Troubleshooting JKK Caterpillar G3516B

RENR5979
January 2003
Troubleshooting
G3500C Engines
CWW1-Up (Generator Set)
CWY1-Up (Generator Set)
GDB1-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
System Voltage ..................................................... 69
Troubleshooting Section Turbocharger Turbine Temperature (High) ............ 69
Turbocharger Turbine Temperature (Low) ............. 70
Electronic Troubleshooting
System Overview .................................................... 9
Troubleshooting with a Diagnostic Code
Self-Diagnostics .................................................... 10
Diagnostic Codes .................................................. 72
Electrical Connectors and Functions .................... 11
MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short
Electronic Service Tools ........................................ 18
to +batt ................................................................ 73
Engine Monitoring System .................................... 22
MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short
to ground ............................................................. 74
Programming Parameters
MID 033 - CID 0168 - FMI 02 System Voltage
Programming Parameters ..................................... 29
intermittent/erratic ............................................... 74
Customer Passwords ............................................ 29
MID 033 - CID 0301 - FMI 05 Ignition Transformer
Factory Passwords ................................................ 30
Primary #1 open circuit ....................................... 74
Factory Passwords Worksheet ............................. 30
Flash Programming .............................................. 31
Primary #1 short ................................................. 75
System Configuration Parameters ........................ 31
Replacing the ECM ............................................... 38
Replacing the ITSM .............................................. 40
Troubleshooting Data Sheet ................................. 42
Primary #3 short ................................................. 75
Troubleshooting without a Diagnostic Code
Symptoms ............................................................. 44
Detonation ............................................................ 44
Primary #5 short ................................................. 76
Driven Equipment ................................................. 46
ECM Will Not Accept Factory Passwords ............. 46
Electronic Service Tool Will Not Communicate with
ECM (The Caterpillar Electronic Technician (ET)
Primary #7 short ................................................. 77
Will Not Communicate With an Electronic Control
Module (ECM) and/or the Integrated Temperature
Sensing Module (ITSM)) ..................................... 47
Engine Coolant Temperature (High) ..................... 47
Primary #9 short ................................................. 78
Engine Coolant Temperature (Low) ...................... 49
Engine Cranks but Will Not Start .......................... 49
Primary #11 open circuit ..................................... 78
Engine Misfires, Runs Rough or Is Unstable ........ 50
Engine Oil Filter Differential Pressure ................... 52
Primary #11 short ............................................... 78
Engine Oil Pressure (Low) .................................... 52
Engine Oil Temperature (High) ............................. 53
Engine Overcrank ................................................. 54
Engine Overload ................................................... 55
Primary #13 short ............................................... 79
Engine Overspeed ................................................ 55
Engine Shutdown .................................................. 56
Engine Shutdown (Unexpected) ........................... 56
Engine Shutdown without a Diagnostic Code ....... 58
Primary #15 short ............................................... 80
Engine Starts but Stalls Immediately .................... 59
MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor
Engine Timing Does Not Match Programmed
short to +batt ....................................................... 80
Timing ................................................................. 59
MID 033 - CID 0320 - FMI 08 Engine Speed/Timing
Engine Will Not Crank ........................................... 60
signal abnormal ................................................... 81
Exhaust Port Temperature (High) ......................... 61
Exhaust Port Temperature (Low) .......................... 62
Secondary #1 open circuit .................................. 81
Fuel Energy Content ............................................. 63
Fuel Metering Valve .............................................. 63
Secondary #1 short to ground ............................ 82
Fuel Pressure ....................................................... 63
Gas Fuel Differential Pressure (High) ................... 63
Gas Fuel Differential Pressure (Low) .................... 64
Gas Fuel Flow Rate (Low) .................................... 64
Gas Temperature (High) ....................................... 65
Inlet Air Temperature (High) .................................. 66
Intermittent Engine Shutdown ............................... 66
Jacket Water Inlet Pressure (High) ....................... 67
4
Table of Contents
MID 033 - CID 0407 - FMI 05 Ignition Transformer MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
Secondary #7 open circuit .................................. 84 to ground ............................................................. 95
MID 033 - CID 0407 - FMI 06 Ignition Transformer MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve
Secondary #7 short to ground ............................ 84 malfunction .......................................................... 95
MID 033 - CID 0409 - FMI 05 Ignition Transformer MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short
Secondary #9 open circuit .................................. 84 to +batt ................................................................ 96
MID 033 - CID 0409 - FMI 06 Ignition Transformer MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short
Secondary #9 short to ground ............................ 85 to ground ............................................................. 96
MID 033 - CID 0411 - FMI 05 Ignition Transformer MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
Secondary #11 open circuit ................................ 85 open/short to +batt .............................................. 96
MID 033 - CID 0411 - FMI 06 Ignition Transformer MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
Secondary #11 short to ground .......................... 86 short to ground .................................................... 97
MID 033 - CID 0413 - FMI 05 Ignition Transformer MID 036 - CID 0106 - FMI 03 Air Inlet Pressure
Secondary #13 open circuit ................................ 86 Sensor short to +batt .......................................... 97
MID 033 - CID 0413 - FMI 06 Ignition Transformer MID 036 - CID 0106 - FMI 08 Air Inlet Pressure
Secondary #13 short to ground .......................... 87 Sensor noisy signal ............................................. 98
MID 033 - CID 0415 - FMI 05 Ignition Transformer MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure
Secondary #15 open circuit ................................ 87 open/short to +batt .............................................. 98
MID 033 - CID 0415 - FMI 06 Ignition Transformer MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet
Secondary #15 short to ground .......................... 87 Pressure Sensor noisy signal ............................. 98
MID 033 - CID 0590 - FMI 09 Unable to communicate MID 036 - CID 0110 - FMI 03 Engine Coolant
with Engine ECM ................................................ 88 Temperature open/short to +batt ......................... 99
MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation MID 036 - CID 0110 - FMI 04 Engine Coolant
Sensor open/short to +batt ................................. 88 Temperature short to ground ............................... 99
MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation MID 036 - CID 0145 - FMI 03 12 Volt DC Power
Sensor short to ground ....................................... 88 Supply short to +batt ........................................... 99
MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation MID 036 - CID 0145 - FMI 04 12 Volt DC Power
Sensor open/short to +batt ................................. 89 Supply short to ground ...................................... 100
MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation MID 036 - CID 0168 - FMI 02 System Voltage
Sensor short to ground ....................................... 89 intermittent/erratic ............................................. 100
MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation MID 036 - CID 0172 - FMI 03 Intake Manifold Air
Sensor open/short to +batt ................................. 89 Temp open/short to +batt .................................. 100
MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation MID 036 - CID 0172 - FMI 04 Intake Manifold Air
Sensor short to ground ....................................... 90 Temp short to ground ........................................ 101
MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation MID 036 - CID 0175 - FMI 03 Engine Oil Temperature
Sensor open/short to +batt ................................. 90 open/short to +batt ............................................ 101
MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation MID 036 - CID 0175 - FMI 04 Engine Oil Temperature
Sensor short to ground ....................................... 90 short to ground .................................................. 102
MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation MID 036 - CID 0261 - FMI 13 Engine Timing
Sensor open/short to +batt ................................. 91 calibration required ........................................... 102
MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power
Sensor short to ground ....................................... 91 Supply short to +batt ......................................... 102
MID 033 - CID 1748 - FMI 05 Ignition Transformer MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power
Secondary #17 open circuit ................................ 91 Supply short to ground ...................................... 103
MID 033 - CID 1748 - FMI 06 Ignition Transformer MID 036 - CID 0302 - FMI 05 Ignition Transformer
Secondary #17 short to ground .......................... 92 Primary #2 open circuit ..................................... 103
Secondary #19 open circuit ................................ 92 Primary #2 short ............................................... 104
Secondary #19 short to ground .......................... 93 Primary #4 open circuit ..................................... 104
Primary #17 open circuit ..................................... 93 Primary #4 short ............................................... 104
Primary #17 short to ground ............................... 93 Primary #6 open circuit ..................................... 105
Primary #19 open circuit ..................................... 94 Primary #6 short ............................................... 105
Primary #19 short to ground ............................... 94 Primary #8 open circuit ..................................... 106
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open MID 036 - CID 0308 - FMI 06 Ignition Transformer
circuit ................................................................... 94 Primary #8 short ............................................... 106
5
Table of Contents
MID 036 - CID 0310 - FMI 05 Ignition Transformer MID 036 - CID 0444 - FMI 06 Start Relay short to
Primary #10 open circuit ................................... 106 ground ............................................................... 118
MID 036 - CID 0310 - FMI 06 Ignition Transformer MID 036 - CID 0445 - FMI 03 Run Relay short to
Primary #10 short ............................................. 107 +batt .................................................................. 118
MID 036 - CID 0312 - FMI 05 Ignition Transformer MID 036 - CID 0524 - FMI 03 Desired Engine Speed
Primary #12 open circuit ................................... 107 Sensor short to +batt ........................................ 119
MID 036 - CID 0312 - FMI 06 Ignition Transformer MID 036 - CID 0524 - FMI 04 Desired Engine Speed
Primary #12 short ............................................. 107 Sensor short to ground ..................................... 119
MID 036 - CID 0314 - FMI 05 Ignition Transformer MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Primary #14 open circuit ................................... 108 Pressure open/short to +batt ............................ 119
MID 036 - CID 0314 - FMI 06 Ignition Transformer MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Primary #14 short ............................................. 108 Pressure short to ground .................................. 120
MID 036 - CID 0316 - FMI 05 Ignition Transformer MID 036 - CID 1042 - FMI 09 Unable to communicate
Primary #16 open circuit ................................... 109 with ITSM .......................................................... 120
MID 036 - CID 0316 - FMI 06 Ignition Transformer MID 036 - CID 1440 - FMI 09 Unable to communicate
Primary #16 short ............................................. 109 with Throttle Actuator Drv ................................. 121
MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor MID 036 - CID 1446 - FMI 05 Fuel Metering Module
short to +batt ..................................................... 109 open circuit ........................................................ 121
MID 036 - CID 0320 - FMI 08 Engine Speed/Timing MID 036 - CID 1446 - FMI 09 Unable to communicate
signal abnormal ................................................. 110 with Fuel Metering Module ................................ 121
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short MID 036 - CID 1446 - FMI 12 Fuel Metering Module
to +batt .............................................................. 110 malfunction ........................................................ 122
MID 036 - CID 0324 - FMI 03 Warning Lamp short to MID 036 - CID 1446 - FMI 13 Fuel Metering Module
+batt .................................................................. 110 calibration required ........................................... 122
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor
inputs ................................................................ 111 Module malfunction ........................................... 122
MID 036 - CID 0402 - FMI 05 Ignition Transformer MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation
Secondary #2 open circuit ................................ 111 Sensor open/short to +batt ............................... 122
Secondary #2 short to ground .......................... 111 Sensor short to ground ..................................... 123
Secondary #10 open circuit .............................. 114 Sensor open/short to +batt ............................... 125
Secondary #10 short to ground ........................ 115 Sensor short to ground ..................................... 125
MID 036 - CID 0412 - FMI 05 Ignition Transformer MID 036 - CID 1636 - FMI 09 Loss of Communication
Secondary #12 open circuit .............................. 115 with Engine #2 (Slave) ...................................... 126
MID 036 - CID 0412 - FMI 06 Ignition Transformer MID 036 - CID 1719 - FMI 03 Generator Output
Secondary #12 short to ground ........................ 115 Power Sensor open/short to +batt .................... 126
Secondary #14 open circuit .............................. 116 Power Sensor short to ground .......................... 126
Secondary #14 short to ground ........................ 116 Power Sensor malfunction ................................ 127
MID 036 - CID 0416 - FMI 05 Ignition Transformer MID 036 - CID 1720 - FMI 09 Unable to
Secondary #16 open circuit .............................. 116 communicate with Turbo Compressor Bypass Valve
MID 036 - CID 0416 - FMI 06 Ignition Transformer Solenoid ............................................................ 127
Secondary #16 short to ground ........................ 117 MID 036 - CID 1749 - FMI 05 Ignition Transformer
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay Secondary #18 open circuit .............................. 127
short to +batt ..................................................... 117 MID 036 - CID 1749 - FMI 06 Ignition Transformer
MID 036 - CID 0444 - FMI 05 Start Relay open Secondary #18 short to ground ........................ 128
circuit ................................................................. 118 MID 036 - CID 1751 - FMI 05 Ignition Transformer
Secondary #20 open circuit .............................. 128
6
Table of Contents
MID 036 - CID 1751 - FMI 06 Ignition Transformer MID 111 - CID 1535 - FMI 03 Cyl #5 Exhaust Port
Secondary #20 short to ground ........................ 129 Temp Sensor short to +batt ............................... 140
Primary #18 open circuit ................................... 129 Temp Sensor short to ground ............................ 140
Primary #18 short to ground ............................. 129 Temp Sensor open circuit ................................. 140
Primary #20 open circuit ................................... 130 Temp Sensor short to +batt ............................... 141
Primary #20 short to ground ............................. 130 Temp Sensor short to ground ............................ 141
MID 111 - CID 0591 - FMI 12 EEPROM checksum MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port
fault or ECM not programmed ........................... 130 Temp Sensor open circuit ................................. 141
MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out MID 111 - CID 1537 - FMI 03 Cyl #7 Exhaust Port
Temp Sens short to +batt .................................. 131 Temp Sensor short to +batt ............................... 142
Temp Sens short to ground ............................... 131 Temp Sensor short to ground ............................ 142
Temp Sens open circuit ..................................... 131 Temp Sensor open circuit ................................. 143
MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out MID 111 - CID 1538 - FMI 03 Cyl #8 Exhaust Port
MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In MID 111 - CID 1539 - FMI 03 Cyl #9 Exhaust Port
MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In MID 111 - CID 1540 - FMI 03 Cyl #10 Exhaust Port
MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port
Temp Sensor short to +batt ............................... 135 Temp Sensor short to +batt ............................... 147
Temp Sensor short to ground ............................ 135 Temp Sensor short to ground ............................ 147
Temp Sensor open circuit ................................. 136 Temp Sensor open circuit ................................. 147
7
Table of Contents
MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port E129 Engine Oil Filter Diff Pressure High
Temp Sensor short to +batt ............................... 151 Warning ............................................................. 167
MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port E130 Engine Oil Filter Diff Pressure High
Temp Sensor short to ground ............................ 152 Shutdown .......................................................... 168
MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port E135 Low Jacket Water Pressure Shutdown ...... 168
Temp Sensor open circuit ................................. 152 E223 High Gas Temperature .............................. 168
MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port E224 High Jacket Water Inlet Pressure .............. 169
Temp Sensor short to +batt ............................... 153 E225 Engine Overcrank ...................................... 169
MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port E226 Driven Equipment Not Ready .................... 169
Temp Sensor short to ground ............................ 153 E229 Fuel Energy Content Setting Low .............. 169
MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port E230 Fuel Energy Content Setting High ............. 170
Temp Sensor open circuit ................................. 153 E231 Fuel Quality Out of Range ......................... 170
MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port E242 Engine Overload ........................................ 170
Temp Sensor short to +batt ............................... 154 E243 High Left Turbo Turbine Outlet
MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port Temperature ...................................................... 170
Temp Sensor short to ground ............................ 154 E244 High Right Turbo Turbine Outlet
Temp Sensor open circuit ................................. 155 E245 High Right Turbo Turbine Inlet
Temp Sensor short to +batt ............................... 155 E246 High Left Turbo Turbine Inlet Temperature .. 172
MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port E264 Emergency Stop Activated ........................ 172
Temp Sensor short to ground ............................ 155 E268 Unexpected Engine Shutdown .................. 172
MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port E269 Customer Shutdown Requested ............... 173
Temp Sensor open circuit ................................. 156 E270 Driven Equipment Shutdown Requested .. 173
MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port E337 High Engine Oil to Engine Coolant Diff
Temp Sensor short to +batt ............................... 156 Temp ................................................................. 173
MID 111 - CID 1549 - FMI 04 Cyl #19 Exhaust Port E401 Cylinder #1 Detonation .............................. 173
Temp Sensor short to ground ............................ 157 E402 Cylinder #2 Detonation .............................. 174
Temp Sensor open circuit ................................. 157 E404 Cylinder #4 Detonation .............................. 174
Temp Sensor short to +batt ............................... 157 E406 Cylinder #6 Detonation .............................. 175
Temp Sensor short to ground ............................ 158 E408 Cylinder #8 Detonation .............................. 175
Temp Sensor open circuit ................................. 158 E410 Cylinder #10 Detonation ............................ 176
E411 Cylinder #11 Detonation ............................ 176
Troubleshooting with an Event Code E412 Cylinder #12 Detonation ............................ 176
Event Codes ...................................................... 160 E413 Cylinder #13 Detonation ............................ 176
E004 Engine Overspeed Shutdown .................... 162 E414 Cylinder #14 Detonation ............................ 177
E015 High Engine Coolant Temperature Derate .. 162 E415 Cylinder #15 Detonation ............................ 177
E016 High Engine Coolant Temperature E416 Cylinder #16 Detonation ............................ 177
Shutdown .......................................................... 163 E417 Cylinder #17 Detonation ............................ 177
E017 High Engine Coolant Temperature E418 Cylinder #18 Detonation ............................ 178
Warning ............................................................. 163 E419 Cylinder #19 Detonation ............................ 178
E019 High Engine Oil Temperature Shutdown ... 163 E420 Cylinder #20 Detonation ............................ 178
E020 High Engine Oil Temperature Warning ...... 163 E421 Cylinder #1 Detonation Shutdown ............. 179
E025 High Inlet Air Temperature Derate ............. 164 E422 Cylinder #2 Detonation Shutdown ............. 179
E026 High Inlet Air Temperature Shutdown ........ 164 E423 Cylinder #3 Detonation Shutdown ............. 179
E027 High Inlet Air Temperature Warning .......... 164 E424 Cylinder #4 Detonation Shutdown ............. 179
E038 Low Engine Coolant Temperature E425 Cylinder #5 Detonation Shutdown ............. 180
Warning ............................................................. 165 E426 Cylinder #6 Detonation Shutdown ............. 180
E040 Low Engine Oil Pressure Shutdown .......... 165 E427 Cylinder #7 Detonation Shutdown ............. 180
E042 Low System Voltage Shutdown ................. 165 E428 Cylinder #8 Detonation Shutdown ............. 181
E043 Low System Voltage Warning .................... 165 E429 Cylinder #9 Detonation Shutdown ............. 181
E050 High System Voltage Warning ................... 166 E430 Cylinder #10 Detonation Shutdown ........... 181
E053 Low Fuel Pressure Warning ...................... 166 E431 Cylinder #11 Detonation Shutdown ........... 181
E096 High Fuel Pressure .................................... 166 E432 Cylinder #12 Detonation Shutdown ........... 182
E100 Low Engine Oil Pressure Warning ............. 167 E433 Cylinder #13 Detonation Shutdown ........... 182
E127 Engine Oil Filter Diff Pressure Low E434 Cylinder #14 Detonation Shutdown ........... 182
Warning ............................................................. 167 E435 Cylinder #15 Detonation Shutdown ........... 183
E128 Engine Oil Filter Diff Pressure Low E436 Cylinder #16 Detonation Shutdown ........... 183
Shutdown .......................................................... 167 E437 Cylinder #17 Detonation Shutdown ........... 183
8
Table of Contents
E438 Cylinder #18 Detonation Shutdown ........... 183 E848 Cyl #8 Exhaust Port Temp Deviating Low .. 203
E439 Cylinder #19 Detonation Shutdown ........... 184 E849 Cyl #9 Exhaust Port Temp Deviating Low .. 203
E440 Cylinder #20 Detonation Shutdown ........... 184 E850 Cyl #10 Exhaust Port Temp Deviating
E801 Cylinder #1 High Exhaust Port Temp ........ 184 Low ................................................................... 203
E802 Cylinder #2 High Exhaust Port Temp ........ 185 E851 Cyl #11 Exhaust Port Temp Deviating
E810 Cylinder #10 High Exhaust Port Temp ...... 188 E855 Cyl #15 Exhaust Port Temp Deviating
E811 Cylinder #11 High Exhaust Port Temp ...... 188 Low ................................................................... 205
E821 Cyl #1 Exhaust Port Temp Deviating High .. 192 Low ................................................................... 207
E822 Cyl #2 Exhaust Port Temp Deviating High .. 192 E864 Low Gas Fuel Differential Pressure ........... 208
E823 Cyl #3 Exhaust Port Temp Deviating High .. 193 E865 High Gas Fuel Differential Pressure .......... 208
E824 Cyl #4 Exhaust Port Temp Deviating High .. 193 E866 Low Gas Fuel Flow Rate ........................... 208
E825 Cyl #5 Exhaust Port Temp Deviating High .. 193 E867 Improper Gas Flow Control Valve
E826 Cyl #6 Exhaust Port Temp Deviating High .. 194 Response .......................................................... 209
E827 Cyl #7 Exhaust Port Temp Deviating High .. 194 E868 Gas Flow Control Valve Malfunction .......... 209
E828 Cyl #8 Exhaust Port Temp Deviating High .. 195
E829 Cyl #9 Exhaust Port Temp Deviating High .. 195 Diagnostic Functional Tests
E830 Cyl #10 Exhaust Port Temp Deviating +5V Sensor Voltage Supply ................................ 210
High ................................................................... 195 +8V Sensor Voltage Supply ................................ 218
E831 Cyl #11 Exhaust Port Temp Deviating Analog Sensor Signal ......................................... 226
High ................................................................... 196 Bypass Valve ...................................................... 235
E832 Cyl #12 Exhaust Port Temp Deviating CAT Data Link ..................................................... 243
High ................................................................... 196 Desired Speed Input (4 - 20 mA) ........................ 248
E833 Cyl #13 Exhaust Port Temp Deviating Detonation Sensors ............................................ 252
High ................................................................... 197 ECM Output Circuit (Fuel Control) ...................... 261
E834 Cyl #14 Exhaust Port Temp Deviating ECM Output Circuit (Starting Motor) ................... 271
High ................................................................... 197 ECM Status Indicator Output .............................. 281
E835 Cyl #15 Exhaust Port Temp Deviating Electrical Power Supply ...................................... 288
High ................................................................... 197 Engine Speed/Timing Sensor ............................. 295
E836 Cyl #16 Exhaust Port Temp Deviating Fuel Metering Valve ............................................ 302
High ................................................................... 198 Generator Output Power Sensor ......................... 309
E837 Cyl #17 Exhaust Port Temp Deviating Ignition Transformers Primary Circuit .................. 316
High ................................................................... 198 Ignition Transformers Secondary Circuit and Spark
E838 Cyl #18 Exhaust Port Temp Deviating Plugs ................................................................. 327
High ................................................................... 199 Inspecting Electrical Connectors ........................ 333
E839 Cyl #19 Exhaust Port Temp Deviating Integrated Temperature Sensing Module
High ................................................................... 199 (ITSM) ............................................................... 338
E840 Cyl #20 Exhaust Port Temp Deviating PWM Sensor ....................................................... 346
High ................................................................... 199 Throttle Actuator ................................................. 353
E841 Cyl #1 Exhaust Port Temp Deviating Low .. 200
E842 Cyl #2 Exhaust Port Temp Deviating Low .. 200 Calibration Procedures
E843 Cyl #3 Exhaust Port Temp Deviating Low .. 201 Engine Speed/Timing Sensor - Calibrate ........... 359
E845 Cyl #5 Exhaust Port Temp Deviating Low .. 201 Index Section
E847 Cyl #7 Exhaust Port Temp Deviating Low .. 202 Index ................................................................... 362
9
Troubleshooting Section
Troubleshooting Section Air/Fuel Ratio Control

The master ECM provides control of the air/fuel
mixture for performance and for efficiency at
Electronic Troubleshooting low emission levels. The system consists of an
electronic fuel metering valve, output drivers in the
master ECM, and maps in the master ECM. The
i01804687 control compensates for changes in the BTU of the
fuel in order to maintain desired emission levels.
System Overview
The following steps describe the basic operation:
SMCS Code: 1901-038
1. The master ECM determines the desired flow
Introduction rates for the air and for the fuel. The flow rates
are determined by these factors:
Two Electronic Control Modules (ECM) are used
to control the engine. One module is the master • Desired engine speed
ECM and the other module is the slave ECM. Each
module is an environmentally sealed unit that is • Actual engine speed
mounted in a terminal box on the engine.
• Calculated engine load
The master ECM controls most of the functions of
the engine. The master ECM monitors various inputs 2. The command for the flow of the fuel is sent to
from sensors in order to activate relays, solenoids, the electronic fuel metering valve via the CAN
etc at the appropriate levels. The master ECM data link.
supports the following five primary functions:
This process is repeated continuously during engine
• Engine speed governing operation.
• Air/Fuel ratio control Start/Stop Sequencing

• Start/Stop sequencing The master ECM contains the logic and the
outputs for control of starting and of shutdown. The
• Engine monitoring and protection customer programmable logic responds to signals
from the following components: engine control,
• Control of the ignition and detonation of the left emergency stop switch, remote start switch, data
cylinder bank link, and other inputs.
The slave ECM primarily supports the control of To control the engine at the appropriate times, the
ignition and of detonation of the right cylinder bank. master ECM provides +Battery voltage to the relays
for the starting motor and for the gas shutoff valve.
Engine Speed Governing
When the programmable logic determines that
The master ECM maintains the desired engine it is necessary to crank the engine, the master
speed by controlling the actuator for the throttle. ECM supplies +Battery voltage to the relay for
The actuator is located at the inlet to the aftercooler. the starting motor. The master ECM removes the
The actuator is electrically controlled and electrically voltage when the programmable crank terminate
actuated. speed is reached or when a programmable cycle
crank time has expired.
The master ECM issues a throttle command that
represents a percent of the level of electrical The engine has an energize-to-run type of gas
current. The output can be viewed on the Caterpillar shutoff valve. When the programmable logic
Electronic Technician (ET). determines that fuel is required to start the engine
or to run the engine, the master ECM supplies
Desired engine speed is determined by the status +Battery voltage to the valve.
of the idle/rated switch, the desired speed input
(analog voltage or 4 to 20 mA), and parameters For more information on programmable parameters,
such as maximum engine high idle speed that are see Troubleshooting, “Programming Parameters”.
programmed into the software. Actual engine speed
is detected via a signal from the speed/timing
sensor. Parameters such as governor gain can be
programmed with Cat ET.
10
Engine Monitoring and Protection • Diagnostic

The master ECM monitors both the engine operation • Event
and the electronic system.
Diagnostic Code – When a problem with the
Problems with engine operation such as low oil electronic system or a component is detected,
pressure produce an event code. The master ECM the master ECM or the slave ECM generates a
can issue a warning, a derating, or a shutdown. This diagnostic code. The code indicates the specific
depends on the severity of the condition. For more problem with the circuitry.
information, see Troubleshooting, “Troubleshooting
With An Event Code”. Diagnostic codes can have two different states:
Problems with the electronic system such as an • Active

open circuit produce a diagnostic code. For more
information, see Troubleshooting, “Troubleshooting • Logged
With A Diagnostic Code”.
Active Code – An active diagnostic code indicates
that an active problem has been detected. Active
Ignition Control codes require immediate attention. Always service
active codes prior to servicing logged codes.
Each ECM provides variable ignition timing that is
sensitive to detonation.
Logged Code – Every generated code is stored
in the memory of the ECM that detected the
Each cylinder has an ignition transformer that is
problem. The code is logged. Each ECM can
located under the valve cover for the cylinder.
store a maximum of ten different codes at one
To initiate combustion, an ECM sends a pulse of
time. Logged codes remain in the memory of the
approximately 100 volts to the primary coil of an
ECM even if the power is removed from the ECM.
ignition transformer at the appropriate time and for
Logged codes may be useful to help troubleshoot
the appropriate duration. The transformer steps up
intermittent problems. Logged codes can also be
the voltage in order to create a spark across the
used to review the performance of the engine and
spark plug electrode.
the electronic system.
Detonation sensors monitor the engine for excessive
Logged codes may not indicate that a repair is
detonation. The G3520C Engine has ten detonation
needed. The problem may have been temporary.
sensors. Each sensor monitors two adjacent
The problem may have been resolved since the
cylinders. The sensors generate data on vibration
logging of the code. For example, if the system is
that is processed by each ECM in order to
powered and a sensor is disconnected, an ECM
determine detonation levels. If detonation reaches
will detect the problem. The ECM will generate
an unacceptable level, the appropriate ECM
an active diagnostic code for the problem. The
retards the ignition timing of the affected cylinder
ECM will also log the code. When the sensor is
or cylinders. If retarding the timing does not limit
connected, the active code will disappear. The
detonation to an acceptable level, the master ECM
logged code will remain in the memory of the ECM
shuts down the engine.
until the code is cleared.
The master ECM and the slave ECM provide
A code is cleared from memory when one of the
extensive diagnostics for the ignition system. The
following conditions occur:
master ECM also provides a switch for ignition
timing in order to allow operation with alternate fuels
such as propane that require a timing offset. • The service technician manually clears the code.
• The code does not recur for 1000 hours.
i01804722
• A new code is logged and there are already ten
Self-Diagnostics codes in memory. In this case, the oldest code
is cleared.
SMCS Code: 1901-038
Event Code – An event code is generated when
Each Electronic Control Module (ECM) has the an ECM detects an abnormal engine operating
ability to detect problems with the electronic system condition. For example, an event code will be
and with engine operation. When an ECM detects a generated if the oil pressure is too low. In this case,
problem, the ECM generates a code. An alarm may the event code indicates the symptom of a problem.
also be generated. There are two types of codes:
11
i01816322 Terminal Box

Electrical Connectors and
Functions
SMCS Code: 1408-038
Harness Wire Identification

Caterpillar identifies different wires with eleven
different solid colors. Table 1 lists the color codes of
the wiring.
Table 1
Color Codes for Wiring
Code Color
BK Black
BR Brown
BU Blue
GN Green
GY Gray
OR Orange
PK Pink
PU Purple Illustration 1 g00927440
RD Red Rear view of the engine

(1) Terminal box
WH White
(2) Emergency stop button
YL Yellow
The terminal box contains the master Electronic
Control Module (ECM) and the slave ECM. The
In addition to the color, the entire length of each electrical connectors for the terminal box are
wire is stamped with a specific circuit number that located between the terminal box and the engine.
is repeated on every 25 mm (1 inch) of the wire.
The actual wires are identified on the 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. For all
Caterpillar engine harnesses with electronic ignition
systems, the code of J011-RD identifies the 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, you may assume that the wire is
16 AWG.
12
g00931950
Illustration 2
Components inside the terminal box
(3) Master ECM (11) Slave ECM
(4) Ground strap for the master ECM (12) Connector P3 for the slave ECM
(5) Master ECM connector P2 (13) Connector P4 for the slave ECM
(6) Master ECM connector P1 (14) Ground strap for the slave ECM
(7) Ignition harness for the left bank (15) Ignition harness for the right bank
(8) Service tool connector J5 for the (16) Connector J10/P10 for the terminating
Caterpillar Electronic Technician (ET) resistor for the CAN data link
(9) Connector J6 for the customer (17) Connector J9
(10) Connector J7 (18) Connector J8 for the detonation sensors
13
Junction Box
g00927512
Illustration 3
The junction box is located on left side of the engine.
(1) Junction box (5) 2.5 amp circuit breaker for the start
(2) 2.5 amp circuit breaker for the engine command from the master ECM
control (6) Positive terminal for the connection of
(3) 10 amp circuit breaker for the customer the engine’s power supply
(4) 35 amp circuit breaker for the engine (7) Negative terminal for the connection of
the engine’s power supply
The junction box contains all of the circuit breakers

for the engine. The junction box also contains the
magnetic switches for the electric starting motors.
Sensors
Sensors provide information to the electronic control
modules. The information enables the modules to
control the engine as efficiently as possible over a
wide range of operating conditions. The information
is used for monitoring engine operation.
The sensors also enable the activation of alarms, of

derates, and of shutoffs in response to abnormal
operation. Illustrations 4, 5, and 6 show the locations
of the sensors.
14
g00928525
Illustration 4
Right side of the engine
(1) Engine oil temperature sensor
(2) Pressure sensor for unfiltered oil
(3) Pressure sensor for filtered oil
(4) Pressure switch for the coolant pump
(inlet)
g00928526
Illustration 5
Top view of the engine
(5) Engine coolant temperature sensor (7) Engine coolant pressure sensor (outlet)
(6) Inlet air pressure sensor (8) Inlet air temperature sensor
15
Pressure switch for the coolant pump (inlet) (4) – A

pressure switch is located at the inlet for the engine
jacket water. If the inlet pressure is too high, the
switch will activate a shutdown. To observe the
status of the switch, use Cat ET to view the “Engine
Coolant Pump Pressure” parameter. The contacts of
the switch are between pin B and pin C. The contact
opens at 462 ± 41 kPa (67 ± 6 psi). Closure of the
contact is required in order for the engine to run.
Engine coolant temperature sensor (5) – The

temperature sensor is located in the water
temperature regulator housing. To monitor the
coolant temperature, the element must be in contact
with the coolant. If overheating occurs due to low
coolant level or no coolant, the sensor will not
function properly. A high coolant temperature will
activate an alarm, a derating, or a shutdown. A low
coolant temperature will only activate an alarm. The
trip points for the activation can be programmed
with Cat ET. The engine can be restarted after a
shutdown due to high engine coolant temperature.
However, another shutdown will occur after one
minute if the temperature remains high. To observe
the value of the output of the sensor, use Cat ET to
view the “Engine Coolant Temperature” parameter.
The sensor can measure a range of −40 to 150 C
(−40 to 302 F).
g00928527
Illustration 6
Left side of the engine Inlet air pressure sensor (6) – The sensor for inlet air
(9) Detonation sensor pressure is connected to the air inlet manifold. The
(10) Speed/timing sensor sensor monitors the absolute manifold air pressure.
This is the atmospheric pressure plus the gauge
The functions of the sensors are described below. pressure. The information is used by the master
ECM to determine the engine load. To observe
Engine oil temperature sensor (1) – An oil the output value of the sensor, use Cat ET to view
temperature sensor measures the engine oil the “Inlet Manifold Air Pressure (abs)” parameter.
temperature. A high oil temperature will activate The sensor measures pressure in the range of
an alarm or a shutdown. The trip points can 20 to 339 kPa (3 to 49 psi).
be programmed with the Caterpillar Electronic
Technician (ET). The master ECM compares the Engine coolant pressure sensor (7) – A pressure
oil temperature to the coolant temperature. An switch is located at the outlet for the engine jacket
engine oil temperature that is significantly high in water. If the outlet pressure is too low, the master
comparison to a lower coolant temperature will ECM will activate a shutdown. The trip point is
activate an alarm or a shutdown. To observe the calculated according to the equation in Table 2. The
output value of the sensor, use Cat ET to view the trip point for the shutdown depends on the value
“Engine Oil Temperature” parameter. The sensor of the signal from the engine coolant temperature
measures temperature in the range of −40 to 120 C sensor.
(−40 to 248 F).
Table 2
Oil pressure sensors (2) and (3) – The engine oil Calculation of the Trip Point for the Engine
pressure is measured before the oil filters and Coolant Pressure Shutdown
after the oil filters. An alarm or a shutdown can be
activated by any of the following occurrences: low (5.665 X T) − 420.46 = X
filtered oil pressure, low oil filter differential pressure, “T” is the temperature of the jacket water in Degree
and high oil filter differential pressure. The trip point Celsius.
for the activation of an alarm or a shutdown for oil
filter differential pressure can be programmed with “X” is the trip point for the shutdown in kPa.
Cat ET. To observe the value of the output of the
sensor, use Cat ET to view the “Engine Oil Pressure”
or the “Unfiltered Engine Oil Pressure” parameter.
Both of the sensors measure pressure in the range
of 0 to 1135 kPa (0 to 165 psi).
16
To convert kPa to psi, divide the kPa by 6.89. To

observe the value of the output of the engine coolant
pressure sensor, use Cat ET to view the “Engine
Coolant Pressure (abs)” parameter. The sensor
measures pressure in the range of 0 to 472 kPa
(0 to 69 psi). The measured pressure is absolute.
Inlet air temperature sensor (8) – A sensor for

monitoring the air inlet temperature is located in
the elbow before the number one cylinder head.
Excessive inlet air temperature can activate an
alarm, a derating, or a shutdown during high load or
low load operation. The trip points for activation can
be programmed with Cat ET. To observe the value
of the output of the sensor, use Cat ET to view the
“Inlet Air Temperature” parameter. The sensor can
measure a range of −40 to 120 C (−40 to 248 F).
Detonation sensors (9) – The detonation sensors

monitor the engine for mechanical engine vibrations.
Each sensor monitors two cylinders. The sensor
produces a voltage signal that is proportional to the
engine detonation. This information is processed by
the electronic control modules in order to determine
detonation levels. To eliminate detonation, the
electronic control modules retard the timing of
the cylinder, if necessary. If excessive detonation
continues, the master ECM will shut down the
engine. To observe the value of the output of the
sensors, use the Caterpillar Electronic Technician
(ET) to view the “Cylinder #X Detonation Level”. The
“X” is the number for the particular cylinder.
Speed/timing sensor (10) – The engine speed/timing

sensor is located on the rear end of the left
camshaft. The engine speed/timing sensor provides
accurate information to the electronic control
modules about the position of the crankshaft and
the engine rpm. The modules use the position of
the crankshaft in order to determine ignition timing.
If an overspeed occurs, the master ECM shuts
down the engine. The speed for the trip point of
the shutdown can be programmed with Cat ET. To
observe the engine speed in rpm, use Cat ET to
view the “Engine Speed” parameter.
Thermocouples
Thermocouples provide information to the
Integrated Temperature Sensing Module (ITSM).
The information is used to monitor engine operation.
The thermocouples also enable alarms and shutoffs
to be activated.
17
g00928709
Illustration 7
(1) Thermocouple for the temperature of a (3) Thermocouples for the temperature of
cylinder exhaust port the turbocharger exhaust outlets
(2) Thermocouple for the temperature of an (4) Thermocouple for the temperature of the
exhaust inlet to a turbocharger turbine turbocharger exhaust outlet
Cylinder Exhaust Temperature (1) – Thermocouples Exhaust Outlet from the Turbocharger Turbine (3) –
measure the exhaust temperatures from the exhaust A thermocouple is mounted at the outlet for the
port of each cylinder. An alarm or a shutdown exhaust gas of each turbocharger turbine. The
is activated if the exhaust temperature from any 60 Hz engine has two thermocouples for the
cylinder is too high or if the exhaust temperature exhaust gas of the turbochargers. The 50 Hz
from any cylinder deviates excessively from the engine has one thermocouple for the exhaust gas
average temperature of all of the cylinders. The trip of the turbocharger. An alarm or a shutdown is
points can be programmed with Cat ET. To observe activated if the temperature of the exhaust from
the value of the output of the thermocouples, use either turbine is too high or too low. The trip points
Cat ET to view the “Cylinder #X Exhaust Port”. The can be programmed with Cat ET. To observe the
“X” is the number for the particular cylinder. The value of the output of the thermocouples, use Cat
thermocouples measure temperature in the range of ET to view the “Left Bank Turbine Outlet Temp”
0 to 600 C ± 10 C (32 to 1112 F ± 18 F). or the “Right Bank Turbine Outlet Temp”. The
thermocouples measure temperature in the range of
Exhaust Inlet to the Turbocharger Turbine (2) – A 0 to 600 C ± 10 C (32 to 1112 F ± 18 F).
thermocouple is mounted at the inlet for the exhaust
gas of each turbocharger turbine. An alarm or a
shutdown is activated if the temperature of the
exhaust to the turbine is too high or too low. The trip
points can be programmed with Cat ET. To observe
the value of the output of the thermocouples,
use Cat ET to view the “Left Bank Turbine Inlet
Temp” or the “Right Bank Turbine Inlet Temp”. The
thermocouples measure temperature in the range of
0 to 600 C ± 10 C (32 to 1112 F ± 18 F).
18
Integrated Temperature Sensing Module • Program parameters.

• Calibrate sensors.
The tools that are listed in Table 3 are required in
order to enable a service technician to perform the
procedures.
g00929153
Illustration 8
(5) Integrated temperature sensing module
The Integrated Temperature Sensing Module

(ITSM) (5) monitors all of the thermocouples. The
ITSM broadcasts the temperature readings of the
thermocouples over the Cat data link for use by
other modules.
The ITSM also calculates the average temperature

for each cylinder bank (left and right). Event codes
are generated if the following conditions occur:
• The average temperature is higher than the limit

that is programmed.
• The average temperature is lower than the limit

that is programmed.
• The temperature of a cylinder deviates

significantly from the average temperature for all
of the cylinders.
i01816616
Electronic Service Tools

SMCS Code: 0785
Caterpillar Electronic Service Tools are designed to

help the service technician perform the following
functions:
• Obtain data.
• Diagnose problems.
• Read parameters.
19
Table 3
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 Caterpillar Electronic Technician (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.
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.
20
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
• Flash downloading
• Set parameters
Connecting Cat ET with the 171-4401
Communication Adapter II
The battery supplies the communication adapter
with 24 VDC. Use the following procedure to
connect Cat ET and the communication adapter
to the engine. Illustration 9 g00927657
(1) PC
1. Set the engine control to the OFF/RESET mode. (2) 196-0055 Serial Cable or the 160-0141 Serial Cable
(3) 171-4401 Communication Adapter II
(4) 207-6845 Adapter Cable
(5) 7X-1414 Data Link Cable
2. Connect cable (2) to the RS232 serial port of

PC (1).
3. Connect cable (2) to communication adapter (3).
5. Connect cable (4) to cable (5).
6. Connect cable (5) to the service tool connector

of the terminal box.
7. Set the engine control to the STOP mode.

The engine should be OFF. If Cat ET and the
communication adapter do not communicate with
the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate With ECM”.
21
If Cat ET displays “Duplicate Type on data link.

Unable to Service”, check the harness code for
the slave ECM.
The harness inside the terminal box for the

slave ECM has a jumper wire (harness code)
that connects terminals J3-29 and J3-60. The
ECM that is connected to the harness reads
the harness code. This allows the ECM to
operate as the slave ECM. The jumper wire
must be connected in order for the Cat ET to
communicate with the modules. The jumper wire
must be connected in order for the engine to
crank. The jumper wire must remain connected
in order for the engine to run.
Check the continuity between terminals J3-29

and J3-60. Verify that the jumper wire is in good
condition. Make repairs, as needed.
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.
1. Set the engine control to the OFF/RESET mode.
g00927681
Illustration 10
(1) PC
(2) 7X-1425 Serial Cable
(3) 139-4166 Adapter Cable
(4) 7X-1701 Communication Adapter
(5) 7X-1414 Data Link Cable
2. Connect cable (2) to the RS232 serial port of

PC (1).
5. Connect cable (3) to cable (5).
6. Connect cable (5) to the service tool connector

of the terminal box.
7. Set the engine control to the ON mode. The

engine should be OFF. If Cat ET and the
communication adapter do not communicate with
the ECM, refer to Troubleshooting, “Electronic
Service Tool Will Not Communicate With ECM”.
If Cat ET displays “Duplicate Type on data link.

