. Harness side of the ECM P2 connector
(8) Wastegate actuator’s circuit driver
Reconnect all of the connectors. Verify that the (9) Return
STOP. terminals P2-8 and P2-9.
• Not OK – When an open circuit was created, a D. Fabricate a jumper wire of the appropriate
526-05 diagnostic code was not generated. The length with the appropriate connectors. Insert
ECM may have a problem. the jumper wire into the open terminals P2-8
and P2-9. Verify that the sockets are contacting
Repair: It is unlikely that the ECM has failed. the pins. This will replace the wiring for the
Exit this procedure and perform this procedure wastegate actuator with a short circuit.
following procedure: E. Switch the 16 amp circuit breaker for the ECM
ON.
Troubleshooting, “Replacing the ECM”. F. If a 526-05 diagnostic code and/or a 526-06
diagnostic code is logged, clear the code.
If the problem is resolved with a new ECM, install
the original ECM and verify that the problem G. Turn the engine control switch to the START
returns. If the new ECM operates correctly and position and crank the engine. Allow a minimum
the original ECM does not operate correctly, of 30 seconds for the generation of any codes.
replace the original ECM. Follow the instructions Then turn the engine control switch to the STOP
in Troubleshooting, “Replacing the ECM”. position.
STOP. H. Observe the “Active Diagnostic” screen on Cat

Check the Operation of the ECM Expected Result:
A. Prevent fuel from entering the engine. Verify A 526-06 diagnostic code is generated.
Results:
OFF/RESET position. Verify that the 16 amp • OK – When the wiring for the wastegate actuator
circuit breaker for the ECM is OFF. was replaced with a short circuit, a 526-06
diagnostic code was generated. The ECM is
operating correctly. The problem appears to be
resolved. The initial diagnostic code was probably
caused by a poor electrical connection.