Unable to Service”, check the harness code for
the slave ECM.
22
The harness inside the terminal box for the 2. Highlight the desired parameter. Then click on
slave ECM has a jumper wire (harness code) the “Change” button in the lower left corner of
that connects terminals J3-29 and J3-60. The the screen.
ECM that is connected to the harness reads
the harness code. This allows the ECM to The “Change Monitor System” screen will appear.
operate as the slave ECM. The jumper wire
must be connected in order for the Cat ET to 3. Change the “State” to “On” or “Off”.
communicate with the modules. The jumper wire
must be connected in order for the engine to 4. Set the “Trip Point” and the “Delay Time”
crank. The jumper wire must remain connected according to the “Allowed Values” in the lower
in order for the engine to run. half of the screen.
Check the continuity between terminals J3-29 5. Click the “OK” button.
condition. Make repairs, as needed. If a password is required, the “Enter Passwords”
screen will appear. Enter the correct passwords
and then click the “OK” button.
i01865799
Engine Monitoring System The new settings will be effective immediately.
SMCS Code: 7490 Monitoring Parameters

The master Electronic Control Module (ECM) “Low System Voltage”
monitors the operating parameters of the engine.
The master ECM can initiate responses if a specific The trip point for this parameter is set at the factory.
engine parameter exceeds an acceptable range. The trip point cannot be changed. This parameter
Three possible responses may be available for is always ON. This parameter cannot be turned off.
each parameter: “WARNING”, “DERATE”, and If the system voltage decreases to the trip point or
“SHUTDOWN”. Some of the responses are not if the system voltage goes below the trip point, the
available for some of the parameters. Use the ECM will generate a warning or a shutdown.
Caterpillar Electronic Technician (ET) to perform the
following activities:
“High Engine Coolant Temperature”
• Select the available responses. The trip points for this parameter can be
programmed by the customer. The shutdown
• Program the level for monitoring. response is always ON. The shutdown response
cannot be turned off. If the engine coolant
• Program delay times for each response. temperature increases to the trip point or if the
The default settings for the parameters are engine coolant temperature exceeds the trip point,
programmed at the factory. To accommodate the ECM will generate a warning, a derating, or a
unique applications and sites, the parameters may shutdown.
be reprogrammed with Cat ET. The screens of Cat
ET provide guidance for the changing of trip points. “Low Engine Coolant Temperature”
Note: Some of the parameters are protected by The trip point for this parameter can be programmed
factory passwords. Other parameters can be by the customer. If the engine coolant temperature
changed with customer passwords. decreases to the trip point or if the engine coolant
temperature goes below the trip point, the ECM will
generate a warning.
Changing the Settings of the
Monitoring System “Engine Overspeed”
Use the following procedure to change settings of The trip point for this parameter is set at the factory.
the parameters: This parameter is always ON. This parameter cannot
be turned off. If the engine speed increases to the
1. Use Cat ET and select the “Service/Monitoring trip point or if the engine speed exceeds the trip
System” screen. point, the ECM will activate an engine shutdown.
A typical trip point is 118 percent of the engine’s
rated speed for generator set applications.
23
“High Engine Oil Temperature” “Low Gas Fuel Differential Pressure”

The trip point for a warning for this parameter can The trip point for this parameter can be programmed
be programmed by the customer. The trip point for by the customer. If the fuel differential pressure
a shutdown is set at the factory. This parameter decreases to the trip point or if the fuel differential
is always ON. This parameter cannot be turned pressure goes below the trip point, the ECM will
off. If the engine oil temperature increases to the generate a warning.
trip point or if the engine oil temperature exceeds
the trip point, the ECM will generate a warning or “High Gas Fuel Differential Pressure”
a shutdown.
The trip point for this parameter can be programmed
“High Oil Filter Differential Pressure” by the customer. If the fuel differential pressure
increases to the trip point or if the fuel differential
The trip point for a warning for this parameter can pressure exceeds the trip point, the ECM will
be programmed by the customer. The trip point for generate a warning.
a shutdown is set at the factory. This parameter is
always ON. This parameter cannot be turned off. If “High System Voltage”
the engine oil filter differential pressure increases
to the trip point or if the engine oil filter differential The trip point for this parameter is set at the factory.
pressure exceeds the trip point, the ECM will The trip point cannot be changed. This parameter
generate a warning or a shutdown. is always ON. This parameter cannot be turned off.
If the system voltage increases to the trip point or if
“Low Oil Filter Differential Pressure” the system voltage exceeds the trip point, the ECM
will generate a warning.
The trip point for a warning for this parameter can
be programmed by the customer. The trip point for a Trip Points of the Engine Load for High
shutdown for this parameter is set at the factory. This
parameter is always ON. This parameter cannot be Inlet Air Temperature
turned off. If the engine oil filter differential pressure
The trip points for these parameters can be
decreases to the trip point or if the engine oil filter
differential pressure goes below the trip point, the programmed by the customer. The shutdown
ECM will generate a warning or a shutdown. response is always ON. The shutdown response
cannot be turned off. This feature provides a trip
point between high engine load and low engine
“High Fuel Temperature” load. The trip point is used for events that involve
high inlet air temperature. The trip point for the
The trip point for this parameter can be programmed events is based on the engine load. The possible
by the customer. If the fuel temperature increases responses of the system include warning, derating,
to the trip point or if the fuel temperature exceeds and shutdown.
the trip point, the ECM will generate a warning.
If the load is greater than the trip point, the trip point
“Low Fuel Pressure” for the “High Inlet Air Temperature at High Engine
Load” event is used for the logging of the high inlet
The trip point for this parameter can be programmed air temperature.
by the customer. If the fuel pressure decreases to
the trip point or if the fuel pressure goes below the If the load is less than the trip point, the trip point
trip point, the ECM will generate a warning. for the “High Inlet Air Temperature at Low Engine
Load” event is used for the logging of the high inlet
“High Engine Oil to Engine Coolant air temperature.
Differential Temperature”
“High Inlet Air Temperature at Low
The trip point for a warning for this parameter can Engine Load”
be programmed by the customer. The trip point
for a shutdown for this parameter is set at the The “Service/Configuration” screen of Cat ET
factory. The shutdown response is always ON. The defines the “High Inlet Air Temp Engine Load Set
shutdown response cannot be turned off. If the Point”. The ECM can activate a warning, a derating,
differential temperature of the jacket water and or a shutdown if the inlet air temperature increases
the engine oil increases to the trip point or if the to the trip point or if the inlet air temperature
differential temperature of the jacket water and exceeds the trip point during the low load operation
the engine oil exceeds the trip point, the ECM will that is defined.
generate a warning or a shutdown.
24
“High Inlet Air Temperature at High For example, if the desired engine speed is 1507
Engine Load” rpm and a derating is activated, the desired engine
speed will be reduced to 1477 rpm in 20 seconds.
The “Service/Configuration” screen of Cat ET If the condition that activated the derating is gone
defines the “High Inlet Air Temp Engine Load Set after 20 seconds, the desired engine speed will
Point”. The ECM can activate a warning, a derating, return to 1507 rpm in 20 seconds. In this example,
or a shutdown if the inlet air temperature increases the incident lasted for 40 seconds.
to the trip point or if the inlet air temperature
exceeds the trip point during the high load operation Engine Overload
that is defined.
The derating for “Engine Overload” is programmed
to be ON at the factory. This derating cannot be
“High Fuel Pressure” adjusted via Cat ET. The default value for the
derating is 110 percent of the rated load.
The trip point for this parameter can be programmed
by the customer. The ECM will activate a warning if For example, if the desired engine speed is 1507
the fuel pressure increases to the trip point or if the
rpm and a derating is activated, the desired engine
fuel pressure exceeds the trip point. speed will be reduced to 1356 rpm in 20 seconds.
If the condition that activated the derating is gone
Engine Power Derating after 20 seconds, the desired engine speed will
return to 1507 rpm in 20 seconds. In this example,
The master ECM can automatically derate the the incident lasted for 40 seconds.
engine power in order to protect the engine from
undesirable operating conditions. The master ECM If more than one derating is active, the master
can derate the engine power in response to the ECM will automatically use the largest value that is
following operating conditions: programmed for a derating of the desired engine
speed. When a derating of 0 percent is achieved,
• E015 High Engine Coolant Temperature all of the deratings are deactivated.
• E025 High Inlet Air Temperature at Low Engine Default Settings of the Monitoring
Load
System
• E025 High Inlet Air Temperature at High Engine
Load Examples of the default settings for the parameters
are listed in Table 4. The values may have changed.
• E242 Engine Overload Use the Cat ET to determine the programming
for your engine. Many of the items can be
Coolant Temperature and Inlet Air Temperature reprogrammed in order to accommodate the
requirements of individual sites.
The derating for the engine coolant and the inlet
air temperatures can be programmed to be ON or
OFF with Cat ET. The default setting for the derating
is OFF. The temperature for the trip point and the
delay time are also programmable. The range for
the temperature for the trip point and the delay time
is limited.
If one of these three deratings is activated, the

master ECM will reduce the desired engine
speed by 0.1 percent per each second. After the
condition which activated the derating returns
to the pre-derate condition, the master ECM will
increase desired engine speed by 0.1 percent per
each second. The derating is deactivated when a
derating of 0 percent is achieved and the original
desired engine speed is restored.
25
Table 4
Default Settings of the Programmable Monitoring System
Security Range of
System Trip Delay in
Parameter Event Code State Level Range the Delay
Response Point Seconds
Password in Seconds
“Low System E043 (1) Warning 20 volts 20

On (1) This item cannot be programmed.
Voltage” E042 (3) Shutdown 18 volts 10
“E017 (1)” Warning On 113 C
“High Engine
Coolant “E016 (3)” Shutdown On (1) 111 C 80 to 129 C
Temperature”
“E015 (2)” Derating Off 109 C 20 Customer 1 to 60
“Low Engine
Coolant E038 (1) Warning On 5 C 5 to 80 C
Temperature”
“Engine 1770 1200 to
E004 (3) Shutdown 0 Factory 0
Overspeed” rpm 2125 rpm
“High Engine Oil E020 (1) Warning 102 C Customer 85 to 102 C

20
Temperature” E019 (3) Shutdown 104 C Factory 85 to 104 C
103
“High Oil Filter E129 (1) Warning On (1) Customer
kPa 80 to 138
Differential
138 kPa
Pressure” E130 (3) Shutdown Factory
kPa 10
“Low Oil Filter E127 (1) Warning 35 kPa Customer
Differential 5 to 80 kPa
Pressure” E128 (3) Shutdown 5 kPa Factory
“High Fuel
E223 (1) 60 C 20 0 to 60 C
Temperature”
On 1 to 60
“Low Fuel Warning 105 Customer 100 to 135
E053 (1) 10
Pressure” kPa kPa
“High Engine Oil E337 (1) 14 C
to Engine Coolant
On (1) 20 0 to 20 C
Differential E337 (3) Shutdown 20 C Factory
Temperature”
“Low Gas Fuel
Differential E864 (1) 5 kPa
Pressure”
On 10 Customer 0 to 35 kPa
“High Gas Fuel
Differential E865 (1) Warning 35 kPa
Pressure”
“High System
E050 (1) On (1) 34 volts 20 ec This item cannot be programmed.
Voltage”
“High Inlet Air E027 (1) On 69 C 32 to 85 C

Temperature
E025 (2) Derating Off 100 C
at Low Engine
Load” E026 (3) Shutdown On (1) 73 C
20
“High Inlet Air E027 (1) Warning On 53 C 32 to 100 C
Customer 1 to 60
Temperature at
E025 (2) Derating Off 100 C
High Engine
Load” E026 (3) Shutdown On (1) 57 C
“High Fuel 135 100 to 135
E096 (1) Warning On 10
Pressure” kPa kPa
(1) This parameter is permanently active. The parameter cannot be turned off.
26
Separate timers are used in the master ECM for

each response that is associated with a parameter.
If a trip point is exceeded, the timer for that event is
started.
For example, the warning for “High Engine Coolant

Temperature E017 (1)” can be set to 95 C with
a five second delay. The timer starts counting if
the coolant temperature exceeds 95 C. If the
temperature is not reduced to less than 95 C within
five seconds, the event becomes active and the
event is logged.
Conditions for Parameters

Some of the programmable parameters are
dependent on the status of a master ECM output
before the parameters are allowed to function. Some
of the parameters are allowed to function after the
crank terminate relay has been energized for more
than 30 seconds. Other parameters are allowed to
function after the output for the fuel control relay is
energized. Some parameters are not dependent
upon any conditions.
The conditions are designed to eliminate false

events during start-up if the customer has
programmed a delay time to zero. The conditions
are listed in Table 5.
Table 5
Conditions for Activation for Monitoring the Parameters
Parameter Condition
“Low System Voltage” None
“High Engine Coolant Temperature” The crank terminate relay is energized for more than 30 seconds.
“Low Engine Coolant Temperature” None
“Engine Overspeed” None
“High Engine Oil Temperature” The crank terminate relay is energized for more than 30 seconds.
“High Oil Filter Differential Pressure”
“Low Oil Filter Differential Pressure”
“High Fuel Temperature”
“Low Fuel Pressure” The fuel control relay is energized.
“High Engine Oil to Engine Coolant Differential The crank terminate relay is energized for more than 30 seconds.
Temperature”
“Low Gas Fuel Differential Pressure” The fuel control relay is energized.
“High Gas Fuel Differential Pressure”
“High System Voltage” None
“High Inlet Air Temperature at Low Engine Load” The crank terminate relay is energized for more than 30 seconds.
“High Inlet Air Temperature at High Engine Load”
“High Fuel Pressure” The fuel control relay is energized.
27
Use care when you program the trip points and the
delay times. Ensure that the response of the master
ECM is correct for the application. The monitoring
system will accept any settings within the ranges.
If the trip point for a shutdown is programmed to

activate before the trip point for a warning, the
engine will shut down and the warning will not be
activated.
Programmable Parameters of the

Integrated Temperature Sensing
Module
The Integrated Temperature Sensing Module (ITSM)
monitors the temperatures of the cylinder exhaust
ports, of the inlets of the turbocharger turbine, and
of the outlets of the turbocharger turbines.
If a temperature exceeds an acceptable range, the

ITSM can initiate a “WARNING” or “SHUTDOWN”.
Both of the responses are available for all of the
parameters. Use Cat ET to perform the following
activities:
• Select the available responses.

• Program the level for monitoring.
• Program delay times for each response.
Note: To initiate the responses, the ITSM sends
commands to the master ECM via the Cat Data
Link. If the connection between the ITSM and the
master ECM is not correct, the ITSM cannot initiate
any response.
The default settings for the parameters are

programmed at the factory. To accommodate
unique applications and sites, the parameters may
be reprogrammed with Cat ET. The screens of Cat
ET provide guidance for changing trip points.
Table 6 lists default examples of the values for

the parameters. However, the values may have
changed. Use Cat ET to determine the programming
for your engine. The items can be reprogrammed
in order to accommodate the requirements of
individual sites.
Use care when you program the trip points and the
delay times. Ensure that the response of the ITSM is
correct for the application. The monitoring system
will accept any setting within the ranges.
If the trip point for a shutdown is programmed to

activate before the trip point for a warning, the
engine will shut down and the warning will not be
activated.
28
Table 6
Default Settings for the Integrated Temperature Sensing Module
Parameter Event Code System State Trip Delay in Security Range Range
Response Point Seconds Level of the
Password Delay in
Seconds
“High Exhaust E801 (1)
Temperature” through E820 Warning 655 C
(1) 100 to 665
30 1 to 60
E801 (3) C

through E820 Shutdown 665 C
(3)
“Exhaust Port E821 (1)
Temperature through E840 Warning 50 C 60 10 to 50 C 1 to 60
High Deviation” (1)
E821 (3)
100 to 200
through E840 Shutdown 200 C 10 1 to 10
C
(3)
“Exhaust Port E841 (1)
Temperature through E860 Warning On 50 C 60 Customer 10 to 50 C 1 to 60
Low Deviation” (1)
E841 (3)
10 to 200
through E860 Shutdown 200 C 10 1 to 10
C
(3)
“High Turbo E245 (1) 100 to 710
Warning 710 C
Turbine Inlet E246 (1) C
Temperature” 30 1 to 60
E245 (3) 100 to 730
Shutdown 730 C
E246 (3) C
“High Turbo E243 (1)
Warning 615 C
Turbine Outlet E244 (1) 100 to 625
Temperature” 60 1 to 60
E243 (3) C

Shutdown 625 C
E244 (3)
Separate timers are used in the ITSM for each

response that is associated with a parameter. If a
trip point is exceeded, the timer for that event is
started.
For example, the warning for the “High Exhaust

Temperature” (E801 (1)) can be set to 655 C with
a 30 second delay. The timer starts counting if the
exhaust port temperature of the number 1 cylinder
reaches 655 C. If the temperature is not reduced
to less than 655 C within 30 seconds, the event
becomes active and the event is logged.
29
Programming Parameters The customer passwords can be changed, if

necessary. The customer passwords or a factory
password is needed in order to change the
i01829539 customer passwords. If the customer passwords
are forgotten, factory passwords can be acquired
Programming Parameters from Caterpillar.
SMCS Code: 1901 After the customer passwords are entered, the
passwords are required in order to change certain
Programmable parameters enable the engine to be parameters. Once the passwords are entered
configured in order to meet the requirements of the successfully, the passwords are not requested
application. The system configuration parameters again until another screen is accessed or the data
must be programmed when the application is link is interrupted.
installed. Perform this programming before the initial
engine start-up. This feature is enabled by programming two
customer passwords. Use the following procedure
Data from a gas analysis and data on engine to program the passwords. The same procedure is
performance are required in order to determine the used to change the passwords:
correct settings for the ignition timing and the fuel
control. Incorrect programming of parameters may 1. Access the “Service/Configuration” screen of the
lead to complaints about performance and/or to Caterpillar Electronic Technician (ET).
engine damage.
2. Highlight the “Customer Password #1” parameter.
Programmable parameters can be classified into Click on the “Change” button in the lower right
the following types: engine identification, timing corner of the screen.
control, air/fuel ratio control, speed control, and
start/stop control. Note: Be sure to record the customer passwords.
Store the passwords securely. The passwords can
If an Electronic Control Module (ECM) is replaced, have a maximum of eight characters. Alphanumeric
the appropriate parameters must be copied from characters may be used. The passwords are case
the old ECM. This can be done with the “Copy sensitive.
Configuration” feature of the Caterpillar Electronic
Technician (ET). Alternatively, the settings can be 3. Enter the password in the “Change Parameter
recorded on paper and then programmed into the Value” dialog box and click on the “OK” button.
new module.
4. Highlight the “Customer Password #2” parameter.
NOTICE Click on the “Change” button in the lower right
Changing the parameters during engine operation can corner of the screen.
cause the engine to operate erratically. This can cause
engine damage. 5. Enter the password in the “Change Parameter
Value” dialog box and click on the “OK” button.
Only change the settings of the parameters when the
engine is STOPPED. The passwords are now programmed into the
memory of the Master Electronic Control Module
(ECM).
i01758130
Make a copy of Table 7 and record your passwords.
Customer Passwords Store the passwords securely.
SMCS Code: 0785 Table 7

Customer Passwords
Certain monitoring system parameters and system
configuration parameters may be protected with Customer Password #1
customer passwords. Use of the passwords helps Customer Password #2
to prevent free access to the modification of the
parameters. If the customer passwords are not
programmed, all of the parameters are unprotected.
30
i01865997 Factory passwords are not required for the first hour
of operation for a new master ECM. After the hour
Factory Passwords expires, factory passwords are required for some of
the programming.
SMCS Code: 0785
Factory level security passwords are required for i01727016

clearing certain logged events and for changing
certain programmable parameters. Because of the Factory Passwords Worksheet
passwords, only authorized personnel can make
changes to some of the programmable items in SMCS Code: 0785
an Electronic Control Module (ECM). When the
correct passwords are entered, the changes are Note: A mistake in recording this information will
programmed into the master ECM. result in incorrect passwords.
Table 8
Factory passwords are required to program the
following shutdowns: Factory Passwords Worksheet
Dealer Code
• “Engine Overspeed”
Customer’s Name
• “High Engine Oil Temperature” Address
• “High Oil Filter Differential Pressure”

• “Low Oil Filter Differential”
Telephone Number
• “High Engine Oil to Engine Coolant Differential Information from the “Enter Factory Passwords”
Temperature” Screen on the Caterpillar Electronic Technician (ET)
The “Enter Factory Passwords” screen on Cat ET Serial Number for Cat ET
will display the following parameters. To obtain the Engine Serial Number
proper passwords, the information must be given to
an authorized Caterpillar dealer: ECM Serial Number
Diagnostic Clock(1)
• Current master ECM
Total Tattletale
• Serial number of the service tool Reason Code
Factory Passwords
• Serial number of the engine
Factory Password (No. 1)
• Serial number of the master ECM
Factory Password (No. 2)
• Diagnostic clock (1) Do not obtain this information from the service meter.
• Total Tattletale
• Reason
The old interlock code is required to change the
interlock code on a used ECM. The passwords are
controlled by Caterpillar. The passwords may only
be obtained by an authorized Caterpillar dealer.
The passwords may only be used for one

programming session. After you exit the “Enter
Factory Passwords” screen on Cat ET, a different
set of passwords will be required before you can
program the master ECM.
31
i01866010 A list of flash files will appear.

Flash Programming 6. Select the correct file from the list of flash files.
Read the “Description” and the “File Info” in
SMCS Code: 1901-591 order to verify that the correct file is selected.
Select “Open”.
Software is located in the flash memory of the
master Electronic Control Modules (ECM), the slave 7. Select the “Begin Flash” button in order to
ECM, and the Integrated Temperature Sensing program the personality module.
Module (ITSM). The Caterpillar Electronic Technician
(ET) can be used to flash new software into an ECM When the flash is completed, this message will
or the ITSM. This is the only method for updating the appear: “Flash Completed Successfully”.
software. The component that contains the software
cannot be physically removed from the module. 8. Program the configuration parameters and the
This eliminates the risk of moisture entry into a monitoring system parameters.
module due to improper seal installation. The flash
is accomplished by transferring the data from Cat The parameters must be programmed in order
ET to the module via data link wiring. The Software, to ensure proper engine operation. Refer to
JERD2124 or Software, JERD2129 is used. Troubleshooting, “Engine Monitoring System”
and Troubleshooting, “System Configuration
Flash Programming Parameters”.
If the slowest baud rate of Cat ET is selected, flash 9. Start the engine and check for proper operation.
programming can last up to 15 minutes. Be sure to
set the baud rate to the fastest rate for your PC. a. If a diagnostic code of 268-02 “Check
Programmable Parameters” is generated,
To select the baud rate, use the “Utilities/ program any parameters that were not in the
Preferences” option on the Cat ET. Select the original software.
“Communications” tab and click on “Advanced...”.
Then select the baud rate from the “Advanced b. Access the “Configuration” screen under
Communication Settings” menu and click the “OK” the “Service” menu in order to determine
button. the parameters that require programming.
Look under the “Tattletale” column. All of the
If a communication error occurs, select a slower parameters should have a tattletale of 1 or
baud rate in order to improve the reliability. more. If a parameter has a tattletale of 0,
program that parameter.
1. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service “WinFlash” Error Messages
Tools”.
If you receive any error messages during flash
2. Set the engine control to the STOP mode. 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 is in the the “ECM Summary” under the “Information” menu.
OFF/RESET or START mode. Make sure that you are flashing the correct file for
your engine.
3. Select “WinFlash” from the “Utilities” menu on
the Cat ET.
i01828990
“WinFlash” will try to detect an ECM. Allow a few
moments for “WinFlash” to detect the electronic
System Configuration
control modules and connect to the electronic Parameters
control modules.
SMCS Code: 1901
4. When an ECM has been detected, the “ECM
Selector” window will appear. Select the Certain parameters are unique for each engine
appropriate ECM and then select “OK”. application. Table 9 is a list of the parameters
that can be configured for G3520C Engines. The
The “Flash File Selection” window will appear. parameters are described below. The values of the
parameters can be viewed on the “Configuration”
5. The flash files are located on a disk drive and screen of the Caterpillar Electronic Technician (ET).
in a directory. Select the correct disk drive and
the directory from “Drives” and “Directories” on
Cat ET.
32
Table 9 (Table 9, contd)
Configuration Parameters for G3520C Engines Configuration Parameters for G3520C Engines
Air/Fuel Ratio Control Override
“Fuel Quality” “Requested Detonation Derate Percentage Override”
“Gas Specific Gravity” Information for the Electronic Control Module (ECM)
“Fuel Specific Heat Ratio” “Engine Serial Number”
“Air/Fuel Ratio Proportional Gain” “Equipment ID”
“Air/Fuel Ratio Integral Gain” “Customer Password #1”
“NOx Emission Gain Adjustment” “Customer Password #2”
Speed Control “Total Tattletale”
“Low Idle Speed”
“Minimum Engine High Idle Speed” Governing of the Air/Fuel Ratio
“Maximum Engine High Idle Speed” Control and of the Engine Speed
“Engine Accel. Rate” Gain and stability can be adjusted for the following
“Desired Speed Input Configuration” functions:
“Governor Type Setting” • Primary governor
“Grid Status”
• Auxiliary governor
“Engine Speed Droop”
“Governor Proportional Gain” • Fuel metering valve
“Governor Integral Gain” For the two governors, compensation can also be
“Governor Derivative Gain” adjusted.
“Auxiliary 1 Proportional Governor Gain” Gain determines the speed of the control’s response
“Auxiliary 1 Integral Governor Gain”
in adjusting for the difference between the actual
condition and the desired condition. Increasing the
“Auxiliary 1 Derivative Governor Gain” gain provides a faster response to the difference
between the actual condition and the desired
Start/Stop Control
condition.
“Driven Equipment Delay Time”
Stability controls the speed for elimination of the
“Crank Terminate Speed”
error in the difference between the actual condition
“Engine Purge Cycle Time” and the desired condition. The stability dampens
the response to the error. Increasing the stability
“Engine Cooldown Duration”
provides less damping.
“Cycle Crank Time”
Compensation is used to adjust for the time delay
“Engine Overcrank Time”
between the control signal and the movement of the
“Engine Speed Drop Time” actuator. If the compensation is too low, the engine
speed will slowly hunt. If the compensation is too
“Engine Pre-Lube Time Out Period” high, the engine speed will rapidly fluctuate.
Monitoring and Protection
Illustration 11 shows some typical curves for
“High Inlet Air Temp Engine Load Set Point” transient responses.
Power Monitoring
“Generator Output Power Sensor Scale Factor”
“Generator Output Power Sensor Offset”
“Engine Full Load Rating”
“Engine Driven Equipment Load”
(continued)
33
If you have a problem with instability, always

investigate other causes before you adjust the
settings. For example, diagnostic codes and
unstable gas pressure can cause instability.
When you adjust the primary governor, make

sure that the “Grid Status” parameter is “Off”. To
change the gain, stability, or compensation, use the
“Real Time Graphing” feature on the “Information”
drop-down menu of Cat ET. The graph provides
the best method for observing the effects of the
adjustment.
When you adjust the auxiliary governor, make sure

that the “Grid Status” parameter is “On”.
After you make adjustments, always test the stability

by operating the engine through the entire range of
speeds and of loads in order to ensure stability.
Air/Fuel Ratio Control

Before the initial start-up, a current gas analysis
is required. Periodic gas analyses are also
recommended. Data from the gas analysis must
be entered into Caterpillar Software, LEKQ6378,
“Methane Number Program”. The results are
Illustration 11 g00806254 programmed into the ECM.
(Y) Engine speed
(X) Time
Note: It is very important to use the Caterpillar
(1) The gain is too high and the stability is too low. There is a large Software, LEKQ6378, “Methane Number
overshoot on start-up and there are secondary overshoots on Program”. Use of only the data from the gas
transient loads. analysis can result in incorrect settings.
(2) The gain is slightly high and the stability is slightly low. There
is a slight overshoot on start-up but the response to transient
loads is optimum. “Fuel Quality”
(3) The gain is slightly low and the stability is slightly high. There
is optimum performance on start-up but slow response for This is the fuel’s Low Heat Value (LHV). The fuel
transient loads.
(4) The gain is too low and the stability is too high. The response ratio control of the ECM will compensate for some
for transient loads is too slow. inaccuracy in this setting. The ECM assumes a
(5) The response to transient loads is adjusted for optimum corrected value that is multiplied by the “Fuel
performance. Correction Factor”. This factor can be displayed on
the Cat ET screen.
Illustration 12 is a graphic representation of
adjusting the compensation. The “Fuel Quality” parameter can be used to
change the air/fuel ratio when the engine is
not operating with charge density feedback. To
richen the air/fuel mixture, reduce the value. The
calculation will compensate for the reduced LHV by
increasing the fuel flow. To lean the air/fuel mixture,
increase the value. The calculation will compensate
for the increased LHV by reducing the fuel flow.
g00806274
Illustration 12 “Gas Specific Gravity”
The increased width of the line for the actuator voltage indicates
that the linkage is more active as the compensation increases. This is the fuel’s specific gravity in relation to the
(Y) Actuator voltage specific gravity of air. The ECM does not use this
(X) Time in seconds information. The ECM provides the information to
the fuel metering valve via the Cat Data Link. The
The default values should be sufficient for initial fuel metering valve requires an input for the “Gas
start-up. However, the values may not provide Specific Gravity” in order to precisely meter the
optimum performance. air/fuel ratio.
34
“Fuel Specific Heat Ratio” When you adjust the exhaust emissions, make a
small change in the value of the gain. Wait until
This is a ratio of the fuel’s specific heat at a constant the system stabilizes. Check the emissions again.
pressure and the fuel’s specific heat at a constant Repeat the process until the desired emissions level
volume. The ratio is also known as “k”. The ratio is achieved.
is related to the expansion of the gas across the
fuel metering valve. The ECM does not use this Speed Control
information. The ECM provides the information to
the fuel metering valve via the Cat Data Link. The
fuel metering valve requires an input for the “Fuel “Low Idle Speed”
Specific Heat Ratio” in order to precisely meter the
air/fuel ratio. Program this parameter to the desired low idle rpm.
The low idle rpm can be programmed from 500 to
1100 rpm.
“Air/Fuel Ratio Proportional Gain”
The “Air/Fuel Ratio Proportional Gain” determines “Minimum Engine High Idle Speed”
the response of the fuel metering valve to the
magnitude of error for the fuel ratio. The factory Program this parameter to the desired minimum high
default setting is 0. This value should not require idle rpm. The actual high idle speed is regulated by
adjustment. If problems occur, this is one of the the desired speed input. The regulation is linear in
last parameters that should be adjusted. The proportion to the input. An input of 0 percent results
adjustable range is −50 to +50. Negative values in the minimum high idle rpm and an input of 100
reduce the magnitude and positive values increase percent results in the maximum high idle rpm.
the magnitude.
For the 50 Hz arrangement, the minimum high idle
speed can be programmed between 900 and 1500
“Air/Fuel Ratio Integral Gain” rpm. The default value is 1400 rpm.
The “Air/Fuel Ratio Integral Gain” determines the
For the 60 Hz arrangement, the minimum high idle
response of the fuel metering valve to the error that
speed can be programmed between 900 and 1800
is accumulated over time for the air/fuel ratio. The rpm. The default value is 1600 rpm.
factory default setting is 0. This value should not
require adjustment. If problems occur, this is one of
the last parameters that should be adjusted. The “Maximum Engine High Idle Speed”
adjustable range is −50 to +50. Negative values
reduce the magnitude and positive values increase Program this parameter to the desired maximum
the magnitude. high idle rpm. The actual high idle speed is
regulated by the desired speed input. The
regulation is linear in proportion to the input. An
“NOx Emission Gain Adjustment” input of 0 percent results in the minimum high idle
rpm and an input of 100 percent results in the
This is an adjustment for the level of the engine’s maximum high idle rpm.
exhaust emissions for engine operation at full load.
The gain adjustment provides a multiplier for the For the 50 Hz arrangement, the maximum high idle
mathematical point on the map for the desired speed can be programmed between 1500 and
charge density. The gain adjustment affects the fuel
1900 rpm. The default value is 1600 rpm.
correction factor that is used in the calculation of
the fuel flow. To richen the air/fuel mixture, increase For the 60 Hz arrangement, the maximum high idle
the gain adjustment. To lean the air/fuel mixture,
speed can be programmed between 1800 and
decrease the gain adjustment. 2200 rpm. The default value is 2000 rpm.
Use an accurate emissions analyzer to check the
exhaust emissions and make adjustments with the Speed Selection
gain.
The engine operates at one of two speed settings.
A small change in the “NOx Emission Gain The settings are “Idle” and “Rated”. The current
Adjustment” causes a large change in the actual setting is displayed on the “Status Group 5” screen
exhaust emissions. For example, an adjustment of on Cat ET. The master ECM automatically selects
0.01 in the parameter’s value will result in a change the setting that is appropriate according to the
of 20 to 40 ppm in the actual level of NOx. position of the “Idle/Rated” switch and the oil
pressure.
35
If the “Idle/Rated” switch is in the “Idle” position, the Engine Speed Droop
master ECM will always select the “Idle” setting. The
engine will operate at the speed that is programmed This programmable parameter allows precise control
into the “Low Idle Speed” parameter. of the droop for applications such as load sharing.
The “Governor Type Setting” parameter must be
If the “Idle/Rated” switch is in the “Rated” position set to “Droop”. The droop can be programmed to a
and the oil pressure is below the low oil pressure value between 0 and 10 percent.
warning, the master ECM will automatically select
the “Idle” setting. If the “Idle/Rated” switch is in “Governor Proportional Gain”
the “Rated” position and the oil pressure is above
the low oil pressure warning, the master ECM will This parameter is based on a proportional multiplier.
automatically select the “Rated” setting. In this case, This parameter changes the reaction of the throttle
the engine will operate at the actual high idle speed. actuator when the “Grid Status” parameter is “Off”.
If this gain is adjusted and the “Grid Status” is “On”,
“Engine Accel. Rate” the stability is not affected. If changing this gain
causes no effect, check the “Grid Status” in order
This parameter controls the rate for engine response to make sure that the status is “Off”.
to a change in the desired engine speed. For
example, the engine can be programmed to “Governor Integral Gain”
accelerate at a rate of 50 rpm per second when the
“Idle/Rated” switch is turned to the “Rated” position. This parameter is based on an integral multiplier.
This parameter changes the reaction of the throttle
“Desired Speed Input Configuration” actuator when the “Grid Status” parameter is “Off”.
If this gain is adjusted and the “Grid Status” is
This parameter determines the signal input to the “On”, the stability is not affected. If changing the
ECM for control of the desired speed. The signal compensation causes no effect, check the “Grid
can be either 0 to 5 VDC or 4 to 20 mA. Status” in order to make sure that the status is “Off”.
Note: The ECM is not configured to accept a pulse “Governor Derivative Gain”
width modulated signal for input of the desired
engine speed. If you try to select a Pulse Width This parameter is based on a derivative multiplier
Modulated input (PWM), the ECM will reject the when the “Grid Status” parameter is “Off”. If the
selection. An error will be generated. gain is changed and the “Grid Status” is “On”, the
stability of the engine will not change. If changing
“Governor Type Setting” the stability causes no effect, check the “Grid
Status” in order to make sure that the status is “Off”.
The “Governor Type Setting” parameter can be set
to “Droop Operation” or to “Isochronous Mode”. “Auxiliary 1 Proportional Governor Gain”
This setting is dependent upon the application of
the engine. This parameter is based on a proportional multiplier
when the engine’s “Grid Status” parameter is “On”.
Perform the following procedure in order to program If the gain is changed and the “Grid Status” is
the “Governor Type Setting” parameter. Select “Off”, the stability of the engine will not change. If
the “Service/Configuration” menu. Highlight the changing this gain causes no effect, check the “Grid
“Governor Type Setting” parameter. Left click on Status” in order to make sure that the status is “On”.
“Change” in the lower left corner of the screen. The
“Change Parameter Value” should appear. Select a
new value of either “Droop” or “Isochronous” and
“Auxiliary 1 Integral Governor Gain”
then left click “OK”. The new programmed value
should appear on the “Configuration” screen as This parameter is based on an integral multiplier
when the engine’s “Grid Status” parameter is “On”.
either “Droop” or “Isochronous”.
If the gain is changed and the “Grid Status” is
“Off”, the stability of the engine will not change. If
“Grid Status” changing this gain causes no effect, check the “Grid
Status” in order to make sure that the status is “On”.
This parameter should be used for generators that
are paralleled to a utility bus or to an infinite bus.
“Grid Status” can be observed on Cat ET. The “Grid
Status” parameter can be set to “On” or “Off” by
an input from the customer supplied equipment. To
set the “Grid Status” parameter to “On”, apply a
ground to terminal J6-28.
36
“Auxiliary 1 Derivative Governor Gain” “Engine Cooldown Duration”

This parameter is based on a derivative multiplier When the ECM receives a “Stop” request, the
when the engine’s “Grid Status” parameter is “On”. engine will continue to run in the “Cooldown
If the gain is changed and the “Grid Status” is Mode” for the programmed cooldown period. The
“Off”, the stability of the engine will not change. If “Cooldown Mode” is exited early if a request for
changing this gain causes no effect, check the “Grid an emergency stop is received by the ECM. If the
Status” in order to make sure that the status is “On”. “Engine Cooldown Duration” is programmed to
zero, the engine will immediately shut down when
Refer to Systems Operation/Testing and Adjusting, the ECM receives a “Stop” request.
“Engine Governing - Adjust” for more information on
adjusting the parameters for the governor. “Cycle Crank Time”
Start/Stop Control Parameters The “Cycle Crank Time” is the amount of time for
activation of the starting motor and the gas shutoff
valve for start-up. If the engine does not start within
“Driven Equipment Delay Time”
the specified time, the attempt to start is suspended
for a “Rest Cycle” that is equal to the “Cycle Crank
The ECM accepts an input from the driven
Time”.
equipment that indicates when the equipment is
ready for operation. When the input is grounded,
the driven equipment is ready. The ECM will not “Engine Overcrank Time”
start the engine until this input is grounded.
The “Engine Overcrank Time” determines the length
The ECM can be programmed to wait for a certain of time for the ECM to attempt to start the engine.
period of time after receiving a start command An event is generated if the engine does not start
before starting the engine. This allows the driven within this period of time.
equipment to get ready for operation.
Example Setting
When the ECM receives a start command, the ECM
will wait for the amount of time that is programmed Table 10
into the “Driven Equipment Delay Time”. If the Examples of the Settings for Start-up
“Driven Equipment Delay Time” elapses and the
Parameter Time
input is not grounded, an event code is activated.
The engine will not start. “Purge Cycle Time” 10 seconds
If the “Driven Equipment Delay Time” is programmed “Cycle Crank Time” 30 seconds
to “0” the delay is disabled. If the ECM receives
a start command and the driven equipment is not “Overcrank Time” 45 seconds
ready, an event code is activated. The engine will
not start.
The following sequence will occur if the parameters
are programmed according to the example in Table
“Crank Terminate Speed” 10:
The ECM disengages the starting motor when the 1. The fuel and the ignition are OFF. The engine will
engine speed exceeds the programmed “Crank crank for 10 seconds in order to purge gas from
Terminate Speed”. The default value of 250 rpm the engine via the exhaust system.
should be sufficient for all applications.
2. The fuel and the ignition are enabled. The
“Engine Purge Cycle Time” engine will continue to crank for a maximum of
30 seconds.
The “Engine Purge Cycle Time” is the duration for
the engine to crank without fuel before the crank 3. If the engine does not start, the ignition, the fuel,
cycle. The ignition is disabled during this time. The and the starting motor are disabled for a 30
“Engine Purge Cycle Time” allows any unburned second “Rest Cycle”.
fuel to exit through the exhaust before you crank
the engine.
37
With this example, a complete cycle is 70 seconds: Note: For the wattmeter’s output, the ECM uses
a purge cycle of 10 seconds, a cycle crank of a range of 0.2 to 4.8 volts. The signal from the
30 seconds, and a rest cycle of 30 seconds. A wattmeter is monitored for the system’s diagnostics.
maximum of one crank cycle is recommended. The If the voltage is less than 0.2 VDC, the input is
“Overcrank Time” of 45 seconds allows one crank assumed to have a short circuit to ground. If
cycle. the voltage is greater than 4.8 VDC, the input is
assumed to have a short circuit to a +Battery source
“Engine Speed Drop Time” or an open circuit. The ECM generates a diagnostic
code for either condition. If the engine’s load is
After the cooldown period has elapsed, the ECM greater than 25 percent and a diagnostic code is
shuts off the gas shutoff valve. The ignition continues generated, the engine is shut down.
until the engine speed drops below 40 rpm. If the
engine rpm does not drop at least 100 rpm within “Generator Output Power Sensor Scale
the programmed drop time, the ECM terminates the Factor”
ignition and the ECM issues an emergency stop.
This parameter is a scale for the wattmeter’s output.
“Engine Pre-Lube Time Out Period” The scale provides a linear relationship between
the wattmeter’s voltage output and the generator’s
At the time of this publication, this parameter is output of ekW. The scale corresponds to an output
not active. from the wattmeter of 1 volt.
For example, suppose that a scale factor of 293

“Monitoring and Protection” is used. This indicates that the wattmeter’s output
of 1.0 volt to the ECM is equal to the generator’s
“High Inlet Air Temp Engine Load output of 293 ekW. When the wattmeter’s output
Setpoint” is 2.0 volts, the generator’s output is 586 ekW.
When the wattmeter’s output is 0.5 volts, the
The programmable setpoint is a value that separates generator’s output is 196.5 ekW. Illustration 13 is a
low engine load from high engine load for events representation of the scale’s slope.
that are activated by high inlet air temperature.
An “Engine Load Factor” can be displayed on a
Cat ET status screen. If the load factor is less than
the setpoint and the inlet air temperature reaches
the trip point, a “High Inlet Air Temperature at
Low Engine Load” event is activated. If the load
factor is greater than the setpoint and the inlet air
temperature reaches the trip point, a “High Inlet
Air Temperature at High Engine Load” event is
activated.
Power Monitoring
The “Generator Output Power Sensor” parameters
configure the ECM for monitoring the generator’s g00933190
Illustration 13
output in ekW. Monitoring the output power of the
generator helps enable the ECM to determine the
The maximum programmable value for the scale
engine load.
is 1048 kW per volt. The minimum programmable
value for the scale is obtained from a calculation.
The ECM uses input from a wattmeter in order to
The equation is provided in in Table 11.
calculate the generator’s output. The signal from
the wattmeter is based on the total real power that Table 11
is produced by the generator.
Minimum Programmable Value for the “Generator
Output Power Sensor Scale Factor”
( R − O ) ÷ 4.6 kW/V
R is the generator’s rated power.
O is the “Generator Output Power Sensor Offset”.
38
“Generator Output Power Sensor Offset” Override Parameters

Because the output from different wattmeters can “Requested Detonation Derate
vary, this parameter is used to fine tune the value of
the signal. This parameter is used to compensate Percentage Override”
for losses in the wiring between the wattmeter
and the ECM. The value of this parameter can be This parameter is not operational.
either a positive value or a negative value. The
value of this parameter is added to the value that is Information for the ECM
determined by the “Generator Output Power Sensor
Scale Factor”. “Engine Serial Number”
For example, a wattmeter may produce a signal of The engine serial number is programmed into the
2.0 volts for a generator’s output of 600 ekW. If a ECM at the factory. The number is stamped on the
scale factor of 293 is used, the ECM will calculate engine Information Plate.
the generator’s output at 586 ekW when the
generator’s actual output is 600 ekW. In this case,
an offset of 16 provides the necessary accuracy for “Equipment ID”
the ECM: 586 + 16 = 300
The customer can assign an “Equipment ID” for the
The total real power of the generator is calculated purpose of identification.
according to the equation in Table 12.
Customer Passwords
Table 12
Calculation of the Generator’s Total Output Two customer passwords can be entered. The
passwords are used to protect certain configuration
( V × S ) + O = Generator’s total output parameters from unauthorized changes.
V is the voltage from the wattmeter.
Note: Factory level security passwords are required
S is the “Generator Output Power Sensor Scale Factor”. for clearing certain logged events and for changing
O is the “Generator Output Power Sensor Offset”.
certain programmable parameters. Because of the
passwords, only authorized personnel can make
changes to some of the programmable items in the
The minimum programmable value for the offset is ECM. When the correct passwords are entered, the
−327 kW. The maximum programmable value for changes are programmed into the ECM.
the offset is 200 kW.
“Total Tattletale”
The “Generator Total Real Power” value can be
displayed on the Cat ET status screen. This item displays the number of changes that have
been made to the configuration parameters.
“Engine Full Load Rating”
To determine the percentage of the engine’s load i01819437
during operation, the ECM must be provided with
the engine’s rated load. The “Engine Full Load
Replacing the ECM
Rating” is the engine’s full load rating in kW. The
SMCS Code: 1901-510
rating is stamped on the engine’s Information Plate.
Electronic control modules contain no moving parts.
“Engine Driven Equipment Load” Replacement of an Electronic Control Module (ECM)
can consume much time. Before you replace an
This is the load of the auxiliary equipment such ECM, follow the troubleshooting procedures in this
as a radiator that is directly driven by the engine. manual in order to be sure that replacement of the
The value is in units of ekW. To determine the ECM will correct the problem.
percentage of the engine’s load during operation,
the ECM adds this load to the generator’s load.
39
Note: The master ECM and the slave ECM should 2. Replace the ECM.
not be interchanged in order to determine if an
ECM is faulty. If the master ECM and the slave ECM Note: This procedure describes replacement of
are interchanged, all of the configuration data for the master ECM. Replacement of the slave ECM
each ECM must be transferred into the Caterpillar is similar.
Electronic Technician (ET). The appropriate
configuration data must then be re-entered into the a. Set the engine control to the OFF/RESET
appropriate ECM. Failure to program each ECM mode.
correctly may result in improper engine operation.
Verify that the suspect ECM is the cause of the

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

the suspect ECM. Verify that the problem recurs. If
the problem recurs, replace the suspect ECM with
the test ECM.
Note: If the parameters cannot be read from the

suspect ECM, the parameters must be obtained
from records or from the factory.
Perform the following procedure to replace the ECM.

g00931487
Illustration 14
1. Use the “Service/Copy Configuration/ECM
Junction box
Replacement” function of the Caterpillar
Electronic Technician (ET).
b. Switch 35 amp circuit breaker (1) to the OFF
position.
Save the file. You can select “Load from ECM”.
You may also select the “Print” function in order
to obtain a paper copy of the parameter settings.
Note: Before you replace an ECM, record all of the

logged events.
a. Connect the Cat ET with the communications

adapter. Select “Service/Copy
Configuration/ECM Replacement” from
the pull-down menu on Cat ET.
Cat ET will load the configuration parameters

and the monitoring system parameters of the
suspect ECM.
b. Select “Load from ECM” in the lower left

corner of the Cat ET screen. Select the
suspect ECM and select “OK”.
After the loading is complete, the Cat ET will

display this message: “The data has been
g00928794
successfully loaded from the ECM”. Select Illustration 15
“OK”. The master ECM is on the left side of the terminal box. The slave
ECM is on the right side of the terminal box.
c. Select “File/Disconnect F8” from the pull-down (2) Mounting nut
menu. (3) ECM connector
(4) ECM connector
Note: Do not terminate the Cat ET.
40
c. Use a 4 mm Allen wrench to disconnect h. A window with the message “Program ECM
connectors (3) and (4). 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. 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
Note: Rubber grommets behind the ECM are held in normally protected with factory passwords.
place by the mounting studs. The grommets help to
reduce vibration. The grommets may fall when the 5. Calibrate the speed/timing sensor.
ECM is removed. Be sure not to lose the grommets.
See Troubleshooting, “Engine Speed/Timing
e. Remove the ECM from the terminal box. Sensor - Calibrate”.
3. Install the replacement ECM.

i01819812
a. Use the mounting hardware to install the

new ECM. Use a mounting nut to fasten the
Replacing the ITSM
ground strap for the ECM to the upper left SMCS Code: 1901-510
mounting stud. Then install the other three
mounting nuts. The Integrated Temperature Sensing Module (ITSM)
contains no moving parts. Replacement of the ITSM
Check the mounting hardware and the can consume much time. Before you replace an
ECM for correct installation. A correctly ITSM, follow the troubleshooting procedures in this
installed ECM will move slightly on the rubber manual in order to be sure that replacement of the
grommets. If the ECM cannot move slightly ITSM will correct the problem.
on the grommets, check that the washers,
spacers, and grommets are positioned Use the following guidelines to verify that the
correctly. suspect ITSM is the cause of the problem:
b. Use a 4 mm Allen wrench to connect the P1 Install a test ITSM in place of the suspect ITSM.
and P2 connectors to the ECM. Tighten the Transfer the software from the suspect ITSM to
screws to a torque of 6 ± 1 N·m (55 ± 9 lb in). the test ITSM. Program all the parameters for the
test ITSM in order to match the parameters of the
4. Program the configuration parameters and suspect ITSM. The parameters must match. Refer
the monitoring system parameters into the to the following steps for details on programming
replacement ECM. the parameters.
a. Switch 35 amp circuit breaker (1) to the ON If the test ITSM resolves the problem, reconnect
position. the suspect ITSM. Verify that the problem recurs. If
the problem recurs, replace the suspect ITSM with
b. Set the engine control to the “STOP” mode. the test ITSM.
c. Select “File/Select ECM” from the pull-down Use the following procedure to replace the ITSM:
menu.
Note: If the parameters cannot be read from the
d. Select the replacement ECM and click “OK”. suspect ITSM, the parameters must be obtained
from records or from the factory.
e. Select “Service/Copy Configuration/ECM
Replacement” from the pull-down menu. Click 1. Use the “Service/Copy Configuration/ECM
“OK” on the window. Replacement” function of the Caterpillar
Electronic Technician (ET) in order to transfer the
f. Select “Program ECM” from the lower left software from the suspect ITSM.
corner of the screen. Select the replacement
ECM and click “OK”. If the correct ECM is You may also select the “Print” function in order
shown, select “Yes”. to obtain a paper copy of the parameter settings.
g. After the loading is complete, a window with Note: Before you replace an ITSM, record all of the
the message “Programming Conflict Warning” logged events.
will appear. Select “OK”.
41
a. Connect Cat ET with the communications

adapter. Select “Service/Copy
Configuration/ECM Replacement” from
the pull-down menu.
Cat ET will load the configuration parameters

and the monitoring parameters from the ECM.
b. Select “Load from ECM” in the lower left

corner of the screen. Select the suspect ITSM
and select “OK”.
After the loading is complete, Cat ET will

display this message: “The data has been
successfully loaded from the ECM”. Select
“OK”.
c. Select “File/Disconnect F8” from the pull-down

menu.
Note: Do not exit from Cat ET.

g00929088
Illustration 17
2. Replace the ITSM. Connectors for the ITSM
(2) Connectors for the harness to the thermocouples
a. Set the engine control to the OFF/RESET (3) Connectors for the harness to the terminal box for the master
mode. ECM
c. Disconnect connectors (2) and (3) from the

ITSM.
g00931487
Illustration 16
Junction box
b. Switch 35 amp circuit breaker (1) to the OFF g00929047

Illustration 18
position. Mounting hardware for the ITSM
(4) Nut
(5) Ground strap
(6) Washer
(7) Mounting flange on the ITSM
d. Remove the four mounting nuts (4) and

washers (6) from mounting flanges (7) of the
ITSM. Ground strap (5) must also be lifted
from one of the studs.
e. Remove the ITSM from the engine.

42
3. Install the replacement ITSM. Orient the 54-pin i01804739

connector toward the bottom of the engine.
Troubleshooting Data Sheet
a. Use the mounting hardware to install the
new ITSM. Be sure to install ground strap (5) SMCS Code: 0785
between one of the washers on the mounting
flange and the nut. To help troubleshoot a gas engine, complete the
information in Table 13. Be sure to include the units
Note: One of the washers is a lock washer. Be sure of measurement.
to install the lock washer between ground strap (5)
and mounting flange (7). The lock washer improves
the electrical conductivity between the ground strap
and the mounting flange.
Check the mounting hardware and the

ITSM for correct installation. A properly
installed ITSM will move slightly on the rubber
grommets. If the ITSM cannot move slightly
on the grommets, check that the mounting
hardware is installed correctly.
b. Connect connectors (2) and (3) to the ITSM.
4. Program the configuration parameters and

the monitoring system parameters into the
replacement ITSM.
a. Switch 35 amp circuit breaker (1) to the ON

position.
b. Set the engine control to the STOP mode.
c. Select “File/Select ECM” from the pull-down

menu of Cat ET.
d. Select the “Replacement ITSM” and click

“OK”.
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
ITSM 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 ITSM, factory

passwords are not required. Also, the ITSM does
not require calibration.
43
Table 13
Data Sheet for Troubleshooting
Customer and installation
Engine model and driven equipment
Engine serial number Application
Service hours Compression ratio Altitude Ignition timing
LHV of fuel Methane number of fuel Fuel rate Pressure to the regulator
Differential pressure of the regulator Brand of oil and type of oil
Engine rpm Percent load Throttle angle Detonation level Air restriction
Inlet manifold Inlet manifold air Location of temperature probe
air pressure temperature
Turbocharger left Temperature of left Pressure in the exhaust stack

boost pressure the turbocharger
right exhaust right
Exhaust stack % O2 PPM of NOx PPM of CO Brand of exhaust analyzer

temperature
Cylinder exhaust (1) (3) (5) (7) (9) (11) (13) (15) (17) (19)
port temperatures
(2) (4) (6) (8) (10) (12) (14) (16) (18) (20)
Aftercooler water in Jacket water in Engine oil in

temperature temperature temperature
out out out
Comments
Report the Service Information The providing of complete, accurate information will
help Caterpillar to provide better service to you and
After you have successfully repaired the engine, to the customer.
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 1800 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.
44
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: 1000-035
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 i01829505
this manual that best describe the symptoms. See
Troubleshooting, “Troubleshooting With A Diagnostic Detonation
Code” or see Troubleshooting, “Troubleshooting
With Event Codes”. Check each probable cause SMCS Code: 1000-035
according to the tests that are recommended.
Probable Causes
Be sure to check the connectors. This is specially
true for problems that are intermittent. See • Excessive load
Troubleshooting, “Inspecting Electrical Connectors”.
• Excessive inlet manifold air pressure
Narrow the probable cause. Consider the operator
information, the conditions of operation, and the • High inlet air temperature
history of the engine.
• Incorrect air/fuel ratio
45
• Incorrect timing Check the Ignition Timing

• Faulty circuit for the timing selection switch Note: Data from a fuel analysis is required for this
procedure.
• Changes in the fuel quality
Use the Caterpillar Electronic Technician (ET)
• The engine speed/timing sensor is not calibrated. to check the ignition timing during engine
operation with a load. Compare the timing to the
• Faulty circuit for the detonation sensor(s) recommended timing in the Engine Performance,
“Fuel Usage Guide”.
• Excessive deposits in the combustion chamber
Adjust the ignition timing according to the
recommended timing in the Engine Performance,
Recommended Repairs “Fuel Usage Guide”.
Excessive Load Check the Timing Selection Switch
Make sure that the load is not excessive. Reduce
Check the position of the timing selection switch.
the load. If necessary, disengage the driven
Verify that the switch is in the correct position for
equipment and test the engine.
the type of gas that is used.
Check the Inlet Manifold Air Pressure If the position of the switch is correct, troubleshoot
the circuit for the switch. Refer to the electrical
The calculated engine load increases when the inlet schematic for the engine.
manifold air pressure increases. Measure the inlet
manifold air pressure during engine operation with
a load. For specific data on the engine, refer to the
Check for Event Codes Regarding the
engine Technical Marketing Information. Fuel
Check for the following event codes:
Check the Inlet Air Temperature
High inlet air temperature can cause detonation. • “E229 (1) Fuel Energy Content Setting Low”
(warning)
Check the inlet air temperature. Look for the
following event codes:
• “E230 (1) Fuel Energy Content Setting High”
(warning)
• “E025 (2) High Inlet Air Temperature” (derating)
• “E026 (3) High Inlet Air Temperature” (shutdown) • “E231 (3) Fuel Quality Out Of Range” (shutdown)
Refer to Troubleshooting, “Fuel Energy Content”.
• “E027 (1) High Inlet Air Temperature” (warning)
Refer to Troubleshooting, “Inlet Air Temperature Calibrate the Engine Speed/Timing
(High)”. Sensor
Air/Fuel Ratio Note: Only perform this procedure if work on the

engine may have affected the engine timing. Also,
An air/fuel mixture that is too rich will cause perform this procedure if the engine speed/timing
detonation. Verify that the exhaust emissions are sensor has not been calibrated.
correct. Refer to Systems Operation/Testing and
Adjusting, “Air/Fuel Ratio Control - Adjust”. Calibrate the engine speed/timing sensor. Refer to
Troubleshooting, “Engine Speed/Timing Sensor -
A change in the fuel energy content will change the Calibrate”.
air/fuel ratio. Obtain a fuel analysis.
Check the Detonation Sensors
The fuel supply pressure must be adequate and
stable. Troubleshoot the detonation sensors. Refer to
Troubleshooting, “Detonation Sensors”.
Make sure that the fuel metering valve is operating
correctly. Check for Deposits in the Cylinders
Overfilling of engine oil can lead to deposits. Make
sure that the engine oil level is correct.
46
Note: Excessive deposits contribute to guttering of Check the resistance of the circuit between
the valves. terminals P1-21 and P1-31 at the master ECM. The
correct resistance of the circuit is 5 ohms or less.
Use a borescope to inspect the cylinders. Look for If the resistance is greater than 5 ohms, locate the
the following conditions: source of the excessive resistance. Make repairs,
as needed.
• Deposits on the valve seats
i01804809
• Deposits on the valve faces
ECM Will Not Accept Factory
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke Passwords
• Signs of internal leaks SMCS Code: 1901-035
Signs of internal leaks include excessive Probable Causes

consumption of engine oil, blue smoke, and
excessive detonation. One of the following items may not be recorded
correctly on the Caterpillar Electronic Technician
If excessive deposits and/or signs of internal leaks (ET):
are found, investigate the cause of the condition.
Make repairs, as needed.
• Passwords
i01758344 • Serial Numbers
Driven Equipment • Total Tattletale
SMCS Code: 1400-035 • Reason Code
Probable Causes Recommended Repairs

• The master Electronic Control Module (ECM) has 1. Verify that the correct passwords were entered.
received a “Start Inhibit” or a “Shutdown” signal. Check every character in each password. Set
the engine control to the OFF/RESET mode for
• The circuit for the signal is faulty. 30 seconds and then retry.
2. Verify that Cat ET is on the “Factory Password”

Recommended Repairs screen.
Check the Driven Equipment 3. Verify that the following information from Cat ET
has been recorded correctly:
Determine whether the driven equipment has
generated a “Start Inhibit” or “Shutdown” • Serial Number of the engine
request. Determine the cause for the request.
Service the driven equipment according to the • Serial Number of the Electronic Control Module
recommendations of the OEM of the equipment. (ECM)
Check the Circuit for the Switch • Serial Number of the Cat ET
The circuit for the switch must remain closed in • Total Tattletale
order to allow the engine to run. Check the wiring
between the driven equipment and the ECM • Reason Code
connector for damage and/or corrosion. Refer to
Troubleshooting, “Inspecting Electrical Connectors”. • Diagnostic Clock
Repair the wiring, as needed.
47
i01804831 2. Disconnect the communication adapter and the

cables from the service tool connector. Then
Electronic Service Tool Will reconnect the communication adapter.
Not Communicate with ECM
If you are using the 171-4401 Communication
(The Caterpillar Electronic Adapter II, refer to Manual, “Communication
Technician (ET) Will Not Adapter II User’s Manual”.
Communicate With an 3. Verify that power supply voltage is present

between terminals A and B of the J5 service tool
Electronic Control Module connector. If the communication adapter is not
(ECM) and/or the Integrated receiving power, the display will be blank.
Temperature Sensing Module
Electronic Service Tool
(ITSM))
In order to eliminate Cat ET as the problem, connect
SMCS Code: 0785-035 Cat ET to a different engine. If the same problem
occurs with a different engine, check Cat ET and
Probable Causes the related equipment in order to determine the
cause of the problem.
• Electrical power supply
Check the Harness Code for the Slave
• Electrical connectors ECM
• Communication adapter and/or cables The harness inside the terminal box has a jumper
wire (harness code) that connects terminals J3-29
• Electronic service tool and J3-60. The ECM that is connected to the
harness reads the harness code. This allows the
• A problem with the harness code for the slave ECM to operate as the slave ECM.
ECM
If the jumper wire is disconnected, the slave ECM
Recommended Repairs will assume the function of a master ECM. Cat ET
will not communicate with any of the modules. Cat
ET will display “Duplicate Type on data link. Unable
Electrical Power Supply to Service”.
Check power to the module. Refer to
Troubleshooting, “Electrical Power Supply”. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. Check the
Note: If a module is not receiving power, the module continuity between terminals J3-29 and J3-60. Verify
will not communicate. that the jumper wire is in good condition. Make
repairs, as needed.
Electrical Connectors
i01829526
Check the following components:
Engine Coolant Temperature
• Power supply connections and ground to the (High)
module
SMCS Code: 1395-035
• Wiring harnesses and the connectors for the
module
Probable Causes
Refer to Troubleshooting, “Inspecting Electrical
Connectors”. • High ambient temperature and/or high inlet air
temperature
Communication Adapter and/or Cables • Low coolant level and/or coolant leakage
1. Check the condition of the fuse for the
communication adapter.
• Insufficient flow of air or coolant through the
radiator or heat exchanger
• Faulty water temperature regulators

48
• Faulty coolant temperature sensor and/or circuit Heat Exchanger
• Insufficient flow of coolant through the engine Check for sufficient flow and temperature of
the cooling water through the heat exchanger.
• Exhaust restriction If the flow of cooling water through the heat
exchanger is insufficient, determine the location of
• Excessive load the obstruction. If the temperature of the cooling
water is too high, determine the cause. Make the
• Incorrect ignition timing necessary repairs.
• Incorrect air/fuel ratio Check the Water Temperature Regulators

Recommended Repairs Check the water temperature regulators for proper
operation. Refer to Systems Operation/Testing and
Adjusting, “Testing the Cooling System”.
Check for High Ambient Temperature
and/or High Inlet Air Temperature Replace the water temperature regulators, if
necessary.
Determine if the ambient air temperature is within
the design specifications for the cooling system.
Check the Coolant Temperature Sensor
Check for high inlet air temperature. Refer to and/or the Circuit
Troubleshooting, “Inlet Air Temperature (High)”.
Check the reading of the coolant temperature on
Determine the cause of the high air temperature. the Caterpillar Electronic Technician (ET). The
Make corrections, when possible. temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable.
Check for a Low Coolant Level and/or
If the reading on Cat ET for the coolant temperature
Coolant Leakage is not reasonable, troubleshoot the circuit
and the coolant temperature sensor. Refer to
Note: Low coolant level can be the effect of Troubleshooting, “Analog Sensor Signal”.
overheating rather than the cause.
Check the coolant level. Check the Flow of Coolant Through the
Engine
Run the engine to operating temperature. Inspect
the cooling system for leaks. During normal operation, check the status of the
following components:
Determine whether the leak occurs before the
engine overheats. • Switch for the inlet pressure of the jacket water
Add coolant, if necessary. If leaking is found, make • Sensor for the outlet pressure of the jacket water
the necessary repairs.
If the flow of coolant through the engine is not
sufficient, determine the cause of the obstruction.
Check for Insufficient Flow of Air and Make necessary repairs.
Coolant Through the Radiator or Heat
Exchanger Check the Exhaust Restriction
Radiator Check the back pressure of the exhaust system.
Refer to Systems Operation/Testing and Adjusting,
Check the fins of the radiator for obstructions. “Air Inlet and Exhaust System”.
Check the fan for proper operation.
If the back pressure exceeds the specifications for
If the radiator fins are obstructed, clean the fins. the engine, determine the cause of the excessive
If the fan does not operate properly, make the back pressure. Make the necessary repairs.
necessary repairs.
49
Excessive Load Recommended Repairs

Make sure that the load is not excessive. Reduce Check the Jacket Water Heater
equipment and test the engine. Determine if the jacket water heaters are functioning
properly.
Ignition Timing
If the jacket water heaters are not functioning
Note: Data from a fuel analysis is required for this properly, determine the cause of the malfunction of
procedure. the heaters. Make the necessary repairs.
Use an electronic service tool to check for the Check the Coolant Temperature Sensor
correct desired ignition timing. Compare the
timing to the recommended timing in the Engine and/or the Circuit
Performance, “Fuel Usage Guide”.
Check the reading of the coolant temperature with
Adjust the ignition timing according to the the Caterpillar Electronic Technician (ET). The
recommended timing in the Engine Performance, temperature should rise steadily as the engine is
“Fuel Usage Guide”. warmed. Ensure that the temperature is reasonable.
If the reading on Cat ET for the coolant temperature

Air/Fuel Ratio is not reasonable, troubleshoot the circuit
and the coolant temperature sensor. Refer to
An air/fuel mixture that is too rich will cause Troubleshooting, “Analog Sensor Signal”.
overheating. Verify that the exhaust emissions are
correct. Refer to Systems Operation/Testing and
Adjusting, “Air/Fuel Ratio Control - Adjust”. Check the Water Temperature Regulators
A change in the fuel energy content will change the The water temperature regulators should not
air/fuel ratio. Obtain a fuel analysis. begin to open until jacket water reaches opening
temperature for the regulators. Allow the engine to
The fuel supply pressure must be adequate and cool and then start the engine. Check the hose at
stable. the outlet for the jacket water. If the hose is warm
and normal operating temperature is not achieved
Strike the gas pressure regulator with a soft hammer. yet, a regulator may be stuck open.
If the engine speed changes, inspect the internal
parts of the gas pressure regulator for wear. Inspect If the water temperature regulators are
the gas pressure regulator’s diaphragm for leaks. malfunctioning, check the water temperature
Make sure that the valve moves freely. The valve regulators according to Systems Operation/Testing
must seat correctly. and Adjusting, “Testing the Cooling System”.
Replace the water temperature regulators, if
Ensure that the fuel metering valve is operating necessary.
correctly.
i01758447
i01727368 Engine Cranks but Will Not

Engine Coolant Temperature Start
(Low) SMCS Code: 1000-035; 1400-035
SMCS Code: 1395-035
Probable Causes
Probable Causes
• Fuel supply
• Faulty jacket water heater
• Electrical connectors or power supply
• Faulty coolant temperature sensor and/or circuit
• No signal from the speed/timing sensor
• Ignition system
• Excessive load
50
Recommended Repairs Make sure that the correct transformers and spark
plugs are installed. Inspect the extenders for signs
Fuel Supply or pin holes and arcing.
Make sure that fuel is supplied at a sufficient Maintain the spark plug according to Operation and
pressure that is stable. Make sure that the size of Maintenance Manual, “Ignition System Spark Plugs
the fuel line is sufficient. Inspect the fuel system - Check/Adjust/Replace”.
for leaks.
Make sure that the ignition timing is correct.
The following conditions can cause the engine to
malfunction: Excessive Load
• Low fuel pressure Make sure that the load is not excessive. Reduce
• High fuel pressure equipment and test the engine.
• Poor fuel quality i01829527
Make sure that the fuel pressure is correct.

When possible, interview the operator in order
Engine Misfires, Runs Rough
to determine if fuel quality is in question. Try to or Is Unstable
determine if the source of the fuel was changed.
SMCS Code: 1000-035
Inspect the fuel system components: fuel filter,
gas pressure regulator, gas shutoff valve, and fuel Probable Causes
metering valve. Verify that the system’s components
are operating correctly.
• Cold cylinder
Replace the fuel filter, if necessary.
• Electrical connectors or power supply
Electrical Connectors or Power Supply • Ignition system
There may be an intermittent interruption of power. • Fuel supply
Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect • Incorrect air/fuel ratio
the power supply connections and the ground.
• Air inlet restriction
Inspect the wiring from the power supply to the
master ECM and to the slave ECM. Check the power • Exhaust restriction
and ground connections. Refer to Troubleshooting,
“Electrical Power Supply”. • Binding of the throttle actuator
No Signal from the Engine Speed/Timing • Incorrect valve lash
Sensor
• Cylinder head and related components
Make sure that the speed/timing sensor is installed
correctly. Refer to Troubleshooting, “Engine • Throttle
Speed/Timing Sensor”.
Recommended Repairs
Make sure that the timing wheel is correctly installed.
Note: If the symptom only occurs under certain
Ignition System operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under
Inspect the ignition transformers for loose the conditions. Troubleshooting the symptom under
connections, moisture, short circuits, and open other conditions can give misleading results.
circuits. Inspect the primary wiring and the
secondary electrical connections. The Caterpillar Electronic Technician (ET) and the
Integrated Temperature Sensing Module (ITSM)
can be used to detect a misfiring cylinder. Use the
following procedure:
51
1. Use the “Data Link/Select ECM” option on the • Low fuel pressure
Cat ET to select the ITSM.
• High fuel pressure
2. Select “Diagnostics/Diagnostic Tests”.
• Poor fuel quality
3. Select the suspect cylinder and click the “Start”
button in the lower left corner of the screen. Make sure that the fuel pressure is correct.
Cat ET will display a graph of the cylinder’s to determine if fuel quality is in question. Try to
exhaust gas temperature. The output voltage of determine if the source of the fuel was changed.
the transformer’s secondary circuit, the engine
speed, and the desired engine speed are also Inspect the fuel system components: fuel filter,
displayed. gas pressure regulator, gas shutoff valve, and fuel
metering valve. Verify that the system’s components
Cold Cylinder are operating correctly.
Locate the misfiring cylinder. Check the following Replace the fuel filter, if necessary.
components for failure: spark plug, extender,
ignition transformer, and primary wiring. Inspect the Air/Fuel Ratio
extender for signs of pin holes and/or arcing.
An air/fuel mixture that is too rich or too lean will
Refer to Troubleshooting, “Ignition Transformers have an adverse effect on engine operation. Verify
Secondary Circuit and Spark Plugs”. that the exhaust emissions are correct. Refer to
Systems Operation/Testing and Adjusting, “Air/Fuel
Electrical Connectors or Power Supply Ratio Control - Adjust”.
There may be an intermittent interruption of power. A change in the fuel energy content will change the
Check the wiring harnesses and the connectors. air/fuel ratio. Obtain a fuel analysis.
Inspect the connectors in the terminal boxes.
Inspect the power supply connections and the The fuel supply pressure must be adequate and
ground. stable.
Inspect the wiring from the power supply to Air Inlet Restriction
the control modules. Refer to Troubleshooting,
“Electrical Power Supply”. The maximum allowable air inlet restriction is
3.75 kPa (15 inches of H2O). If the indication is
Ignition System higher than the maximum permissible restriction,
clean the filter element or install a new filter element.
Inspect the ignition transformers for the following Check the restriction again. If the restriction remains
items: loose connections, moisture, short circuits, too high, inspect the air inlet piping for obstructions.
and open circuits. Inspect the primary wiring and
the secondary electrical connections. For more information, refer to Systems
Operation/Testing and Adjusting, “Restriction of Air
Make sure that the correct transformers and spark Inlet and Exhaust”.
plugs are installed. Inspect the extenders for signs
of pin holes and of arcing. Exhaust Restriction
Maintain the spark plug according to the engine’s Check for restriction in the exhaust system. Refer
Operation and Maintenance Manual. to Systems Operation/Testing and Adjusting,
“Restriction of Air Inlet and Exhaust”.
Make sure that the ignition timing is correct.
Check for Binding of the Throttle Actuator
Fuel Supply
Set the engine control to the OFF/RESET mode.
Make sure that fuel is supplied at a sufficient Switch the 35 amp circuit breaker OFF. Move the
pressure that is stable. Make sure that the size of throttle plate while you feel the motion. If the motion
the fuel line is sufficient. Inspect the fuel system is sticky and/or rough, investigate the cause of the
for leaks. binding. Make the necessary repairs.
The following conditions can cause the engine to

malfunction:
52
Incorrect Valve Lash Check the Oil Pressure Sensors and/or

Circuits
Check the valve lash. Refer to Systems Operation,
Testing And Adjusting, “Valve Lash and Valve Use the Caterpillar Electronic Technician (ET) to
Bridge Adjustment”. compare the readings for the filtered oil pressure
and the unfiltered oil pressure while the engine is
Cylinder Head and Related Components OFF. Make sure that the sensors are correctly wired.
Measure the cylinder compression. Refer to the If the readings are not approximately zero for both
engine’s Operation and Maintenance Manual, of the sensors, the sensors are wired improperly.
“Cylinder Pressure - Measure/Record”. Troubleshoot the sensor circuit(s). Refer to
Troubleshooting, “Analog Sensor Signal”.
Inspect the components of the valve train for good
condition. Check for signs of damage and/or wear Check the Oil Filter Bypass Valve
to the valves, cylinder head gasket, etc. Inspect
the condition of the camshafts. If a camshaft is An oil filter bypass valve that is stuck in the closed
replaced, new valve lifters must be installed. position can cause a high reading for differential
pressure when the oil is cold. An oil filter bypass
Throttle valve that is stuck in the open position can cause
a low reading for differential pressure when the
Make sure that the throttle actuator is operating oil is hot. Check the operation of the oil filter
properly. If the motion of the actuator is sticky bypass valve. For more information, see Systems
and/or rough, service the actuator. Operation/Testing and Adjusting, “Measuring Engine
Oil Pressure”.
For electrohydraulic actuators, make sure that the
hydraulic oil is not contaminated. If the oil filter bypass valve is faulty, repair the valve,
when possible. Replace the valve, if necessary.
i01727473
i01727510
Engine Oil Filter Differential
Pressure Engine Oil Pressure (Low)
SMCS Code: 1348-035-PX
SMCS Code: 1308-035
Probable Causes Probable Causes

• Low engine oil level
• Plugged oil filter or faulty oil filter
• Incorrect viscosity
• Faulty oil pressure sensor and/or circuit
• Contaminated engine oil
• Malfunctioning of the oil filter bypass valve
• Faulty oil pressure sensors
Recommended Repairs
• Improper circulation of the engine oil
Check the Oil Filters
• Worn components
Check the oil filter differential pressure. Do not
allow the differential pressure to exceed 103 kPa Recommended Repairs
(15 psi). If the oil filter differential pressure is too
high, change the oil filter elements. Low Engine Oil Level
Inspect the oil filters for good condition. Replace
Check the oil level. Add oil, as needed.
any suspect oil filter.
53
Contaminated Engine Oil • There is a problem with the engine oil pump.
Check the gears of the engine oil pump for
Engine oil that is contaminated with another liquid excessive wear. Engine oil pressure is reduced
will cause low engine oil pressure. High engine by gears that have too much wear.
oil level can be an indication of contamination.
Obtain an analysis of the engine oil. Determine the • The engine oil pump’s pressure regulating valve
reason for contamination of the engine oil and make or a bypass valve is stuck in the open position.
the necessary repairs. Change the engine oil and Clean the valve. Replace parts, if necessary.
the engine oil filter. For the correct engine oil to
use, refer to Operation and Maintenance Manual, Worn Components
“Engine Oil”.
Excessive clearance at the crankshaft or camshaft
Incorrect Viscosity bearings will cause low engine oil pressure. Also,
inspect the clearance between the rocker arm
Make sure that the engine is supplied with the shafts and the rocker arms. Check the engine
correct engine oil. For the correct engine oil to components for excessive clearance.
use, refer to Operation and Maintenance Manual,
“Engine Oil”. Obtain an analysis of the engine oil. Check the
analysis for the level of wear metals in the engine oil.
Faulty Engine Oil Pressure Sensors
i01727521
Use the Caterpiller Electronic Technician (ET) to
compare the readings of the filtered engine oil Engine Oil Temperature (High)
pressure and the unfiltered engine oil pressure
while the engine is OFF. Both readings should be SMCS Code: 1348-035
close to zero pressure.
If a reading is significantly different from zero, Probable Causes

replace the suspect engine oil pressure sensor.
• Faulty oil temperature sensor and/or circuit
Improper Circulation of the Engine Oil • Insufficient flow of coolant through the oil cooler
Several factors could cause improper circulation of • Insufficient flow of oil through the oil cooler
the engine oil:
• The engine oil filter is clogged. Replace the Recommended Repairs

engine oil filter.
Check the Oil Temperature Sensor and/or
• An engine oil line or a passage for engine oil is the Circuit
disconnected or broken.
Check the reading of the oil temperature on
• The engine oil cooler is clogged. Thoroughly the Caterpillar Electronic Technician (ET). The
clean the engine oil cooler. temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable.
• There is a problem with a piston cooling jet.
Breakage, a restriction, or incorrect installation If the reading on Cat ET for the oil temperature
of a piston cooling jet will cause seizure of the is not reasonable, troubleshoot the circuit for the
piston. oil temperature sensor. Refer to Troubleshooting,
“Analog Sensor Signal”.
• The inlet screen of the suction tube for the engine
oil pump can have a restriction. This restriction
will cause cavitation and a loss of engine oil Check the Flow of Coolant Through the
pressure. Check the inlet screen on the suction Oil Cooler
tube and remove any material that may be
restricting engine oil flow. Oil Coolers that are Cooled with Jacket Water
• The suction tube is drawing in air. Check the joints Check for “High Engine Coolant Temperature”
of the tube for cracks or a damaged O-ring seal. events. Refer to Troubleshooting, “Engine coolant
Temperature (High)”.
54
Oil Coolers that are Cooled by the Separate If the gas pressure is low, refer to Troubleshooting,
Circuit “Fuel Pressure”.
Compare the temperature of the coolant at the inlet If the throttle does not open, troubleshoot the
of the oil cooler to the regulated temperature. If the electrohydraulic oil system. The gas supply lines
inlet temperature is OK, check the temperature of may require purging before servicing.
the coolant at the outlet of the oil cooler.
Check for Active Shutdowns
A high temperature difference indicates an
insufficient flow rate. Investigate the cause of the Use the Caterpillar Electronic Technician (ET) to
obstruction. Make the necessary repairs. check for active diagnostic codes or event codes
which may prevent the engine from starting.
Check the Flow of Oil Through the Oil
Cooler Correct the cause of the active code. Before the
engine can be started, the control system must
Run the engine at normal operating temperature. be power cycled. Set the engine control to the
Determine the pressure differential between the inlet OFF/RESET mode. Then set the control to the STOP
and the outlet of the oil cooler. For comparative mode.
data, refer to the Technical Marketing Information
for the engine. Check the Status of the Relay for the
Starting Motor
If the pressure differential between the inlet and
the outlet of the oil cooler exceeds the data that is Attempt to start the engine while you observe the
published for the engine, there is an insufficient flow status of the relay for the starting motor on Cat ET.
of oil through the oil cooler. Determine the cause of
the obstruction. Make the necessary repairs. If the status of the relay for the starting motor
indicates that the engine should crank but no
i01875065
cranking occurs, troubleshoot the starting circuit.
Refer to Systems Operation/Testing and Adjusting,
Engine Overcrank “Air/Electric Starting System”.
SMCS Code: 1400-035 If the engine should crank and cranking occurs,
check the engine rpm.
Probable Causes
Check the Engine Speed
• The gas supply to the engine is insufficient.
The master ECM must detect a minimum of 50 rpm
• A feature for engine protection prevents the before the gas and the ignition are supplied to the
engine from starting. engine. Use Cat ET to monitor the engine speed
while you crank the engine.
• The starting motor circuit is faulty.
If no engine speed is displayed on Cat ET or if
• There is no engine speed signal to the master the engine speed is not stable, troubleshoot the
Electronic Control Module (ECM). speed/timing sensor. Refer to Troubleshooting,
“Engine Speed/Timing Sensor”.
• The ignition system is not functioning or the switch
for the ignition timing is not in the correct position. Check for Diagnostic Codes
• The quality of the gas does not match the Check for active diagnostic codes that relate to
parameter for “Fuel Quality”. the ignition system. If there is at least one active
diagnostic code that relates to the ignition system,
Recommended Repairs troubleshoot the diagnostic code.
Check the position of the timing selection switch.

Check the Gas Supply to the Engine Verify that the switch is in the correct position for
the type of gas that is used.
Check for low gas pressure. Observe the angle of
the throttle plate while you crank the engine.
55
Check the Fuel Quality i01804850
Compare the Low Heat Value (LHV) of the gas Engine Overspeed
supply to the “Fuel Quality” parameter that is
programmed by the customer into the master ECM. SMCS Code: 1000-035
The master ECM uses the setting for start-up and
for air/fuel ratio control at low loads. Probable Causes
If the LHV of the fuel does not match the “Fuel • Low trip point for engine overspeed
Quality” parameter that is programmed into the
master ECM, program the master ECM with the • Signal from the signal driver in the master
correct setting for the “Fuel Quality” parameter. Electronic Control Module (ECM) for the actuator
of the throttle
i01804844
• Energy of the driven equipment
Engine Overload
• Slow governor response
SMCS Code: 1000-035
• Binding of the throttle actuator
Probable Causes
Recommended Repairs
• Excessive inlet manifold air pressure
Check the Trip Point
• The Low Heat Value (LHV) of the gas or the
specific gravity of the gas is significantly different Note: Do not program the trip point for engine
from the value that is programmed. overspeed higher than the maximum ratings of the
driven equipment.
Recommended Repairs The trip point or engine overspeed may be too low.
Verify that the trip point for the engine overspeed is
Check the Inlet Manifold Air Pressure properly programmed. Typically, this parameter is
set at 118 percent of rated speed.
The calculated engine load increases when the inlet
manifold air pressure increases. Measure the inlet This parameter requires a factory password in order
manifold air pressure during engine operation with to change the trip point. Change the trip point to an
a load. For specific data on the engine, refer to the acceptable speed.
engine Technical Marketing Information.
Check for Diagnostic Codes that Relate
Obtain a Fuel Analysis and Program the
to the Signal from the Signal Driver in the
Fuel Energy Content
Master ECM
Obtain an analysis of the gas in order to determine
the LHV. Program the correct LHV for the “Fuel Check for diagnostic codes that relate to the
Quality” configuration parameter. actuator of the throttle.
If the LHV of the gas does not match the “Fuel Investigate the diagnostic code(s). Make the
Quality” parameter value that is programmed into necessary repairs.
the ECM, program the master ECM with the correct
value for the “Fuel Quality” parameter by selecting Check the Driven Equipment
the “Change” button in the lower left corner of the
screen. Type the correct value and then select “OK”. Determine if the driven equipment has additional
inputs of energy that could drive the engine beyond
If the quality of the gas is not consistent, obtain the rated rpm. Make corrections to the installation in
several analyses over a period of time. Program order to prevent the overspeed from recurring.
the “Fuel Quality” configuration parameter to the
average value of the LHV. Check for Slow Governor Response
Observe the “Speed Governor Adjustment” screen
on the Caterpillar Electronic Technician (ET). Look
for the engine response to the worst cases for
step-loading and unloading.
56
Check for Binding of the Throttle Actuator The correct resistance between the terminals is less
than 5 ohms. If the resistance is greater than 5
Set the engine control to the OFF/RESET mode. ohms, locate the source of the excessive resistance.
Switch the 35 amp circuit breaker OFF. Move the Make repairs, as needed.
throttle plate while you feel the motion. If the motion
is sticky and/or rough, investigate the cause of the Inspect the Stop Switches
binding. Make the necessary repairs.
Inspect the stop switches for evidence of damage
i01727572
that has been caused by vibration. Disassemble the
switches. Inspect the components for looseness,
Engine Shutdown cracks, and abrasion. Use an ohmmeter and toggle
the switches in order to check for proper electrical
SMCS Code: 1400-035 operation.
Replace any faulty components.

Probable Causes
• The “Emergency Stop” button is pressed. i01804861
• The circuit for the emergency stop is faulty. Engine Shutdown

(Unexpected)
• The normal stop switch that is installed by the
customer is activated. SMCS Code: 1400-035
• The circuit for the normal stop switch is faulty.
Probable Causes
• Either switch is activated by excessive vibration.
• There is a problem with the Gas Shutoff Valve
(GSOV).
Recommended Repairs
• Incorrect input(s) for the mode of operation to the
Talk to the operator master Electronic Control Module (ECM)
Ask the operator if the stop was intentional. Make • There is a problem with the “Crank Terminate”
sure that the reason for the stop has been corrected. relay.
Reset the control system. Resume normal operation.
• There is a problem with the relay for the starting
If the stop was accidental, reset the control system. motor.
Resume normal operation.
• A shutdown has been requested by the driven
Check the Circuit for the Stop Switches equipment.
Note: The circuit for the normal stop switch and the • There is a problem with the “Run” relay.
circuit for the emergency stop switch must remain
closed in order for the engine to run. • The “Crank Terminate Speed” is incorrectly
programmed.
Inspect the wiring between the switches and the
connector of the electronic control module. Look for • The “Cycle Crank Time” is incorrectly
damage and/or corrosion. Refer to Troubleshooting, programmed.
“Inspecting Electrical Connectors”.
• The “Engine Overcrank Time” is incorrectly
For the emergency stop switch, close the switch programmed.
and check the resistance between terminals 22 and
31 of the P1 connector. • The delay time for the driven equipment is
excessive.
For the normal stop switch, close the switch and
check the resistance between terminals 23 and 31 • There is a problem with the harness code for the
of the P1 connector. slave ECM.
57
Recommended Repair Check the “Crank Terminate Speed”
Check the Circuit for the GSOV The “Crank Terminate Speed” is a parameter that
can be configured. The master Electronic Control
Troubleshoot for the following diagnostic codes: Module (ECM) disengages the starting motor
when the engine exceeds the programmed “Crank
• 17-05 Fuel Shutoff Valve open circuit Terminate Speed”. The default value of 250 rpm
should be sufficient for all applications.
• 17-06 Fuel Shutoff Valve short to ground
If the “Crank Terminate Speed” is too slow, the
• 17-12 Fuel Shutoff Valve malfunction engine will shut down. Use the Caterpillar Electronic
Technician (ET) to check the programmed “Crank
Refer to Troubleshooting, “ECM Output Circuit (Fuel Terminate” speed. Use Cat ET to adjust the “Crank
Control)”. Make repairs, as needed. Terminate Speed”, if necessary.
Check the Inputs for the Mode of Check the “Cycle Crank Time”
Operation to the Master ECM The “Cycle Crank Time” is a parameter that can
be configured. This parameter determines the time
Troubleshoot for the “336-02 Incorrect ECS Switch for engagement of the starting motor and the gas
inputs” diagnostic code. shutoff valve during the crank cycle. If the engine
does not start within the programmed “Cycle Crank
Refer to Troubleshooting, “Electrical Power Supply”. Time”, the attempt to start is suspended for an
Make repairs, as needed. equal “Rest” cycle.
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
the Driven Equipment Use Cat ET to check the “Engine Overcrank Time”.
Use Cat ET to increase the “Engine Overcrank
Determine whether a shutdown for the driven Time”, if necessary.
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 master ECM provides
Troubleshoot for the “445-03 Run Relay short to a switch input for the driven equipment in order to
+batt” diagnostic code. delay engine start-up until the driven equipment
is ready. The master ECM will not attempt to start
Refer to Troubleshooting, “ECM Status Indicator the engine until the switch input for the driven
Output”. Make repairs, as needed. equipment closes to ground and the prelubrication
(if equipped) is complete.
58
An event code is generated if the “Driven Equipment Recommended Repairs

Delay Time” elapses without closure of the switch
input. To disable this feature, program the delay External Shutdown or Customer
time to zero.
Shutdown
If the programmed delay time is too long, the engine
may not start. Use Cat ET to check the “Driven Check the master ECM and the Integrated
Equipment Delay Time”. Use Cat ET to program the Temperature Sensing Module (ITSM) for logged
delay time to a reasonable amount of time. codes of events that are shutdowns.
Check the Harness Code for the Slave Power Supply to the Engine Control
ECM System
The harness inside the terminal box has a jumper 1. Refer to Troubleshooting, “Electrical Power
wire (harness code) that connects terminals J3-29 Supply”.
and J3-60. The ECM that is connected to the
harness reads the harness code. This allows the 2. Inspect the ground strap and the power supply
ECM to operate as the slave ECM. The jumper wire for connections that are loose and/or corroded.
must remain connected in order for the engine to
run. 3. Inspect the electronic control modules and
the terminal box for proper installation of the
The engine will shut down if the jumper wire connectors.
becomes disconnected during engine operation.
4. Check the 35 amp circuit breaker on the power
Check the continuity between terminals J3-29 distribution box. Check the wiring connections to
and J3-60. Verify that the jumper wire is in good the 35 amp circuit breaker for proper installation.
Speed/Timing Sensor
i01804877 A loss of supply voltage to the speed/timing sensor
will cause a shutdown. Refer to Troubleshooting,
Engine Shutdown without a “Engine Speed/Timing Sensor”.
Diagnostic Code
Fuel Supply
SMCS Code: 1400-035
• Check the fuel supply pressure.
Probable Causes
• Inspect the fuel lines for foreign objects and for
• An external shutdown or a customer shutdown obstructions that can block the fuel supply.
was requested.
Misfiring Cylinders
• The power supply becomes disconnected from
the engine control system. For a shutdown that is due to misfiring cylinders,
the shutdown is likely to occur only when the engine
• The master Electronic Control Module (ECM) is operating under a load.
has lost the supply voltage for the speed/timing
sensor. The Caterpillar Electronic Technician (ET) and the
ITSM can be used to detect a misfiring cylinder.
• There is a problem with the fuel supply. Use the following procedure:
• A cylinder or cylinders are misfiring. 1. Use the “Data Link/Select ECM” screen on Cat
ET to select the ITSM.
2. Select “Diagnostics/Diagnostic Tests”.
3. Select the suspect cylinder and click the “Start”

button in the lower left corner of the screen.
59
Cat ET will display a graph of the cylinder’s Electrical Connectors or Power Supply
exhaust gas temperature. The transformer’s
secondary circuit, the engine speed, and the 1. Inspect the power supply connections and the
desired engine speed are also displayed. ground. Check the wiring harnesses and the
connectors from the power supply to the power
Locate the misfiring cylinder. Check the following distribution box. Check the wiring harnesses
components for failure: spark plug, extender, and the connectors from the power distribution
ignition transformer, and primary wiring. Inspect the box to the terminal box. Inspect the connectors
extender for signs of pin holes and/or arcing. in the terminal box. Refer to Troubleshooting,
Refer to Troubleshooting, “Ignition Transformers
Secondary Circuit and Spark Plugs”. 2. Use the Caterpillar Electronic Technician (ET) to
check for the 168-02 diagnostic code for “System
Voltage intermittent/erratic”. If this diagnostic
i01804883
code is logged, proceed to Troubleshooting,
Engine Starts but Stalls “Electrical Power Supply”.
Immediately Engine Speed/Timing Sensor