OFF.
632


STOP.
• Not OK – When the wiring for the wastegate



If the problem is resolved with a new ECM, install

returns. If the new ECM operates correctly and
STOP.
633
Index Section
Index
Numerics E096 High Fuel Pressure .................................... 178
E100 Low Engine Oil Pressure Warning ............. 179
+5V Sensor Voltage Supply......................... 230, 241 E101 High Crankcase Pressure Warning............ 179
+8V Sensor Voltage Supply......................... 254, 263 E127 Engine Oil Filter Diff Pressure Low
Warning ............................................................. 179
E128 Engine Oil Filter Diff Pressure Low
A Shutdown........................................................... 180
E129 Engine Oil Filter Diff Pressure High
Air Starting Motor (Malfunction)............................. 38 Warning ............................................................. 180
Probable Causes ............................................... 38 E130 Engine Oil Filter Diff Pressure High
Recommended Repairs ..................................... 39 Shutdown........................................................... 180
Air/Fuel Pressure Module ............................ 274, 283 E135 Low Jacket Water Pressure Shutdown....... 180
Analog Sensor Signal.................................. 291, 300 E200 Continuous Cylinder Misfire ....................... 181
E201 Cylinder #1 Intermittent Misfire .................. 181
C E203 Cylinder #3 Intermittent Misfire .................. 182
Choke Actuator Solenoid............................. 309, 317 E205 Cylinder #5 Intermittent Misfire .................. 182
Combustion Sensor ..................................... 325, 332 E206 Cylinder #6 Intermittent Misfire .................. 183
Crankcase Pressure (High) ................................... 39 E207 Cylinder #7 Intermittent Misfire .................. 183
Probable Causes ............................................... 39 E208 Cylinder #8 Intermittent Misfire .................. 183
Recommended Repairs ..................................... 40 E209 Cylinder #9 Intermittent Misfire .................. 184
Customer Passwords............................................. 29 E210 Cylinder #10 Intermittent Misfire ................ 184
Cylinder Firing Pulse ................................... 340, 351 E211 Cylinder #11 Intermittent Misfire ................ 184
E212 Cylinder #12 Intermittent Misfire ................ 185
D E214 Cylinder #14 Intermittent Misfire ................ 185
Desired Speed Input (4 - 20 mA)......................... 368 E216 Cylinder #16 Intermittent Misfire ................ 186
Detonation ............................................................. 40 E223 High Gas Temperature ............................... 186
Probable Causes ............................................... 40 E224 High Jacket Water Inlet Pressure ............... 186
Recommended Repairs ..................................... 40 E225 Engine Overcrank ...................................... 187
Detonation Sensors ..................................... 374, 386 E226 Driven Equipment Not Ready..................... 187
Diagnostic Codes .................................................. 74 E229 Fuel Energy Content Setting Low .............. 187
Active Diagnostic Codes .................................... 75 E230 Fuel Energy Content Setting High.............. 187
Logged Diagnostic Codes.................................. 75 E231 Fuel Quality Out of Range.......................... 188
Diagnostic Functional Tests................................. 230 E233 Low Engine Pre-Lube Pressure ................. 188
Driven Equipment (Prevention of Operation)......... 41 E242 Engine Overload ........................................ 188
Probable Causes ............................................... 41 E243 High Left Turbo Turbine Outlet
Recommended Repairs ..................................... 41 Temperature....................................................... 188
E244 High Right Turbo Turbine Outlet
Temperature....................................................... 189
E E245 High Right Turbo Turbine Inlet
Temperature....................................................... 189
E004 Engine Overspeed Shutdown .................... 175 E246 High Left Turbo Turbine Inlet Temperature.. 190
E013 High Crankcase Pressure Shutdown ......... 175 E264 Emergency Stop Activated......................... 190
E016 High Engine Coolant Temperature E266 Low Hydrax Oil Pressure ........................... 190
Shutdown........................................................... 175 E268 Unexpected Engine Shutdown ................... 191
E017 High Engine Coolant Temperature E269 Customer Shutdown Requested ................ 191
Warning ............................................................. 176 E270 Driven Equipment Shutdown Requested ... 191
E019 High Engine Oil Temperature Shutdown .... 176 E337 High Engine Oil to Engine Coolant Diff
E020 High Engine Oil Temperature Warning....... 176 Temp .................................................................. 191
E026 High Inlet Air Temperature Shutdown ........ 177 E384 Left Air Inlet Restriction.............................. 192
E027 High Inlet Air Temperature Warning ........... 177 E385 Right Air Inlet Restriction ........................... 192
E038 Low Engine Coolant Temperature E386 Low Engine Coolant or Engine Oil Level.... 192
Warning ............................................................. 177 E401 Cylinder #1 Detonation............................... 193
E040 Low Engine Oil Pressure Shutdown........... 177 E402 Cylinder #2 Detonation............................... 193
E042 Low System Voltage Shutdown.................. 178 E403 Cylinder #3 Detonation............................... 193
E043 Low System Voltage Warning .................... 178 E404 Cylinder #4 Detonation............................... 193
E050 High System Voltage Warning ................... 178 E405 Cylinder #5 Detonation............................... 194
634
Index Section
E406 Cylinder #6 Detonation............................... 194 E821 Cyl #1 Exhaust Port Temp Deviating High.. 214
E410 Cylinder #10 Detonation............................. 195 E825 Cyl #5 Exhaust Port Temp Deviating High.. 216
E415 Cylinder #15 Detonation............................. 196 E830 Cyl #10 Exhaust Port Temp Deviating
E416 Cylinder #16 Detonation............................. 197 High ................................................................... 218
E421 Cylinder #1 Detonation Shutdown.............. 197 E831 Cyl #11 Exhaust Port Temp Deviating
E422 Cylinder #2 Detonation Shutdown.............. 197 High ................................................................... 219
E430 Cylinder #10 Detonation Shutdown............ 200 High ................................................................... 221
E431 Cylinder #11 Detonation Shutdown............ 200 E836 Cyl #16 Exhaust Port Temp Deviating
E432 Cylinder #12 Detonation Shutdown............ 200 High ................................................................... 221
E433 Cylinder #13 Detonation Shutdown............ 201 E841 Cyl #1 Exhaust Port Temp Deviating Low .. 222
E498 Fuel Pressure Present During Initial E845 Cyl #5 Exhaust Port Temp Deviating Low .. 223
Cranking ............................................................ 202 E846 Cyl #6 Exhaust Port Temp Deviating Low .. 224
E601 Cylinder #1 Continuous Misfire .................. 202 E847 Cyl #7 Exhaust Port Temp Deviating Low .. 224
E604 Cylinder #4 Continuous Misfire .................. 203 E850 Cyl #10 Exhaust Port Temp Deviating Low.. 226
E610 Cylinder #10 Continuous Misfire ................ 205 E856 Cyl #16 Exhaust Port Temp Deviating Low.. 229
E611 Cylinder #11 Continuous Misfire ................ 205 ECM Output Circuit (Fuel Control)............... 400, 412
E612 Cylinder #12 Continuous Misfire ................ 206 ECM Output Circuit (Prelubrication Oil
E613 Cylinder #13 Continuous Misfire ................ 206 Pump) ........................................................ 424, 437
E614 Cylinder #14 Continuous Misfire ................ 206 ECM Output Circuit (Starting Motor) ........... 449, 460
E615 Cylinder #15 Continuous Misfire ................ 207 ECM Status Indicator Output............................... 470
E616 Cylinder #16 Continuous Misfire ................ 207 ECM Will Not Accept Factory Passwords .............. 42
E801 Cylinder #1 High Exhaust Port Temp ......... 207 Probable Causes ............................................... 42
E802 Cylinder #2 High Exhaust Port Temp ......... 208 Recommended Repairs ..................................... 42
E803 Cylinder #3 High Exhaust Port Temp ......... 208 Electrical Connectors and Functions ..................... 16
E804 Cylinder #4 High Exhaust Port Temp ......... 208 Harness Wire Identification................................ 16
E805 Cylinder #5 High Exhaust Port Temp ......... 209 Sensors.............................................................. 19
E806 Cylinder #6 High Exhaust Port Temp ......... 209 Terminal Box ...................................................... 17
E807 Cylinder #7 High Exhaust Port Temp ......... 210 Electrical Power Supply ............................... 478, 485
E808 Cylinder #8 High Exhaust Port Temp ......... 210 Electrohydraulic System Oil Pressure (Low) ......... 42
E809 Cylinder #9 High Exhaust Port Temp ......... 211 Probable Causes ............................................... 42
E810 Cylinder #10 High Exhaust Port Temp ....... 211 Recommended Repairs ..................................... 42
E811 Cylinder #11 High Exhaust Port Temp ....... 212 Electronic Service Tool Will Not Communicate with
E812 Cylinder #12 High Exhaust Port Temp ....... 212 ECM or ICSM....................................................... 43
E813 Cylinder #13 High Exhaust Port Temp ....... 213 Probable Causes ............................................... 43
E814 Cylinder #14 High Exhaust Port Temp ....... 213 Recommended Repairs ..................................... 43
E815 Cylinder #15 High Exhaust Port Temp ....... 213 Electronic Service Tools ........................................ 25
E816 Cylinder #16 High Exhaust Port Temp ....... 214 Caterpillar Electronic Technician (ET)................ 27
635
Index Section
Electronic Troubleshooting .................................... 10 Excessive Engine Oil Consumption....................... 60

Engine Coolant Level (Low)................................... 44 Probable Causes ............................................... 60
Probable Causes ............................................... 44 Recommended Repairs ..................................... 60
Recommended Repairs ..................................... 44 Exhaust Emission Too High/Fuel Consumption Too
Engine Coolant Temperature (High) ...................... 44 High ..................................................................... 61
Probable Causes ............................................... 44 Probable Causes ............................................... 61
Recommended Repairs ..................................... 45 Recommended Repairs ..................................... 61
Engine Coolant Temperature (Low)....................... 46 Exhaust Port Temperature (High) .......................... 62
Engine Cranks but Will Not Start ........................... 47 Exhaust Port Temperature (Low) ........................... 63
Engine Misfires, Runs Rough or Is Unstable......... 49
Probable Causes ............................................... 49
Recommended Repairs ..................................... 49 F
Engine Monitoring System .................................... 28
Engine Oil Filter Differential Pressure ................... 51 Factory Passwords ................................................ 29
Probable Causes ............................................... 51 Factory Passwords Worksheet .............................. 30
Recommended Repairs ..................................... 51 Flash Programming ............................................... 30
Engine Oil Level (Low)........................................... 52 Flash Programming............................................ 30
Probable Causes ............................................... 52 Fuel Actuator Solenoid ................................ 506, 514
Recommended Repairs ..................................... 52 Fuel Energy Content.............................................. 63
Engine Oil Pressure (Low)..................................... 52 Probable Causes ............................................... 63
Recommended Repairs ..................................... 52 Fuel Pressure ........................................................ 64
Engine Oil Temperature (High) .............................. 53 Probable Causes ............................................... 64
Recommended Repairs ..................................... 53
Engine Overcrank.................................................. 54
Probable Causes ............................................... 54 G
Engine Overload.................................................... 55 Gas Temperature (High) ........................................ 64
Engine Overspeed................................................. 55
Probable Causes ............................................... 55
Recommended Repairs ..................................... 55 I
Engine Pre-Lube Pressure (Low) .......................... 56
Probable Causes ............................................... 56 Ignition Transformers Primary Circuit .......... 522, 531
Recommended Repairs ..................................... 56 Ignition Transformers Secondary Circuit and Spark
Engine Shutdown .................................................. 56 Plugs.................................................................. 542
Probable Causes ............................................... 56 Important Safety Information ................................... 2
Recommended Repairs ..................................... 57 Inlet Air Restriction ................................................ 65
Engine Shutdown (Unexpected)............................ 57 Probable Causes ............................................... 65
Recommended Repair ....................................... 57 Inlet Air Temperature (High) .................................. 65
Engine Shutdown without a Diagnostic Code........ 58 Probable Causes ............................................... 65
Recommended Repairs ..................................... 59 Inspecting Electrical Connectors ......................... 546
Engine Speed/Timing Sensor...................... 493, 499 Integrated Combustion Sensing Module
Engine Starts but Stalls Immediately..................... 59 (ICSM) ....................................................... 552, 556
Probable Causes ............................................... 59 Intermittent Engine Shutdown ............................... 66
Recommended Repairs ..................................... 59 Probable Causes ............................................... 66
Event Codes ........................................................ 173 Recommended Repairs ..................................... 66
Active Event Codes.......................................... 174
Diagnostic Codes and Event Codes ................ 174
Logged Event Codes ....................................... 175 J
Operator Information........................................ 174
Other Symptoms .............................................. 174 Jacket Water Inlet Pressure (High) ........................ 67
Troubleshooting................................................ 174 Probable Causes ............................................... 67
636
Index Section
Jacket Water Pressure (Low)................................. 68 MID 036 - CID 0175 - FMI 04 Engine Oil Temperature
Probable Causes ............................................... 68 short to ground .................................................... 84
Recommended Repairs ..................................... 68 MID 036 - CID 0190 - FMI 02 Loss of Engine Speed
Jacket Water to Engine Oil Differential Temperature signal ................................................................... 85
(Low).................................................................... 68 MID 036 - CID 0190 - FMI 08 Engine Speed signal