SMCS Code: 1250-035; 1400-035 Make sure that the speed/timing sensor is
installed correctly. See Troubleshooting, “Engine
Probable Causes Speed/Timing Sensor”.
• Fuel supply Make sure that the timing wheel is correctly installed.
• Electrical connectors or power supply Ignition System

• Engine speed/timing sensor Inspect the ignition transformers for the following
items: loose connections, moisture, short circuits,
• Ignition system and open circuits. Inspect the primary wiring and
the secondary electrical connections.
• Excessive load
Make sure that the correct transformers and spark
Recommended Repairs plugs are installed. Inspect the extenders for signs
of pin holes and of arcing.
Fuel Supply Maintain the spark plug according to the engine’s
Operation and Maintenance Manual.
Make sure that fuel is supplied at a sufficient
pressure that is stable. Make sure that the size of
the fuel line is sufficient. Inspect the fuel system Excessive Load
for leaks.
Make sure that the load is not excessive. Reduce
The following conditions can cause the engine to the load. If necessary, disengage the driven
malfunction: equipment and test the engine.
• Low fuel pressure i01804902
• High fuel pressure Engine Timing Does Not Match

• Poor fuel quality Programmed Timing
Make sure that the fuel pressure is correct. SMCS Code: 1000-035; 1400-035
to determine if fuel quality is in question. Try to Probable Causes
determine if the source of the fuel was changed.
• The timing may be retarded due to detonation.
Inspect the fuel system components: fuel filter, gas
pressure regulator, gas shutoff valve, fuel metering • The timing may be retarded due to the selection
valve, and actuator for the throttle. Verify that the of the map for speed or the map for load.
system’s components are operating correctly.
• The input for the selection of the base timing may
Replace the fuel filter, if necessary. be incorrect.
60
Recommended Repairs Recommended Repairs

Note: If the symptom only occurs under certain Batteries and/or Battery Cables
operating conditions (high idle, full load, engine
operating temperature, etc), test the engine under 1. Inspect the main power switch, battery posts,
the conditions. Troubleshooting the symptom under and battery cables for loose connections and
other conditions can give misleading results. corrosion. If the battery cables are corroded,
remove the battery cables and clean the battery
Detonation cables. Tighten any loose connections.
Use the Caterpillar Electronic Technician (ET) 2. Inspect the batteries.

to review the logged codes. Look for codes
“E401-1” through “E416-1”. Refer to the topic in a. Charge the batteries. Refer to Special
Troubleshooting for the particular event code. Instruction, SEHS7633, “Battery Test
Procedure”.
Map
b. Load test the batteries. Refer to Special
Use the “Service/Configuration” screen of Cat ET Instruction, SEHS9249, “Use of 4C-4911
in order to verify the value that is programmed Battery Load Tester for 6, 8 and 12 Volt Lead
for the timing. Check the “First Desired Timing”, Acid Batteries”.
the “Second Desired Timing”, and the “Desired
Timing” parameters. Refer to Troubleshooting, Starting Circuit
“Programming Parameters”.
Check the starting circuit. Refer to the schematic
Timing Selection diagram in Troubleshooting, “ECM Output Circuit
(Starting Motor)”.
Verify that the input for the selection of the base
timing is correct. An open circuit between terminals Starting Motor or Flywheel Ring Gear
J1-20 and J1-31 selects the “First Desired Timing”.
A short circuit between terminals J1-20 and J1-31 If the pinion engages the flywheel but the flywheel
selects the “Second Desired Timing”. does not turn, there may be a problem with the
starting motor. If the starting motor turns but the
flywheel does not turn, inspect the gear teeth, the
i01822829
clutch jaws, or other parts.
Engine Will Not Crank Inspect the pinion and the flywheel ring gear for
SMCS Code: 1000-035; 1400-035 damage. If the teeth of the pinion and/or of the
flywheel ring gear are worn or broken, replace the
parts.
Probable Causes
If the pinion does not engage correctly with the
• Batteries and/or battery cables flywheel, the pinion shaft may be stuck. Remove the
pinion. Grease the splines of the drive shaft and
• Starting circuit the pinion.
• Starter motor pinion or flywheel ring gear If the pinion does not engage the flywheel, the
clutch jaws may be broken.
• Low air pressure
Before you remove the starting motor, turn the
• Static load crankshaft by hand. Ensure that a mechanical
failure inside the engine is not preventing the
• Internal mechanical problem crankshaft from turning. If the crankshaft will turn by
hand, try the starting motor again. If the starting
• There is a problem with the harness code for the motor does not turn the crankshaft, remove the
slave Electronic Control Module (ECM). starting motor. Repair the starting motor or replace
the starting motor.
61
Low Air Pressure • Excessive load

Determine the cause of the low air pressure. Inspect • Incorrect timing
the air lines for leaks. Repair any leaks in the air
lines. • Exhaust restriction
Static Load • A buildup of deposits in the cylinder or internal
oil leaks
Make sure that the driven equipment is not
preventing the crankshaft from turning. Try to turn Recommended Repairs
the crankshaft by hand. If necessary, disengage the
driven equipment and test the engine.
Check the Inlet Air Temperature
Internal Mechanical Problem High inlet air temperature can cause detonation.
Check the inlet air temperature.
If the crankshaft will not turn and the driven
equipment is disengaged, remove the spark plugs. Refer to Troubleshooting, “Inlet Air Temperature
Check for fluid in the cylinders. If this is not the (High)”.
problem, the engine must be disassembled in
order to investigate internal mechanical problems. Inlet Air Restriction
Possible internal problems include the following
conditions:
The maximum allowable inlet air restriction is
3.75 kPa (15 inches of H2O). If the indication is
• Bearing seizure higher than the maximum permissible restriction,
clean the filter element or install a new filter element.
• Piston seizure Check the restriction again. If the restriction remains
too high, inspect the air inlet piping before the air
• Valve and piston contact cleaner for obstructions.
Check the Harness Code for the Slave Air/Fuel Ratio
ECM
An air/fuel mixture that is too rich will increase
The harness inside the terminal box for the slave the exhaust temperature. Verify that the exhaust
ECM has a jumper wire (harness code) that emissions are correct. Refer to Systems
connects terminals J3-29 and J3-60. The ECM that Operation/Testing and Adjusting, “Air/Fuel Ratio
is connected to the harness reads the harness Control - Adjust”.
code. This allows the ECM to operate as the slave
ECM. The jumper wire must be connected in order A change in the fuel energy content will change the
for the engine to crank. The jumper wire must air/fuel ratio. Obtain a fuel analysis.
remain connected in order for the engine to run.
The fuel supply pressure must be adequate and
Check the continuity between terminals J3-29 stable.
Excessive Load
i01829531 Make sure that the load is not excessive. Reduce
Exhaust Port Temperature equipment and test the engine.
(High)
Check the Ignition Timing
SMCS Code: 1059-035
Note: Data from a fuel analysis is required for this
procedure.
Probable Causes
• High inlet air temperature to check the ignition timing during engine
operation with a load. Compare the timing to the
• Inlet air restriction recommended timing in the Engine Performance,
• Air/fuel ratio
62
Adjust the ignition timing according to the Recommended Repairs

“Fuel Usage Guide”. Check for Misfire
Measure the Exhaust Restriction Operation with a low load can result in low exhaust
temperatures. Operate the engine at low idle or
Measure the exhaust restriction during engine near low idle in order to identify a misfire problem.
operation with a load. For data that is specific to the
engine, refer to the Technical Marketing Information. Troubleshoot the cause of the misfire. Refer to
Troubleshooting, “Engine Misfires,Runs Rough or Is
Investigate the cause of the exhaust restriction. Unstable”.
Perform adjustments and/or make repairs, as
needed. Check for Diagnostic Codes from the
Integrated Temperature Sensing Module
Check for Deposits in the Cylinder and
(ITSM)
Check for Internal Oil Leaks
Use a borescope to inspect the cylinders. Look for to check for diagnostic codes that relate to
the following conditions: the thermocouples for exhaust temperatures.
Troubleshoot the code.
• Deposits on the valve seats
Check for Suspect Thermocouples
Observe the temperatures from the thermocouples
• Deposits on the cylinder walls that are above the after the engine is shut off.
upper limit of the piston stroke
When the engine is operating properly, the
• Signs of internal oil leaks temperatures from similar locations are reduced at
Other signs of internal oil leaks include high oil a similar rate. Also, the temperatures from similar
consumption and blue smoke. locations are comparable.
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
the cause for the low temperature.
i01727687
Exhaust Port Temperature Check for Insufficient Ignition

(Low) Use Cat ET to check for logged diagnostic codes
that relate to the ignition system. Troubleshoot
SMCS Code: 1059-035 the code. Refer to Troubleshooting, “Ignition
Transformers Primary Circuit”.
Probable Causes If no logged diagnostic codes are present for
the suspect cylinder, inspect the components
• Operation with a light load of the ignition system for the cylinder. Refer to
Troubleshooting, “Ignition Transformers Secondary
• Active diagnostic code from the Integrated Circuit and Spark Plugs”.
Temperature Sensing Module (ITSM)
• A faulty thermocouple Check the Cylinder Compression
• Insufficient ignition Measure the cylinder pressures of the suspect bank

in order to check for problems that are related to
• Low cylinder compression compression.
63
If low compression is found, investigate the cause Check the Fuel Metering Valve
of the low compression. Make repairs, as needed.
Shut OFF the fuel supply. Disconnect the fuel lines
from the fuel metering valve. Visually inspect the
i01804917
internal mechanism of the valve. Check for binding
Fuel Energy Content due to dirt and/or contamination. Check for binding
due to wear of internal components.
SMCS Code: 1250-035
Clean the valve, if necessary. If the valve is binding
due to wear of internal components, refer to the
Probable Causes literature that is provided by the OEM of the valve.
• The Low Heat Value (LHV) of the gas or the

specific gravity of the gas is significantly different i01727704
from the value that is programmed into the
electronic control module. Fuel Pressure
SMCS Code: 1250-035
• Condensation is forming in the gas.
Recommended Repairs Probable Causes

• Incorrect setting of the gas pressure regulator
Obtain a Fuel Analysis and Program the
“Fuel Quality” Parameter • Faulty gas pressure regulator
the LHV. Program the “Fuel Quality” parameter to
Recommended Repairs
the actual value of the LHV.
Check the Gas Pressure Regulator
If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program Use the Caterpillar Electronic Technician (ET)
the “Fuel Quality” parameter to the average value to observe the absolute fuel pressure and the
of the LHV. fuel differential pressure. The fuel metering valve
requires a gas supply that is regulated to a pressure
between 10 to 35 kPa (1.5 to 5 psi).
Check the Dryer for the Gas
If the fuel pressure is not within the acceptable
Check the dryer for the gas for proper operation. range, adjust the gas pressure regulator in order
Repair the dryer, if necessary.
to achieve the correct pressure. Verify that the
emissions are within specifications.
i01804920
If the gas pressure regulator cannot be adjusted to
Fuel Metering Valve the correct setting, repair the regulator or replace
the regulator.
SMCS Code: 1274-038
i01369481
Probable Causes
Gas Fuel Differential Pressure
• Low operating voltage for the fuel metering valve (High)
• Internal binding of the fuel metering valve SMCS Code: 1250-035
Recommended Repairs Probable Causes

Check the Operating Voltage for the Fuel • Excessive fuel supply pressure
Metering Valve
• Leaks in the piping after the fuel metering valve
Check the operating voltage for the fuel metering
valve. Refer to Troubleshooting, “Electrical Power
Supply”.

64
Recommended Repairs Adjust the gas pressure regulator in order to

achieve the correct pressure.
Check the Fuel Supply Pressure
Check the pressure of the fuel supply to the fuel the correct setting, repair the regulator or replace
metering valve for high pressure. The maximum the regulator.
allowable pressure to the fuel metering valve is
35 kPa (5 psi). Check the Fuel Supply for Obstructions
Adjust the gas pressure regulator in order to Check the fuel filter for restriction. Replace the fuel
achieve the correct pressure. filter, if necessary.
If the gas pressure regulator cannot be adjusted to Inspect the screen inside the inlet of the fuel
the correct setting, repair the regulator or replace metering valve for cleanliness. Clean the screen, if
the regulator. necessary.
Check for Leaks Inspect the fuel supply lines to the fuel metering
valve for obstructions. Clean the lines and make
Use a gas detector to check for leaks in the piping repairs, as needed.
between the outlet of the fuel metering valve and
the turbocharger compressor. Check the Gas Shutoff Valve (GSOV) for proper
operation. Verify that the valve is fully open when
Repair the piping, if necessary. the valve is energized. Verify that the GSOV does
not stick in a partially open position. Repair the
GSOV. Replace the GSOV, if necessary.
i01804929
Gas Fuel Differential Pressure Check the Fuel Outlet for Obstructions
(Low) Inspect the piping for obstructions between the fuel
metering valve and the inlet to the turbocharger
SMCS Code: 1250-035 compressor.
Probable Causes Clean the piping and make repairs, as needed.
• Improper installation of the fuel metering valve i01727721
• Low fuel supply pressure Gas Fuel Flow Rate (Low)

• Obstructed fuel supply SMCS Code: 1250-035
• Obstructed fuel outlet Probable Causes

Recommended repairs • High fuel temperature
Check the Installation of the Fuel • Faulty gas pressure regulator or low fuel supply
pressure
Metering Valve
An “E864 Low Gas Fuel Differential Pressure” event • Obstructions in the fuel supply
will be generated if the fuel metering valve is
installed backward. Ensure that the fuel metering • Inadequate fuel energy content or moisture in
the gas
valve is installed properly.
Check the Gas Pressure Regulator

The fuel metering valve requires a minimum
pressure of 10 kPa (1.5 psi) for the gas supply.
Check the outlet pressure from the gas pressure
regulator.
65
Recommended Repairs Obtain a Fuel Analysis
Check the Fuel Temperature If the fuel energy content is too low, the fuel metering
valve could demand an excessive supply of fuel.
Measure the temperature of the gas that is entering
the fuel metering valve. Compare the measurement Check Cat ET for a “E230 (1) Fuel Energy Content
to the reading for the fuel temperature on the Setting High” event code. If the code is present,
Caterpillar Electronic Technician (ET). Check Cat ET refer to Troubleshooting, “Fuel Energy Content”.
for a “E223 High Gas Temperature” event code.
If the temperature on Cat ET is different, determine the LHV. Program the Fuel Energy Content to the
the reason for the faulty signal from the fuel metering actual value of the LHV.
valve.
If the quality of the gas is not consistent, obtain
If the fuel temperature is high, determine the cause several analyses over a period of time. Program
of the high fuel temperature. Check for proper the Fuel Energy Content to the average value of
operation of the equipment that treats the gas prior the LHV.
to the engine.
Check the Dryer for the Gas
If there is an active “E223 High Gas Temperature”
event code, refer to Troubleshooting, “Gas Check the dryer for the gas for proper operation.
Temperature (High)”. Repair the dryer, if necessary.

i01758553
Check the Gas Pressure Regulator Gas Temperature (High)

Check the outlet pressure from the gas pressure SMCS Code: 1250-035
regulator. The fuel metering valve requires a
minimum pressure of 10 kPa (1.5 psi) for the gas
supply.
Probable Causes
If the pressure of the gas supply is too low, adjust • The temperature of the gas is too high.
the gas pressure regulator in order to achieve the
correct pressure. • The fuel metering valve has sent faulty data to the
master Electronic Control Module.
the correct setting, repair the regulator or replace Recommended Repairs
the regulator.
Investigate the Cause of the High
Check the Fuel Supply for Obstructions Temperature
Check the fuel filter for restriction. Replace the fuel Check for proper operation of the equipment that
filter, if necessary. treats the gas prior to the engine.
Inspect the screen inside the inlet of the fuel If a problem is found for the equipment that treats
metering valve for cleanliness. Clean the screen, if the gas prior to the engine, repair the equipment,
necessary. as needed.
Inspect the fuel supply lines to the fuel metering
valve for obstructions. Clean the lines and make
Check the Data from the Fuel Metering
repairs, as needed. Valve
Check the Gas Shutoff Valve (GSOV) for proper Measure the temperature of the gas that is entering
operation. Verify that the valve is fully open when the fuel metering valve. Compare the measurement
the valve is energized. Verify that the GSOV does to the reading for the temperature on the Caterpillar
not stick in a partially open position. Repair the Electronic Technician (ET).
GSOV. Replace the GSOV, if necessary.
If the measurement for the temperature is
significantly different from the reading on Cat ET,
determine the reason for the faulty data from the
fuel metering valve. Make repairs, as needed.
66
i01623042 High Altitude

Inlet Air Temperature (High) Make sure that the settings for the engine are
correct for the altitude.
SMCS Code: 1087-035
Check the Temperature Sensor and/or
Probable Causes the Circuit
• High ambient air temperature Allow the sensor to cool and remove the sensor.
Check the reading for the inlet air temperature.
• High coolant temperature If the sensor is OK, the reading and the ambient
temperature are approximately equal.
• High inlet air restriction and/or high altitude
If the reading is not correct, switch the sensor with
• Faulty inlet air temperature sensor and/or circuit a sensor that is known to be good. Verify that the
problem is solved.
• Insufficient flow of cooling water through the
aftercooler
Check for Sufficient Flow of Cooling
• Insufficient flow of air through the aftercooler Water Through the Aftercooler
Check the inlet temperature of the coolant for the
Recommended Repairs aftercooler. Compare the reading to the regulated
temperature. If the temperature is OK, check
High Ambient Air Temperature the outlet temperature of the coolant. A high
temperature differential indicates an insufficient flow
Determine if the ambient air temperature is within rate.
the design specifications for the cooling system.
If there is a high differential between the inlet
Determine the cause of the high air temperature. temperature and the outlet temperature of the
Make corrections, when possible. coolant for the aftercooler, perform the following
procedures:
Coolant Temperature
• Check the water circuit of the aftercooler for
Refer to Troubleshooting, “Engine Coolant obstructions.
• Check the pump for proper operation.
Check for High Inlet Air Restriction
and/or High Altitude • Make repairs, if necessary.
When inlet air pressure is low, the turbocharger Check for Sufficient Flow of Air Through
works harder in order to achieve the desired the Aftercooler
inlet manifold pressure. This increases inlet air
temperature. Determine the pressure differential of the inlet air
across the aftercooler. For specific data, refer to the
Measure the inlet air pressure while the engine is Technical Marketing Information for the engine.
operating under load. For specific data, refer to the
Technical Marketing Information for the engine. If the pressure differential of the air across the
aftercooler does not match the specifications, clean
Inlet Air Restriction the aftercooler.
Check for plugged air filters. Check for obstructions

i01804935
to the air inlet.
Replace the air filters and/or remove the obstruction

Intermittent Engine Shutdown
from the air inlet. SMCS Code: 1400-035
Note: Use this procedure only if the engine shuts

down completely and the engine must be restarted.
67
Probable Causes Fuel Supply

• Active engine shutdown 1. Check the fuel lines for the following problems:
restrictions, obstructions, collapsed lines, and
• Electrical connectors pinched lines. If problems are found with the fuel
lines, repair the lines and/or replace the lines.
• Circuit breaker
2. Check the restriction of the fuel filter. If the fuel
• Engine speed/timing signal pressure is low, replace the fuel filter.
• Fuel supply 3. Check the fuel quality.
• Spark plug 4. Check the fuel pressure. Refer to Systems

Operation/Testing and Adjusting, “Fuel System”
for the correct pressure values. If the fuel
Recommended Repairs pressure is still low, check the gas regulator and
the fuel metering valve.
Active Engine Shutdown
Use the Caterpillar Electronic Technician (ET) to
Spark Plug
check for any active engine shutdowns and/or
An engine shutdown that is due to a faulty spark
logged engine shutdowns. Determine the reason for
plug is likely to occur when the engine is operating
the shutdown. After correcting the problem, set the
under a load. Refer to Troubleshooting, “Ignition
engine control to the OFF/RESET mode for at least
Transformers Secondary Circuit and Spark Plugs”.
15 seconds before you try to restart the engine.
Electrical Connectors i01368495
1. Check the wiring harnesses and the connectors. Jacket Water Inlet Pressure
Inspect the connectors in the terminal boxes. (High)
Inspect the power supply connections and the
ground. Refer to Troubleshooting, “Inspecting SMCS Code: 1350-035
Electrical Connectors”.
2. Use Cat ET to check for the 168-02 diagnostic Probable Causes

code for “System Voltage Intermittent”. If
this diagnostic code is logged, proceed to • The circuit for the engine coolant pump pressure
Troubleshooting, “Electrical Power Supply”. switch (inlet) is OPEN.
3. Inspect the wiring from the power supply to • The pressure at the inlet for the jacket water is
the power distribution box. Inspect the wiring excessive.
from the power distribution box to the electronic
control modules. Check the power and ground Recommended Repairs
connections at each electronic control module.
Refer to Troubleshooting, “Electrical Power Check the Circuit for the Engine Coolant
Supply” for more information.
Pump Pressure Switch (Inlet)
Circuit Breakers The circuit for the switch must remain closed in
order to avoid an “E224 High Jacket Water Inlet
Check the 35 amp circuit breaker on the power Pressure” event. Check wiring for damage or
distribution box. The circuit breaker may exceed corrosion. Refer to Troubleshooting, “Inspecting
the trip point due to overheating. Reset the circuit Electrical Connectors”.
breaker if the circuit breaker is tripped.
If a problem with the wiring for the circuit is found,
Engine Speed/Timing Signal repair the wiring, as needed.
Loss of the signal from the speed/timing sensor will

cause a shutdown. Use Cat ET to check for logged
diagnostic codes. For more information, refer to
Troubleshooting, “Engine Speed/Timing Sensor”.
68
Check the Inlet Pressure of the Jacket Check the Flow of Coolant
Water
The engine coolant pump pressure switch (inlet) observe the pressure at the jacket water outlet with
is designed to open across pin B and pin C at a the engine OFF. Then observe the reading during
pressure of 462 ± 41 kPa (67 ± 6 psi). Use a gauge engine operation.
to check the pressure at the inlet for the jacket
water. If the reading is not reasonable or if the reading is
not within specifications, install a pressure gauge
If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) near the pressure sensor at the jacket water outlet.
but the event code “E224 High Jacket Water Inlet Compare the gauge reading with the reading from
Pressure” is occurring, replace the pressure switch Cat ET.
at the inlet for the jacket water.
If the readings from the comparative gauge do not
If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) agree approximately with Cat ET, troubleshoot the
is measured at the inlet for the jacket water, the circuit for the pressure sensor at the jacket water
high pressure may be caused by a restriction in outlet. Refer to Troubleshooting, “PWM Sensor”.
the jacket water system. Inspect the system for
restrictions. Make repairs, as needed. If the readings from the comparative gauge agree
approximately with Cat ET, check the following
Note: If the outlet pressure of the coolant is greater components:
than approximately 444 kPa (64 psi), a 109-08
diagnostic code will be generated. The “Engine • Check the water temperature regulators for
Coolant Outlet Pressure Sensor noisy signal” proper operation.
diagnostic will be generated although there is no
malfunction in the electrical circuit. If this code • Check for plugging of the radiator or the heat
is generated, verify the actual outlet pressure of exchanger.
the coolant with a pressure gauge. If the actual
pressure is greater than approximately 444 kPa • Inspect the jacket water pump for damage to the
(64 psi), reduce the pressure. This will prevent a impeller.
false 109-08 from being logged.
Make the necessary repairs.
i01727750
i01866678
Jacket Water Pressure (Low) Jacket Water to Engine Oil
SMCS Code: 1350-035 Differential Temperature (Low)
Probable Causes SMCS Code: 1350-035
• Low coolant level Probable Causes

• Insufficient flow of coolant • High engine oil temperature or low engine coolant
temperature
Recommended Repairs
• Faulty temperature sensor and/or circuit
Check the Coolant Level and Inspect the
Cooling System for Leaks
Check coolant level. If the coolant level is low, Recommended Repairs
inspect the cooling system for leaks.
Check for Event Codes for the Engine Oil
If the coolant level is low, fill the cooling system. If and for the Engine Coolant
leaks are found, make the necessary repairs.
check for the following event codes:
• E019 (3) High Engine Oil Temperature (shutdown)

69
• E020 (1) High Engine Oil Temperature (warning) i01368006
• E038 (1) Low Engine Coolant Temperature System Voltage

(warning)
SMCS Code: 1400-035
• E337 (1) Hign Engine Oil to Engine Coolant Diff
Temp (warning) Probable Causes
• E337 (3) High Engine Oil to Engine Coolant Diff There is a problem with the electrical system.
Temp (shutdown)
If one or more of the codes is active, troubleshoot Recommended Repairs

the code. Refer to Troubleshooting, “Troubleshooting
with an Event Code”. Troubleshoot the electrical system. Refer to
Troubleshooting, “Electrical Power Supply”.
Check the Engine Oil Temperature and
the Engine Coolant Temperature i01727763

Turbocharger Turbine
check the temperature of the engine oil and the Temperature (High)
engine coolant.
SMCS Code: 1052-035
If the engine oil temperature is high, refer to
Troubleshooting, “Engine Oil Temperature (High)”.
Probable Causes
If the temperature of the engine coolant is low, refer
to Troubleshooting, “Engine Coolant Temperature • High inlet manifold temperature
(Low)”.
• Advanced timing
Check the Temperature Sensors and/or • Exhaust restriction
Circuits
• A buildup of deposits in the cylinder or internal
Use a separate device to measure the temperatures oil leaks
of the engine oil and the engine coolant. Compare
the measured temperatures to the readings on Cat Recommended Repairs
ET.
If one or both of the readings are incorrect, Check for Event Codes for High Inlet
troubleshoot the circuit(s). Refer to Troubleshooting, Manifold Air Temperature
“Analog Sensor Signal”.
Check the Water Temperature Regulators check for the following event codes:
The water temperature regulators should not • E025 (2) High Inlet Air Temperature (derating)
begin to open until jacket water reaches opening
temperature for the regulators. Allow the engine to • E026 (3) High Inlet Air Temperature (shutdown)
cool and then start the engine. Check the tube at
the outlet for the jacket water. If the tube is warm • E027 (1) High Inlet Air Temperature (warning)
and normal operating temperature is not achieved
yet, a regulator may be stuck open. If one or more of the codes is active, refer to
Troubleshooting, “Inlet Air Temperature (High)”.
Check the water temperature regulators according
to Systems Operation/Testing and Adjusting, Check the Ignition Timing
“Testing the Cooling System”. Replace the water
temperature regulators, if necessary. Note: Data from a fuel analysis is required for this
procedure.
Use Cat ET to check the ignition timing during

engine operation with a load. Compare the
timing to the recommended timing in the Engine
Performance, “Fuel Usage Guide”.
70
Adjust the ignition timing according to the • Low cylinder compression

Recommended Repairs
Measure the Exhaust Restriction Check for Misfire
Measure the exhaust restriction during engine
Operation with a low load can result in low exhaust
operation with a load. For data that is specific to the temperatures. Operate the engine at low idle or
engine, refer to the Technical Marketing Information.
near low idle in order to identify a misfire problem.
Investigate the cause of the exhaust restriction. Troubleshoot the cause of the misfire. Refer to
Perform adjustments and/or make repairs, as
Troubleshooting, “Engine Misfires, Runs Rough or Is
needed.
Unstable”.
Check for Deposits in the Cylinder and Check for Diagnostic Codes from the
Check for Internal Oil Leaks Integrated Temperature Sensing Module
Use a borescope to inspect the cylinders. Look for (ITSM)
the following conditions:
• Deposits on the valve seats to check for diagnostic codes that relate to the
thermocouples. Troubleshoot the code.
Check the Temperatures of the Cylinder
• Deposits on the cylinder walls that are above the Exhaust Ports
upper limit of the piston stroke
Observe the temperatures for the exhaust ports of
• Signs of internal oil leaks the cylinders in the suspect bank.
Other signs of internal oil leaks include high oil If any of the temperatures for the exhaust ports are
consumption and blue smoke. significantly different, determine the reason for the
difference in the exhaust port temperatures. Make
Note: Excessive deposits contribute to guttering of repairs, as needed.
the valves.
If excessive deposits and/or signs of internal

Check for Suspect Thermocouples
oil leaks are found, investigate the cause of the
condition. Make repairs, as needed. Observe the temperatures from the thermocouples
for the turbocharger(s) after the engine is shut off.
i01804955 When the engine is operating properly, the

temperatures from similar locations are reduced at
Turbocharger Turbine a similar rate. Also, the temperatures from similar
Temperature (Low) locations are comparable.
SMCS Code: 1052-035 If any discrepancies are found, switch the suspect
thermocouple for another thermocouple. If the
temperature problem follows the thermocouple,
Probable Causes replace the thermocouple.
• Operation with a light load If the temperature problem stays at the original
location of the thermocouple, investigate the cause
• Diagnostic code from the Integrated Temperature for the low temperature.
Sensing Module (ITSM)
Check for Diagnostic Codes that Relate
• Low temperature from the cylinder exhaust ports
to Ignition
• A faulty temperature sensor
Use Cat ET to check for diagnostic codes that relate
• Faulty ignition to the ignition system. Troubleshoot the code.
71
Check the Ignition System

Inspect the components of the ignition system for
the suspect cylinder bank. Refer to Troubleshooting,
“Ignition Transformers Secondary Circuit and Spark
Plugs”.
Check the Cylinder Compression

Measure the cylinder pressures of the suspect bank
in order to check for problems that are related to
compression.
If low compression is found, investigate the cause

of the low compression. Make repairs, as needed.
72
Troubleshooting with a Table 14

Failure Mode Identifiers
Diagnostic Code
FMI Description of Failure
00 “Data valid but above normal operating
i01875210
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 (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 the module identifier (MID), the properly”
component identifier (CID), and the failure mode
08 “Abnormal frequency, pulse, or period”
identifier (FMI).
09 “Abnormal update”
Module Identifier (MID) – The MID is a code with
10 “Abnormal rate of change”
two or three digits that indicates the electronic
module which generated the diagnostic code. The 11 “Failure mode not identifiable”
MID for the master Electronic Control Module (ECM)
is 36. The MID for the slave ECM is 33. The MID for 12 “Bad device or component”
the Integrated Temperature Sensing Module (ITSM) 13 “Out of calibration”
is 111. Some electronic displays do not display the
MID because the module which generates the code 14 “Not used”
is obvious. 15 “Not used”
Component Identifier (CID) – The CID is a number 16 “Parameter not available”

with three or four digits. The CID indicates the 17 “Module not responding”
component that generated the code. For example,
the CID number 0017 identifies the fuel shutoff 18 “Sensor supply fault”
valve. 19 “Condition not met”
Failure Mode Identifier (FMI) – The FMI is a two digit 20 “Not used”
code that indicates the type of failure. Table 14 is a
list of the failure mode identifiers that are adapted The master ECM will generate all of the diagnostic
from the “SAE J1587” standard. codes that are applicable to G3500 engines that
have a single ECM. The diagnostic codes that are
generated by the slave ECM are a subset of the
diagnostic codes that are generated by the master
ECM. All of the diagnostic codes that are pertinent
to the slave ECM have the same setting conditions
and the same conditions for clearing as the master
ECM.
Note: Do not confuse diagnostic codes with

event codes. For information on event codes, see
Troubleshooting, “Troubleshooting with an Event
Code”.
Illustration 19 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.
73
This information is a valuable indicator for

troubleshooting intermittent problems.
A code is cleared from memory when one of the

• The service technician manually clears the code.

codes in memory. In this case, the oldest code
is cleared.
Some diagnostic codes may be easily triggered.

Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the
failure of an electronic module. Diagnostic codes
Illustration 19 g00791619 that are logged repeatedly may indicate a problem
Typical operating range of an oil temperature sensor
that needs special investigation.
(1) In these areas, the output voltage of the sensor is too high
or too low. The output is outside of the normal range. The
Note: Always clear logged diagnostic codes after
electronic problem will generate a diagnostic code. investigating and correcting the problem which
(2) In this area, the oil temperature above 102 C (216 F) is generated the code.
higher than the normal range. The output voltage of the sensor
will generate an event code for a warning, a derating, or a
shutdown for high oil temperature. The sensor does not have i01775013
an electronic problem.
(3) This area represents the normal operating temperature for the
engine oil. The normal output voltage of the sensor is between
MID 033 - CID 0041 - FMI 03 8
0.2 and 4.1 volts. Volt DC Supply short to +batt
Active Diagnostic Codes SMCS Code: 5574-038
An active diagnostic code represents a problem Conditions Which Generate This Code:
with the electronic control system. Correct the
problem as soon as possible. The voltage supply from the slave Electronic Control
Module (ECM) to the detonation sensors on the right
When an active diagnostic code is generated, the side of the engine has exceeded the normal range.
“Active Alarm” indicator (“Engine Control Alarm
Status” on Cat ET) is activated in order to alert the System Response:
operator. If the condition that generated the code is
momentary, the message disappears from the list Default values are assumed for the inputs to the
of active diagnostic codes. The diagnostic code slave ECM from all of the detonation sensors on the
becomes logged. right side of the engine. All of the diagnostic codes
for the detonation sensors on the right side of the
engine are disabled while this code is active.
Logged Diagnostic Codes
The fuel is shut off. The shutdown output is
When an ECM generates a diagnostic code, the activated. The code is logged.
ECM logs the code in permanent memory. Each
ECM has an internal diagnostic clock. Each ECM Possible Performance Effect:
will record the following information when a code is
generated: Since the engine protection is disabled, the engine
is shut down.
• The hour of the first occurrence of the code
Troubleshooting:
• The hour of the last occurrence of the code
Perform the following diagnostic procedure: “+8V
• The number of occurrences of the code Sensor Voltage Supply”
74
Results: • The power supply voltage is less than 6 VDC for

a minimum of 0.060 seconds. The power supply
• OK – STOP. voltage returns to the normal range within 0.015
seconds.
i01775014
• There are three voltage readings of less than 6
MID 033 - CID 0041 - FMI 04 8 VDC within 6 seconds.
Volt DC Supply short to ground System Response:
SMCS Code: 5574-038 The alarm output is activated. The code is logged.
Conditions Which Generate This Code: Note: If power supply voltage is lost and the voltage
does not return, the slave ECM will not log this
The voltage supply from the slave Electronic Control diagnostic code. The engine will shut down.
Module (ECM) to the detonation sensors on the
right side of the engine is below the normal range. Possible Performance Effect:
System Response: The intermittent problem may not affect engine

operation. However, the engine may experience
Default values are assumed for the inputs to the speed burps, intermittent shutdowns, and/or
slave ECM from all of the detonation sensors on the complete shutdowns.
right side of the engine. All of the diagnostic codes
for the detonation sensors on the right side of the Perform the following diagnostic procedure:
engine are disabled while this code is active. “Electrical Power Supply”
The fuel is shut off. The shutdown output is Results:

activated. The code is logged.
• OK – STOP.
Possible Performance Effect:
Since the engine protection is disabled, the engine i01769134
is shut down. MID 033 - CID 0301 - FMI 05

Troubleshooting: Ignition Transformer Primary
#1 open circuit
Sensor Voltage Supply”
SMCS Code: 1561-038
Results:
Conditions Which Generate This Code:
• OK – STOP. The primary circuit of the transformer is diagnosed
with an open circuit.
i01874059
System Response:
MID 033 - CID 0168 -
FMI 02 System Voltage The alarm output is activated. The code is logged.
intermittent/erratic Possible Performance Effect:
SMCS Code: 1408-038 The cylinder will misfire.
Conditions Which Generate This Code: Troubleshooting:
The slave Electronic Control Module (ECM) has One of the following conditions is the source of the
been powered for at least 5 seconds. The engine diagnostic code:
has been running. Either of the following conditions
occur: • A broken circuit driver’s wire for the transformer
• A broken return wire for the transformer
75
• An open circuit within the primary winding of the i01758839

transformer
MID 033 - CID 0303 - FMI 05
• An internal failure of the slave electronic control Ignition Transformer Primary
module (ECM)
#3 open circuit
Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit” SMCS Code: 1561-038
Results: Conditions Which Generate This Code:
• OK – STOP. The primary circuit of the transformer is diagnosed

i01758737 System Response:
MID 033 - CID 0301 - FMI 06 The alarm output is activated. The code is logged.
Ignition Transformer Primary
#1 short
The cylinder will misfire.
SMCS Code: 1561-038
Troubleshooting:
One of the following conditions is the source of the
The path for the circuit driver of the transformer is diagnostic code:
diagnosed with a short circuit.
System Response:
• An open circuit in the wiring from the slave
Electronic Control Module (ECM) to the
transformer
The alarm output is activated. The code is logged.

• An open circuit within the primary winding of the
transformer
• An internal failure of the slave ECM
Troubleshooting: Perform the following diagnostic procedure: “Ignition
Transformers Primary Circuit”
diagnostic code: Results:
• A short circuit in the wiring from the slave • OK – STOP.
transformer
i01758841
• A short circuit within the primary winding of the
transformer MID 033 - CID 0303 - FMI 06
#3 short
Transformers Primary Circuit” SMCS Code: 1561-038
• OK – STOP. The path for the circuit driver of the transformer is

System Response:

76
Possible Performance Effect: • An internal failure of the slave ECM

The cylinder will misfire. Perform the following diagnostic procedure: “Ignition
Troubleshooting:
Results:
diagnostic code: • OK – STOP.
• A short circuit in the wiring from the slave i01758849
• A short circuit within the primary winding of the Ignition Transformer Primary
transformer
#5 short
• An internal failure of the slave ECM SMCS Code: 1561-038
The path for the circuit driver of the transformer is
Results:
• OK – STOP. System Response:
i01758846 The alarm output is activated. The code is logged.
MID 033 - CID 0305 - FMI 05 Possible Performance Effect:

Ignition Transformer Primary The cylinder will misfire.
#5 open circuit
Troubleshooting:
SMCS Code: 1561-038
Conditions Which Generate This Code: diagnostic code:
The primary circuit of the transformer is diagnosed • A short circuit in the wiring from the slave
with an open circuit. Electronic Control Module (ECM) to the
transformer
System Response:
The alarm output is activated. The code is logged. transformer

Troubleshooting:
Results:
transformer

transformer
77
i01758852 Possible Performance Effect:

MID 033 - CID 0307 - FMI 05 The cylinder will misfire.
Troubleshooting:
#7 open circuit
SMCS Code: 1561-038 diagnostic code:
Conditions Which Generate This Code: • A short circuit in the wiring between the slave
Electronic Control Module (ECM) and the
The primary circuit of the transformer is diagnosed transformer
System Response: transformer
The alarm output is activated. The code is logged. • An internal failure of the slave ECM
Possible Performance Effect: Perform the following diagnostic procedure: “Ignition
Results:
Troubleshooting:
• OK – STOP.
diagnostic code:
i01758859
• An open circuit in the wiring from the slave MID 033 - CID 0309 - FMI 05
transformer Ignition Transformer Primary
• An open circuit within the primary winding of the #9 open circuit
transformer
SMCS Code: 1561-038
• An internal failure of the slave ECM Conditions Which Generate This Code:
Transformers Primary Circuit” The primary circuit of the transformer is diagnosed
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.

Ignition Transformer Primary Troubleshooting:
#7 short
Conditions Which Generate This Code: • An open circuit in the wiring from the slave
The path for the circuit driver of the transformer is transformer
78
• An internal failure of the slave ECM i01758872
Perform the following diagnostic procedure: “Ignition MID 033 - CID 0311 - FMI 05
Transformers Primary Circuit” Ignition Transformer Primary
Results: #11 open circuit
• OK – STOP. SMCS Code: 1561-038

i01758861
The primary circuit of the transformer is diagnosed
MID 033 - CID 0309 - FMI 06 with an open circuit.
System Response:
#9 short
SMCS Code: 1561-038
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 slave Transformers Primary Circuit”
transformer Results:
• A short circuit within the primary winding of the • OK – STOP.
transformer
Results: #11 short

System Response:

79

Troubleshooting:
Results:
• A short circuit in the wiring between the slave i01758889
transformer
#13 short
• An internal failure of the slave ECM SMCS Code: 1561-038
Results:

#13 open circuit
Troubleshooting:
SMCS Code: 1561-038
The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the slave
with an open circuit. Electronic Control Module (ECM) and the
transformer
System Response:

Troubleshooting:
Results:
transformer

transformer
80

Troubleshooting:
#15 open circuit
The alarm output is activated. The code is logged. • An internal failure of the slave ECM
Results:
Troubleshooting:
• OK – STOP.
diagnostic code:
i01775725
• An open circuit in the wiring from the slave MID 033 - CID 0320 - FMI 03
transformer Speed/Timing Sensor short to
• An open circuit within the primary winding of the +batt
transformer
SMCS Code: 1912-038
• An internal failure of the slave ECM Conditions Which Generate This Code:
Transformers Primary Circuit” To activate this code, all of the following conditions
must occur:
Results:
The slave Electronic Control Module (ECM) has
been powered for at least one second. The pattern
• OK – STOP. of the timing reference gear is lost for more than one
second. The engine speed is greater than 150 rpm.
i01758902 Neither of the following diagnostic codes are active:
MID 033 - CID 0315 - FMI 06 • 145 - 03 12 Volt DC Power Supply short to +batt
• 145 - 04 12 Volt DC Power Supply short to ground
#15 short
Note: The 0320 - 03 code is set after the pattern
SMCS Code: 1561-038 of the timing reference gear is lost for more than
one second. However, the logic hesitates for 1.5
Conditions Which Generate This Code: seconds before the code is activated. If a 145 - 03
or 145 - 04 is activated during the 1.5 seconds,
The path for the circuit driver of the transformer is then the 0320 - 03 code is deactivated.
System Response:

81
System Response: Results:
If the engine is running, the ignition signals stop. • OK – STOP.

The shutdown output is activated. The code is
logged.
i01864730
Possible Performance Effect: MID 033 - CID 0401 - FMI

If the engine is running, the engine will be shut 05 Ignition Transformer
down. If the engine is not running, the engine will
not start.
Secondary #1 open circuit
SMCS Code: 1561-038
Troubleshooting:
Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor”
The transformer’s secondary circuit is diagnosed
Results:
System Response:
• OK – STOP.
The status of the transformer’s secondary output is
i01775729 set to 120 percent. The alarm output is activated
and the code is logged.
MID 033 - CID 0320 - FMI 08
Engine Speed/Timing signal Possible Performance Effect:
abnormal The cylinder will misfire.
SMCS Code: 1912-038 Troubleshooting:
Conditions Which Generate This Code: One of the following conditions is the source of the
diagnostic code:
The slave Electronic Control Module (ECM) must be
powered for at least one second. The engine speed • A problem with the transformer’s ground
is greater than 150 rpm. One of the following two
conditions occurs: • An open circuit within the secondary winding of
the transformer
• An invalid pattern for the timing reference gear
is detected. For example, reverse rotation is • A problem with the connection to the spark plug’s
detected. terminal post
• The pattern for the timing reference gear is lost • The spark plug has internal damage or an open
for less than one second. circuit.
System Response: • The spark plug gap is too wide.