Probable Causes ............................................... 68 abnormal.............................................................. 85
Recommended Repairs ..................................... 68 MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power
Supply short to +batt ........................................... 85
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power
M Supply short to ground ........................................ 86
MID 036 - CID 0301 - FMI 05 Ignition Transformer
Mechanical Noise (Knock) in Engine..................... 69 Primary #1 open circuit........................................ 86
Probable Causes ............................................... 69 MID 036 - CID 0301 - FMI 06 Ignition Transformer
Recommended Repairs ..................................... 69 Primary #1 short .................................................. 86
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open MID 036 - CID 0302 - FMI 05 Ignition Transformer
circuit ................................................................... 75 Primary #2 open circuit........................................ 87
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short MID 036 - CID 0302 - FMI 06 Ignition Transformer
to ground.............................................................. 76 Primary #2 short .................................................. 87
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve MID 036 - CID 0303 - FMI 05 Ignition Transformer
malfunction .......................................................... 76 Primary #3 open circuit........................................ 87
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short MID 036 - CID 0303 - FMI 06 Ignition Transformer
to +batt................................................................. 76 Primary #3 short .................................................. 88
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short MID 036 - CID 0304 - FMI 05 Ignition Transformer
to ground.............................................................. 77 Primary #4 open circuit........................................ 88
MID 036 - CID 0094 - FMI 03 Fuel Pressure MID 036 - CID 0304 - FMI 06 Ignition Transformer
open/short to +batt .............................................. 77 Primary #4 short .................................................. 89
MID 036 - CID 0094 - FMI 08 Fuel Pressure MID 036 - CID 0305 - FMI 05 Ignition Transformer
Noisy.................................................................... 77 Primary #5 open circuit........................................ 89
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0305 - FMI 06 Ignition Transformer
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0306 - FMI 05 Ignition Transformer
short to ground .................................................... 78 Primary #6 open circuit........................................ 90
MID 036 - CID 0101 - FMI 03 Crankcase Pressure MID 036 - CID 0306 - FMI 06 Ignition Transformer
MID 036 - CID 0101 - FMI 04 Crankcase Pressure MID 036 - CID 0307 - FMI 05 Ignition Transformer
short to ground .................................................... 79 Primary #7 open circuit........................................ 90
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure MID 036 - CID 0307 - FMI 06 Ignition Transformer
Sensor short to +batt ........................................... 79 Primary #7 short .................................................. 91
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure MID 036 - CID 0308 - FMI 05 Ignition Transformer
Sensor noisy signal.............................................. 80 Primary #8 open circuit........................................ 91
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure MID 036 - CID 0308 - FMI 06 Ignition Transformer
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet MID 036 - CID 0309 - FMI 05 Ignition Transformer
Pressure Sensor noisy signal .............................. 81 Primary #9 open circuit........................................ 92
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0309 - FMI 06 Ignition Transformer
Temperature open/short to +batt ......................... 81 Primary #9 short .................................................. 93
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0310 - FMI 05 Ignition Transformer
Temperature short to ground ............................... 81 Primary #10 open circuit...................................... 93
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0310 - FMI 06 Ignition Transformer
intermittent/erratic ................................................ 82 Primary #10 short ................................................ 93
MID 036 - CID 0172 - FMI 03 Intake Manifold Air MID 036 - CID 0311 - FMI 05 Ignition Transformer
Temp open/short to +batt..................................... 82 Primary #11 open circuit...................................... 94
MID 036 - CID 0172 - FMI 04 Intake Manifold Air MID 036 - CID 0311 - FMI 06 Ignition Transformer
Temp short to ground........................................... 83 Primary #11 short ................................................ 94
MID 036 - CID 0174 - FMI 03 Fuel Temperature MID 036 - CID 0312 - FMI 05 Ignition Transformer
open/short to +batt .............................................. 83 Primary #12 open circuit...................................... 95
MID 036 - CID 0174 - FMI 04 Fuel Temperature short MID 036 - CID 0312 - FMI 06 Ignition Transformer
to ground.............................................................. 83 Primary #12 short ................................................ 95
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature MID 036 - CID 0313 - FMI 05 Ignition Transformer
open/short to +batt .............................................. 84 Primary #13 open circuit...................................... 95
637
Index Section
MID 036 - CID 0313 - FMI 06 Ignition Transformer MID 036 - CID 0410 - FMI 05 Cylinder 10 -
Primary #13 short ................................................ 96 Transformer Secondary open circuit.................. 107