If the engine is running, the ignition signals stop. Perform the following diagnostic procedure: “Ignition
The shutdown output is activated. The code is Transformers Secondary Circuit and Spark Plugs”
logged.
Results:
• OK – STOP.
If the engine is running, the engine will be shut
down. If the engine is not running, the engine will
not start.
Troubleshooting:

82

MID 033 - CID 0401 - FMI The status of the transformer’s secondary output is
06 Ignition Transformer set to 120 percent. The alarm output is activated
Secondary #1 short to ground
SMCS Code: 1561-038
Troubleshooting:
with a short circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
• A problem with the transformer’s ground
set to zero percent. The alarm output is activated • An open circuit within the secondary winding of
and the code is logged. the transformer
Possible Performance Effect: • A problem with the connection to the spark plug’s
terminal post
• The spark plug has internal damage or an open
Troubleshooting: circuit.
One of the following conditions is the source of the • The spark plug gap is too wide.
diagnostic code:
• A short circuit within the secondary winding of Transformers Secondary Circuit and Spark Plugs”
the transformer
Results:
• The spark plug is fouled.
• OK – STOP.
• The spark plug gap is closed.
Perform the following diagnostic procedure: “Ignition i01864797
Transformers Secondary Circuit and Spark Plugs”
MID 033 - CID 0403 - FMI
Results: 06 Ignition Transformer
• OK – STOP. Secondary #3 short to ground
SMCS Code: 1561-038
i01864795
MID 033 - CID 0403 - FMI
05 Ignition Transformer The transformer’s secondary circuit is diagnosed
with a short circuit.
System Response:
SMCS Code: 1561-038
Conditions Which Generate This Code: set to zero percent. The alarm output is activated
with an open circuit. Possible Performance Effect:

83
Troubleshooting: • The spark plug gap is too wide.

One of the following conditions is the source of the Perform the following diagnostic procedure: “Ignition
diagnostic code: Transformers Secondary Circuit and Spark Plugs”
• A short circuit within the secondary winding of Results:

the transformer
• OK – STOP.
i01864800
MID 033 - CID 0405 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Ignition Transformer
Results:
SMCS Code: 1561-038
• OK – STOP.
i01864798
MID 033 - CID 0405 - FMI with a short circuit.
05 Ignition Transformer System Response:
SMCS Code: 1561-038 set to zero percent. The alarm output is activated
with an open circuit. The cylinder will misfire.
System Response: Troubleshooting:
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 diagnostic code:
• A short circuit within the secondary winding of
Possible Performance Effect: the transformer
Generation of the diagnostic code does not affect • The spark plug is fouled.
engine performance. However, the engine will
probably misfire. This will cause the engine to run • The spark plug gap is closed.
rough. The engine may shut down.
Troubleshooting: Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the Results:

diagnostic code:
• OK – STOP.
• An open circuit within the secondary winding of
the transformer
• A problem with the connection to the spark plug’s

terminal post

circuit.
84
i01864802 i01864806
MID 033 - CID 0407 - FMI MID 033 - CID 0407 - FMI
05 Ignition Transformer 06 Ignition Transformer
Secondary #7 open circuit Secondary #7 short to ground
SMCS Code: 1561-038 SMCS Code: 1561-038
Conditions Which Generate This Code: Conditions Which Generate This Code:
The transformer’s secondary circuit is diagnosed The transformer’s secondary circuit is diagnosed
with an open circuit. 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
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.
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 One of the following conditions is the source of the
diagnostic code: diagnostic code:
• A problem with the transformer’s ground • A short circuit within the secondary winding of
the transformer
the transformer • The spark plug is fouled.
• A problem with the connection to the spark plug’s • The spark plug gap is closed.
terminal post
• The spark plug has internal damage or an open Transformers Secondary Circuit and Spark Plugs”
circuit.
Results:
• The spark plug gap is too wide.
• OK – STOP.
i01864809
Results: MID 033 - CID 0409 - FMI

• OK – STOP. 05 Ignition Transformer
SMCS Code: 1561-038

85
The cylinder will misfire. • The spark plug is fouled.

Troubleshooting: • The spark plug gap is closed.
• A problem with the transformer’s ground Results:
• An open circuit within the secondary winding of • OK – STOP.

the transformer
i01864818
terminal post MID 033 - CID 0411 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
• The spark plug gap is too wide. SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Results: with an open circuit.
i01864812 The status of the transformer’s secondary output is

set to 120 percent. The alarm output is activated
MID 033 - CID 0409 - FMI and the code is logged.
06 Ignition Transformer Possible Performance Effect:
SMCS Code: 1561-038
Troubleshooting:
The transformer’s secondary circuit is diagnosed diagnostic code:
System Response:
The status of the transformer’s secondary output is the transformer
set to zero percent. The alarm output is activated
and the code is logged. • A problem with the connection to the spark plug’s
terminal post
The cylinder will misfire. circuit.
86
• The spark plug gap is too wide. i01864822
Perform the following diagnostic procedure: “Ignition MID 033 - CID 0413 - FMI
Results: Secondary #13 open circuit

i01864821
MID 033 - CID 0411 - FMI with an open circuit.
06 Ignition Transformer
System Response:
SMCS Code: 1561-038 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 diagnostic code:


the transformer
Troubleshooting:
terminal post
diagnostic code:
circuit.
the transformer
• The spark plug is fouled. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Results:
• OK – STOP.
87

MID 033 - CID 0413 - FMI The cylinder will misfire.
Troubleshooting:
Conditions Which Generate This Code: • A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed • An open circuit within the secondary winding of
with a short circuit. the transformer
System Response: • A problem with the connection to the spark plug’s

terminal post
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.
Troubleshooting:
Results:
the transformer i01864829

MID 033 - CID 0415 - FMI
• The spark plug gap is closed. Secondary #15 short to ground
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1561-038

• OK – STOP. with a short circuit.

05 Ignition Transformer set to zero percent. The alarm output is activated
SMCS Code: 1561-038
Troubleshooting:
with an open circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
and the code is logged. • The spark plug is fouled.
88
• The spark plug gap is closed. i01761131
Transformers Secondary Circuit and Spark Plugs” Cylinder #1 Detonation Sensor
Results: open/short to +batt

i01796190
The run relay and the crank terminate relay are
MID 033 - CID 0590 - FMI 09 energized. The signal from the detonation sensor
Unable to communicate with for cylinders 1 and 3 to the slave Electronic Control
Module (ECM) is greater than 4.8 VDC for ten
Engine ECM seconds.
SMCS Code: 1901-038 Neither of the following diagnostic codes are active:
• 0041 - 03 8 Volt DC Supply short to +batt
The master Electronic Control Module (ECM) has
sent ten consecutive messages to the slave ECM
• 0041 - 04 8 Volt DC Supply short to ground
via the Cat data link. None of the messages have System Response:
been received by the slave ECM. Alternatively,
the master ECM has sent messages to the slave The shutdown output is activated. The code is
ECM over a period of time, and two-thirds of the logged.
messages have not been received by the slave
ECM. Neither ECM is being flashed. Possible Performance Effect:
Note: Although there is a failure to communicate The engine is shut down.
with the slave ECM, the master ECM may still be
able to communicate with the Caterpillar Electronic Troubleshooting:
Technician (ET).
Perform the following diagnostic procedure:
System Response: “Detonation Sensors”
The alarm output is activated. Results:
The code is logged by the slave ECM.
• OK – STOP.
Engine ignition is terminated.
i01761136
Note: If Cat ET cannot communicate with the master
ECM, the values will display “Unavailable”. MID 033 - CID 1501 - FMI 04
Cylinder #1 Detonation Sensor
short to ground
The engine is shut down.
SMCS Code: 1559-038
Perform the following diagnostic procedure: “Cat
Data Link” Conditions Which Generate This Code:
Results: The run relay and the crank terminate relay are
energized. The signal from the detonation sensor
• OK – STOP. for cylinders 1 and 3 to the slave Electronic Control
Module (ECM) is less than 1.0 VDC for ten seconds.
Neither of the following diagnostic codes are active:

89
• 0041 - 04 8 Volt DC Supply short to ground i01761200
System Response: MID 033 - CID 1505 - FMI 04

logged. short to ground
Possible Performance Effect: SMCS Code: 1559-038
The engine is shut down. Conditions Which Generate This Code:
Troubleshooting: The run relay and the crank terminate relay are
Perform the following diagnostic procedure: for cylinders 5 and 7 to the slave Electronic Control
“Detonation Sensors” Module (ECM) is less than 1.0 VDC for ten seconds.
Results: Neither of the following diagnostic codes are active:
• OK – STOP. • 0041 - 03 8 Volt DC Supply short to +batt

i01761195
System Response:
MID 033 - CID 1505 - FMI 03
Cylinder #5 Detonation Sensor The shutdown output is activated. The code is
logged.
open/short to +batt
SMCS Code: 1559-038
Troubleshooting:
energized. The signal from the detonation sensor Perform the following diagnostic procedure:
for cylinders 5 and 7 to the slave Electronic Control “Detonation Sensors”
Module (ECM) is greater than 4.8 VDC for ten
seconds. Results:
• OK – STOP.
i01761212
MID 033 - CID 1509 - FMI 03
System Response: Cylinder #9 Detonation Sensor
The shutdown output is activated. The code is open/short to +batt
logged.
SMCS Code: 1559-038
Troubleshooting: energized. The signal from the detonation sensor for
cylinders 9 and 11 to the slave Electronic Control
Perform the following diagnostic procedure: Module (ECM) is greater than 4.8 VDC for ten
“Detonation Sensors” seconds.

90
System Response: i01761230
The shutdown output is activated. The code is MID 033 - CID 1513 - FMI
logged. 03 Cylinder #13 Detonation
Possible Performance Effect: Sensor open/short to +batt
The engine is shut down. SMCS Code: 1559-038
Troubleshooting: Conditions Which Generate This Code:
Perform the following diagnostic procedure: The run relay and the crank terminate relay are
“Detonation Sensors” energized. The signal from the detonation sensor
for cylinders 13 and 15 to the slave Electronic
Results: Control Module (ECM) is greater than 4.8 VDC for
ten seconds.
• OK – STOP.
i01761215 • 0041 - 03 8 Volt DC Supply short to +batt

MID 033 - CID 1509 - FMI 04 • 0041 - 04 8 Volt DC Supply short to ground
System Response:
short to ground
SMCS Code: 1559-038 logged.
Conditions Which Generate This Code: Possible Performance Effect:
The run relay and the crank terminate relay are The engine is shut down.
energized. The signal from the detonation sensor for
cylinders 9 and 11 to the slave Electronic Control Troubleshooting:
Neither of the following diagnostic codes are active: “Detonation Sensors”
• 0041 - 03 8 Volt DC Supply short to +batt Results:
• 0041 - 04 8 Volt DC Supply short to ground • OK – STOP.
System Response:
i01761234
logged. MID 033 - CID 1513 - FMI
04 Cylinder #13 Detonation
Sensor short to ground
SMCS Code: 1559-038
Troubleshooting:
“Detonation Sensors” The run relay and the crank terminate relay are
Results: cylinders 13 and 15 to the slave Electronic Control
• OK – STOP.

91
System Response: MID 033 - CID 1517 - FMI

logged. Sensor short to ground
Possible Performance Effect: SMCS Code: 1559-038
Troubleshooting: The run relay and the crank terminate relay are
Perform the following diagnostic procedure: cylinders 17 and 19 to the slave Electronic Control
“Detonation Sensors” Module (ECM) is less than 1.0 VDC for ten seconds.

i01761242
System Response:
MID 033 - CID 1517 - FMI
03 Cylinder #17 Detonation The shutdown output is activated. The code is
logged.
Sensor open/short to +batt
SMCS Code: 1559-038
Troubleshooting:
energized. The signal from the detonation sensor Perform the following diagnostic procedure:
for cylinders 17 and 19 to the slave Electronic “Detonation Sensors”
Control Module (ECM) is greater than 4.8 VDC for
ten seconds. Results:
• OK – STOP.
i01760803
MID 033 - CID 1748 - FMI
System Response: 05 Ignition Transformer
The shutdown output is activated. The code is Secondary #17 open circuit
logged.
SMCS Code: 1561-038
Troubleshooting: with an open circuit.
Perform the following diagnostic procedure: System Response:

“Detonation Sensors”
Results: set to 120 percent. The alarm output is activated
• OK – STOP.

92


the transformer
i01760805
circuit.
Results:

SMCS Code: 1561-038
Troubleshooting:
System Response:
terminal post
Troubleshooting: • The spark plug gap is too wide.

• A short circuit within the secondary winding of Results:

the transformer
• OK – STOP.
93

Troubleshooting:
Conditions Which Generate This Code: • An open circuit in the wiring from the slave
The transformer’s secondary circuit is diagnosed transformer
The status of the transformer’s secondary output is • An internal failure of the slave ECM
and the code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:
One of the following conditions is the source of the i01760305

diagnostic code:
MID 033 - CID 1752 - FMI 06
• A short circuit within the secondary winding of Ignition Transformer Primary
the transformer
#17 short to ground
• The spark plug is fouled. SMCS Code: 1561-038
• The spark plug gap is closed. Conditions Which Generate This Code:
Transformers Secondary Circuit and Spark Plugs” The path for the circuit driver of the transformer is
Results:
System Response:

#17 open circuit
94
Results: #19 short to ground

i01760309
MID 033 - CID 1754 - FMI 05 diagnosed with a short circuit.
System Response:
#19 open circuit
SMCS Code: 1561-038
with an open circuit. Troubleshooting:
diagnostic code:

• A short circuit in the wiring between the slave
transformer
Troubleshooting:
transformer
diagnostic code:
• An open circuit in the wiring from the slave Transformers Primary Circuit”
• An open circuit within the primary winding of the • OK – STOP.
transformer
Transformers Primary Circuit” Fuel Shutoff Valve open circuit
Results: SMCS Code: 1259-038
• OK – STOP. Conditions Which Generate This Code:
• The output to the fuel control relay from the

master Electronic Control Module (ECM) is OFF.
• When no electrical load is provided, a resistor in

the fuel shutoff valve rises to the +Battery side.
95
Note: This code cannot be detected by the master Possible Performance Effect:
ECM when the output for the fuel control relay is
ON. The output is normally ON when the engine The engine will not start due to the lack of fuel.
control is in the START mode and the engine RPM
is greater than zero. Troubleshooting:
System Response: The condition is probably caused by a short circuit

in the harness or by an internal short circuit in the
No fuel is provided to the engine. The alarm output fuel control relay.
is activated. The code is logged.
Perform the following diagnostic procedure: “ECM
Possible Performance Effect: Output Circuit (Fuel Control)”
The engine will not start due to the lack of fuel. Results:
Troubleshooting: • OK – STOP.
The most likely cause is one of the following
i01758598
conditions:
MID 036 - CID 0017 - FMI 12
• An open circuit in the harness or in the fuel
control relay Fuel Shutoff Valve malfunction
• A short circuit to the +Battery in the harness or SMCS Code: 1259-038
in the fuel control relay
Output Circuit (Fuel Control)” The driver in the master Electronic Control Module
(ECM) for the gas shutoff valve is OFF but the
Results: engine still runs.
The master ECM will disable the ignition system

i01805813 and the gas shutoff valve in order to shut down
MID 036 - CID 0017 - FMI 06 the engine. The shutdown output is activated. The
code is logged.
Fuel Shutoff Valve short to
ground
SMCS Code: 1259-038
Troubleshooting:
• The output for the fuel control relay is ON. Output Circuit (Fuel Control)”
• The master Electronic Control Module (ECM) Results:
detects excessive current on the output for the
fuel control relay.
• OK – STOP.
Note: This condition cannot be detected by the
master ECM when the output for the fuel control
relay is OFF. The output is normally OFF when the
engine control is in the STOP mode.
System Response:
The master ECM will continue attempting to

energize the relay. The engine may shut down due
to a lack of fuel. The alarm output is activated. The
code is logged.
96
i01805819 • The detonation sensors on the left side of the

engine
MID 036 - CID 0041 - FMI 03 8
Volt DC Supply short to +batt System Response:
SMCS Code: 5574-038 Default values are assumed for the inputs to the
master ECM from all of the 8 volt sensors. All of the
Conditions Which Generate This Code: diagnostic codes for the 8 volt sensors to the ECM
are disabled while this code is active.
The voltage supply from the master Electronic
Control Module (ECM) to one of the following The fuel is shut off. The shutdown output is
sensors has exceeded the normal range. activated. The code is logged.
• Sensor for engine coolant pressure (outlet) Possible Performance Effect:
• Sensor for inlet air pressure Since the engine protection is disabled, the engine
is shut down.
• The detonation sensors on the left side of the
engine Troubleshooting:
System Response: Perform the following diagnostic procedure: “+8V

Default values are assumed for the inputs to the
master ECM from all of the 8 volt sensors. All of the Results:
diagnostic codes for the 8 volt sensors to the ECM
are disabled while this code is active. • OK – STOP.
The fuel is shut off. The shutdown output is i01758614
MID 036 - CID 0100 - FMI
03 Engine Oil Pressure
Since the engine protection is disabled, the engine open/short to +batt
is shut down.
SMCS Code: 1924-038
Troubleshooting:
Sensor Voltage Supply” The signal from the filtered oil pressure sensor
to the master Electronic Control Module (ECM) is
Results: greater than 4.8 VDC for at least five seconds.
• OK – STOP. Additionally, neither of the following diagnostic

codes are active:
i01805824
• 262 - 03 5 Volt Sensor DC Power Supply short
MID 036 - CID 0041 - FMI 04 8 to +batt
Volt DC Supply short to ground • 262 - 04 5 Volt Sensor DC Power Supply short
to ground
SMCS Code: 5574-038
System Response:
The master ECM assumes the last valid value for
The voltage supply from the master Electronic the engine oil pressure. The monitoring of the oil
Control Module (ECM) to one of the following pressure is disabled. This disables the engine
sensors is below the normal range. protection for low oil pressure and for excessive oil
pressure.
• Sensor for engine coolant pressure (outlet)
• Sensor for inlet air pressure
97
The fuel is shut off. The shutdown output is Troubleshooting:

Perform the following diagnostic procedure: “Analog
Possible Performance Effect: Sensor Signal”
Since the engine protection is disabled, the engine Results:

is shut down.
• OK – STOP.
Troubleshooting:
i01780399
This condition indicates an open circuit or a short
circuit to a positive voltage source. MID 036 - CID 0106 - FMI 03 Air
Perform the following diagnostic procedure: “Analog Inlet Pressure Sensor short to
Sensor Signal”
+batt
Results: SMCS Code: 5574-038-PX
i01758623 The duty cycle for the inlet manifold pressure sensor
is greater than the maximum value.
MID 036 - CID 0100 - FMI 04
Engine Oil Pressure short to Additionally, neither of the following diagnostic
codes are active:
ground
SMCS Code: 1924-038
System Response:
The signal from the filtered oil pressure sensor to
the master Electronic Control Module (ECM) is less The fuel is shut off. The shutdown output is
than 0.2 VDC for at least five seconds. activated. The code is logged.
Additionally, neither of the following diagnostic Possible Performance Effect:

codes are active:
to +batt Troubleshooting:
• 262 - 04 5 Volt Sensor DC Power Supply short This condition indicates a possible open circuit or
to ground a possible short circuit.
System Response: Perform the following diagnostic procedure: “PWM

Sensor”
The master ECM assumes the last valid value for
the engine oil pressure. The monitoring of the oil Results:
pressure is disabled. This disables the engine
protection for low oil pressure and for excessive oil • OK – STOP.
pressure.

Since the engine protection is disabled, the engine

is shut down.
98

MID 036 - CID 0106 - FMI 08 Air The alarm output is activated. The code is logged.
Inlet Pressure Sensor noisy
signal
The engine performance is not affected.
SMCS Code: 5574-038-PX
Troubleshooting:
The condition indicates a possible open circuit or
The duty cycle or the frequency for the inlet manifold a short circuit.
pressure sensor is out of range.
Perform the following diagnostic procedure: “PWM
Additionally, neither of the following diagnostic Sensor”
codes are active:
Results:
• OK – STOP.
The fuel is shut off. The shutdown output is MID 036 - CID 0109 - FMI
activated. The code is logged. 08 Engine Coolant Outlet
Possible Performance Effect: Pressure Sensor noisy signal
The engine is shut down. SMCS Code: 5574-038-PX
Perform the following diagnostic procedure: “PWM The duty cycle or the frequency of the signal from
Sensor” the pressure sensor for the outlet of the engine
coolant is out of range.
Results:
Additionally, neither of the following diagnostic
codes are active:
• OK – STOP.
i01793903
MID 036 - CID 0109 - FMI
03 Coolant Outlet Pressure System Response:
open/short to +batt The alarm output is activated. The code is logged.
SMCS Code: 5574-038-PX Possible Performance Effect:
Conditions Which Generate This Code: The engine performance is not affected.
The duty cycle of the pressure sensor for the outlet Troubleshooting:
of the engine coolant is greater than the maximum
limit. Perform the following diagnostic procedure: “PWM
Sensor”
Additionally, neither of the following diagnostic
codes are active: Results:
• 41 - 03 8 Volt DC Supply short to +batt • OK – STOP.

99

MID 036 - CID 0110 - FMI 03 The master ECM assumes the last valid value for
Engine Coolant Temperature the engine coolant temperature. The monitoring of
the coolant temperature is disabled. This disables
open/short to +batt the engine protection for low coolant temperature
and for high coolant temperature.
SMCS Code: 1906-038
Conditions Which Generate This Code: activated. The code is logged.
The signal from the engine coolant temperature Possible Performance Effect:
sensor to the master Electronic Control Module
(ECM) is greater than 4.8 VDC for at least five Since the engine protection is disabled, the engine
seconds. is shut down.
The master ECM assumes the last valid value for Perform the following diagnostic procedure: “Analog
engine coolant temperature. The monitoring of the Sensor Signal”
coolant temperature is disabled. This disables the
engine protection for low coolant temperature and Results:
for high coolant temperature.
• OK – STOP.
i01866770
MID 036 - CID 0145 - FMI 03 12
Since the engine protection is disabled, the engine Volt DC Power Supply short to
is shut down.
+batt
Troubleshooting:
SMCS Code: 5574-038
This condition indicates a possible open circuit or
a possible short circuit. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Analog The master Electronic Control Module (ECM) has
Sensor Signal” been powered for at least five seconds. The 12 volt
sensor supply voltage becomes greater than 14.2 V
Results: for at least one second.
System Response:
• OK – STOP.
If the engine is running, the fuel is shut off. The
i01758638 shutdown output is activated. The code is logged.
Engine Coolant Temperature
The engine is shut down or the engine will not start.
short to ground
Troubleshooting:
SMCS Code: 1906-038
Conditions Which Generate This Code: Speed/Timing Sensor”
The signal from the engine coolant temperature Results:
(ECM) is less than 0.2 VDC for at least five seconds. • OK – STOP.
100
i01866808 Note: If power supply voltage is lost and the voltage

does not return, the master ECM will not log this
MID 036 - CID 0145 - FMI 04 12 diagnostic code. The engine will shut down.
Volt DC Power Supply short to
ground
The intermittent problem may not affect engine
SMCS Code: 5574-038 operation. However, the engine may experience
speed burps, intermittent shutdowns, and/or
Conditions Which Generate This Code: complete shutdowns.
The master Electronic Control Module (ECM) has Troubleshooting:

been powered for at least five seconds. The 12 volt
sensor supply voltage becomes less than 11 VDC Perform the following diagnostic procedure:
for at least one second. “Electrial Power Supply”
If the engine is running, the fuel is shut off. The • OK – STOP.
shutdown output is activated. The code is logged.
Possible Performance Effect: i01875963
The engine is shut down or the engine will not start. MID 036 - CID 0172 - FMI 03
Intake Manifold Air Temp
Troubleshooting:
open/short to +batt
Speed/Timing Sensor” SMCS Code: 5574-038-TA

• OK – STOP. been powered for at least five seconds. The signal
from the inlet manifold temperature sensor to the
i01758658 master ECM is greater than 4.8 VDC for at least
five seconds. Additionally, neither of the following
MID 036 - CID 0168 - diagnostic codes are active:
FMI 02 System Voltage
intermittent/erratic to +batt
SMCS Code: 1408-038 • 262 - 04 5 Volt Sensor DC Power Supply short
to ground
System Response:
been powered for at least 5 seconds. The engine is The master ECM assumes the last valid value for
running. Either of the two following conditions occur: the inlet manifold air temperature. The monitoring
of the inlet manifold air temperature is disabled.
• The power supply voltage is less than 6 VDC for This disables the engine protection for high inlet
a minimum of 0.060 seconds. The voltage returns manifold air temperature. The air/fuel ratio control
to the normal range within 0.015 seconds. cannot compensate for the inlet air temperature.
• There are three voltage readings of less than 6 The fuel is shut off. The shutdown output is
VDC within 7 seconds. activated. The code is logged.
System Response: Possible Performance Effect:
The alarm output is activated. The code is logged. The engine is shut down.
101
Troubleshooting: i01758680
The condition indicates a possible open circuit or a MID 036 - CID 0175 - FMI
short circuit to a positive voltage source. 03 Engine Oil Temperature
Perform the following diagnostic procedure: “Analog open/short to +batt
Sensor Signal”
SMCS Code: 5574-038-TA
Results:
• OK – STOP.
The signal from the engine oil temperature sensor
to the master Electronic Control Module (ECM) is
i01758674 greater than 4.8 VDC for at least five seconds.
MID 036 - CID 0172 - FMI 04 Additionally, neither of the following diagnostic
Intake Manifold Air Temp short codes are active:
to ground • 262 - 03 5 Volt Sensor DC Power Supply short
to +batt
SMCS Code: 5574-038-TA

to ground
The signal from the inlet manifold temperature System Response:
(ECM) is less than 0.2 VDC for at least five seconds. The master ECM assumes the last valid value for the
engine oil temperature. The monitoring of the engine
Additionally, neither of the following diagnostic oil temperature is disabled. Also, the monitoring
codes are active: for a high difference in temperature between the
engine oil and the engine coolant is disabled. This
• 262 - 03 5 Volt Sensor DC Power Supply short disables the engine protection for both parameters.
to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short logged.
to ground
System Response:
Since engine protection is disabled, the engine is
The master ECM assumes the last valid value for shut down.
the inlet manifold air temperature. The monitoring
of the inlet manifold air temperature is disabled. Troubleshooting:
This disables the engine protection for high inlet
manifold air temperature. The air/fuel ratio control The condition indicates a possible open circuit or a
cannot compensate for the inlet air temperature. short circuit to a positive voltage source.
The fuel is shut off. The shutdown output is Perform the following diagnostic procedure: “Analog
activated. The code is logged. Sensor Signal”
Possible Performance Effect: Results:
• OK – STOP.
Troubleshooting:

Sensor Signal”
Results:
• OK – STOP.
102
i01758708 i01636386
MID 036 - CID 0175 - FMI 04 MID 036 - CID 0261 - FMI 13
Engine Oil Temperature short Engine Timing calibration
to ground required
SMCS Code: 5574-038-TA SMCS Code: 1905-038
The signal from the engine oil temperature sensor to The timing calibration has not been performed.
the master Electronic Control Module (ECM) is less
than 0.2 VDC for at least five seconds. System Response:
Additionally, neither of the following diagnostic The alarm output is activated. The code is logged.
codes are active:
to +batt The timing will be advanced or the timing will be
retarded. Either condition will result in reduced
• 262 - 04 5 Volt Sensor DC Power Supply short engine performance. If the condition is not
to ground corrected, engine damage will result.
The master ECM assumes the last valid value for Calibrate the engine speed/timing sensor.
the engine oil temperature. The monitoring of the
engine oil temperature is disabled. Also, monitoring Perform the following diagnostic procedure: “Engine
for a high difference in temperature between the Speed/Timing Sensor - Calibrate”
engine oil and the engine coolant is disabled. This
disables the engine protection for both parameters. Results:
The shutdown output is activated. The code is • OK – STOP.

logged.
i01805835
Since engine protection is disabled, the engine is

MID 036 - CID 0262 - FMI 03 5
shut down. Volt Sensor DC Power Supply
Troubleshooting:
short to +batt
SMCS Code: 5574-038
Sensor Signal”
Results: The supply voltage from the master Electronic
Control Module (ECM) to the sensors for the
• OK – STOP. following parameters is exceeding the normal level:
• Inlet air temperature

• Engine oil temperature
• Unfiltered engine oil pressure
• Filtered engine oil pressure
103
If the engine is equipped with a desired speed System Response:

potentiometer, a short circuit in the signal wire for
the desired speed potentiometer can generate this All of the inputs to the master ECM for the 5 volt
code. sensors assume default values. All other diagnostic
codes for the 5 volt sensors are disabled while this
System Response: diagnostic code is active. The “Status” screen of
the Caterpillar Electronic Technician (ET) indicates
All of the inputs to the master ECM for the 5 volt a “Sensor Supply Fault” for each sensor. This
sensors assume default values. All other diagnostic indicates that the sensors are not operating due to
codes for the 5 volt sensors are disabled while an active diagnostic code.
this diagnostic code is active. The “Status” screen
of Caterpillar Electronic Technician (ET) indicates The shutdown output is activated. The code is
a “Sensor Supply Fault” for each sensor. This logged.
indicates that the sensors are not operating due to
an active diagnostic code. Possible Performance Effect:
The shutdown indicator is activated. The code is Since engine protection is disabled, the engine is
logged. shut down.
Possible Performance Effect: Troubleshooting:
Since engine protection is disabled, the engine is The condition indicates a possible short circuit to
shut down. ground or a short circuit between the sensor supply
and the return.
Troubleshooting:
Perform the following diagnostic procedure: “+5V Sensor Voltage Supply”
Results:
Results:
• OK – STOP.
• OK – STOP.
i01758830
i01805855
MID 036 - CID 0302 - FMI 05
MID 036 - CID 0262 - FMI 04 5 Ignition Transformer Primary
Volt Sensor DC Power Supply #2 open circuit
short to ground
SMCS Code: 1561-038
SMCS Code: 5574-038
The supply voltage from the master Electronic with an open circuit.
Control Module (ECM) to the sensors for the
following parameters is less than the normal level: System Response:
• Inlet air temperature The alarm output is activated. The code is logged.
• Engine oil temperature Possible Performance Effect:
• Unfiltered engine oil pressure The cylinder will misfire.
• Filtered engine oil pressure Troubleshooting:
If the engine is equipped with a desired speed One of the following conditions is the source of the
potentiometer, a short circuit in the signal wire for diagnostic code:
the desired speed potentiometer can generate this
code. • An open circuit in the wiring from the master
transformer
104
• An open circuit within the primary winding of the i01758842

transformer
MID 036 - CID 0304 - FMI 05
• An internal failure of the master ECM Ignition Transformer Primary
Perform the following diagnostic procedure: “Ignition #4 open circuit
SMCS Code: 1561-038
Results:
• OK – STOP.
i01758836
System Response:
MID 036 - CID 0302 - FMI 06
Ignition Transformer Primary The alarm output is activated. The code is logged.
#2 short Possible Performance Effect:
SMCS Code: 1561-038 The cylinder will misfire.
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:
• An open circuit in the wiring from the master
transformer
Troubleshooting:
• An internal failure of the master ECM
One of the following conditions is the source of the Transformers Primary Circuit”
diagnostic code:
Results:
• A short circuit in the wiring between the master
transformer
• OK – STOP.
• A short circuit within the primary winding of the i01758843

transformer
MID 036 - CID 0304 - FMI 06
• An internal failure of the master ECM Ignition Transformer Primary
Perform the following diagnostic procedure: “Ignition #4 short
SMCS Code: 1561-038
Results:
• OK – STOP.
System Response:

105
Possible Performance Effect: • An internal failure of the master ECM

Troubleshooting:
Results:
• A short circuit in the wiring between the master i01758851
transformer
#6 short
• An internal failure of the master ECM SMCS Code: 1561-038
Results:

#6 open circuit
Troubleshooting:
SMCS Code: 1561-038
The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the master
transformer
System Response:

Troubleshooting:
Results:
transformer

transformer
106

Troubleshooting:
#8 open circuit
Conditions Which Generate This Code: • A short circuit in the wiring between the master
The alarm output is activated. The code is logged. • An internal failure of the master ECM
Results:
Troubleshooting:
• OK – STOP.
diagnostic code:
i01758862
• An open circuit in the wiring from the master MID 036 - CID 0310 - FMI 05
transformer Ignition Transformer Primary
• An open circuit within the primary winding of the #10 open circuit
transformer
SMCS Code: 1561-038
• An internal failure of the master ECM Conditions Which Generate This Code:
Transformers Primary Circuit” The primary circuit of the transformer is diagnosed
Results:
System Response:

#8 short
Conditions Which Generate This Code: • An open circuit in the wiring from the master
The path for the circuit driver of the transformer is transformer
107
• An internal failure of the master ECM i01758879
Results: #12 open circuit

i01758867
MID 036 - CID 0310 - FMI 06 with an open circuit.
System Response:
#10 short
SMCS Code: 1561-038
diagnosed with a short circuit. Troubleshooting:
diagnostic code:

transformer
Troubleshooting:
transformer
diagnostic code:
• A short circuit in the wiring between the master Transformers Primary Circuit”
• A short circuit within the primary winding of the • OK – STOP.
transformer
Results: #12 short

System Response:

108

Troubleshooting:
Results:
• A short circuit in the wiring between the master i01758894
transformer
#14 short
• An internal failure of the master ECM SMCS Code: 1561-038
Results:

#14 open circuit
Troubleshooting:
SMCS Code: 1561-038
The primary circuit of the transformer is diagnosed • A short circuit in the wiring between the master
transformer
System Response:

Troubleshooting:
Results:
transformer

transformer
109

Troubleshooting:
#16 open circuit
The alarm output is activated. The code is logged. • An internal failure of the master ECM
Results:
Troubleshooting:
• OK – STOP.
diagnostic code:
i01760423
• An open circuit in the wiring from the master MID 036 - CID 0320 - FMI 03
transformer Speed/Timing Sensor short to
• An open circuit within the primary winding of the +batt
transformer
SMCS Code: 1912-038
• An internal failure of the master ECM Conditions Which Generate This Code:
Transformers Primary Circuit” To activate this code, all of the following conditions
must occur:
Results:
been powered for at least one second. The pattern
• OK – STOP. of the timing reference gear is lost for more than one
second. The engine speed is greater than 150 rpm.
i01758913 Neither of the following diagnostic codes are active:
MID 036 - CID 0316 - FMI 06 • 145 - 03 12 Volt DC Power Supply short to +batt
• 145 - 04 12 Volt DC Power Supply short to ground
#16 short
Note: The 0320 - 03 code is set after the pattern
SMCS Code: 1561-038 of the timing reference gear is lost for more than
one second. However, the logic hesitates for 1.5
Conditions Which Generate This Code: seconds before the code is activated. If a 145 - 03
or 145 - 04 is activated during the 1.5 seconds,
The path for the circuit driver of the transformer is then the 0320 - 03 code is deactivated.
System Response:
System Response:
If the engine is running, the ignition signals stop.
The alarm output is activated. The code is logged. The shutdown output is activated. The code is
logged.
110
If the engine is running, the engine will be shut MID 036 - CID 0323 - FMI 03
down. If the engine is not running, the engine will Shutdown Lamp short to +batt
not start.
SMCS Code: 7400-038-IND
Troubleshooting:
Speed/Timing Sensor” The master Electronic Control Module (ECM)
detects excessive current for the shutdown output.
Results:
Note: This diagnostic condition cannot be detected
• OK – STOP. when the shutdown output is OFF.
i01760426
System Response:
MID 036 - CID 0320 - FMI 08 The master ECM limits the current for the shutdown
output to 0.3 amperes. The code is logged.
Engine Speed/Timing signal
abnormal Possible Performance Effect:
SMCS Code: 1912-038 The engine operation is not affected.
The master Electronic Control Module (ECM) must Perform the following diagnostic procedure: “ECM
be powered for at least one second. The engine Status Indicator Output”
speed is greater than 150 rpm. One of the following
two conditions occurs: Results:
• An invalid pattern for the timing reference gear • OK – STOP.

is detected. For example, reverse rotation is
detected. i01760430
• The pattern for the timing reference gear is lost MID 036 - CID 0324 - FMI 03
for less than one second.
Warning Lamp short to +batt
System Response:
SMCS Code: 7400-038-IND
If the engine is running, the ignition signals stop.
The shutdown output is activated. The code is Conditions Which Generate This Code:
logged.
The master Electronic Control Module (ECM)
Possible Performance Effect: detects excessive current for the alarm output.
If the engine is running, the engine will be shut Note: This diagnostic condition cannot be detected
down. If the engine is not running, the engine will when the alarm output is OFF.
not start.
System Response:
Troubleshooting:
The master ECM limits the current for the alarm
Perform the following diagnostic procedure: “Engine output to 0.3 amperes. The code is logged.
Results:
The engine operation is not affected.
• OK – STOP.
111
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: “ECM The cylinder will misfire.
Status Indicator Output”
Troubleshooting:
Results:
• OK – STOP. diagnostic code:
i01760434
MID 036 - CID 0336 - FMI 02 • An open circuit within the secondary winding of
the transformer
Incorrect ECS Switch inputs
SMCS Code: 7332-038 terminal post
Conditions Which Generate This Code: • The spark plug has internal damage or an open
circuit.
detects an invalid combination on these inputs • The spark plug gap is too wide.
from the Engine Control Switch (ECS): “Switched
+Battery”, “Start”, “Stop”, and “Auto”. Perform the following diagnostic procedure: “Ignition
System Response:
Results:
logged. • OK – STOP.
i01864834
If the engine is running, the engine will be shut
down.
MID 036 - CID 0402 - FMI
Troubleshooting:
“Electrical Power Supply” SMCS Code: 1561-038

Results:

SMCS Code: 1561-038
Troubleshooting:
diagnostic code:
System Response:
112
Results: Secondary #4 short to ground

i01864835
System Response:

the transformer
Troubleshooting:
the transformer
• A problem with the connection to the spark plug’s i01864837

terminal post
MID 036 - CID 0406 - FMI
circuit.
SMCS Code: 1561-038
Transformers Secondary Circuit and Spark Plugs” Conditions Which Generate This Code:
Results: The transformer’s secondary circuit is diagnosed

• OK – STOP.
113


the transformer
i01864848
circuit.
Results: with an open circuit.

SMCS Code: 1561-038
Troubleshooting:
System Response:
terminal post
114
• The spark plug gap is too wide. i01864850
Results: Secondary #10 open circuit

i01864849
MID 036 - CID 0408 - FMI with an open circuit.
System Response:
SMCS Code: 1561-038 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 diagnostic code:


the transformer
Troubleshooting:
terminal post
diagnostic code:
circuit.
the transformer
• The spark plug is fouled. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Results:
• OK – STOP.
115

Troubleshooting:
Conditions Which Generate This Code: • A problem with the transformer’s ground
The transformer’s secondary circuit is diagnosed • An open circuit within the secondary winding of
with a short circuit. the transformer
System Response: • A problem with the connection to the spark plug’s

terminal post
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.
Troubleshooting:
Results:
the transformer i01864861

MID 036 - CID 0412 - FMI
• The spark plug gap is closed. Secondary #12 short to ground
Transformers Secondary Circuit and Spark Plugs” SMCS Code: 1561-038


SMCS Code: 1561-038
Troubleshooting:
diagnostic code:
System Response:
116
Results: Secondary #14 short to ground

i01864862
System Response:

the transformer
Troubleshooting:
the transformer
• A problem with the connection to the spark plug’s i01864864

terminal post
MID 036 - CID 0416 - FMI
circuit.
SMCS Code: 1561-038
Transformers Secondary Circuit and Spark Plugs” Conditions Which Generate This Code:
Results: The transformer’s secondary circuit is diagnosed

• OK – STOP.
117


the transformer
i01866568
terminal post MID 036 - CID 0443 - FMI 03
• The spark plug has internal damage or an open Crank Terminate Relay short
circuit.
to +batt
The master Electronic Control Module (ECM) detects
Results: excessive current for the crank terminate relay.
• OK – STOP. Note: This diagnostic condition cannot be detected
when the output for the crank terminate relay is
i01864865 OFF. The output is normally OFF when the engine
control is in the STOP mode.
MID 036 - CID 0416 - FMI
System Response:
Secondary #16 short to ground The master ECM will limit the current for the crank
terminate relay to 0.3 amperes. The alarm output is
SMCS Code: 1561-038 activated. The code is logged.
The transformer’s secondary circuit is diagnosed Perform the following diagnostic procedure: “ECM
with a short circuit. Status Indicator Output”
The status of the transformer’s secondary output is • OK – STOP.


118
i01866572 Note: This diagnostic condition can only be

detected by the master ECM when the output for the
MID 036 - CID 0444 - FMI 05 starting motor relay is ON. The output is normally
Start Relay open circuit ON when the engine control is changed from the
STOP mode to the START mode. The output is ON
SMCS Code: 1426-038 until the crank terminate relay is energized.
Conditions Which Generate This Code: System Response:
The output from the master Electronic Control The master ECM will continue to attempt to energize
Module (ECM) for the starting motor relay is OFF. the relay. The alarm output is activated. The code is
An open circuit or a short circuit to the +Battery logged.
is detected.
Note: This diagnostic condition can only be
detected by the master ECM when the output for the The engine will probably be unable to crank.
starting motor relay is OFF. The output is normally
OFF when the engine control is in the STOP mode Troubleshooting:
or when the crank terminate relay is energized.
This condition indicates an short circuit in the
System Response: harness or the relay.
An internal resistor rises to the +Battery side when Perform the following diagnostic procedure: “ECM
no electrical load is present. The alarm output is Output Circuit (Starting Motor)”
Results:
• OK – STOP.
The engine will be unable to crank.
i01866579
Troubleshooting:
MID 036 - CID 0445 - FMI 03
The harness or the relay probably has an open
circuit. Run Relay short to +batt
Perform the following diagnostic procedure: “ECM SMCS Code: 4493-038
Output Circuit (Starting Motor)”
Results:
detects excessive current for the run relay.
• OK – STOP.
i01866577 when the output for the “Run” relay is OFF. The
output is normally OFF when the engine control is
MID 036 - CID 0444 - FMI 06 in the STOP mode.
Start Relay short to ground
System Response:
SMCS Code: 1426-038
The master ECM will limit the current to 0.3 amperes.
Conditions Which Generate This Code: The “Status” screen of the Caterpillar Electronic
Technician (ET) will display “Relay Fault”. The code
The master Electronic Control Module (ECM) is logged.
detects excessive current for the output of the
starting motor relay. Troubleshooting:

Status Indicator Output”
119
Results: i01761093
• OK – STOP. MID 036 - CID 0524 - FMI 04

Desired Engine Speed Sensor
i01761091 short to ground
MID 036 - CID 0524 - FMI 03 SMCS Code: 5574-038
Desired Engine Speed Sensor
short to +batt
SMCS Code: 5574-038 been powered up for at least five seconds. The
current to the master ECM for the desired speed
Conditions Which Generate This Code: input is less than 2 mA for more than five seconds.
The master Electronic Control Module (ECM) has System Response:
been powered up for at least five seconds. The
current to the master ECM for the desired speed When the “Idle/Rated” switch is in the “Rated”
input is greater than 22 mA for more than five position, the master ECM assumes a default value
seconds. for the desired engine speed.
System Response: The alarm output is activated. The code is logged.
When the “Idle/Rated” switch is in the “Rated” Possible Performance Effect:
position, the master ECM assumes a default value
for the desired engine speed. The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed”
The alarm output is activated. The code is logged. that is programmed on the “Service/Configuration”
screen of the Caterpillar Electronic Technician (ET).
Troubleshooting:
The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed” The diagnostic code is generated by one of the
that is programmed on the “Service/Configuration” following conditions:
screen of the Caterpillar Electronic Technician (ET).
Troubleshooting:
• An open circuit or a short circuit to ground
The diagnostic code is generated by one of the

• An open circuit or a short circuit to the +Battery
following conditions: Perform the following diagnostic procedure:
“Desired Speed Input (4 - 20 mA)”
• A short circuit to the +Battery side
Results:
• A short circuit to ground
• OK – STOP.
“Desired Speed Input (4 - 20 mA)”
i01761094
Results:
MID 036 - CID 0542 - FMI 03
• OK – STOP. Unfiltered Engine Oil Pressure
open/short to +batt
SMCS Code: 1924-038
The signal to the master Electronic Control Module

(ECM) from the sensor for unfiltered engine oil
pressure is greater than 4.8 VDC for at least five
seconds. Also, neither of the following diagnostic
codes are active:
120
• 262 - 03 5 Volt Sensor DC Power Supply short Troubleshooting:

to +batt
• 262 - 04 5 Volt Sensor DC Power Supply short Sensor Signal”
to ground
Results:
System Response:
• OK – STOP.
The master ECM assumes the last valid value
for unfiltered engine oil pressure. Monitoring for
i01798248
restriction of the oil filters is disabled.

MID 036 - CID 1042 - FMI 09
Unable to communicate with
ITSM
Engine operation is not affected. SMCS Code: 1901-038
Troubleshooting:
Sensor Signal”
been powered up for at least five seconds. The
Integrated Temperature Sensing Module (ITSM) has
Results:
sent ten consecutive messages to the master ECM
via the CAT Data Link. None of the messages have
• OK – STOP. been received by the master ECM.
i01761095 Note: This diagnostic code is logged by the master

ECM only. This code is not activated or logged by
MID 036 - CID 0542 - FMI 04 the ITSM. Although there is a failure to communicate
Unfiltered Engine Oil Pressure with the master ECM, the ITSM may still be able
to communicate with the Caterpillar Electronic
short to ground Technician (ET).
SMCS Code: 1924-038 System Response:
Conditions Which Generate This Code: The alarm output is activated. The code is logged.
The signal to the master Electronic Control Module Note: If Cat ET cannot communicate with the ITSM,
(ECM) from the sensor for unfiltered engine oil the values for the ITSM “Status Parameter” will
pressure is less than 0.2 VDC for at least five display “Unavailable”.
seconds. Also, neither of the following diagnostic
codes are active: Troubleshooting:
• 262 - 03 5 Volt Sensor DC Power Supply short Perform the following diagnostic procedure: “CAT
to +batt Data Link”
• 262 - 04 5 Volt Sensor DC Power Supply short Results:

to ground
• OK – STOP.
System Response:
The master ECM assumes the last valid value

for unfiltered engine oil pressure. Monitoring for
restriction of the oil filters is disabled.