Primary #14 open circuit...................................... 96 Transformer Secondary short to ground ............ 108
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short MID 036 - CID 0413 - FMI 06 Cylinder 13 -
to +batt................................................................. 98 Transformer Secondary short to ground ............ 111
MID 036 - CID 0324 - FMI 03 Warning Lamp short to MID 036 - CID 0414 - FMI 05 Cylinder 14 -
+batt..................................................................... 99 Transformer Secondary open circuit.................. 111
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch MID 036 - CID 0414 - FMI 06 Cylinder 14 -
inputs ................................................................... 99 Transformer Secondary short to ground ............ 111
MID 036 - CID 0338 - FMI 05 Pre-Lube Relay open MID 036 - CID 0415 - FMI 05 Cylinder 15 -
circuit ................................................................... 99 Transformer Secondary open circuit.................. 112
MID 036 - CID 0338 - FMI 06 Pre-Lube Relay short MID 036 - CID 0415 - FMI 06 Cylinder 15 -
to ground.............................................................. 99 Transformer Secondary short to ground ............ 112
MID 036 - CID 0339 - FMI 05 Engine Pre-lube MID 036 - CID 0416 - FMI 05 Cylinder 16 -
Pressure Switch open circuit ............................. 100 Transformer Secondary open circuit.................. 113
MID 036 - CID 0401 - FMI 05 Cylinder 1 - Transformer MID 036 - CID 0416 - FMI 06 Cylinder 16 -
Secondary open circuit ...................................... 100 Transformer Secondary short to ground ............ 113
MID 036 - CID 0401 - FMI 06 Cylinder 1 - Transformer MID 036 - CID 0443 - FMI 03 Crank Terminate Relay
Secondary short to ground ................................ 101 short to +batt ..................................................... 113
MID 036 - CID 0402 - FMI 05 Cylinder 2 - Transformer MID 036 - CID 0444 - FMI 05 Start Relay open
Secondary open circuit ...................................... 101 circuit ................................................................. 114
MID 036 - CID 0402 - FMI 06 Cylinder 2 - Transformer MID 036 - CID 0444 - FMI 06 Start Relay short to
Secondary short to ground ................................ 101 ground................................................................ 114
MID 036 - CID 0403 - FMI 05 Cylinder 3 - Transformer MID 036 - CID 0445 - FMI 03 Run Relay short to
Secondary open circuit ...................................... 102 +batt................................................................... 114
MID 036 - CID 0403 - FMI 06 Cylinder 3 - Transformer MID 036 - CID 0524 - FMI 03 Desired Engine Speed
Secondary short to ground ................................ 102 Sensor short to +batt ......................................... 115
MID 036 - CID 0404 - FMI 05 Cylinder 4 - Transformer MID 036 - CID 0524 - FMI 04 Desired Engine Speed
Secondary open circuit ...................................... 102 Sensor short to ground ...................................... 115
MID 036 - CID 0404 - FMI 06 Cylinder 4 - Transformer MID 036 - CID 0525 - FMI 05 Choke Actuator open
Secondary short to ground ................................ 103 circuit ................................................................. 115
MID 036 - CID 0405 - FMI 05 Cylinder 5 - Transformer MID 036 - CID 0525 - FMI 06 Choke Actuator short
Secondary open circuit ...................................... 103 to ground............................................................ 116
MID 036 - CID 0405 - FMI 06 Cylinder 5 - Transformer MID 036 - CID 0526 - FMI 05 Wastegate Valve
Secondary short to ground ................................ 104 open................................................................... 116
MID 036 - CID 0406 - FMI 05 Cylinder 6 - Transformer MID 036 - CID 0526 - FMI 06 Wastegate Valve
Secondary open circuit ...................................... 104 short................................................................... 116
MID 036 - CID 0406 - FMI 06 Cylinder 6 - Transformer MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Secondary short to ground ................................ 105 Pressure open/short to +batt ............................. 117
MID 036 - CID 0407 - FMI 05 Cylinder 7 - Transformer MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Secondary open circuit ...................................... 105 Pressure short to ground ................................... 117
MID 036 - CID 0407 - FMI 06 Cylinder 7 - Transformer MID 036 - CID 1040 - FMI 09 ICSM #1 not
Secondary short to ground ................................ 105 communicating on link ....................................... 117
MID 036 - CID 0408 - FMI 05 Cylinder 8 - Transformer MID 036 - CID 1041 - FMI 09 ICSM #2 not
Secondary open circuit ...................................... 106 communicating on link ....................................... 118
Secondary short to ground ................................ 106 Sensor open/short to +batt ................................ 118
Secondary open circuit ...................................... 107 Sensor short to ground ...................................... 118
Secondary short to ground ................................ 107 Sensor open/short to +batt ................................ 119
638
Index Section
Sensor short to ground ...................................... 119 Probe short to ground........................................ 130
Sensor short to +batt ......................................... 119 Probe noisy........................................................ 130
Sensor open/short to +batt ................................ 120 Probe noisy........................................................ 131
Sensor short to +batt ......................................... 121 Probe noisy........................................................ 133
MID 036 - CID 1844 - FMI 05 Fuel Actuator open MID 109 - CID 1111 - FMI 02 Cylinder #11
circuit ................................................................. 125 Combustion Probe noisy.................................... 137
MID 036 - CID 1844 - FMI 06 Fuel Actuator short to MID 109 - CID 1111 - FMI 04 Cylinder #11
ground................................................................ 125 Combustion Probe short to ground.................... 137
MID 109 - CID 0253 - FMI 02 Personality Module MID 109 - CID 1113 - FMI 02 Cylinder #13
mismatch ........................................................... 126 Combustion Probe noisy.................................... 138
MID 109 - CID 0591 - FMI 12 EEPROM checksum MID 109 - CID 1113 - FMI 04 Cylinder #13
fault or ECM not programmed............................ 126 Combustion Probe short to ground.................... 138
MID 109 - CID 1040 - FMI 09 ICSM #1 not MID 109 - CID 1115 - FMI 02 Cylinder #15
communicating on link ....................................... 126 Combustion Probe noisy.................................... 138
MID 109 - CID 1043 - FMI 02 Cylinder #1 Firing MID 109 - CID 1115 - FMI 04 Cylinder #15
Signal noisy ....................................................... 127 Combustion Probe short to ground.................... 139
MID 109 - CID 1043 - FMI 03 Cylinder #1 Firing MID 109 - CID 1490 - FMI 03 Rt Turbo Turbine Out
Signal open/short to +batt ................................. 127 Temp Sens short to +batt................................... 139
Signal short to ground ....................................... 127 Temp Sens short to ground ............................... 139
Signal abnormal signal ...................................... 128 Temp Sens open circuit ..................................... 140
MID 109 - CID 1044 - FMI 02 All Cylinders Firing MID 109 - CID 1491 - FMI 03 Rt Turbo Turbine In
Signal noisy ....................................................... 128 Temp Sens short to +batt................................... 140
Signal open/short to +batt ................................. 129 Temp Sens short to ground ............................... 140
Signal short to ground ....................................... 129 Temp Sens open circuit ..................................... 141
Probe noisy........................................................ 129 Temp Sensor short to +batt ............................... 141
639
Index Section
Temp Sensor short to ground ............................ 141 Temp Sensor open circuit .................................. 152
Temp Sensor open circuit .................................. 142 Temp Sensor short to +batt ............................... 152
Temp Sensor short to +batt ............................... 142 Temp Sensor short to ground ............................ 152
Temp Sensor short to ground ............................ 142 Temp Sensor open circuit .................................. 153
MID 109 - CID 1532 - FMI 05 Cyl #2 Exhaust Port MID 110 - CID 0253 - FMI 02 Personality Module
Temp Sensor open circuit .................................. 143 mismatch ........................................................... 153
MID 109 - CID 1533 - FMI 03 Cyl #3 Exhaust Port MID 110 - CID 0591 - FMI 12 EEPROM checksum
Temp Sensor short to +batt ............................... 143 fault or ECM not programmed............................ 153
MID 109 - CID 1533 - FMI 04 Cyl #3 Exhaust Port MID 110 - CID 1041 - FMI 09 ICSM #2 not
Temp Sensor short to ground ............................ 143 communicating on link ....................................... 154
MID 109 - CID 1533 - FMI 05 Cyl #3 Exhaust Port MID 110 - CID 1044 - FMI 02 All Cylinders Firing
Temp Sensor open circuit .................................. 143 Signal noisy ....................................................... 154
Temp Sensor short to +batt ............................... 144 Signal open/short to +batt ................................. 154
Temp Sensor short to ground ............................ 144 Signal short to ground ....................................... 155
Temp Sensor open circuit .................................. 144 Signal abnormal signal ...................................... 155
MID 109 - CID 1535 - FMI 03 Cyl #5 Exhaust Port MID 110 - CID 1102 - FMI 02 Cylinder #2 Combustion
Temp Sensor short to +batt ............................... 145 Probe noisy........................................................ 156
Temp Sensor short to ground ............................ 145 Probe short to ground........................................ 156
Temp Sensor open circuit .................................. 145 Probe noisy........................................................ 156
Temp Sensor short to +batt ............................... 146 Probe short to ground........................................ 157
Temp Sensor short to ground ............................ 146 Probe noisy........................................................ 157
Temp Sensor open circuit .................................. 146 Probe short to ground........................................ 158
Temp Sensor short to +batt ............................... 147 Probe noisy........................................................ 158
Temp Sensor short to ground ............................ 147 Probe short to ground........................................ 159
MID 109 - CID 1537 - FMI 05 Cyl #7 Exhaust Port MID 110 - CID 1110 - FMI 02 Cylinder #10
Temp Sensor open circuit .................................. 148 Combustion Probe noisy.................................... 159
Temp Sensor short to +batt ............................... 148 Combustion Probe short to ground.................... 159
Temp Sensor short to ground ............................ 148 Combustion Probe noisy.................................... 160
Temp Sensor open circuit .................................. 149 Combustion Probe short to ground.................... 160
Temp Sensor short to +batt ............................... 149 Combustion Probe noisy.................................... 161