121
i01830219 Table 15
MID 036 - CID 1440 - FMI 09 X = 3.0 V −

G × 1.75 V
Unable to communicate with 300 CFM
Throttle Actuator Drv G is the flow of the fuel in CFM.
Conditions Which Generate This Code: The “Status Parameter” for “Fuel Valve Position”
will display “0 %” on the Caterpillar Electronic
The master Electronic Control Module (ECM) has Technician (ET). The alarm output is activated. The
been powered for at least five seconds. Messages code is logged.
on the CAN data link between the master ECM
and the throttle actuator have been lost for 0.48 Possible Performance Effect:
seconds, indicating a short circuit or an open circuit
on one of the wires or both of the wires for the CAN Engine performance is affected.
data link.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Fuel
The fuel is shut off. The shutdown output is Metering Valve”
Results:
• OK – STOP.
If the engine is not running, the engine will not start.
If the engine is running, the engine is shut down.
i01761115
Troubleshooting:
MID 036 - CID 1446 - FMI 09
Perform the following diagnostic procedure: Unable to communicate with
“Throttle Actuator”
Fuel Metering Module
Results:
SMCS Code: 1741-038
i01761112 The master Electronic Control Module (ECM) has

been powered up for more than 5 seconds. Ten
MID 036 - CID 1446 - FMI 05 consecutive messages have been sent from the fuel
Fuel Metering Module open metering valve to the master ECM via the CAN Data
Link. None of the messages have been received
circuit by the master ECM.
Conditions Which Generate This Code: The “Alarm Status” is activated. The “Status
Parameter” for “Fuel Valve Position”, “Fuel Pressure
To generate this diagnostic code, all of the following (abs)”, “Fuel Valve Differential Pressure”, and “Fuel
conditions must occur: Temperature” are frozen on the Caterpillar Electronic
Technician (ET). The alarm output is activated. The
• The master Electronic Control Module (ECM) has code is logged.
been powered up for more than 5 seconds.
• The battery voltage is greater than 20 VDC.
Engine performance is affected.
• The flow rate of the fuel is less than 8497 L/min
(300 CFM). Troubleshooting:
• The voltage of the signal is less than “X” for 5 Perform the following diagnostic procedure: “Fuel
seconds. The calculation for “X” is given in Table Metering Valve”
15.
122
Results: Troubleshooting:
• OK – STOP. Perform the following diagnostic procedure: “Fuel

Metering Valve”
i01761117
Results:
MID 036 - CID 1446 - FMI 12 Fuel
• OK – STOP.
Metering Module malfunction
SMCS Code: 1741-038 i01761123

MID 036 - CID 1447 - FMI 12
Fuel Metering Sensor Module
The fuel metering valve sends a signal to the master
Electronic Control Module (ECM) via the CAN data malfunction
link. The signal indicates that there is a problem
SMCS Code: 1741-038
with the fuel metering valve.
System Response: Conditions Which Generate This Code:
The code is logged. The shutdown output is The fuel metering valve sends a signal to the master
activated. Electronic Control Module (ECM) via the CAN data
link. The signal indicates that there is a problem
Possible Performance Effect: with the fuel metering valve’s sensor module.
System Response:
Troubleshooting: The code is logged. The shutdown output is

activated.
Metering Valve” Possible Performance Effect:

Results:
Troubleshooting:
• OK – STOP.
i01619975 Metering Valve”
MID 036 - CID 1446 - FMI 13 Fuel Results:
Metering Module calibration
• OK – STOP.
required
SMCS Code: 1741-038 i01761169

MID 036 - CID 1502 - FMI 03
The “Gas Fuel Properties” have not been
programmed for the fuel metering valve.
open/short to +batt
System Response: SMCS Code: 1559-038

The code is logged. The alarm output is activated.
The fuel metering valve is shutdown. This prevents for cylinders 2 and 4 to the master Electronic
the engine from running.
ten seconds.
123
Neither of the following diagnostic codes are active: Results:

System Response: MID 036 - CID 1506 - FMI 03

The shutdown output is activated. The code is Cylinder #6 Detonation Sensor
logged.
open/short to +batt
SMCS Code: 1559-038
Troubleshooting:
for cylinders 6 and 8 to the master Electronic
ten seconds.
Results:
• OK – STOP.
i01761191
MID 036 - CID 1502 - FMI 04
Cylinder #2 Detonation Sensor System Response:
short to ground The shutdown output is activated. The code is

logged.
SMCS Code: 1559-038
energized. The signal from the detonation sensor for Troubleshooting:
cylinders 2 and 4 to the master Electronic Control
Module (ECM) is less than 1.0 VDC for ten seconds. Perform the following diagnostic procedure:
Results:
• OK – STOP.
i01761210
System Response:

MID 036 - CID 1506 - FMI 04
logged. Cylinder #6 Detonation Sensor
short to ground
SMCS Code: 1559-038
Troubleshooting:
Perform the following diagnostic procedure: energized. The signal from the detonation sensor for
“Detonation Sensors” cylinders 6 and 8 to the master Electronic Control

124

System Response:
i01761225

logged.
MID 036 - CID 1510 - FMI
SMCS Code: 1559-038
“Detonation Sensors” energized. The signal from the detonation sensor for
Results:
• OK – STOP. Neither of the following diagnostic codes are active:
i01761217 • 0041 - 03 8 Volt DC Supply short to +batt

MID 036 - CID 1510 - FMI • 0041 - 04 8 Volt DC Supply short to ground
03 Cylinder #10 Detonation System Response:
SMCS Code: 1559-038 logged.
Conditions Which Generate This Code: Possible Performance Effect:
The run relay and the crank terminate relay are The engine is shut down.
for cylinders 10 and 12 to the master Electronic Troubleshooting:
ten seconds. Perform the following diagnostic procedure:
Results:
• OK – STOP.
i01761236
System Response:

MID 036 - CID 1514 - FMI
SMCS Code: 1559-038
Troubleshooting:
“Detonation Sensors” for cylinders 14 and 16 to the master Electronic
ten seconds.
125
Neither of the following diagnostic codes are active: Results:

System Response: MID 036 - CID 1518 - FMI

The shutdown output is activated. The code is 03 Cylinder #18 Detonation
logged.
SMCS Code: 1559-038
Troubleshooting:
for cylinders 18 and 20 to the master Electronic
ten seconds.
Results:
• OK – STOP.
i01761239
MID 036 - CID 1514 - FMI
04 Cylinder #14 Detonation System Response:
Sensor short to ground The shutdown output is activated. The code is

logged.
SMCS Code: 1559-038
energized. The signal from the detonation sensor for Troubleshooting:
Module (ECM) is less than 1.0 VDC for ten seconds. Perform the following diagnostic procedure:
Results:
• OK – STOP.
i01761252
System Response:

MID 036 - CID 1518 - FMI
SMCS Code: 1559-038
Troubleshooting:
Perform the following diagnostic procedure: energized. The signal from the detonation sensor for
“Detonation Sensors” cylinders 18 and 20 to the master Electronic Control

126

System Response:
i01830443

logged.
MID 036 - CID 1719 - FMI
03 Generator Output Power
SMCS Code: 5574-038-PWR
If the generator is equipped with EMCP II, the
“Detonation Sensors” EMCP II is not providing information to the master
ECM via the CAT data link.
Results:
If the generator is equipped with a generator output
• OK – STOP. power sensor, the input signal from the generator
output power sensor to the master ECM is greater
i01796209 than 4.8 VDC for at least 5 seconds.
MID 036 - CID 1636 - FMI 09 System Response:

Loss of Communication with If the engine load is less than 25 percent, the
Engine #2 (Slave) diagnostic code remains active until the engine
control is set to the OFF/RESET mode.
SMCS Code: 1901-038
If the engine load is greater than 25 percent, the
Conditions Which Generate This Code: diagnostic code is logged and the engine is shut
down.
The slave Electronic Control Module (ECM) has sent
ten consecutive messages to the master ECM via Troubleshooting:
the Cat data link. None of the messages have been
received by the master ECM. Perform the following diagnostic procedure:
“Generator Output Power Sensor”
Note: Although there is a failure to communicate
with the master ECM, the slave ECM may still be Results:
able to communicate with the Caterpillar Electronic
Technician (ET). • OK – STOP.
System Response:
i01830444
The alarm output is activated. MID 036 - CID 1719 - FMI

The code is logged by the master ECM. 04 Generator Output Power
Engine ignition is terminated.
Note: If Cat ET cannot communicate with the slave
ECM, the values will display “Unavailable”. Conditions Which Generate This Code:
Possible Performance Effect: This diagnostic code is not applicable to generators
that are equipped with EMCP II.
The input signal from the generator output power
Perform the following diagnostic procedure: “Cat sensor to the master Electronic Control Module
Data Link”
(ECM) is less than 0.2 VDC for at least 5 seconds.
127
If the engine load is less than 25 percent, the MID 036 - CID 1720 - FMI 09
diagnostic code remains active until the engine Unable to communicate with
control is set to the OFF/RESET mode.
Turbo Compressor Bypass
If the engine load is greater than 25 percent, the
diagnostic code is logged and the engine is shut
Valve Solenoid
down. SMCS Code: 1052-038-BV
Perform the following diagnostic procedure: The master Electronic Control Module (ECM) cannot
“Generator Output Power Sensor” communicate with the actuator for the bypass valve.
Results: System Response:
• OK – STOP. The fuel is shut off. The shutdown output is
i01830447
MID 036 - CID 1719 - FMI
If the engine is not running, the engine will not start.
12 Generator Output Power If the engine is running, the engine is shut down.
Sensor malfunction
SMCS Code: 5574-038-PWR “Bypass Valve”
Conditions Which Generate This Code: Results:
This diagnostic code is applicable to generators • OK – STOP.

that are equipped with EMCP II only.
i01760808
determined that the generator output information
from the EMCP II may be invalid.
MID 036 - CID 1749 - FMI
System Response: Secondary #18 open circuit
If the engine load is less than 25 percent, the SMCS Code: 1561-038
diagnostic code remains active until the engine
control is set to the OFF/RESET mode. Conditions Which Generate This Code:
If the engine load is greater than 25 percent, the The transformer’s secondary circuit is diagnosed
diagnostic code is logged and the engine is shut with an open circuit.
down.
System Response:
Troubleshooting:
Perform the following diagnostic procedure: set to 120 percent. The alarm output is activated
“Generator Output Power Sensor” and the code is logged.
Results: Possible Performance Effect:
• OK – STOP. The cylinder will misfire.
Troubleshooting:

diagnostic code:

128
• An open circuit within the secondary winding of i01760821

the transformer
MID 036 - CID 1751 - FMI
• A problem with the connection to the spark plug’s 05 Ignition Transformer
terminal post
circuit. SMCS Code: 1561-038
• The spark plug gap is too wide. Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition The transformer’s secondary circuit is diagnosed
Transformers Secondary Circuit and Spark Plugs” with an open circuit.
• OK – STOP. The status of the transformer’s secondary output is

i01760946
MID 036 - CID 1749 - FMI
06 Ignition Transformer The cylinder will misfire.
Secondary #18 short to ground Troubleshooting:
SMCS Code: 1561-038 One of the following conditions is the source of the
diagnostic code:

the transformer
System Response:

terminal post
circuit.

Troubleshooting: Transformers Secondary Circuit and Spark Plugs”
One of the following conditions is the source of the Results:
diagnostic code:
• OK – STOP.
the transformer

Results:
• OK – STOP.
129

Troubleshooting:
Conditions Which Generate This Code: • An open circuit in the wiring from the master
The transformer’s secondary circuit is diagnosed transformer
The status of the transformer’s secondary output is • An internal failure of the master ECM
and the code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:
One of the following conditions is the source of the i01760307

diagnostic code:
MID 036 - CID 1753 - FMI 06
• A short circuit within the secondary winding of Ignition Transformer Primary
the transformer
#18 short to ground
• The spark plug is fouled. SMCS Code: 1561-038
• The spark plug gap is closed. Conditions Which Generate This Code:
Transformers Secondary Circuit and Spark Plugs” The path for the circuit driver of the transformer is
Results:
System Response:

#18 open circuit
130
Results: #20 short to ground

i01760312
MID 036 - CID 1755 - FMI 05 diagnosed with a short circuit.
System Response:
#20 open circuit
SMCS Code: 1561-038
with an open circuit. Troubleshooting:
diagnostic code:

• A short circuit in the wiring between the master
transformer
Troubleshooting:
transformer
diagnostic code:
• An open circuit in the wiring from the master Transformers Primary Circuit”
• An open circuit within the primary winding of the • OK – STOP.
transformer
Transformers Primary Circuit” EEPROM checksum fault or
Results: ECM not programmed

detects a problem within the EPROM circuit.
System Response:
Monitoring of the exhaust temperature is lost. Also,

protection against high exhaust temperatures is lost.
131
The alarm output is activated. The code is logged. i01728777
Troubleshooting: MID 111 - CID 1489 - FMI 04

Left Turbo Turbine Out Temp
There is a problem with the ITSM.
Sens short to ground
Replace the ITSM. Follow the instructions in
Troubleshooting, “Replacing the ITSM”. SMCS Code: 5574-038
• OK – STOP. The Integrated Temperature Sensing Module (ITSM)

detects one of the following conditions for the input
from the thermocouple of the turbocharger:
i01728761
MID 111 - CID 1489 - FMI 03 • A short circuit to the −Battery side
Left Turbo Turbine Out Temp • A short circuit to the ground
Sens short to +batt System Response:
SMCS Code: 5574-038 Monitoring of the temperature for the port of the
turbine is lost. Also, protection for the port is lost.
Conditions Which Generate This Code: The code is logged. The “Status” screen of the
Caterpillar Electronic Technician (ET) displays
The Integrated Temperature Sensing Module (ITSM) “Shorted to Ground” for the port of the turbine.
detects a short circuit to the +Battery side for the
input from the thermocouple of the turbocharger. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the temperature for the port of the Troubleshooting:
The code is logged. The “Status” screen of the Perform the following diagnostic procedure:
Caterpillar Electronic Technician (ET) displays “Integrated Temperature Sensing Module (ITSM)”
“Open/Shorted High” for the port of the turbine.
Results:
This diagnostic code remains active until the
condition that caused the problem is not present
for 30 seconds.
• OK – STOP.
Engine operation is not affected. MID 111 - CID 1489 - FMI 05

Troubleshooting:
Left Turbo Turbine Out Temp
Sens open circuit
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038

detects an open circuit for the input from the
thermocouple of the turbocharger.
System Response:
Monitoring of the exhaust temperature for the port

of the turbine is lost. Also, protection for the port is
lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays
132
Engine operation is not affected. MID 111 - CID 1490 - FMI 04 Rt

Turbo Turbine Out Temp Sens
Troubleshooting:
short to ground

i01728785
MID 111 - CID 1490 - FMI 03 Rt • A short circuit to the −Battery side
Turbo Turbine Out Temp Sens • A short circuit to the ground
short to +batt System Response:
Results:
for 30 seconds.
• OK – STOP.
Engine operation is not affected. MID 111 - CID 1490 - FMI 05 Rt

Troubleshooting:
Turbo Turbine Out Temp Sens
open circuit

133
Monitoring of the exhaust temperature for the port MID 111 - CID 1491 - FMI 04 Rt
of the turbine is lost. Also, protection for the port is Turbo Turbine In Temp Sens
the Caterpillar Electronic Technician (ET) displays short to ground
SMCS Code: 5574-038
Engine operation is not affected.
Troubleshooting: detects one of the following conditions for the input
“Integrated Temperature Sensing Module (ITSM)” • A short circuit to the −Battery side
Results: • A short circuit to the ground
Monitoring of the temperature for the port of the

i01728795 turbine is lost. Also, protection for the port is lost.
The code is logged. The “Status” screen of the
MID 111 - CID 1491 - FMI 03 Rt Caterpillar Electronic Technician (ET) displays
Turbo Turbine In Temp Sens “Shorted to Ground” for the port of the turbine.
short to +batt Possible Performance Effect:
SMCS Code: 5574-038 Engine operation is not affected.
The Integrated Temperature Sensing Module (ITSM) Perform the following diagnostic procedure:
detects a short circuit to the +Battery side for the “Integrated Temperature Sensing Module (ITSM)”
input from the thermocouple of the turbocharger.
Results:
System Response:
Monitoring of the temperature for the port of the

• OK – STOP.
The code is logged. The “Status” screen of the i01728800
“Open/Shorted High” for the port of the turbine. MID 111 - CID 1491 - FMI 05 Rt
Turbo Turbine In Temp Sens
condition that caused the problem is not present open circuit
for 30 seconds.
SMCS Code: 5574-038
Troubleshooting: detects an open circuit for the input from the
“Integrated Temperature Sensing Module (ITSM)” System Response:
Results: Monitoring of the exhaust temperature for the port

• OK – STOP. lost. The code is logged. The “Status” screen of
134
Engine operation is not affected. MID 111 - CID 1492 - FMI 04 Left
Troubleshooting:
short to ground

i01728804
MID 111 - CID 1492 - FMI 03 Left • A short circuit to the −Battery side
Turbo Turbine In Temp Sens • A short circuit to the ground
short to +batt System Response:
Results:
for 30 seconds.
• OK – STOP.
Engine operation is not affected. MID 111 - CID 1492 - FMI 05 Left
Troubleshooting:
open circuit

135
Monitoring of the exhaust temperature for the port • OK – STOP.

i01728826
“Open/Shorted High” for the port of the turbine. MID 111 - CID 1531 - FMI 04 Cyl
Possible Performance Effect: #1 Exhaust Port Temp Sensor
short to ground
SMCS Code: 1919
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)”
Results:
from the thermocouple of the cylinder.
• OK – STOP. • A short circuit to the −Battery side
i01728819 • A short circuit to the ground
MID 111 - CID 1531 - FMI 03 Cyl System Response:
#1 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the
short to +batt cylinder is lost. Also, protection for the cylinder is
lost.
SMCS Code: 1919
The thermocouple is removed from the calculation
Conditions Which Generate This Code: for the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM) The code is logged. The “Status” screen of the
detects a short circuit to the +Battery side for the Caterpillar Electronic Technician (ET) displays
input from the thermocouple of the cylinder. “Shorted to ground” for the cylinder.
System Response: The diagnostic code remains active until the

condition that caused the code is not present for
Monitoring of the exhaust temperature for the 30 seconds.
cylinder is lost. Also, protection for the cylinder is
lost. Possible Performance Effect:
The thermocouple is removed from the calculation Engine operation is not affected.
for the average temperature of the engine.
Troubleshooting:
Caterpillar Electronic Technician (ET) displays Perform the following diagnostic procedure:
“Open/Shorted High” for the cylinder. “Integrated Temperature Sensing Module (ITSM)”
The diagnostic code remains active until the Results:

30 seconds. • OK – STOP.
Troubleshooting:

136

MID 111 - CID 1531 - FMI 05 Cyl Monitoring of the exhaust temperature for the
#1 Exhaust Port Temp Sensor cylinder is lost. Also, protection for the cylinder is
lost.
open circuit
SMCS Code: 1919 for the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM) “Open/Shorted High” for the cylinder.
thermocouple of the cylinder. The diagnostic code remains active until the
System Response: 30 seconds.
Monitoring of the exhaust temperature for the Possible Performance Effect:
lost. Engine operation is not affected.
The thermocouple is removed from the calculation Troubleshooting:
The code is logged. The “Status” screen of the “Integrated Temperature Sensing Module (ITSM)”
“Open/Shorted High” for the cylinder. Results:
The diagnostic code remains active until the • OK – STOP.
30 seconds.
i01728835
MID 111 - CID 1532 - FMI 04 Cyl
Engine operation is not affected. #2 Exhaust Port Temp Sensor
Troubleshooting: short to ground
Perform the following diagnostic procedure: SMCS Code: 1919
Results:
• OK – STOP. from the thermocouple of the cylinder.
i01728833 • A short circuit to the −Battery side

MID 111 - CID 1532 - FMI 03 Cyl • A short circuit to the ground
#2 Exhaust Port Temp Sensor System Response:
short to +batt
Monitoring of the exhaust temperature for the
SMCS Code: 1919 cylinder is lost. Also, protection for the cylinder is
lost.
The Integrated Temperature Sensing Module (ITSM) for the average temperature of the engine.
input from the thermocouple of the cylinder.
137
The code is logged. The “Status” screen of the Results:

“Shorted to ground” for the cylinder. • OK – STOP.
The diagnostic code remains active until the
i01728852
30 seconds. MID 111 - CID 1533 - FMI 03 Cyl
Possible Performance Effect: #3 Exhaust Port Temp Sensor
short to +batt
SMCS Code: 1919
Troubleshooting:
Results:
i01728837 Monitoring of the exhaust temperature for the

MID 111 - CID 1532 - FMI 05 Cyl lost.
#2 Exhaust Port Temp Sensor The thermocouple is removed from the calculation
open circuit for the average temperature of the engine.
SMCS Code: 1919 The code is logged. The “Status” screen of the
Conditions Which Generate This Code: “Open/Shorted High” for the cylinder.
The Integrated Temperature Sensing Module (ITSM) The diagnostic code remains active until the
detects an open circuit for the input from the condition that caused the code is not present for
thermocouple of the cylinder. 30 seconds.
Monitoring of the exhaust temperature for the Engine operation is not affected.
lost. Troubleshooting:
The thermocouple is removed from the calculation Perform the following diagnostic procedure:
for the average temperature of the engine. “Integrated Temperature Sensing Module (ITSM)”

“Open/Shorted High” for the cylinder. • OK – STOP.
30 seconds.
Troubleshooting:

138
i01728912 i01728915
MID 111 - CID 1533 - FMI 04 Cyl MID 111 - CID 1533 - FMI 05 Cyl
#3 Exhaust Port Temp Sensor #3 Exhaust Port Temp Sensor
short to ground open circuit
SMCS Code: 1919 SMCS Code: 1919
The Integrated Temperature Sensing Module (ITSM) The Integrated Temperature Sensing Module (ITSM)
detects one of the following conditions for the input detects an open circuit for the input from the
from the thermocouple of the cylinder. thermocouple of the cylinder.
• A short circuit to the −Battery side System Response:
• A short circuit to the ground Monitoring of the exhaust temperature for the
System Response: lost.
Monitoring of the exhaust temperature for the The thermocouple is removed from the calculation
cylinder is lost. Also, protection for the cylinder is for the average temperature of the engine.
lost.
The thermocouple is removed from the calculation Caterpillar Electronic Technician (ET) displays
for the average temperature of the engine. “Open/Shorted High” for the cylinder.
The code is logged. The “Status” screen of the The diagnostic code remains active until the
Caterpillar Electronic Technician (ET) displays condition that caused the code is not present for
“Shorted to ground” for the cylinder. 30 seconds.
The diagnostic code remains active until the Possible Performance Effect:
30 seconds. Engine operation is not affected.
Possible Performance Effect: Troubleshooting:
Engine operation is not affected. Perform the following diagnostic procedure:

Troubleshooting:
Results:
“Integrated Temperature Sensing Module (ITSM)” • OK – STOP.
Results:
i01728917
• OK – STOP. MID 111 - CID 1534 - FMI 03 Cyl

#4 Exhaust Port Temp Sensor
short to +batt
SMCS Code: 1919

139

Troubleshooting:

i01728928
Engine operation is not affected. MID 111 - CID 1534 - FMI 05 Cyl
Troubleshooting: #4 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919
Results:
i01728923 thermocouple of the cylinder.

short to ground cylinder is lost. Also, protection for the cylinder is
lost.
SMCS Code: 1919
detects one of the following conditions for the input Caterpillar Electronic Technician (ET) displays
from the thermocouple of the cylinder. “Open/Shorted High” for the cylinder.
• A short circuit to the −Battery side The diagnostic code remains active until the
• A short circuit to the ground 30 seconds.
Monitoring of the exhaust temperature for the Engine operation is not affected.
lost. Troubleshooting:
The thermocouple is removed from the calculation Perform the following diagnostic procedure:
for the average temperature of the engine. “Integrated Temperature Sensing Module (ITSM)”

“Shorted to ground” for the cylinder. • OK – STOP.
140
i01728934 • A short circuit to the ground

short to +batt cylinder is lost. Also, protection for the cylinder is
lost.
SMCS Code: 1919
detects a short circuit to the +Battery side for the Caterpillar Electronic Technician (ET) displays
input from the thermocouple of the cylinder. “Shorted to ground” for the cylinder.
Troubleshooting:
i01728953
MID 111 - CID 1535 - FMI 05 Cyl
Perform the following diagnostic procedure: open circuit
SMCS Code: 1919
Results:
i01728940 thermocouple of the cylinder.
short to ground cylinder is lost. Also, protection for the cylinder is
lost.
SMCS Code: 1919
detects one of the following conditions for the input Caterpillar Electronic Technician (ET) displays
from the thermocouple of the cylinder. “Open/Shorted High” for the cylinder.
• A short circuit to the −Battery side

141
The diagnostic code remains active until the i01728968

30 seconds. MID 111 - CID 1536 - FMI 04 Cyl
short to ground
SMCS Code: 1919
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module (ITSM)
Results: from the thermocouple of the cylinder.
• OK – STOP. • A short circuit to the −Battery side

• A short circuit to the ground
i01728959
System Response:
MID 111 - CID 1536 - FMI 03 Cyl
short to +batt lost.
SMCS Code: 1919 The thermocouple is removed from the calculation
The Integrated Temperature Sensing Module (ITSM) Caterpillar Electronic Technician (ET) displays
detects a short circuit to the +Battery side for the “Shorted to ground” for the cylinder.
System Response: condition that caused the code is not present for
30 seconds.
cylinder is lost. Also, protection for the cylinder is Possible Performance Effect:
lost.
for the average temperature of the engine. Troubleshooting:
“Open/Shorted High” for the cylinder.
Results:
30 seconds.
• OK – STOP.
Troubleshooting:
open circuit
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919

thermocouple of the cylinder.
142

Troubleshooting:

i01728999
short to ground
SMCS Code: 1919
Results:
i01728993 from the thermocouple of the cylinder.
MID 111 - CID 1537 - FMI 03 Cyl • A short circuit to the −Battery side
#7 Exhaust Port Temp Sensor • A short circuit to the ground
short to +batt
System Response:
SMCS Code: 1919
Conditions Which Generate This Code: cylinder is lost. Also, protection for the cylinder is
lost.
detects a short circuit to the +Battery side for the The thermocouple is removed from the calculation
input from the thermocouple of the cylinder. for the average temperature of the engine.
System Response: The code is logged. The “Status” screen of the

Monitoring of the exhaust temperature for the “Shorted to ground” for the cylinder.
lost. The diagnostic code remains active until the
The thermocouple is removed from the calculation 30 seconds.
Caterpillar Electronic Technician (ET) displays Engine operation is not affected.
143
Perform the following diagnostic procedure: MID 111 - CID 1538 - FMI 03 Cyl
“Integrated Temperature Sensing Module (ITSM)” #8 Exhaust Port Temp Sensor
Results: short to +batt
• OK – STOP. SMCS Code: 1919

i01729006
MID 111 - CID 1537 - FMI 05 Cyl detects a short circuit to the +Battery side for the
#7 Exhaust Port Temp Sensor input from the thermocouple of the cylinder.
open circuit System Response:
SMCS Code: 1919 Monitoring of the exhaust temperature for the
Conditions Which Generate This Code: lost.
The Integrated Temperature Sensing Module (ITSM) The thermocouple is removed from the calculation
detects an open circuit for the input from the for the average temperature of the engine.
System Response: Caterpillar Electronic Technician (ET) displays
cylinder is lost. Also, protection for the cylinder is The diagnostic code remains active until the
lost. condition that caused the code is not present for
30 seconds.
for the average temperature of the engine. Possible Performance Effect:
The code is logged. The “Status” screen of the Engine operation is not affected.
“Open/Shorted High” for the cylinder. Troubleshooting:
The diagnostic code remains active until the Perform the following diagnostic procedure:
condition that caused the code is not present for “Integrated Temperature Sensing Module (ITSM)”
30 seconds.
Results:

• OK – STOP.
Results: short to ground


144

Troubleshooting:
“Shorted to ground” for the cylinder. “Integrated Temperature Sensing Module (ITSM)”

i01729257
short to +batt
SMCS Code: 1919
Results:
i01729025 input from the thermocouple of the cylinder.

open circuit cylinder is lost. Also, protection for the cylinder is
lost.
SMCS Code: 1919
detects an open circuit for the input from the Caterpillar Electronic Technician (ET) displays
thermocouple of the cylinder. “Open/Shorted High” for the cylinder.

Troubleshooting:
145
Results: i01729264

i01761374 open circuit
MID 111 - CID 1539 - FMI 04 Cyl SMCS Code: 1919
short to ground
SMCS Code: 1919 detects an open circuit for the input from the
System Response:
detects one of the following conditions for the input Monitoring of the exhaust temperature for the
from the thermocouple of the cylinder. cylinder is lost. Also, protection for the cylinder is
lost.
• A short circuit to the ground for the average temperature of the engine.
Monitoring of the exhaust temperature for the “Open/Shorted High” for the cylinder.
“Shorted to ground” for the cylinder.
Troubleshooting:
condition that caused the code is not present for Perform the following diagnostic procedure:
30 seconds. “Integrated Temperature Sensing Module (ITSM)”
• OK – STOP.
Troubleshooting:
i01729267
“Integrated Temperature Sensing Module (ITSM)” MID 111 - CID 1540 - FMI 03 Cyl
Results:
short to +batt
• OK – STOP.
SMCS Code: 1919

146

Troubleshooting:
Engine operation is not affected. • OK – STOP.

Troubleshooting:
i01729271

MID 111 - CID 1540 - FMI 05 Cyl
Results:
open circuit
i01729270 Conditions Which Generate This Code:
MID 111 - CID 1540 - FMI 04 Cyl The Integrated Temperature Sensing Module (ITSM)
#10 Exhaust Port Temp Sensor detects an open circuit for the input from the
short to ground
System Response:
SMCS Code: 1919
lost.
detects one of the following conditions for the input The thermocouple is removed from the calculation
from the thermocouple of the cylinder. for the average temperature of the engine.
• A short circuit to the −Battery side The code is logged. The “Status” screen of the
• A short circuit to the ground “Open/Shorted High” for the cylinder.

147

i01729273
MID 111 - CID 1541 - FMI 03 Cyl detects one of the following conditions for the input
#11 Exhaust Port Temp Sensor from the thermocouple of the cylinder.
short to +batt • A short circuit to the −Battery side
SMCS Code: 1919
The Integrated Temperature Sensing Module (ITSM) Monitoring of the exhaust temperature for the
detects a short circuit to the +Battery side for the cylinder is lost. Also, protection for the cylinder is
input from the thermocouple of the cylinder. lost.
System Response: The thermocouple is removed from the calculation
cylinder is lost. Also, protection for the cylinder is The code is logged. The “Status” screen of the
lost. Caterpillar Electronic Technician (ET) displays
for the average temperature of the engine. The diagnostic code remains active until the
The code is logged. The “Status” screen of the 30 seconds.
“Open/Shorted High” for the cylinder. Possible Performance Effect:
The diagnostic code remains active until the Engine operation is not affected.
30 seconds. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
Results:
Troubleshooting:

• OK – STOP.
i01729277
Results:
MID 111 - CID 1541 - FMI 05 Cyl
• OK – STOP. #11 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919

148

Troubleshooting:

i01729281
short to ground
SMCS Code: 1919
Results:
short to +batt
System Response:
SMCS Code: 1919
lost.

149

i01729284
SMCS Code: 1919 Monitoring of the exhaust temperature for the
30 seconds.
30 seconds.
Results:

• OK – STOP.


150

Troubleshooting:

i01729297
short to +batt
SMCS Code: 1919
Results:

lost.
SMCS Code: 1919

Troubleshooting:
151
Results: i01729306

MID 111 - CID 1544 - FMI 04 Cyl SMCS Code: 1919
short to ground
SMCS Code: 1919 detects an open circuit for the input from the
System Response:
lost.
Troubleshooting:
• OK – STOP.
Troubleshooting:
i01729307
Results:
short to +batt
• OK – STOP.
SMCS Code: 1919

152

Troubleshooting:

Troubleshooting:
i01729312

MID 111 - CID 1545 - FMI 05 Cyl
Results:
open circuit
short to ground
System Response:
SMCS Code: 1919
lost.

153

i01729314
MID 111 - CID 1546 - FMI 03 Cyl detects one of the following conditions for the input
#16 Exhaust Port Temp Sensor from the thermocouple of the cylinder.
short to +batt • A short circuit to the −Battery side
SMCS Code: 1919
The Integrated Temperature Sensing Module (ITSM) Monitoring of the exhaust temperature for the
detects a short circuit to the +Battery side for the cylinder is lost. Also, protection for the cylinder is
input from the thermocouple of the cylinder. lost.
System Response: The thermocouple is removed from the calculation
cylinder is lost. Also, protection for the cylinder is The code is logged. The “Status” screen of the
lost. Caterpillar Electronic Technician (ET) displays
for the average temperature of the engine. The diagnostic code remains active until the
The code is logged. The “Status” screen of the 30 seconds.
“Open/Shorted High” for the cylinder. Possible Performance Effect:
The diagnostic code remains active until the Engine operation is not affected.
30 seconds. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
Results:
Troubleshooting:

• OK – STOP.
i01729319
Results:
MID 111 - CID 1546 - FMI 05 Cyl
• OK – STOP. #16 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919

154

Troubleshooting:

i01761445
short to ground
SMCS Code: 1919-038
Results:
short to +batt
System Response:
SMCS Code: 1919-038
lost.

155

i01761455
SMCS Code: 1919-038 Monitoring of the exhaust temperature for the
30 seconds.
30 seconds.
Results:

• OK – STOP.


156

Troubleshooting:

i01761437
short to +batt
SMCS Code: 1919-038
Results:

lost.
SMCS Code: 1919-038

Troubleshooting:
157
Results: i01761460

MID 111 - CID 1549 - FMI 04 Cyl SMCS Code: 1919-038
short to ground
SMCS Code: 1919-038 detects an open circuit for the input from the
System Response:
lost.
Troubleshooting:
• OK – STOP.
Troubleshooting:
i01761438
Results:
short to +batt
• OK – STOP.
SMCS Code: 1919-038

158

Troubleshooting:

Troubleshooting:
i01761461

MID 111 - CID 1550 - FMI 05 Cyl
Results:
open circuit
short to ground
System Response:
SMCS Code: 1919-038
lost.

159
Troubleshooting:

Results:
• OK – STOP.
160
Troubleshooting with an
Event Code
i01875986
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) that detected the
event.
Both the master ECM and the slave ECM can

indicate active events. The master ECM will
diagnose all of the events that are applicable to g00791619
G3500 engines that have a single ECM. The events Illustration 20
that are diagnosed by the slave ECM are a subset Typical operating range of an oil temperature sensor
of the events that are diagnosed by the master (1) In these areas, the output voltage of the sensor is too high
ECM. All of the events that are pertinent to the slave or too low. The output is outside of the normal range. The
ECM have the same setting conditions and the electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 C (216 F) is
same conditions for clearing as the master ECM. above the normal range. The output voltage of the sensor
will generate an event code for a warning, a derating, or a
Event codes alert the operator that an abnormal shutdown for high oil temperature. The sensor does not have
engine operating condition such as low oil pressure an electronic problem.
or high coolant temperature has been detected. (3) This area represents the normal operating temperature for the
engine oil. The normal output voltage of the sensor is between
Events do not indicate problems with the electronic 0.2 and 4.1 volts.
system. Event codes also indicate the nature of the
problem. The Caterpillar Electronic Technician (ET) The following format is used for event codes:
is designed to run on a personal computer. Event
codes may be viewed on a personal computer that
has the Cat ET software.
• “EXXX (X) Description of the code”
The “E” means that the code is an event code.
Illustration 20 represents the operating range of an The “XXX” represents a numeric identifier for the
oil temperature sensor. The diagram is a reference. event code. The fourth “(X)” represents a numeric
Do not use the diagram to troubleshoot the oil identifier for the severity of the code. This is followed
temperature sensor. by a description of the code. Refer to 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.
161
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 that information, the conditions of operation, and the
detected the event. history of the engine.
Note: Do not confuse event codes with diagnostic

codes. For information on diagnostic codes, see
Operator Information
Troubleshooting, “Troubleshooting with a Diagnostic Obtain the following information from the operator:
Code”.
Perform the following tasks before you troubleshoot • The occurrence and the time of the occurrence
the event code:
• Determine the conditions for the occurrence. The
conditions will include the engine rpm and the
• Gather enough information about the complaint in load.
order to describe the symptom(s) adequately.
• Determine if there are any systems that were
• Verify that the complaint is not due to normal installed by the dealer or the customer that could
engine operation.
cause the symptom.
• Repair all active diagnostic codes. See • Determine whether any other occurrences
Troubleshooting, “Troubleshooting With A
happened in addition to the symptom.
Diagnostic Code”.
Troubleshooting Diagnostic Codes and Event Codes

Examine the following information regarding any
For basic troubleshooting of the engine, perform
codes:
the following steps first in order to diagnose a
malfunction.
• The probable cause of the symptom is correlated
to the code.
1. Gather information about the complaint from the
operator.
• The code was generated when the symptom
occurred.
2. Verify that the complaint is not due to normal
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 • The complaint is not due to normal engine
operation.
items:
• Fuel supply Other Symptoms

• Oil level If other occurrences happened in addition to the
symptom, investigate the following conditions:
• Oil supply
• The other occurrences are related to the
• Wiring symptom.
• Connectors • The symptoms have a probable cause that is

common.
4. Check the diagnostic codes and event codes.
Repair any active codes. Active Event Codes
If these inspections do not reveal any problems, An active event code represents a problem with
identify the probable causes with the procedures engine operation. Correct the problem as soon
in this manual that best describe the symptoms. as possible.
Check each probable cause according to the tests
that are recommended.
162
Both the master ECM and the slave ECM can i01761523
indicate active events. When an event code is
active, the “Active Alarm” indicator (“Engine Control E004 Engine Overspeed
Alarm Status” on Cat ET) is activated in order to Shutdown
alert the operator. If the condition that generated
the code is momentary, the message disappears. SMCS Code: 1348-038
The event code will be logged in the memory of the
ECM that detected the event. Conditions Which Generate This Code:
Active event codes are listed in ascending The engine rpm has exceeded the trip point that
numerical order on Cat ET. The code with the lowest is programmed into the master Electronic Control
number is listed first. Module (ECM) and the delay time has expired.
The master ECM has determined that the detected
Logged Event Codes speed is accurate.
The master ECM and the slave ECM can log events. System Response:
When an ECM generates an event code the ECM
logs the code in permanent memory. Each ECM has The gas shutoff valve and the ignition are shut
an internal diagnostic clock. Each ECM will record off. The shutdown output is activated. The code is
the following information when a code is generated: logged.
• The hour of the first occurrence of the code Possible Performance Effect:
• The hour of the last occurrence of the code The engine is shut down.
• The number of occurrences of the code Troubleshooting:
This information can be helpful for troubleshooting Refer to Troubleshooting, “Engine Overspeed”.
intermittent problems. Logged codes can also be
used to review the performance of the engine. Results:
A code is cleared from memory when one of the • OK – STOP.

i01637572
• The service technician manually clears the code.
E015 High Engine Coolant
Temperature Derate
codes in memory. In this case, the oldest code SMCS Code: 1395-038
is cleared.
Logged events are listed in chronological order on
Cat ET. The most recent event code is listed first. The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine
Note: Always clear logged event codes after coolant temperature has exceeded the trip point
investigating and correcting the problem which and the delay time has expired. No other codes for
generated the code. the engine coolant are active.
System Response:
The alarm output is activated. The event is logged.
The engine power is reduced.
Troubleshooting:
Refer to Troubleshooting, “Engine Coolant

163
• OK – STOP. Refer to Troubleshooting, “Engine Coolant

i01633543
Results:
• OK – STOP.
Temperature Shutdown
SMCS Code: 1395-038 i01633603

E019 High Engine Oil
Temperature Shutdown
The crank terminate relay is set and the engine has
been running for at least 30 seconds. The engine SMCS Code: 1348-038
coolant temperature has exceeded the trip point
and the delay time has expired. No other codes for Conditions Which Generate This Code:
the engine coolant are active.
System Response: been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and
The fuel is shut off. The shutdown output is the delay time has expired. No other codes for the
activated. The code is logged. engine oil temperature are active.
Possible Performance Effect: System Response:
The engine is shut down. The fuel is shut off. The shutdown output is
Troubleshooting:
Temperature (High)”. The engine is shut off.
• OK – STOP. Refer to Troubleshooting, “Engine Oil Temperature

(High)”.
i01633545
Results:
• OK – STOP.
Temperature Warning
SMCS Code: 1395-038 i01633605

E020 High Engine Oil
Temperature Warning
been running for at least 30 seconds. The engine SMCS Code: 1348-038
coolant temperature has exceeded the trip point
and the delay time has expired. No other codes for Conditions Which Generate This Code:
the engine coolant are active.
System Response: been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and
The alarm output is activated. The code is logged. the delay time has expired. No other codes for the
engine oil temperature are active.
System Response:
The engine operation is not immediately affected.
However, if the coolant temperature continues to The alarm output is activated. The code is logged.
rise, the engine will be shut down.
164
The engine operation is not immediately affected. E026 High Inlet Air
However, if the engine oil temperature continues to Temperature Shutdown
rise, the engine can be shut down.
SMCS Code: 1050-038
Troubleshooting:
Refer to Troubleshooting, “Engine Oil Temperature
(High)”. The crank terminate relay is set and the engine has
been running for at least 30 seconds. The inlet air
Results: temperature has exceeded the trip point and the
delay time has expired. No other codes for the inlet
• OK – STOP. air temperature are active.
i01637574
System Response:
E025 High Inlet Air The fuel is shut off. The shutdown output is
Temperature Derate
SMCS Code: 1050-038
Troubleshooting:
been running for at least 30 seconds. The inlet air Refer to Troubleshooting, “Inlet Air Temperature
temperature has exceeded the setpoint and the (High)”.
delay time has expired. No other codes for the inlet
air temperature are active. Results:
System Response:
• OK – STOP.
The alarm output is activated. The event is logged.
i01633756
E027 High Inlet Air
The engine power is reduced. Temperature Warning
Troubleshooting: SMCS Code: 1050-038
Refer to Troubleshooting, “Inlet Air Temperature Conditions Which Generate This Code:
(High)”.
Results: been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the
• OK – STOP. delay time has expired. No other codes for the inlet
air temperature are active.
System Response:

However, if the inlet air temperature continues to
rise, the engine may be shut down.
165
Refer to Troubleshooting, “Inlet Air Temperature The engine is shut down.

(High)”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Oil Pressure
• OK – STOP. (Low)”.
Results:
i01633757
E038 Low Engine Coolant • OK – STOP.

Temperature Warning
i01633763
SMCS Code: 1395-038
E042 Low System Voltage
Conditions Which Generate This Code: Shutdown
The crank terminate relay is set and the engine SMCS Code: 1400-038
has been running for at least 30 seconds. The
temperature of the engine coolant is less than the Conditions Which Generate This Code:
trip point and the delay time has expired. No other
codes for the coolant temperature are active. The voltage is less than the trip point and the delay
time has expired. No other codes for the system
System Response: voltage are present.
The alarm output is activated. The code is logged. System Response:
Possible Performance Effect: The shutdown output is activated. The code is

logged.
Troubleshooting:
Temperature (Low)”. Troubleshooting:
Results: Refer to Troubleshooting, “System Voltage”.
• OK – STOP. Results:
i01633762
• OK – STOP.
E040 Low Engine Oil Pressure i01633765

Shutdown E043 Low System Voltage
SMCS Code: 1348-038-PX Warning
Conditions Which Generate This Code: SMCS Code: 1400-038
The crank terminate relay is set and the engine has Conditions Which Generate This Code:
been running for at least 10 seconds. The engine
oil pressure is less than the trip point and the The voltage is less than the trip point and the delay
delay time has expired. No codes for the engine oil time has expired. No other codes for the system
pressure sensor are active. voltage are present.
The fuel is shut off. The shutdown output is The alarm output is activated. The code is logged.
166
The engine operation is not immediately affected. The alarm output is activated. The code is logged.
However, if the system voltage continues to be
reduced, the engine will be shut down. Possible Performance Effect:
Troubleshooting: The engine operation is not immediately affected.