Temp Sensor short to ground ............................ 149 Combustion Probe short to ground.................... 161
Temp Sensor open circuit .................................. 150 Combustion Probe noisy.................................... 161
Temp Sensor short to +batt ............................... 150 Combustion Probe short to ground.................... 162
MID 109 - CID 1541 - FMI 04 Cyl #11 Exhaust Port MID 110 - CID 1489 - FMI 03 Left Turbo Turbine Out
Temp Sensor short to ground ............................ 150 Temp Sens short to +batt................................... 162
Temp Sensor open circuit .................................. 151 Temp Sens short to ground ............................... 163
Temp Sensor short to +batt ............................... 151 Temp Sens open circuit ..................................... 163
Temp Sensor short to ground ............................ 151 Temp Sens short to +batt................................... 163
MID 110 - CID 1492 - FMI 04 Left Turbo Turbine In P
Temp Sens short to ground ............................... 164
MID 110 - CID 1492 - FMI 05 Left Turbo Turbine In Poor Coolant Flow ................................................. 70
Temp Sens open circuit ..................................... 164 Probable Causes ............................................... 70
MID 110 - CID 1532 - FMI 03 Cyl #2 Exhaust Port Recommended Repairs ..................................... 70
Temp Sensor short to +batt ............................... 164 Prelubrication System ................................. 563, 568
MID 110 - CID 1532 - FMI 04 Cyl #2 Exhaust Port Programming Parameters...................................... 29
Temp Sensor short to ground ............................ 165 PWM Sensor ............................................... 573, 586
MID 110 - CID 1532 - FMI 05 Cyl #2 Exhaust Port
Temp Sensor open circuit .................................. 165
MID 110 - CID 1534 - FMI 03 Cyl #4 Exhaust Port R
Temp Sensor short to +batt ............................... 165
MID 110 - CID 1534 - FMI 04 Cyl #4 Exhaust Port Replacing the ECM................................................ 32
Temp Sensor short to ground ............................ 166 Replacing the ICSM............................................... 34
MID 110 - CID 1536 - FMI 03 Cyl #6 Exhaust Port S
Temp Sensor short to +batt ............................... 166
MID 110 - CID 1536 - FMI 04 Cyl #6 Exhaust Port Self-Diagnostics..................................................... 16
Temp Sensor short to ground ............................ 167 Short Spark Plug Life ............................................ 71
MID 110 - CID 1536 - FMI 05 Cyl #6 Exhaust Port Probable Causes ............................................... 71
Temp Sensor open circuit .................................. 167 Recommended Repairs ..................................... 71
MID 110 - CID 1538 - FMI 03 Cyl #8 Exhaust Port Starting Motor Runs, Pinion Engages But Does Not
Temp Sensor short to +batt ............................... 167 Turn the Flywheel ................................................ 71
Temp Sensor short to ground ............................ 168 Recommended Repairs ..................................... 71
MID 110 - CID 1538 - FMI 05 Cyl #8 Exhaust Port Symptoms.............................................................. 38
Temp Sensor open circuit .................................. 168 Diagnostic Codes and Event Codes .................. 38
MID 110 - CID 1540 - FMI 03 Cyl #10 Exhaust Port Operator Information.......................................... 38
Temp Sensor short to +batt ............................... 168 Other Symptoms ................................................ 38
MID 110 - CID 1540 - FMI 04 Cyl #10 Exhaust Port System Configuration Parameters......................... 31
Temp Sensor short to ground ............................ 169 System Overview................................................... 10
MID 110 - CID 1540 - FMI 05 Cyl #10 Exhaust Port Control System .................................................. 10
Temp Sensor open circuit .................................. 169 System Voltage...................................................... 71
Temp Sensor short to +batt ............................... 169 Recommended Repairs ..................................... 71
Temp Sensor short to ground ............................ 170
MID 110 - CID 1542 - FMI 05 Cyl #12 Exhaust Port T
MID 110 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Table of Contents..................................................... 3
Temp Sensor short to +batt ............................... 170 Thermocouple Test...................................... 598, 604
MID 110 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Too Much Vibration................................................ 72
Temp Sensor short to ground ............................ 171 Probable Causes ............................................... 72
MID 110 - CID 1544 - FMI 05 Cyl #14 Exhaust Port Recommended Repairs ..................................... 72
Temp Sensor open circuit .................................. 171 Troubleshooting Data Sheet .................................. 35
MID 110 - CID 1546 - FMI 03 Cyl #16 Exhaust Port Report the Service Information .......................... 37
Temp Sensor short to +batt ............................... 171 Troubleshooting Section ........................................ 10
MID 110 - CID 1546 - FMI 04 Cyl #16 Exhaust Port Troubleshooting with a Diagnostic Code ............... 74
Temp Sensor short to ground ............................ 172 Troubleshooting with an Event Code ................... 173
MID 110 - CID 1546 - FMI 05 Cyl #16 Exhaust Port Troubleshooting without a Diagnostic Code .......... 38
Temp Sensor open circuit .................................. 172 Turbocharger Turbine Temperature (High)............. 72
Probable Causes ............................................... 72
N
Noise Coming from Cylinder (Noisy Cylinder W