However, if the fuel pressure continues to be
Refer to Troubleshooting, “System Voltage”. reduced, the supply may become inadequate for
the fuel metering valve.
Results:
Troubleshooting:
• OK – STOP.
Refer to Troubleshooting, “Fuel Pressure”.
i01877738
Results:
E050 High System Voltage
• OK – STOP.
Warning
SMCS Code: 1400-038 i01637590

E096 High Fuel Pressure
SMCS Code: 1250-038
The voltage is greater than the trip point and the
delay time has expired. No other codes for the
system voltage are present.
The fuel pressure is higher than the trip point and
System Response:
the delay time has expired.
System Response:
Possible Performance Effect: The alarm output is activated. The code is logged.
However, engine components could be damaged if
the system voltage continues to increase. The engine operation is not immediately affected.
However, if the fuel pressure continues to increase,
Troubleshooting: the supply may exceed the maximum limit for the
fuel metering valve.
Refer to Troubleshooting, “System Voltage”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Fuel Pressure”.
• OK – STOP.
Results:
i01637578
• OK – STOP.
E053 Low Fuel Pressure
Warning
SMCS Code: 1250-038
The fuel pressure is less than the trip point and the
delay time has expired.
167
i01633787 Troubleshooting:
E100 Low Engine Oil Pressure Refer to Troubleshooting, “Engine Oil Filter
Warning Differential Pressure”.
SMCS Code: 1348-038 Results:
Conditions Which Generate This Code: • OK – STOP.

The crank terminate relay is set and the engine has i01633814
been running for at least ten seconds. The engine
oil pressure is less than the trip point and the delay E128 Engine Oil Filter Diff
time has expired. There are no active codes for the
engine oil pressure sensor. Pressure Low Shutdown
System Response: SMCS Code: 1308-038
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 30 seconds. The oil filter
The engine operation is not immediately affected. differential pressure is less than the trip point and
However, if the oil pressure continues to be reduced, the delay time has expired. There are no active
the engine may be shut down. codes for the oil pressure sensors.
Troubleshooting: System Response:
Refer to Troubleshooting, “Engine Oil Pressure The fuel is shut off. The shutdown output is
(Low)”. activated. The code is logged.
Results: Possible Performance Effect:

• OK – STOP.
Troubleshooting:
i01633790
Refer to Troubleshooting, “Engine Oil Filter
E127 Engine Oil Filter Diff Differential Pressure”.
Pressure Low Warning
Results:
SMCS Code: 1308-038
• OK – STOP.
i01633828
been running for at least 30 seconds. The engine oil E129 Engine Oil Filter Diff
filter differential pressure is less than the trip point
and the delay time has expired. There are no active Pressure High Warning
codes for the oil pressure sensors.
SMCS Code: 1308-038
System Response:
Possible Performance Effect: been running for at least 30 seconds. The oil filter
differential pressure is greater than the trip point
The engine operation is not immediately affected. and the delay time has expired. There are no active
However, if the engine oil filter differential pressure codes for the oil pressure sensors.
continues to be reduced, the engine may be shut
down. System Response:

168
The engine operation is not immediately affected. E135 Low Jacket Water
However, if the oil filter differential pressure Pressure Shutdown
continues to increase, the engine may be shut
down. SMCS Code: 1350-038
Refer to Troubleshooting, “Engine Oil Filter The crank terminate relay is set and the engine has
Differential Pressure”. been running for at least ten seconds. The pressure
of the jacket water is less than the trip point and the
Results: delay time has expired. There are no active codes
for the pressure sensor at the outlet for the jacket
• OK – STOP. water.
i01633832
System Response:
E130 Engine Oil Filter Diff The fuel is shut off. The shutdown output is
Pressure High Shutdown
SMCS Code: 1308-038
The engine is shut off.
Troubleshooting:
been running for at least 30 seconds. The engine Refer to Troubleshooting, “Jacket Water Pressure
oil filter differential pressure is greater than the trip (Low)”.
point and the delay time has expired. There are no
active codes for the oil pressure sensors. Results:
System Response:
• OK – STOP.
activated. The code is logged. i01633954
Possible Performance Effect: E223 High Gas Temperature

The engine is shut down. SMCS Code: 1250-038
Refer to Troubleshooting, “Engine Oil Filter The crank terminate relay is set and the engine
Differential Pressure”. has been running for at least 30 seconds. The
temperature of the gas has exceeded the trip point
Results: and the delay timer has expired. There are no active
codes for the fuel temperature sensor.
• OK – STOP.
System Response:

However, if the fuel temperature continues to
increase, the air/fuel ratio and the inlet manifold air
temperature can be affected.
169
Refer to Troubleshooting, “Gas Temperature (High)”. Refer to Troubleshooting, “Engine Overcrank”.
Results: Results:
• OK – STOP. • OK – STOP.
i01633956 i01761561
E224 High Jacket Water Inlet E226 Driven Equipment Not

Pressure Ready
The crank terminate relay is set and the engine has The engine is ready to start. However, the master
been running for at least 10 seconds. The trip point Electronic Control Module (ECM) has received a
for high pressure at the inlet for the jacket water has signal which indicates that the driven equipment is
been exceeded and the delay time has expired. not ready for the engine to start.
The fuel is shut off. The shutdown output is The shutdown output is activated. Engine cranking
activated. The code is logged. is prevented. The code is logged.
The engine is shut down. The engine will not start.
Refer to Troubleshooting, “Jacket Water Inlet Refer to Troubleshooting, “Driven Equipment”.

Pressure (High)”.
Results:
Results:
• OK – STOP.
• OK – STOP.
i01633972
i01633959
E229 Fuel Energy Content
E225 Engine Overcrank Setting Low
SMCS Code: 1400-038
SMCS Code: 1250-038
The engine did not start within the programmed
The crank terminate relay is set and the engine
parameters for starting.
has been running for at least 30 seconds. The fuel
System Response: correction factor is less than the trip point for 20
seconds.
The fuel is shut off. Engine cranking is prevented.
The code is logged. System Response:

The engine will not start.
The engine performance may be erratic.
170
Refer to Troubleshooting, “Fuel Energy Content”. Refer to Troubleshooting, “Fuel Energy Content”.
Results: Results:
i01633976 i01761581
E230 Fuel Energy Content E242 Engine Overload

Setting High SMCS Code: 1000-038
SMCS Code: 1250-038 Conditions Which Generate This Code:
The calculation by the master Electronic Control
Module (ECM) for the engine load is greater than
The crank terminate relay is set and the engine
110 percent of the rated load.
has been running for at least 30 seconds. The fuel
correction factor is greater than the trip point for System Response:
20 seconds.
System Response:
The engine power is reduced.
Troubleshooting:
The engine performance may be erratic.
Refer to Troubleshooting, “Engine Overload”.
Troubleshooting:
Results:
Refer to Troubleshooting, “Fuel Energy Content”.
Results: • OK – STOP.
• OK – STOP. i01634015
E243 High Left Turbo Turbine

i01746483
Outlet Temperature
E231 Fuel Quality Out of Range
SMCS Code: 1052-038
SMCS Code: 1250-038
The temperature at the outlet for the left turbocharger
The crank terminate relay is set and the engine has turbine has exceeded the trip point and the delay
been running for at least 30 seconds. The Low Heat time has expired.
Value (LHV) of the fuel is less than the trip point
OR the LHV of the fuel is greater than the trip point System Response:
for 20 seconds.
The following event codes are logged according to
System Response: the trip points for the temperature:
The fuel is shut off. The shutdown output is • E243 (1) High Left Turbo Turbine Outlet
activated. The code is logged. Temperature (warning)
Possible Performance Effect: • E243 (3) High Left Turbo Turbine Outlet
Temperature (shutdown)
171
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.
If a warning is generated, the alarm output is Troubleshooting:

activated.
If a shutdown is generated, the shutdown output Temperature (High)”.
is activated.
Results:
• OK – STOP.
172

E246 High Left Turbo Turbine The gas shutoff valve (GSOV) and the ignition are
Inlet Temperature shut off. The shutdown output is activated. The
code is logged.
SMCS Code: 1052-038
The temperature at the inlet for the left turbocharger
turbine has exceeded the trip point and the delay Troubleshooting:
time has expired.
Refer to Troubleshooting, “Engine Shutdown”.
System Response:
Results:
the trip points for the temperature: • OK – STOP.
• E246 (1) High Left Turbo Turbine Inlet Temperature i01634063

(warning)
E268 Unexpected Engine
• E246 (3) High Left Turbo Turbine Inlet Temperature Shutdown
(shutdown)
If a warning is generated, the alarm output is SMCS Code: 1400-038

activated.
If a shutdown is generated, the shutdown output
is activated. The crank terminate relay is set and the engine
is running. The engine rpm is less than the
Possible Performance Effect: programmed speed of the postlube cycle for 200
ms.
is not immediately affected. System Response:
The engine will be shut down if the trip point for the The fuel is shut off. The shutdown output is
shutdown is exceeded. activated. The code is logged.
Refer to Troubleshooting, “Turbocharger Turbine The engine is shut down.

Troubleshooting:
Results:
Refer to Troubleshooting, “Engine Shutdown
(Unexpected)”.
• OK – STOP.
Results:
i01634059
• OK – STOP.
E264 Emergency Stop
Activated
SMCS Code: 1400-038
The input for the emergency stop is activated.

173
i01634093 i01864896
E269 Customer Shutdown E337 High Engine Oil to Engine

Requested Coolant Diff Temp
The engine is either cranking or running. The input The crank terminate relay is set and the engine has
for the stop is set for 200 ms. been running for at least 30 seconds. The differential
between the temperature of the engine oil and the
System Response: temperature of the engine coolant has exceeded
the trip point. Also, the delay time has expired.
The fuel is shut off. The shutdown output is There are no active codes for the sensors for the
activated. The code is logged. engine oil temperature and the engine coolant.
The engine is shut off. The following event codes are logged according to
the trip points for the temperature differential:
Troubleshooting:
• E337 (1) High Engine Oil to Engine Coolant Diff
Refer to Troubleshooting, “Engine Shutdown”. Temp (warning)
Results: • E337 (3) High Engine Oil to Engine Coolant Diff

Temp (shutdown)
• OK – STOP.
If a warning is activated, the alarm output is
activated.
i01634097
E270 Driven Equipment If a shutdown is activated, the shutdown output is

activated.
Shutdown Requested
SMCS Code: 1400-038
If a warning is generated, the engine operation is
Conditions Which Generate This Code: not immediately affected.
The crank terminate relay is set and the engine is The engine will be shut down if the trip point for the
running. The input requests a shutdown for 200 ms. shutdown is exceeded.
The fuel is shut off. The shutdown output is Refer to Troubleshooting, “Jacket Water to Engine
activated. The code is logged. Oil Differential Temperature (Low)”.
The engine is shut down. • OK – STOP.

Troubleshooting:
i01637607
Refer to Troubleshooting, “Driven Equipment”.
E401 Cylinder #1 Detonation
Results:
SMCS Code: 1000-038
The level of detonation has exceeded the trip point.

There is no active diagnostic code for the cylinder’s
detonation sensor.
174
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
E402 Cylinder #2 Detonation E404 Cylinder #4 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.
Results: Results:
i01637627 i01637642

175
Results: Results:
i01637646 i01637651

Results: Results:
i01637648 i01637653

176
Results: Results:
i01637657 i01637665

Results: Results:
i01637663 i01637696

177
Results: Results:
i01637699 i01637706

Results: Results:
i01637702 i01762523

178
Results: Results:
i01762524 i01762527

Results: Results:
i01762525

SMCS Code: 1000-038

There is no active diagnostic code for the cylinder’s
detonation sensor.
179
i01634664 Results:
E421 Cylinder #1 Detonation • OK – STOP.
Shutdown
i01634838
SMCS Code: 1000-038
Shutdown
Maximum retardation of the timing was unable SMCS Code: 1000-038
to control the detonation adequately during the
number of ignition sparks that are allowed. There Conditions Which Generate This Code:
is no active diagnostic code for the cylinder’s
detonation sensor. The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable
System Response: to control the detonation adequately during the
number of ignition sparks that are allowed. There
The fuel is shut off. The shutdown output is is no active diagnostic code for the cylinder’s
activated. The code is logged. detonation sensor.
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Results:
Troubleshooting:
• OK – STOP. Refer to Troubleshooting, “Detonation”.
i01634746 Results:
Shutdown
i01635415
SMCS Code: 1000-038
Shutdown
Troubleshooting:
180
Refer to Troubleshooting, “Detonation”. The fuel is shut off. The shutdown output is
Results:
• OK – STOP.
i01635416
Troubleshooting:
E425 Cylinder #5 Detonation Refer to Troubleshooting, “Detonation”.
Shutdown
Results:
SMCS Code: 1000-038
• OK – STOP.
The level of detonation has exceeded the trip point. i01635420

number of ignition sparks that are allowed. There Shutdown
detonation sensor. SMCS Code: 1000-038
The fuel is shut off. The shutdown output is The level of detonation has exceeded the trip point.
activated. The code is logged. Maximum retardation of the timing was unable
Possible Performance Effect: number of ignition sparks that are allowed. There
The engine is shut down. detonation sensor.
Results:
• OK – STOP.
i01635417
Troubleshooting:
Shutdown
Results:
SMCS Code: 1000-038
• OK – STOP.

detonation sensor.
181
i01635421 Results:
Shutdown
i01635424
SMCS Code: 1000-038
Shutdown
Troubleshooting:
Results:
Troubleshooting:
i01635423 Results:
Shutdown
i01635428
SMCS Code: 1000-038
Shutdown
Troubleshooting:
182
Results:
• OK – STOP.
i01635429
Troubleshooting:
Shutdown
Results:
SMCS Code: 1000-038
• OK – STOP.

number of ignition sparks that are allowed. There Shutdown
The fuel is shut off. The shutdown output is The level of detonation has exceeded the trip point.
activated. The code is logged. Maximum retardation of the timing was unable
Possible Performance Effect: number of ignition sparks that are allowed. There
The engine is shut down. detonation sensor.
Results:
• OK – STOP.
i01635431
Troubleshooting:
Shutdown
Results:
SMCS Code: 1000-038
• OK – STOP.

detonation sensor.
183
i01635435 Results:
Shutdown
i01762528
SMCS Code: 1000-038
Shutdown
Troubleshooting:
Results:
Troubleshooting:
i01635436 Results:
Shutdown
i01762529
SMCS Code: 1000-038
Shutdown
Troubleshooting:
184
Results:
• OK – STOP.
i01762530
Troubleshooting:
Shutdown
Results:
SMCS Code: 1000-038
• OK – STOP.

E801 Cylinder #1 High Exhaust
number of ignition sparks that are allowed. There Port Temp
The fuel is shut off. The shutdown output is The cylinder exhaust temperature has exceeded
activated. The code is logged. the trip point and the delay time has expired.
The engine is shut down. The following event codes are logged according to
the trip points for the temperature:
Troubleshooting:
• E801 (1) Cylinder #1 High Exhaust Port Temp
Refer to Troubleshooting, “Detonation”. (warning)
Results: • E801 (3) Cylinder #1 High Exhaust Port Temp

(shutdown)
• OK – STOP.
If a warning is generated, the alarm output is
activated.
i01762532
E440 Cylinder #20 Detonation If a shutdown is generated, the shutdown output is

activated and the fuel is shut off.
Shutdown
SMCS Code: 1000-038
Conditions Which Generate This Code: is not immediately affected.
The level of detonation has exceeded the trip point. The engine will be shut down if the trip point for the
Maximum retardation of the timing was unable shutdown is exceeded.
number of ignition sparks that are allowed. There Troubleshooting:
detonation sensor. Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
185
• OK – STOP. The following event codes are logged according to

i01635500
E802 Cylinder #2 High Exhaust (warning)
Port Temp • E803 (3) Cylinder #3 High Exhaust Port Temp

(shutdown)
SMCS Code: 1059-038
Conditions Which Generate This Code: activated.
The cylinder exhaust temperature has exceeded If a shutdown is generated, the shutdown output is
the trip point and the delay time has expired. activated and the fuel is shut off.
The following event codes are logged according to If a warning is generated, the engine performance
the trip points for the temperature: is not immediately affected.
• E802 (1) Cylinder #2 High Exhaust Port Temp The engine will be shut down if the trip point for the
(warning) shutdown is exceeded.
• E802 (3) Cylinder #2 High Exhaust Port Temp Troubleshooting:

(shutdown)
Refer to Troubleshooting, “Exhaust Port Temperature
If a warning is generated, the alarm output is (High)”.
activated.
Results:
If a shutdown is generated, the shutdown output is
activated and the fuel is shut off. • OK – STOP.
i01635505
If a warning is generated, the engine performance E804 Cylinder #4 High Exhaust
Port Temp
shutdown is exceeded. SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded
(High)”. the trip point and the delay time has expired.

i01635503
E803 Cylinder #3 High Exhaust (warning)

(shutdown)
SMCS Code: 1059-038
186
If a warning is generated, the engine performance • OK – STOP.

i01635511
shutdown is exceeded. E806 Cylinder #6 High Exhaust
Troubleshooting: Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Results:
The cylinder exhaust temperature has exceeded
• OK – STOP. the trip point and the delay time has expired.
System Response:
i01635508
E805 Cylinder #5 High Exhaust the trip points for the temperature:
Port Temp
SMCS Code: 1059-038 (warning)
Conditions Which Generate This Code: • E806 (3) Cylinder #6 High Exhaust Port Temp
(shutdown)
the trip point and the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
The following event codes are logged according to activated and the fuel is shut off.
(warning) If a warning is generated, the engine performance
(shutdown) The engine will be shut down if the trip point for the
activated. Troubleshooting:
If a shutdown is generated, the shutdown output is Refer to Troubleshooting, “Exhaust Port Temperature
activated and the fuel is shut off. (High)”.
If a warning is generated, the engine performance • OK – STOP.

Troubleshooting:

(High)”.
187
i01635512 • E808 (1) Cylinder #8 High Exhaust Port Temp

(warning)
(shutdown)
SMCS Code: 1059-038

(shutdown)
activated.
Results:
If a warning is generated, the engine performance E809 Cylinder #9 High Exhaust

Port Temp

• OK – STOP. the trip points for the temperature:
i01635513 • E809 (1) Cylinder #9 High Exhaust Port Temp

(warning)
(shutdown)
SMCS Code: 1059-038
188
The engine will be shut down if the trip point for the i01635556
E811 Cylinder #11 High
Troubleshooting: Exhaust Port Temp
(High)”.
Results:
i01635549
System Response:
E810 Cylinder #10 High The following event codes are logged according to
Exhaust Port Temp
SMCS Code: 1059-038
(warning)
(shutdown)
the trip point and the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
• OK – STOP.
Troubleshooting: Exhaust Port Temp
(High)”.
Results:
189

(shutdown)
activated.
Results:
i01635577

Exhaust Port Temp

i01635570
E813 Cylinder #13 High (warning)
Exhaust Port Temp • E814 (3) Cylinder #14 High Exhaust Port Temp
(shutdown)
SMCS Code: 1059-038

(shutdown)
activated.
Results:
190

Exhaust Port Temp the trip points for the temperature:
SMCS Code: 1059-038 • E816 (1) Cylinder #16 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.
• E815 (1) Cylinder #15 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E815 (3) Cylinder #15 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.
Troubleshooting:
Exhaust Port Temp
(High)”. SMCS Code: 1059-038


Exhaust Port Temp the trip points for the temperature:
SMCS Code: 1059-038 • E817 (1) Cylinder #17 High Exhaust Port Temp
(warning)
The cylinder exhaust temperature has exceeded (shutdown)
activated.
191
If a shutdown is generated, the shutdown output is Results:

• OK – STOP.
i01762535
is not immediately affected. E819 Cylinder #19 High
The engine will be shut down if the trip point for the Exhaust Port Temp
SMCS Code: 1059-038
Troubleshooting:
(High)”. The cylinder exhaust temperature has exceeded
Results:
System Response:
• OK – STOP.
i01762534
E818 Cylinder #18 High • E819 (1) Cylinder #19 High Exhaust Port Temp
(warning)
Exhaust Port Temp
SMCS Code: 1059-038 (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.
i01762536
is not immediately affected. E820 Cylinder #20 High
The engine will be shut down if the trip point for the Exhaust Port Temp
SMCS Code: 1059-038
Troubleshooting:
(High)”. The cylinder exhaust temperature has exceeded
192
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:
• E820 (3) Cylinder #20 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.
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.
i01635593
Troubleshooting: E822 Cyl #2 Exhaust Port Temp

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
The cylinder exhaust temperature is higher than the
average temperature for all of the cylinders. The
i01635587 amount of deviation has exceeded the trip point
E821 Cyl #1 Exhaust Port Temp and the delay time has expired.
Deviating High System Response:
SMCS Code: 1059-038 The following event codes are logged according to
• E822 (1) Cyl #2 Exhaust Port Temp Deviating
The cylinder exhaust temperature is higher than the High (warning)
amount of deviation has exceeded the trip point • E822 (3) Cyl #2 Exhaust Port Temp Deviating
and the delay time has expired. High (shutdown)

activated.
High (warning) Possible Performance Effect:
• E821 (3) Cyl #1 Exhaust Port Temp Deviating If a warning is generated, the engine performance
High (shutdown) is not immediately affected.
193
E824 Cyl #4 Exhaust Port Temp
Troubleshooting: Deviating High
(High)”.
Results:
• OK – STOP. average temperature for all of the cylinders. The
amount of deviation has exceeded the trip point
i01635600
and the delay time has expired.
E823 Cyl #3 Exhaust Port Temp System Response:

Deviating High The following event codes are logged according to
SMCS Code: 1059-038

High (warning)
High (shutdown)
and the delay time has expired. If a warning is generated, the alarm output is
activated.
System Response:
High (warning) If a warning is generated, the engine performance
High (shutdown) The engine will be shut down if the trip point for the
• OK – STOP.
(High)”.
Results:
194

activated.


• OK – STOP.
i01635614

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
Deviating High System Response:

activated.
195
(High)”.
Results:
i01635616

Deviating High The following event codes are logged according to
SMCS Code: 1059-038

High (warning)
High (shutdown)
activated.
System Response:
• OK – STOP.
E830 Cyl #10 Exhaust Port
Troubleshooting: Temp Deviating High
(High)”.
Results:
196

activated.


• OK – STOP.
i01635645
Troubleshooting: E832 Cyl #12 Exhaust Port

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
E831 Cyl #11 Exhaust Port and the delay time has expired.
Temp Deviating High System Response:

activated.
197
(High)”.
Results:
i01635653
E833 Cyl #13 Exhaust Port System Response:

Temp Deviating High The following event codes are logged according to
SMCS Code: 1059-038

High (warning)
High (shutdown)
activated.
System Response:
• OK – STOP.
(High)”.
Results:
198

activated.


• OK – STOP.
i01762537

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
Temp Deviating High System Response:

activated.
199
(High)”.
Results:
i01762538

Temp Deviating High The following event codes are logged according to
SMCS Code: 1059-038

High (warning)
High (shutdown)
activated.
System Response:
• OK – STOP.
(High)”.
Results:
200

activated.

Possible Performance Effect: (Low)”.

• OK – STOP.
i01635667

Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
The cylinder exhaust temperature is less than the
Deviating Low System Response:
• E842 (1) Cyl #2 Exhaust Port Temp Deviating Low
The cylinder exhaust temperature is less than the (warning)
amount of deviation has exceeded the trip point • E841 (3) Cyl #2 Exhaust Port Temp Deviating Low
and the delay time has expired. (shutdown)

activated.
• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance
201
Troubleshooting: Deviating Low
(Low)”.
Results:
i01635668

Deviating Low The following event codes are logged according to
SMCS Code: 1059-038

(warning)
(shutdown)
activated.
System Response:
activated and the fuel is shut off. (Low)”.
• OK – STOP.
(Low)”.
Results:
202

activated.


• OK – STOP.
i01635677

Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
Deviating Low System Response:
The cylinder exhaust temperature is less than the (warning)
amount of deviation has exceeded the trip point • E847 (3) Cyl #7 Exhaust Port Temp Deviating Low
and the delay time has expired. (shutdown)

activated.
203
(Low)”.
Results:
i01635680

Deviating Low The following event codes are logged according to
SMCS Code: 1059-038

(warning)
(shutdown)
activated.
System Response:
• OK – STOP.
Troubleshooting: Temp Deviating Low
(Low)”.
Results:
204

activated.
Low (warning) Possible Performance Effect:
Low (shutdown) is not immediately affected.


• OK – STOP.
i01635688

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
Temp Deviating Low System Response:
The cylinder exhaust temperature is less than the Low (warning)
and the delay time has expired. Low (shutdown)

activated.
205
(Low)”.
Results:
i01635691

Temp Deviating Low The following event codes are logged according to
SMCS Code: 1059-038

Low (warning)
Low (shutdown)
activated.
System Response:
Low (warning) If a warning is generated, the engine performance
Low (shutdown) The engine will be shut down if the trip point for the
• OK – STOP.
(Low)”.
Results:
206

activated.


• OK – STOP.
i01762541

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
Temp Deviating Low System Response:
The cylinder exhaust temperature is less than the Low (warning)
and the delay time has expired. Low (shutdown)

activated.
207
(Low)”.
Results:
i01762544

Temp Deviating Low The following event codes are logged according to
SMCS Code: 1059-038

Low (warning)
Low (shutdown)
activated.
System Response:
Low (warning) If a warning is generated, the engine performance
Low (shutdown) The engine will be shut down if the trip point for the
• OK – STOP.
(Low)”.
Results:
208
The following event codes are logged according to Refer to Troubleshooting, “Gas Fuel Differential
the trip points for the temperature: Pressure (Low)”.
• E860 (1) Cyl #20 Exhaust Port Temp Deviating Results:

Low (warning)
• OK – STOP.
Low (shutdown)
i01637716

activated.
E865 High Gas Fuel Differential
Pressure
activated and the fuel is shut off. SMCS Code: 1250-038
Possible Performance Effect: Conditions Which Generate This Code:
If a warning is generated, the engine performance The Gas Shutoff Valve (GSOV) is energized. The
is not immediately affected. difference in fuel pressure between the inlet and the
outlet of the fuel metering valve is greater than the
The engine will be shut down if the trip point for the trip point. The delay time has expired.
System Response:
Troubleshooting:
(Low)”. Possible Performance Effect:
Results: The engine performance is not immediately

affected.
• OK – STOP.
Troubleshooting:
i01637712 Refer to Troubleshooting, “Gas Fuel Differential
E864 Low Gas Fuel Differential Pressure (High)”.
Pressure Results:
SMCS Code: 1250-038 • OK – STOP.

i01637720
The gas shutoff valve (GSOV) is energized. The

difference in fuel pressure between the outlet and
E866 Low Gas Fuel Flow Rate
the inlet of the fuel metering valve is less than the SMCS Code: 1250-038
trip point. The delay time has expired.
System Response:
The fuel metering valve is fully open. However,
The alarm output is activated. The code is logged. the flow rate that is computed by the valve does
not match the fuel demand for a delay time of 5
Possible Performance Effect: seconds.
The engine performance is not immediately System Response:
affected.
209
The engine performance is not immediately The engine performance is not immediately
affected. affected.
Refer to Troubleshooting, “Gas Fuel Flow Rate Refer to Troubleshooting, “Fuel Metering Valve”.
(Low)”.
Results:
Results:
• OK – STOP.
• OK – STOP.
i01761860
E867 Improper Gas Flow

Control Valve Response
SMCS Code: 1741-038
The fuel metering valve is not responding correctly

to the master Electronic Control Module (ECM) and
the delay time has expired.
System Response:
The engine performance is not immediately

affected.
Troubleshooting:
Refer to Troubleshooting, “Fuel Metering Valve”.
Results:
• OK – STOP.
i01761863
E868 Gas Flow Control Valve

Malfunction
SMCS Code: 1741-038

detected a malfunction for the fuel metering valve
System Response:

210
Diagnostic Functional • The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
Tests desired speed.
A “5 Volt Sensor DC Power Supply short to ground”

i01815596 diagnostic code will be activated if both of these
+5V Sensor Voltage Supply conditions occur:
SMCS Code: 5574-038 • The desired speed signal wire is shorted to

ground.
System Operation Description:
• The “DESIRED SPEED” potentiometer is near
the maximum desired speed or at the maximum
supplies 5.0 ± 0.5 VDC to the sensors for these desired speed.
parameters:

• Engine oil temperature
Terminals J1-2 and J1-18 are connected together
inside the master ECM. A short circuit on one of
these terminals will cause a short circuit on the
other terminal.
A “+5 V sensor supply” diagnostic code is probably

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

record. Before you begin this procedure, use the
Caterpillar Electronic Technician (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.
“DESIRED SPEED” Potentiometer (if equipped)
The master ECM also provides 5.0 ± 0.5 VDC to the

“DESIRED SPEED” potentiometer (if equipped).
A “5 Volt Sensor DC Power Supply short to +batt”

diagnostic code will be activated if both of these
conditions occur:
• The desired speed signal wire is shorted to a

voltage source that is greater than +5 volts.
211
g00951647
Illustration 21
Schematic for the 5 V supply
212
Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
Connectors and Wiring connectors:
• Master ECM J1/P1 connectors

• J6/P6, and J7/P7 connectors on the terminal
box
a. Check the torque of the Allen head screws

for the master ECM connectors. The proper
torque is 6 ± 1 N·m (55 ± 9 lb in).
b. Check the torque of the Allen head screws

for the connectors on the terminal box. The
proper torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g00931487
Illustration 22
Junction box
(1) 35 amp circuit breaker
A. Set the engine control to the OFF/RESET mode.

Switch 35 amp circuit breaker (1) to the OFF
g00929107
position. Illustration 24
Harness side of the master ECM P1 connector
Note: For the following steps, refer to (P1-2) 5 volt supply
Troubleshooting, “Inspecting Electrical Connectors”. (P1-3) Return
(P1-14) Signal for the inlet manifold air temperature
(P1-16) Signal for the desired speed
(P1-17) Signal for the engine oil temperature
(P1-18) 5 volt supply
(P1-24) Signal for the filtered engine oil pressure
(P1-26) Signal for the unfiltered engine oil pressure
(P1-35) Return
g00928823
Illustration 23
Terminal box
(2) J1/P1 connectors for the master ECM
(3) J6/P6 connectors for the customer
(4) J7/P7 connectors for the harness from the 5 volt sensors
213
g00929111
Illustration 25
Harness side of the J6 connector
(J6-5) 5 volt supply
(J6-15) Return
(J6-25) Signal for desired speed
(J6-35) Shield
g00929117
Illustration 26
(J7-3) Signal for the inlet manifold air temperature
(J7-4) Signal for the filtered engine oil pressure
(J7-5) Signal for the engine oil temperature
(J7-6) Signal for the unfiltered engine oil pressure
(J7-17) Return for the inlet manifold air temperature
(J7-18) Return for the filtered engine oil pressure
(J7-19) Return for the engine oil temperature
(J7-20) Return for the unfiltered engine oil pressure
(J7-31) Shield for the inlet manifold air temperature
(J7-32) Shield for the filtered engine oil pressure
(J7-33) Shield for the engine oil temperature
(J7-34) Shield for the unfiltered engine oil pressure
(J7-45) 5 volt supply for the inlet manifold air temperature
(J7-46) 5 volt supply for the filtered engine oil pressure
(J7-47) 5 volt supply for the engine oil temperature
(J7-48) 5 volt supply for the unfiltered engine oil pressure
c. Perform a 45 N (10 lb) pull test on each of

the wires that are associated with the circuit
for the 5 V sensors.
214
g00929157
Illustration 27
(5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor
Results:
• OK – All connectors, pins, and sockets are

connected properly. The connectors and the
wiring do not have corrosion, abrasion, or pinch
points. The components are in good condition
with proper connections. Proceed to Test Step 2.
• Not OK – At least one of the connectors, pins, or

sockets are not connected properly. At least one
of the connectors and the wiring has corrosion,
abrasion, and/or pinch points.
Repair: Perform the necessary repairs and/or

g00929158
replace parts, if necessary.
Illustration 28
Top view of the engine STOP.
(8) Inlet air temperature sensor
Test Step 2. Check for Diagnostic Codes
d. Check the harness and wiring for corrosion,
abrasion and pinch points from the 5 volt A. Connect Cat ET to the service tool connector.
sensors to the master ECM. Refer to Troubleshooting, “Electronic Service
Tools”.
Expected Result:
B. Rotate the “DESIRED SPEED” potentiometer (if
All connectors, pins, and sockets are connected equipped) counterclockwise to the minimum
properly. The connectors and the wiring do not have speed position.
corrosion, abrasion, or pinch points.
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode.
D. Observe the “Active Diagnostic” screen on Cat

ET. Wait at least 30 seconds so that any codes
may become activated. Look for these codes:
215
• 262-03 5 Volt Sensor DC Power Supply short Test Step 4. Check the Wiring for the
to +batt “DESIRED SPEED” Potentiometer
• 262-04 5 Volt Sensor DC Power Supply short A. Set the engine control to the OFF/RESET mode.
to ground Switch the 35 amp circuit breaker OFF.
E. Observe the “Logged Diagnostic” screen on Cat B. Label the wiring that is connected to the
ET. Look for the same codes. “DESIRED SPEED” potentiometer. Disconnect the
wiring from the “DESIRED SPEED” potentiometer.
Expected Result:
C. Disconnect the P1 connector from the master
The 262-03 code or the 262-04 code is not active ECM.
or logged.
D. Measure the resistance between terminals P1-16
Results: and P1-69.
• No codes – There are no active codes or logged Expected Result:

codes. Proceed to Test Step 3.
The resistance is greater than 20,000 ohms.
• Active code – The 262-03 code or the 262-04
code is active. Proceed to Test Step 5. Results:
• Logged code – The 262-03 code or the 262-04 • OK – The resistance is greater than 20,000
code is not active. However, there is at least one ohms. The wiring for the “DESIRED SPEED”
logged code for the 5 volt sensor supply. potentiometer appears to be OK.
Repair: There may be a problem with the wiring Repair: The “DESIRED SPEED” potentiometer may
and/or a connector. Refer to Troubleshooting, have a problem. Perform the following procedure:
1. Check the “DESIRED SPEED” potentiometer in
Verify that the wiring and/or connectors are OK. order to ensure that the potentiometer does
Check for diagnostic codes again. Proceed to not have an internal short circuit. Replace the
Test Step 3, if necessary. “DESIRED SPEED” potentiometer, if necessary.
Continue with this procedure when the
Test Step 3. Check the Analog Speed “DESIRED SPEED” potentiometer is operating
Circuit correctly.
Note: If the engine is not equipped with a “DESIRED 2. Reconnect the wiring to the “DESIRED SPEED”
SPEED” potentiometer, proceed to Test Step 9. potentiometer. Be sure to connect the wires to
the appropriate terminals.
A. Rotate the “DESIRED SPEED” potentiometer (if
equipped) clockwise to the maximum speed 3. Reconnect the P1 connector to the master
position. ECM.
Expected Result: 4. Perform this entire procedure again. Verify that

the original problem is resolved.
The 262-03 code or the 262-04 code is not active.
STOP.
Results:
• Not OK – The resistance is less than 20,000
• No codes – Rotating the “DESIRED SPEED” ohms. There is a problem with the wiring for the
potentiometer clockwise to the maximum speed “DESIRED SPEED” potentiometer. The problem
position did not cause an active code. The +5 V could be between the P1 connector and the J6
sensor voltage supply is operating correctly at connector. Alternatively, the problem could be in
this time. Resume normal operation. STOP. the P6 connector or the wiring that is connected
to the P6 connector.
• Active code – Rotating the “DESIRED SPEED”
potentiometer clockwise to the maximum speed Repair: Perform any necessary repairs or replace
position caused an active code. There is a parts, if necessary.
problem with the analog speed circuit. Proceed
to Test Step 4. STOP.
216
Test Step 5. Isolate the Wiring Harnesses B. Insert terminal P1-18 into the P1 connector. Pull
from the Master ECM on the wire in order to verify that the terminal is
fully inserted into the connector.
Switch the 35 amp circuit breaker OFF. C. Rotate the “DESIRED SPEED” potentiometer
clockwise to the maximum speed position.
B. Reconnect the P1 connector to the master ECM.
D. Switch the 35 amp circuit breaker ON. Set the
C. Use a 151-6320 Wire Removal Tool to remove engine control to the STOP mode.
terminals P1-2 and P1-18. This will disconnect all
of the +5 V wiring from the master ECM. E. Use Cat ET to look for diagnostic codes.
D. Switch the 35 amp circuit breaker ON. Set the Expected Result:
No active codes
E. Use Cat ET to look for diagnostic codes.
Results:
Expected Result:
• No codes – The 262-03 code or the 262-04 code
No active codes is not active. Connecting the wiring for the analog
speed circuit to the master ECM did not cause a
Results: diagnostic code. The wiring for the analog speed
circuit appears to be OK. Proceed to Test Step 7.
• No codes – The 262-03 code or the 262-04 code
is not active. Disconnecting all of the +5 V wiring • Active codes – The 262-03 code or the 262-04
from the master ECM eliminated the active “5 code is active. Connecting the wiring for the
Volt Sensor Supply” diagnostic code. There is a analog speed circuit to the master ECM caused a
problem with a connector and/or the wiring in a diagnostic code. Proceed to Test Step 4.
harness. Proceed to Test Step 6.
Test Step 7. Connect the 5 Volt Wiring for
• Active code – The 262-03 code or the 262-04 the Sensors to the Master ECM
code is active. Disconnecting all of the 5 volt
wiring from the master ECM did not eliminate the A. Set the engine control to the OFF/RESET mode.
active “5 Volt Sensor Supply” diagnostic code. Switch the 35 amp circuit breaker OFF.
There may be a problem with the master ECM.
B. Insert terminal P1-2 into the P1 connector. Pull
Repair: It is unlikely that the master ECM has on the wire in order to verify that the terminal is
failed. Exit this procedure and perform this fully inserted into the connector.
procedure again. If the problem is not resolved,
perform the following steps: C. Switch the 35 amp circuit breaker ON. Set the
Temporarily install a new master ECM. Refer to
Troubleshooting, “Replacing the ECM”. D. Use Cat ET to look for diagnostic codes.
If the problem is resolved with the new ECM, Expected Result:

install the original ECM and verify that the
problem returns. If the new ECM operates No active codes
correctly and the original ECM does not operate
correctly, replace the original ECM. Refer to Results:
Troubleshooting, “Replacing the ECM”.
• No codes – The 262-03 code or the 262-04
STOP. code is not active. Connecting the 5 VDC for the
sensors did not cause a diagnostic code. The
Test Step 6. Connect the 5 Volt Wiring for problem appears to be resolved.
the Analog Speed Circuit to the Master
ECM Repair: The initial diagnostic code was probably
caused by a poor electrical connection. Resume
A. Set the engine control to the OFF/RESET mode. normal operation.
Switch the 35 amp circuit breaker OFF.
STOP.
217
• Active code – The 262-03 code or the 262-04 2. Disconnect the suspect sensor.
code is active. Connecting the 5 VDC for the
sensors caused a diagnostic code. Proceed to 3. Set the engine control to the STOP mode. Use
Test Step 8. Cat ET to clear the logged 262-03 or 262-04
code.
Test Step 8. Disconnect the 5 Volt
Sensors and Look For Active Diagnostic 4. Reconnect the suspect sensor. Verify that the
Codes. diagnostic code recurs.
A. Set the engine control to the OFF/RESET mode. If these conditions are true, replace the sensor.
5. Clear all of the diagnostic codes. Verify that
B. Disconnect the sensors for the following the problem is eliminated.
parameters:
STOP.
• No – The original “5 Volt Sensor” diagnostic code
• Engine oil temperature was still active while all of the 5 volt sensors were
disconnected. Do not reconnect the sensors.
• Unfiltered engine oil pressure Proceed to Test Step 9.
• Filtered engine oil pressure Test Step 9. Check the Harnesses

C. Switch the 35 amp circuit breaker ON. Set the A. Set the engine control to the OFF/RESET mode.
engine control to the STOP mode. Switch the 35 amp circuit breaker OFF.
Note: An “Open Circuit” code will be generated for B. Disconnect the P1 connector. Verify that all of
each sensor that is disconnected. This is normal. the sensors for the following parameters are
Clear the codes after you complete this procedure. disconnected from the engine harness:
D. Observe the “Active Diagnostic” screen on Cat • Inlet air temperature

ET. Verify that the 262-03 code or the 262-04
code is not active. • Engine oil temperature
E. Reconnect the sensors for the following • Unfiltered engine oil pressure
parameters one at a time. After you reconnect
each sensor, wait for at least 30 seconds and • Filtered engine oil pressure
then observe the “Active Diagnostic” screen on
Cat ET. C. Measure the resistance between terminal P1-2
and the points that are listed in Table 16. During
• Inlet air temperature each measurement, wiggle the harnesses in
order to check for an intermittent problem with
• Engine oil temperature the harness. Be sure to wiggle the harnesses
near each of the connectors for the disconnected
• Unfiltered engine oil pressure sensors. Also, wiggle the harness at the P7
connector.
Expected Result:
The original “5 Volt Sensor” diagnostic code is

activated when a particular sensor is disconnected.
Results:
• Yes – The original “5 Volt Sensor” diagnostic

code is activated when a particular sensor is
reconnected. The sensor and/or the wiring for the
sensor has a short circuit.
Repair: Perform the following procedure:
1. Set the engine control to the OFF/RESET mode.

218
Table 16 i01816023
Measure the Resistance for the Engine Harness. +8V Sensor Voltage Supply
Connector and Connector and Terminal
Terminal SMCS Code: 5574-038
P1-2 P1-14 (inlet air temperature) System Operation Description:
5 volt supply
P1-17 (engine oil temperature)
P1-26 (unfiltered engine oil pressure) supplies 8.0 ± 0.8 VDC to these sensors:
P1-24 (filtered engine oil pressure)
• Sensor for engine coolant pressure (outlet)
P1-3 (analog return)
Ground strap for the engine • Sensor for inlet air pressure
P1-69 (−Battery terminal) • The detonation sensors for the left side of the
P1-57 (unswitched +Battery) engine
P1-70 (switched +Battery) Terminals J1-4 and J2-56 are connected together
inside the master ECM. A short circuit on one of
Expected Result: these terminals will cause a short circuit on the
other terminal.
Each check of the resistance is greater than 20,000
ohms. The slave ECM supplies 8.0 ± 0.8 VDC to the
detonation sensors for the right side of the engine.
Results:
A “+8 V sensor supply” diagnostic code is probably
• OK – Each check of the resistance is greater caused by a short circuit or an open circuit in a
than 20,000 ohms. The 5 volt wires in the engine harness. The next likely cause is a sensor problem.
harnesses do not have a problem. The problem The least likely cause is a problem with an ECM.
appears to be resolved. The initial diagnostic
code was probably caused by a poor electrical Logged diagnostic codes provide a historical
connection. record. Before you begin this procedure, use the
Repair: Reconnect all of the connectors. Resume logged codes to a file.
normal operation.
STOP. additional diagnostic codes. Keep your mind on
• Not OK – At least one check of the resistance is Clear the diagnostic codes after the problem is
less than 20,000 ohms. There is a problem with a resolved.
connector and/or at least one of the 5 volt wires
in a harness.
Repair: The problem may be between the P1

connector and the P7 connector. Alternatively, the
problem may be in the engine harness that is
connected to the J7 connector.
Repair the connection and/or the wire, when

possible. Replace parts, if necessary. Verify that
the problem is resolved.
STOP.
219
g00927088
Illustration 29
Schematic for the 8 V supply
220
Connectors and Wiring. connectors:
• J1/P1 and J2/P2 connectors for the master

ECM
• J4/P4 connectors for the slave ECM

• J7/P7 and J8/P8 connectors on the terminal
box

for the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 30
Junction box
(1) 35 amp circuit breaker

Note: For the following steps, refer to

g00929350
Illustration 32
(P1-4) 8 volt supply for the pressure sensors
(P1-5) Return for the pressure sensors
(P1-10) Signal for the inlet air pressure
g00929336
Illustration 31
Terminal box
(5) J8/P8 connectors for the detonation sensors
(6) J4/P4 connectors for the slave ECM
221
g00929355
Illustration 33
(P2-36) Detonation sensor signal for cylinders 2 and 4
(P2-54) Return for the detonation sensors
(P2-56) 8 volt supply for the detonation sensors
(P2-68) Signal for the engine coolant pressure
g00929364
Illustration 35
(J7-1) Signal for the inlet air pressure
(J7-2) Signal for the engine coolant pressure
(J7-15) Return for the inlet air pressure
(J7-16) Return for the engine coolant pressure
(J7-29) Shield for the inlet air pressure
(J7-30) Shield for the engine coolant pressure
(J7-43) 8 volt supply for the inlet air pressure
(J7-44) 8 volt supply for the engine coolant pressure
g00929358
Illustration 34
222
g00929380
Illustration 36
(J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4
(J8-10) 8 V Supply for the detonation sensor for cylinders 17 and
19
(J8-11) Return for the detonation sensor for cylinders 2 and 4
(J8-21) Signal from the detonation sensor for cylinders 2 and 4
(J8-31) Shield for the detonation sensor for cylinders 2 and 4

for the 8 volt sensors.
223
g00929502
Illustration 37
(7) Engine coolant pressure sensor (8) Inlet air pressure sensor
Results:
• OK – All connectors, pins, and sockets are

connected properly. The connectors and the
• Not OK – At least one of the connectors, pins,

and sockets are not connected properly. At least
one of the connectors and/or the wiring has
corrosion, abrasion, and/or pinch points.