Head) ................................................................... 69
Probable Causes ............................................... 69 Wastegate Solenoid .................................... 615, 623
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR5910-02

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Jacket Water Pressure (Low) ................................ 68

Diagnostic Functional Tests

Troubleshooting Section The ECM does not have a removable personality

• Ignition system that is controlled by the ECM Control of Ignition

Air/Fuel Ratio Control

The desired air/fuel ratio is based on maps that • Combustion feedback

The software is also programmed to correct the

Note: When the engine is operating in combustion

The relationship of the modes of operation to the

During start-up, the air choke is maintained at a

If the starting position is set too high and the engine

Start/Stop Control When the programmable logic determines that an

• Diagnostic Code Color

Event Code – An event code is generated by OR Orange

In addition to the color, the entire length of each

For example, a code of J011-RD on the Schematic

The Schematic also identifies the size of the wire.

The engine mounted terminal box is located on the

Note: There is one detonation sensor between each

Note: There is one detonation sensor between each

Note: The switches for connector (14) can be

Integrated Combustion Sensing Module Vee Engines

The engine has an Integrated Combustion Sensing

Exhaust temperatures are monitored for each

Note: For each cylinder, there is one temperature

In-Line Engines i01775381

Electronic Service Tools

Caterpillar Electronic Service Tools are designed to

Note: For each cylinder, there is one temperature

Note: Either the 171-4401 Communication Adapter

Caterpillar Electronic Technician

4. Connect cable (4) to cable (5).

5. Connect cable (5) to the service tool connector

6. Make sure that the engine control switch is in the

Connecting Cat ET with the 7X-1701

Engine Monitoring System

The Electronic Control Module (ECM) monitors the

The status of the parameters can be viewed on

To accommodate unique applications and sites,

• Select the available responses.

Unless the instructions are different, only change

Programming Parameters Note: Be sure to record the customer passwords.

SMCS Code: 1901

• Current ECM Table 4

• Serial number of the ECM Address

• Reason Information from the “Enter Factory Passwords”

The passwords may only be used for one Diagnostic Clock(1)

Factory Passwords Worksheet Flash Programming

To select the baud rate, use the ET

If a communication error occurs, select a slower

1. Connect Cat ET to the service tool connector. “WinFlash” Error Messages

“WinFlash” will try to detect an ECM. System Configuration

9. Start the engine and check for proper operation. Table 5

“Choke (Integral) Stability Percentage”

“Governor Type Setting” Replacing the ECM

b. Use a 4 mm Allen wrench to connect the P1

4. Program the configuration parameters and

a. Switch circuit breaker (1) to the ON position.

b. Turn the engine control switch to the “STOP”