STOP.

A. Connect Cat ET to the service tool connector.
Illustration 38 g00929503 Refer to Troubleshooting, “Electronic Service
Left side of the engine
Tools”.
(9) Detonation sensors
B. Switch the 35 amp circuit breaker ON. Set the
d. Check the harness and wiring for abrasion
and pinch points from the 8 volt sensors to C. Observe the “Active Diagnostic” screen on Cat
the electronic control modules. ET. Wait at least 30 seconds so that any codes
Expected Result:
All connectors, pins, and sockets are connected

• 41-03 8 Volt DC Supply short to +batt
properly. The connectors and the wiring do not have
• 41-04 8 Volt DC Supply short to ground
D. Observe the “Logged Diagnostic” screen on Cat
ET. Look for the same codes.
224
Expected Result: If these conditions are true, repair the sensor

or the sensor’s harness. Replace parts, if
The 41-03 code or the 41-04 code is not active. necessary.
Results: 3. Clear all of the diagnostic codes. Verify that

the problem is eliminated.
• No codes – The 41-03 code or the 41-04 code is
not active. The 8 volt sensor supply is operating STOP.
correctly at this time. STOP.
• No – The original “8 Volt DC Supply” diagnostic
• Active code – The 41-03 code or the 41-04 code code is still active when a particular sensor is
is active. Proceed to Test Step 3. disconnected. Do not reconnect the sensors.
Proceed to Test Step 4.
• Logged code – The 41-03 code or the 41-04
code is not active. However, there is at least one Test Step 4. Isolate the Wiring Harnesses
logged code for the 8 volt sensor supply. from the Electronic Control Modules
Repair: There may be a problem with the wiring A. Set the engine control to the OFF/RESET mode.
and/or a connector. Refer to Troubleshooting, Switch the 35 amp circuit breaker OFF.
B. If you are troubleshooting an 8 volt problem with
Verify that the wiring and/or connectors are OK. the master ECM, use a 151-6320 Wire Removal
Check for diagnostic codes again. Proceed to Tool to remove the wires from the following
Test Step 3, if necessary. terminals:
Test Step 3. Disconnect the 8 Volt • P1-4

Sensors and Look for Active Diagnostic
Codes. • P2-56
A. Turn on the “Active Diagnostic” screen on Cat ET. • P2-57
Verify that the “41-03” or “41-04” code is active.
C. If you are troubleshooting an 8 volt problem with
B. Disconnect each 8 volt sensor one at a time. the slave ECM, use a 151-6320 Wire Removal
After you disconnect each sensor, wait for at Tool to remove the wires from the following
least 30 seconds and then observe the “Active terminals:
Diagnostic” screen on Cat ET.
• P4-56
Note: An “Open Circuit” code will be generated for
each sensor that is disconnected. This is normal. • P4-57
Clear the codes after you complete this procedure.
Expected Result: engine control to the STOP mode.
The original “8 Volt DC Supply” diagnostic E. Wait for at least 30 seconds and then observe
code is deactivated when a particular sensor is the “Active Diagnostics” screen on Cat ET.
disconnected. Determine if a 41-03 code or a 41-04 code is
active.
Results:
Expected Result:
• Yes – The original “8 Volt DC Supply” diagnostic
code is deactivated when a particular sensor is No active codes
disconnected. The sensor and/or the wiring for
the sensor has a short circuit. Results:
Repair: Perform the following procedure: • No codes – The 41-03 code or the 41-04 code is
not active. Disconnecting all of the 8 volt wiring
1. Reconnect the suspect sensor. Verify that the from the ECM eliminated the active “8 Volt DC
diagnostic code recurs. Supply” diagnostic code. There is a problem in a
connector and/or the wiring in a harness. Proceed
2. Disconnect the suspect sensor. Verify that the to Test Step 5.
diagnostic code is deactivated.
225
• Active code – There is an active 41-03 or 41-04 Table 17

code. Disconnecting all of the 8 volt wiring from Points for the Measurement of Resistance for
the ECM did not eliminate the active “8 Volt the Left Side of the Engine
DC Supply” diagnostic code. There may be a
problem with an ECM. Connector and Terminal Connector and Terminal
P1-4 (8 volt supply) P1-5 (digital return)
Repair: Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF. P1-10 (digital sensor
signal)
Insert all of the terminals that were removed. Pull P2-68 (digital sensor
on the wires in order to verify that the terminals signal)
are fully inserted into the connector.
P2-56 (8 volt supply) P2-36 (detonation sensor
It is unlikely that the ECM has failed. Exit this signal)
procedure and perform this procedure again. If P2-37 (detonation sensor
the problem is not resolved, perform the following signal)
steps:
P2-38 (detonation sensor
signal)
Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”. P2-54 (digital return)
If the problem is resolved with the new ECM, signal)
problem returns. If the new ECM operates P2-44 (detonation sensor
correctly and the original ECM does not operate signal)
correctly, replace the original ECM. Refer to P2-55 (digital return)
P1-4 (8 volt supply) Engine ground
STOP. P2-56
Test Step 5. Check the Wiring Harnesses P2-57
on the Left Side of the Engine P1-4 P1-69 (−Battery terminal)
A. Set the engine control to the OFF/RESET mode. P2-56
Switch the 35 amp circuit breaker OFF. P2-57
B. Insert all of the terminals that were removed. Pull P1-4 P1-57 (unswitched
on the wires in order to verify that the terminals +Battery)
P2-56
are fully inserted into the connector.
P2-57
C. Disconnect all of the 8 volt sensors.
P1-4 P1-70 (Switched +Battery)
D. Disconnect the P1 connector and the P2 P2-56
connector for the master ECM.
P2-57
E. Measure the resistance between the terminals
that are listed in Table 17. Expected Result:
During each measurement, wiggle the harnesses Each check of the resistance is greater than 20,000
in order to check for an intermittent problem. ohms.
Be sure to wiggle the wires near each of the
connectors. Results:
• OK – Each check of the resistance is greater than

20,000 ohms. The 8 volt wires and connectors on
the left side of the engine do not have a short
circuit. Proceed to Test Step 6.
• 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 8 volt wires
in a harness.
226
Repair: The problem may be inside the terminal Results:

box. Alternatively, the problem may be in an
engine harness. • OK – Each check of the resistance is greater than
20,000 ohms. The 8 volt wires and connectors on
Repair the connection and/or the wire, when the right side of the engine do not have a short
possible. Replace parts, if necessary. circuit. The problem seems to be resolved. The
initial diagnostic code was probably caused by a
STOP. poor electrical connection.
Test Step 6. Check the Wiring Harnesses Repair: Reconnect all of the connectors and
on the Right Side of the Engine resume normal operation.
A. Disconnect the P3 connector and the P4 STOP.

connector for the slave ECM.
• Not OK – At least one check of the resistance is
B. Measure the resistance between the terminals less than 20,000 ohms. There is a problem with a
that are listed in Table 18. harness on the right side of the engine.
During each measurement, wiggle the harnesses Repair: The problem could be inside the terminal
in order to check for an intermittent problem. box. Alternatively, the problem may be in an
Be sure to wiggle the wires near each of the engine harness.
connectors.
Table 18 possible. Replace parts, if necessary.
Points for the Measurement of Resistance for
the Right Side of the Engine STOP.
Connector and Terminal Connector and Terminal
i01816068
signal) Analog Sensor Signal
P4-37 (detonation sensor
signal) SMCS Code: 5574-038
P4-38 (detonation sensor System Operation Description:
signal)
P4-54 (digital return) Use this procedure to troubleshoot diagnostic codes
for open circuits or short circuits for the sensors of
P4-57 (8 volt supply) P4-39 (detonation sensor these parameters:
signal)
P4-44 (detonation sensor • Engine coolant temperature
signal)
P4-55 (digital return) • Inlet air temperature
P4-56 Engine ground • Engine oil temperature
P4-57
P4-56 P3-69 (−Battery terminal)
P4-57
P4-56 P3-57 (unswitched Note: The engine coolant temperature sensor does
+Battery) not require +5 VDC from the master Electronic
P4-57 Control Module (ECM). The engine coolant
P4-56 P3-70 (switched +Battery) temperature sensor is a passive sensor of the
analog type. The sensor operates without a voltage
P4-57 supply from the master ECM.
Expected Result: The master ECM can be configured for one of these
types of speed control:
Each check of the resistance is greater than 20,000
ohms. • Potentiometer
227
• 4-20 ma
The “DESIRED SPEED” potentiometer (if equipped)
must be supplied with +5 VDC from the master
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.
The -03 code is probably caused by a problem in

an engine harness. There may be an open circuit
in a harness, or a short circuit to a positive voltage
source in a harness. The next likely cause is a
sensor problem. The least likely cause is a problem
with the master ECM.
The -04 code is probably caused by a short circuit

to ground in an engine harness. The next likely
cause is a sensor problem. The least likely cause is
a problem with the master ECM.


correcting the cause of the original diagnostic
code. Clear the diagnostic code after the problem
is resolved.
228
g00951784
Illustration 39
Schematic for the analog sensors
229
Test Step 1. Inspect the Electrical • Master ECM J1/P1 connectors

Connectors and Wiring
box

for the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

for the terminal box’s connectors. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g00931487
Illustration 40
Junction box
A. Set the engine control to the OFF/RESET mode. g00929585

Illustration 42
Switch 35 amp circuit breaker (1) to the OFF Harness side of the master ECM P1 connector
position.
(P1-3) Return
Note: For the following steps, refer to (P1-14) Signal for the inlet manifold air temperature
Troubleshooting, “Inspecting Electrical Connectors”. (P1-16) Signal for the desired speed
(P1-17) Signal for the engine oil temperature
(P1-24) Signal for the filtered engine oil pressure
(P1-26) Signal for the unfiltered engine oil pressure
(P1-27) Signal for the engine coolant temperature
(P1-35) Return
g00928823
Illustration 41
Terminal box
B. Thoroughly inspect each of the following

connectors:
230
g00929111
Illustration 43
(J6-5) 5 volt supply
(J6-15) Return
(J6-25) Signal for desired speed
(J6-35) Shield
g00929594
Illustration 44
(J7-3) Signal for the inlet manifold air temperature
(J7-4) Signal for the filtered engine oil pressure
(J7-5) Signal for the engine oil temperature
(J7-6) Signal for the unfiltered engine oil pressure
(J7-7) Signal for the engine coolant temperature
(J7-17) Return for the inlet manifold air temperature
(J7-18) Return for the filtered engine oil pressure
(J7-19) Return for the engine oil temperature
(J7-20) Return for the unfiltered engine oil pressure
(J7-21) Return for the engine coolant temperature
(J7-31) Shield for the inlet manifold air temperature
(J7-32) Shield for the filtered engine oil pressure
(J7-33) Shield for the engine oil temperature
(J7-34) Shield for the unfiltered engine oil pressure
(J7-35) Shield for the engine coolant temperature
(J7-45) 5 volt supply for the inlet manifold air temperature
(J7-46) 5 volt supply for the filtered engine oil pressure
(J7-47) 5 volt supply for the engine oil temperature
(J7-48) 5 volt supply for the unfiltered engine oil pressure

for the analog sensors.
231
g00929157
Illustration 45
(5) Engine oil temperature sensor (6) Unfiltered oil pressure sensor (7) Filtered oil pressure sensor
• Not OK – At least one of the connectors, pins,

and/or sockets are not connected properly. At
least one of the connectors and/or the wiring has

STOP.

for the Power Supply
g00929599 Refer to Troubleshooting, “Electronic Service
Illustration 46
Tools”.
(8) Engine coolant temperature sensor B. Switch the 35 amp circuit breaker ON. Set the
(9) Engine coolant pressure sensor (outlet) engine control to the STOP mode.
d. Check the harness and wiring for abrasion C. Observe the “Active Diagnostic” screen on ET.
and for pinch points from the analog sensors Allow a minimum of 30 seconds for any codes to
to the master ECM. activate. Look for these codes:
Expected Result: • 262-03 5 Volt Sensor DC Power Supply short
to +batt
properly. The connectors and the wiring do not have • 262-04 5 Volt Sensor DC Power Supply short
corrosion, abrasion, or pinch points. to ground
Results: Expected Result:
• OK – All connectors, pins, and sockets are There are no active “5 Volt Sensor DC Power
connected properly. The connectors and the Supply” diagnostic codes.
232
Results: Results:
• No codes – There are no active “5 Volt Sensor • No active codes – None of the above codes are
DC Power Supply” diagnostic codes. Proceed to active.
Test Step 3.
Repair: If any of the above codes are logged
• Active code – There is an active “5 Volt Sensor DC and the engine is not running properly, refer
Power Supply” diagnostic code. This procedure to Troubleshooting, “Troubleshooting Without a
will not work when this type of code is active. Diagnostic Code”.
Repair: Refer to Troubleshooting, “+5V Sensor If the engine is running properly at this time,
Supply”. there may be an intermittent problem in the
harness that is causing the codes to be logged.
If necessary, return to this functional test in order Refer to Troubleshooting, “Inspecting Electrical
to troubleshoot the analog sensor after the “+5 Connectors”.
V Sensor Supply” diagnostic code has been
resolved. STOP.
STOP. • Active “open/short to +batt” (FMI 03) – There is

an active “open/short to +batt” diagnostic code.
Test Step 3. Check for Active Analog If you are troubleshooting the sensor for engine
Sensor Diagnostic Codes coolant temperature, proceed to Test Step 6.
Otherwise, proceed to Test Step 5.
A. Observe the “Active Diagnostic” screen on Cat
ET. Wait at least 30 seconds so that any codes • Active “short to ground” (FMI 04) – There is an
may become activated. Look for the codes that active “short to ground” diagnostic code. Proceed
are listed in Table 19: to Test Step 4.
Table 19 Test Step 4. Create an Open Circuit for

Analog Sensor Diagnostic Codes the Sensor
100-03 Engine Oil Pressure open/short to +batt A. Set the engine control to the OFF/RESET mode.
100-04 Engine Oil Pressure short to ground
B. Disconnect the sensor that has the “short to
110-03 Engine Coolant Temperature open/short to ground” diagnostic code.
+batt
110-04 Engine Coolant Temperature short to ground C. Set the engine control to the STOP mode.
172-03 Intake Manifold Air Temp open/short to +batt D. Observe the “Active Diagnostic” screen on Cat
172-04 Intake Manifold Air Temp short to ground ET. Allow a minimum of 30 seconds for any
codes to activate. Look for an active “open/short
175-03 Engine Oil Temperature open/short to +batt to +batt” diagnostic code.
175-04 Engine Oil Temperature short to ground
Expected Result:
542-03 Unfiltered Engine Oil Pressure open/short to
+batt There is an active “open/short to +batt” diagnostic
542-04 Unfiltered Engine Oil Pressure short to ground code for the disconnected sensor.
Results:
B. If one of the above codes is active, identify the
type of diagnostic according to the condition: the • Yes – Before the suspect sensor was
diagnostic code is either “open/short to +batt” disconnected, there was an active “short to
(FMI 03) or “short to ground” (FMI 04). ground” diagnostic code for the sensor. After the
suspect sensor was disconnected, there was an
Expected Result: active “open/short to +batt” diagnostic code for
the sensor.
None of the above codes are active.
Repair: Reconnect the sensor. If the active “short
to ground” diagnostic code recurs, replace the
original sensor.
233
Verify that the code does not activate when Test Step 6. Check the Pull-Up Voltage at
the new sensor is installed. Clear the logged the Sensor
diagnostic code from the master ECM.
A. Verify that the suspect sensor’s connector is
STOP. disconnected from the engine harness.
• No – Before the suspect sensor was

disconnected, there was an active “short to
ground” diagnostic code for the sensor. After the
suspect sensor was disconnected, the active
“open/short to +batt” diagnostic code remained.
If you are troubleshooting the sensor for engine
coolant temperature, proceed to Test Step 6.
Otherwise, proceed to Test Step 5. Illustration 48 g00889801
Harness connectors for the various sensors

Test Step 5. Check the Supply Voltage at
the Sensor Connector (A) 5 volt supply
(B) Return
(C) Signal
A. Verify that the suspect sensor is disconnected (1) Signal
from the engine harness. (2) Return
B. At the harness connector for the suspect sensor,

measure the voltage between terminals B and C,
or between terminals 1 and 2.
Expected Result:
The voltage is between 6.0 VDC and 7.0 VDC.

g00889729
Illustration 47
Results:
Harness connectors for the various sensors
(A) 5 volt supply
(B) Return
• OK – The voltage between the signal terminal
(C) Signal and the return terminal is between 6.0 VDC and
7.0 VDC. The pull-up voltage that is created
B. At the harness connector for the suspect sensor, by the master ECM is present at the sensor
measure the voltage between terminals A and B. connector. The signal wire and the return wire for
the suspect sensor appear to be OK. Proceed
Expected Result: to Test Step 8.
The voltage is between 4.5 VDC and 5.5 VDC. • Not OK – The voltage between the signal terminal
and the return terminal is not between 6.0 VDC
Results: and 7.0 VDC. The pull-up voltage that is created
by the master ECM is not present at the sensor
connector. Proceed to Test Step 7.
• OK – The voltage between terminals A and B is
between 4.5 VDC and 5.5 VDC. The 5 volt supply
is present at the sensor connector. Proceed to Test Step 7. Check the Pull-Up Voltage
Test Step 6. at the Master ECM
• Not OK – The voltage between terminals A and A. Set the engine control to the OFF/RESET mode.
terminal B is not between 4.5 VDC and 5.5 VDC. Switch the 35 amp circuit breaker OFF.
The 5 volt supply is not present at the sensor
connector. The 5 volts must be present at the B. Use a 151-6320 Wire Removal Tool to remove
sensor in order to continue this procedure. The the signal wire for the suspect sensor from the
5 volt wiring problem may be inside the terminal P1 connector.
box, or in the engine harness.
C. Use a jumper wire with Deutsch terminals on the
Repair: Verify that the wiring and/or connectors are ends. Insert one end of the jumper wire into the
OK. Repair any faulty wiring and/or connectors, open terminal of the P1 connector.
when possible. Replace parts, if necessary.
Refer to Troubleshooting, “Inspecting Electrical D. Connect a multimeter lead to the end of the
Connectors”. Check for diagnostic codes again. jumper wire that is not inserted into the connector.
STOP.
234
E. At the harness side of the P1 connector, insert a Expected Result:

7X-1710 Multimeter Probe along terminal 3.
No diagnostic codes are activated.
F. Connect the other multimeter lead to the probe.
Results:
G. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. • OK – No diagnostic codes are activated when a
good sensor is temporarily installed. Connecting
H. Measure the pull-up voltage at the master ECM. a new sensor resolved the problem.
Expected Result: Repair: Perform the following procedure:
The voltage is between 6.0 VDC and 7.0 VDC. 1. Reconnect the suspect sensor. Verify that the
“open/short to +batt” diagnostic code recurs.
Results:
2. Disconnect the suspect sensor. Verify that
• OK – The pull-up voltage for the suspect sensor the “open/short to +batt” diagnostic code is
at the master ECM is between 6.0 VDC and 7.0 deactivated.
VDC. The master ECM is producing a pull-up
voltage that is valid. There is a problem with 3. Connect the new connector. Verify that no
the signal wire between P1 and the harness diagnostic codes are activated.
connector for the sensor. There may be a problem
with a connector. If these conditions are true, replace the faulty
sensor with the new sensor. For the proper
Repair: Perform the following procedure: torque value for the new sensor, refer to the
Specifications manual.
Switch the 35 amp circuit breaker OFF. 4. Clear all of the diagnostic codes. Verify that
the problem has been resolved.
Disconnect the multimeter leads.
STOP.
Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P1 connector. • Not OK – The active “open/short to +batt” code
remains. Connecting a new sensor did not resolve
Reinstall the terminal that was removed from the the problem. Proceed to Test Step 9.
P1 connector. Pull on the wire in order to verify
proper installation of the terminal. Test Step 9. Check the Operation of the
Master ECM
Verify that the wiring and/or connectors are OK.
Repair any faulty wiring and/or connectors, when A. Verify that the signal wire for the suspect sensor
possible. Replace any wiring and/or connectors, if has been removed from the P1 connector.
necessary. Refer to Troubleshooting, “Inspecting
Electrical Connectors”. B. Clear any existing diagnostic codes.
STOP. C. Observe the “Active Diagnostic” screen on ET.

Allow a minimum of 30 seconds for any codes
• Not OK – The pull-up voltage for the suspect to activate.
sensor at the master ECM is not between 6.0
VDC and 7.0 VDC. Proceed to Test Step 9. An active “open/short to +batt” diagnostic code
is generated for the sensor.
Test Step 8. Check the Sensor
D. Set the engine control to the OFF/RESET mode.
A. Temporarily connect a sensor that is known to be Switch the 35 amp circuit breaker OFF.
good to the engine harness.
E. Use a jumper wire that is the appropriate length
B. Switch the 35 amp circuit breaker ON. Set the with Deutsch terminals on the ends. Install one
engine control to the STOP mode. end of the jumper wire into the terminal for
the signal wire that was removed from the P1
C. Observe the “Active Diagnostic” screen on Cat connector. Install the other end of the jumper
ET. Allow a minimum of 30 seconds for any wire into terminal 19 of the P1 connector. This
codes to activate. will replace the sensor circuit with a short circuit.
235
F. Switch the 35 amp circuit breaker ON. Set the i01879516

Bypass Valve
G. Observe the “Active Diagnostic” screen on Cat
ET. Allow a minimum of 30 seconds for any SMCS Code: 1052-038-BV
codes to activate.
An active “short to ground” diagnostic code is
generated. A bypass valve is connected between the inlet of
the aftercooler and the inlets for the turbocharger
Expected Result: compressors. The bypass valve is activated by
an actuator. The master Electronic Control Module
Active “open/short to +batt” and “short to ground” (ECM) activates the actuator for the bypass valve
diagnostic codes are generated according to the during these conditions:
above steps.
• Turbocharger surge
Results:
• Engine shutdown
• OK – Active “open/short to +batt” and “short
to ground” diagnostic codes are generated Turbocharger Surge
according to the above steps. The master ECM
is operating correctly. The initial diagnostic A rapid drop in the output power of the generator
code was probably caused by a poor electrical can cause the engine’s speed to quickly increase.
connection. The increased speed of the engine causes the
turbochargers to overspeed temporarily. This is
Repair: Perform the following procedure: called turbocharger surge. Surging can damage
the turbochargers.
Switch the 35 amp circuit breaker OFF. The master ECM continuously monitors the speed
of the engine. The master ECM responds to a rapid
Use a 151-6320 Wire Removal Tool to remove increase in the speed of the engine by activating
the jumper wire from the P1 connector. the actuator for the bypass valve. The actuator
opens the valve.
Reinstall the terminal that was removed from the
P1 connector. Pull on the wire in order to verify The valve allows the compressed air/fuel mixture in
proper installation of the terminal. the aftercooler’s inlet to flow into the intake of the
turbocharger’s compressor. This reduces the boost
Resume normal operation. pressure in the air inlet manifold.
STOP. Engine Shutdown
• Not OK – No active “open/short to +batt” Engine shutdown occurs when the output for the
and “short to ground” diagnostic codes were fuel control relay is OFF and the engine RPM is
generated. The master ECM is not operating above 100. The master ECM activates the actuator
correctly. for the bypass valve until the engine RPM drops to
zero. This scavenges any unburned gases in the
Repair: It is unlikely that the master ECM has components of the system during engine shutdown.
failed. Exit this procedure and perform this entire
procedure again. If the problem is not resolved, CAN Data Link
perform the following steps:
The master ECM and the actuator communicate
Temporarily install a new master ECM. Refer to via the CAN data link. The master ECM sends
Troubleshooting, “Replacing the ECM”. a command signal to the actuator. The actuator
sends the following information to the master ECM:
If the problem is resolved with the new ECM, actuator position, CCM heartbeat, software version,
install the original ECM and verify that the problem and internal fault diagnosis.
returns. If the new ECM operates correctly and
the original ECM does not operate correctly,
replace the ECM. Refer to Troubleshooting,
“Replacing the ECM”.
STOP.
236
If the master ECM cannot communicate with the

actuator, the master ECM activates a 1720-09
diagnostic code and the engine is shut down. A
1720-09 diagnostic code is probably caused by a
problem with an electrical connector or a harness.
The next likely cause is a problem with the actuator.
The least likely cause is a problem with the master
ECM.
Terminating resistors must be connected to each

end of the CAN data link. The terminating resistors
improve the communication between the devices. If
there is an intermittent diagnostic code for any of
the devices that are connected to the CAN data
link, be sure to check the terminating resistor that is
inside the terminal box. Also check the jumper wire
that is connected between terminals J and K on the
actuator for the bypass valve. Make repairs, when
possible. Replace parts, if necessary.
Identification on the CAN Data Link
When the actuator for the bypass valve is powered

up, the actuator looks for a ground on terminal N.
If there is a ground on terminal N, the actuator will
have a unique identification on the CAN data link.
If there is no ground on terminal N and the

actuator is powered up, the actuator for the bypass
valve and the throttle actuator will have the same
identification. The master ECM will not communicate
with the actuator for the bypass valve. Instead,
the master ECM will activate a 1720-09 diagnostic
code. The engine will not start.
The electrical connector for the actuator is designed

so that the terminals for electrical power are
connected before terminal N. For this reason,
electrical power must be removed before the
connector for the actuator is connected.
237
g00935458
Illustration 49
Block diagram of the system for compressor bypass
238
g00951768
Illustration 50
Schematic for the circuit of the actuator for the bypass valve
239

• J9/P9 connectors on the terminal box
• Connectors on the actuator for the bypass
valve
a. Check the torque of the Allen head screw for

the ECM connectors. The proper torque is
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 51
Junction box

position.

Troubleshooting, “Inspecting Electrical Connectors”. g00933941
Illustration 53
Harness side of the ECM P1 connector
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
g00933933
Illustration 52
Terminal box
(2) Ground strap
(4) J9/P9 connectors for the CAN data link g00934039
Illustration 54
(5) J10/P10 connectors for the terminating resistor for the CAN
data link Harness side of the ECM J9 connector
(J9-6) CAN data link +
(J9-12) CAN data link −
(J9-18) CAN shield
240
c. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the actuator
for the bypass valve.
g00935459
Illustration 55
Right side view of the engine
d. Check the wiring for abrasion and for pinch B. Switch the 35 amp circuit breaker ON. Set the
points from the actuator for the bypass valve engine control to the STOP mode.
to the master ECM.
C. Use Cat ET in order to determine if a 1720-09
Expected Result: diagnostic code is active.
All of the connectors, pins, and sockets are Expected Result:

connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points. The 1720-09 code is not active.
Results: Results:
• OK – The components are in good condition with • OK – The 1720-09 code is not active. The
proper connections. Proceed to Test Step 2. communication between the master ECM and the
actuator for the bypass valve appears to be OK
• Not OK – The components are not in good at this time. However, diagnostic codes may be
condition and/or at least one connection is logged.
improper.
Repair: If you are troubleshooting an intermittent
Repair: Perform the necessary repairs and/or problem, refer to Troubleshooting, “Inspecting
replace parts, if necessary. Ensure that all of Electrical Connectors”.
the seals are properly installed. Ensure that the
connectors are properly engaged. Verify that the
repair has eliminated the original problem.
STOP.
Test Step 2. Check for a Diagnostic Code

A. Connect the Caterpillar Electronic Technician
(ET) to the service tool connector on the terminal
box.
241
Terminating resistors must be connected to Repair: The open circuit could be caused by
each end of the CAN data link. The terminating a poor electrical connection in a connector.
resistors improve the communication between the Alternatively, the open circuit could be caused by
devices. If there is an intermittent diagnostic code one of the following components:
for any of the devices that are connected to the
CAN data link, be sure to check the terminating • The harness inside the terminal box
resistor that is inside the terminal box. Also
check the jumper wire that is connected between • The harness between the terminal box and the
terminals J and K on the actuator for the bypass fuel metering valve
valve. Make repairs, when possible. Replace
parts, if necessary. • The harness between the fuel metering valve
and the throttle actuator
STOP.
• The harness between the throttle actuator and
• Not OK (Active 1720-09) – The master ECM has the actuator for the bypass valve
detected a problem with the communication
between the master ECM and the actuator for the • The fuel metering valve
bypass valve. Proceed to Test Step 3.
• The throttle actuator
Test Step 3. Check the CAN Data Link for
Continuity Between the Actuator for the Make repairs, when possible. Replace parts, if
Bypass Valve and the Master ECM necessary.
A. Set the engine control to the OFF/RESET mode. STOP.

B. Disconnect the P1 connector. Disconnect the a Short Circuit
connector for the actuator for the bypass valve.
A. Verify that the engine control is in the OFF/RESET
C. Use a multimeter to check for continuity between mode and that the 35 amp circuit breaker is OFF.
the points that are listed in Table 20. During
each measurement, wiggle the harnesses in B. Use a multimeter to check for continuity between
order to check for an intermittent problem with the points that are listed in Table 21. During
the harness. Be sure to wiggle the harness near each measurement, wiggle the harnesses in
each of the connectors. Be sure to wiggle the order to check for an intermittent problem with
harness near the fuel metering valve and the the harness. Be sure to wiggle the harness near
throttle actuator. each of the connectors. Be sure to wiggle the
harness near the fuel metering valve and the
Table 20 throttle actuator.
Points to Check for Continuity
Table 21
Connector and Harness Connector for the
Terminal Actuator for the Bypass Valve
Connector and Terminal Connector and Terminal
P1-34 Terminal B (CAN data link −)
P1-34 (CAN Data Link −) P1-50 (CAN Data Link +)
P1-50 Terminal A (CAN data link +)
P1-42 (CAN Shield)
P1-42 Terminal M (CAN shield) P1-52 (+ Battery)
Ground strap for the ECM
Expected Result: P1-50 (CAN Data Link +) P1-42 (CAN Shield)

P1-52 (+ Battery)
The continuity of the circuits between the terminals Ground strap for the ECM
is good. P1-42 (CAN Shield) P1-52 (+ Battery)
Ground strap for the ECM
Results:
Expected Result:
• OK – The continuity of the circuits between the
terminals is good. Proceed to Test Step 4.
All of the measurements indicate an open circuit.
• Not OK – At least one of the continuity checks
indicates an open circuit. There is an open circuit
for the CAN data link between the actuator for the
bypass valve and the master ECM.
242
Results: Repair: If there is an intermittent problem

that is causing the code to be logged, refer
• OK – All of the measurements indicate an open to Troubleshooting, “Inspecting Electrical
circuit. The CAN data link does not have a short Connectors”.
circuit.
STOP.
Repair: Reconnect the P1 connector. Reconnect
the connector for the actuator for the bypass • Not OK – The 1720-09 code is active.
valve.
Repair: The active 1720-09 code could be caused
Proceed to Test Step 5. by one of the following components:
• Not OK – At least one of the measurements • The master ECM

indicate a short circuit.
Repair: The short circuit could be caused by
a poor electrical connection in a connector. • The actuator for the bypass valve
Alternatively, the short circuit could be caused by
one of the following components: • The fuel metering valve
• The harness inside the terminal box It is unlikely that any of the components that are
listed above have failed. Exit this procedure and
• The harness between the terminal box and the perform this procedure again. If the 1720-09 code
fuel metering valve remains active, perform the following procedure:
• The harness between the fuel metering valve 1. Temporarily install a new master ECM. Refer to
and the throttle actuator Troubleshooting, “Replacing the ECM”. If the
problem is resolved with the new ECM, install
• The harness between the throttle actuator and the original ECM and verify that the problem
the actuator for the bypass valve returns. If the new ECM operates correctly
and the original ECM does not operate
• The fuel metering valve correctly, replace the original ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the
• The throttle actuator problem is not resolved with a new ECM, install
the original ECM. Continue with this procedure.
Make repairs, when possible. Replace parts, if
necessary. 2. Temporarily install a new actuator for the
throttle actuator. If the new throttle actuator
STOP. operates correctly, the problem is resolved.
If the new throttle actuator does not operate
Test Step 5. Check for a Diagnostic Code correctly, install the original throttle actuator
and continue with this procedure.
A. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. 3. Temporarily install a new actuator for the
bypass valve. If the new actuator for the
B. Use Cat ET in order to determine if a 1720-09 bypass valve operates correctly, the problem
diagnostic code is active. is resolved. If the new actuator for the bypass
valve does not operate correctly, install the
Expected Result: original actuator for the bypass valve and
continue with this procedure.
The 1720-09 code is not active.
4. Temporarily install a new fuel metering valve. If
Results: the new fuel metering valve operates correctly,
the problem is resolved. If the new fuel
• OK – The 1720-09 code is not active. The metering valve does not operate correctly,
problem seems to be resolved. The initial install the original fuel metering valve. Refer
diagnostic code was probably caused by a poor to Troubleshooting, “Inspecting Electrical
electrical connection. Connectors”.
STOP.
243
i01830449
CAT Data Link

SMCS Code: 1901-038
The CAT data link is used to share information

between the following components:
• Master Electronic Control Module (ECM)

• Slave ECM
• Integrated Temperature Sensing Module (ITSM)
• Service tool
• Customer installed components
Illustration 56 shows the information that is shared
between the master ECM and the slave ECM via
the CAT data link.
g00951847
Illustration 56
Each ECM and the ITSM communicate with CAT The most likely cause of a diagnostic code for
ET via the CAT data link. the CAT data link are an open circuit or a short
circuit. Connector terminals that are not fully seated
The CAT data link consists of two wires that are in the connector body can create an open circuit
twisted together. One wire is designated as +. The condition. Be careful not to interchange the + wire
other wire is designated as -. and the - wire in a connector. The CAT data link
will not operate if the + wire and the - wire are
The signals on the data link wires are a square interchanged in a connector.
wave type signal. The signals operate at a very high
frequency. The signals cannot be measured with The CAT data link can fail if a module is not receiving
common service tools. Therefore, only continuity power. This can happen if there is a problem with
measurements can be made on the wires for the the wiring that provides power to the module.
CAT data link.
244
The CAT data link can fail if a module is programmed

with the wrong FLASH file, or if a module has not
been programmed with a FLASH file. Verify that all
modules have been programmed with the proper
FLASH file.
Harness Code for the Slave ECM
The harness inside the terminal box has a jumper

wire (harness code) that connects terminals J3-29
and J3-60. The ECM that is connected to the
harness reads the harness code. This allows the
ECM to operate as the slave ECM.
If the jumper wire is disconnected, the slave ECM

will assume the function of a master ECM. Cat ET
will not communicate with any of the modules. Cat
ET will display “Duplicate Type on data link. Unable
to Service”.
g00951927
Illustration 57
Schematic diagram of the CAT data link
245
Test Step 1. Inspect the Electrical

Connectors and wiring
g00934705
Illustration 60
(8) ITSM
Illustration 58 g00931487 (9) 14-pin connectors for the harness to the terminal box for the
master ECM

connectors:
position.
Note: For the following steps, refer to • Master ECM J1/P1 connectors
• J5, J6, and J9/P9 connectors on the terminal
box
• 14-pin connectors (9) for the ITSM

6 ± 1 N·m (53 ± 9 lb in).

g00951919
Illustration 59
Terminal box for the master ECM
(2) Ground strap
(3) J5 connector for Cat ET
(5) J6 connector for the customer
(6) J9/P9 connectors for the CAT data link
246
Results:
• OK – The components are in good condition with

proper connections. Proceed to Test Step 2.
• Not OK – The components are not in good

condition and/or at least one connection is
improper.

STOP.
g00894447
Test Step 2. Check the CAT Data Link
Illustration 61
Harness side of the master ECM P1 connector A. Verify that the engine control is in the OFF/RESET
(P1-8) CAT data link + mode. Verify that the 35 amp circuit breaker is
(P1-9) CAT data link − OFF.
B. Connect Cat ET to the service tool connector.

Refer to Troubleshooting, “Electronic Service
Tools”.
C. Set the engine control to the STOP mode. Switch

the 35 amp circuit breaker ON.
D. Select the “File/Select ECM” menu on the Cat

ET. Verify that all of the modules are displayed
on the “ECM Selector” screen.
Verify that the following diagnostic codes are not

activated.
g00951936
Illustration 62 • 0590-09 Unable to communicate with Engine
Harness side of the P3 connector for the slave ECM ECM
(P1-8) CAT data link +
(P1-9) CAT data link − • 1636-09 Loss of communication with Engine
(P1-29) Harness code #2 (Slave)
(P1-60) harness code

• 1042-09 Unable to communicate with ITSM
the wires that are associated with the circuit Note: If Cat ET displays “Duplicate Type on data
for the CAT data link. link. Unable to Service”, there may be a problem
with the harness inside the terminal box. Set the
d. Check the harness and wiring for abrasion engine control to the OFF/RESET mode. Switch the
and for pinch points from the slave ECM to 35 amp circuit breaker OFF. Check the continuity
the master ECM. between terminals J3-29 and J3-60. Verify that the
jumper wire is in good condition. Make repairs, as
e. Check the harnesses and wiring for abrasion needed.
and for pinch points from the ITSM to the
master ECM. Expected Result:
Expected Result: All of the modules are displayed on the “ECM
Selector” screen. There are no active diagnostic
The connectors, pins, and sockets are connected codes for the CAT data link.
247
Results: Table 22
Resistance Measurements for the CAT Data Link
• OK – All of the modules are displayed on the
“ECM Selector” screen. There are no active Connector and Terminal Connector and Terminal
diagnostic codes for the CAT data link. The
P1-8 P3-8
problem seems to be resolved.
J5-D
J6-7
and the engine is not running properly, refer
to Troubleshooting, “Troubleshooting Without a Terminal J of the 14-pin
Diagnostic Code”. connector on the ITSM
P3-8 J5-D
If any of the above codes are logged and the
engine is running properly, there may be an P1-9 P3-9
intermittent problem in a connector or a wiring
J5-E
harness. Refer to Troubleshooting, “Inspecting
Electrical Connectors”. J6-17
Terminal N of the 14-pin
STOP. connector on the ITSM
• Not OK – At least one of the modules is not P3-9 J5-E

displayed on the “ECM Selector” screen. There P1-34 Ground strap for the master
may be an active diagnostic code for the CAT ECM
data link. Proceed to Test Step 3.
P1-50 Ground strap for the master
Test Step 3. Check the Continuity of the ECM
Wiring for the CAT Data Link
Expected Result:
Switch the 35 amp circuit breaker OFF. Each check of the resistance between the
connectors is less than 5 ohms.
B. Disconnect Cat ET from the service tool
connector. Each check of the resistance between the connector
and the ground strap is greater than 20,000 ohms.
C. Disconnect the following connectors:
Results:
• P1 connector from the master ECM
• OK – Each check of the resistance for the CAT
• P3 connector from the slave ECM data link is within the specification. The wiring for
the CAT data link appears to be OK.
• P6 connector (if equipped)
• 14-pin connector from the ITSM
1. Connect the following connectors:
D. Measure the resistance between the points that
are listed in Table 22. During each measurement, • P1 connector to the master ECM
wiggle the wires in the harness in order to check
for an intermittent problem. Be sure to wiggle the • P3 connector to the slave ECM
wires near each of the connectors.
• P6 connector (if equipped)
• 14-pin connector to the ITSM
2. Connect Cat ET to the service tool connector.
Tools”.
3. Switch the 35 amp circuit breaker ON. Set the

4. Verify that Cat ET is able to communicate with

each of the modules.
248
5. If Cat ET is unable to communicate with i01820928

a module, there may be a problem with
the supply voltage to the module. Refer to Desired Speed Input (4 - 20
Troubleshooting, “Electrical Power Supply”. mA)
6. If the problem is not resolved, there may be a SMCS Code: 1901-038
problem with the wiring for the CAT data link
between the J6 connector and the customer’s System Operation Description:
equipment. Verify that the wiring for the CAT
data link between the J6 connector and the Note: For this troubleshooting procedure,
customer’s equipment is working properly. the “Desired Speed Input” configuration
parameter must be set to “4-20 mA Input” in the
7. If the problem is not resolved, there may “Service/Configuration” screen of the Caterpillar
be a problem with the module that is not Electronic Technician (ET). Do not select “PWM”.
communicating with Cat ET. The master Electronic Control Module (ECM) cannot
be configured to accept a PWM input signal for
It is unlikely that a module has failed. Exit this control of the engine speed.
procedure and perform this procedure again.
If the problem is not resolved, temporarily The selection of the “4-20 mA Input” setting requires
replace the module that is not communicating. a 4 to 20 mA signal for regulation of the desired
Refer to Troubleshooting, “Replacing the ECM” engine speed. If the “Desired Speed Input” is set
or Troubleshooting, “Replacing the ITSM”. to “0-5 VDC Input”, do not use this procedure to
Verify that the problem is resolved. troubleshoot the circuit.
If the problem is resolved with the new module, When the desired speed input is correspondingly
reinstall the original module and verify that configured, the master ECM controls the engine
the problem returns. If the new module works speed according to the 4 to 20 mA current.
correctly and the original module does not
work correctly, replace the original module. The value of the current corresponds to a range
Refer to Troubleshooting, “Replacing the ECM” of desired engine speeds between minimum high
or Troubleshooting, “Replacing the ITSM”. idle and maximum high idle. The “Minimum Engine
High Idle Speed” and the “Maximum Engine High
STOP. Idle Speed” are set with the “Service/Configuration”
screen of ET. For more information, refer to Systems
• Not OK – At least one check of the resistance for Operation/Testing and Adjusting, “Electronic Control
the CAT data link is incorrect. There is a problem System Parameters”.
with the wiring for the CAT data link.
When the “Idle/Rated” switch is in the Rated
Repair: Repair the connection and/or the wire, position, a current value of 4.0 mA corresponds
when possible. Replace parts, if necessary. Verify to the programmed “Minimum Engine High Idle
that the problem is resolved. Speed”. A current value of 20.0 mA corresponds
to “Maximum Engine High Idle Speed”. Current
STOP. 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”.
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
Desired Engine Speed Sensor short to ground”
diagnostic code.
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
a component. The least likely cause is a problem
with the master ECM.
249

record. Before you begin this procedure, use ET to
print the logged codes to a file.
The troubleshooting procedure may generate

resolved.
g00929645
Illustration 65
Terminal box
g00929621 (2) Ground strap
Illustration 63
Schematic of the 4 to 20 mA desired speed input (4) J6/P6 connectors for the customer
Test Step 1. Inspect the Electrical B. Thoroughly inspect the following components:
• J1/P1 connectors for the master ECM
• Wiring and the connections between the
terminal box and the device that supplies the
4 to 20 mA signal

6 ± 1 N·m (55 ± 9 lb in).

for the terminal box’s connectors. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g00931487
Illustration 64
Junction box

position.

Troubleshooting, “Inspecting Electrical Connectors”. g00905060
Illustration 66
(P1-36) + Signal
(P1-37) - Signal
250
Test Step 2. Check for an Open Circuit

A. Remove the two wires (“+” and “-”) for the 4 to
20 mA signal from the device that supplies the 4
to 20 mA signal.
B. Install a jumper wire between the two wires (“+”

and “-”) that were removed from the device that
supplies the 4 to 20 mA signal.
C. Disconnect the P1 connector from the master

ECM.
D. 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.
Illustration 67 g00929720 Results:

(J6-37) + Signal
• OK – The resistance is less than 5 ohms. The
(J6-27) - Signal
circuit is not open.
c. Perform a 45 N (10 lb) pull test on each of Repair: Remove the jumper wire. Insulate the wire
the wires that are associated with the 4 to 20 leads with electrical tape in order to ensure that
mA circuit. the leads do not create a short circuit.
d. Check the harness and wiring for abrasion Proceed to Test Step 3.
and for pinch points between the device that
supplies the 4 to 20 mA signal and the master • Not OK – The resistance is greater than 5 ohms.
ECM. There is a problem with a connector and/or the
wiring from the P1 connector.
Expected Result:
Repair: The problem may be between the P1
All connectors, pins, and sockets are connected connector and the J6 connector. Alternatively, the
properly. The connectors and the wiring do not have problem may be between the J6 connector and
corrosion, abrasion, or pinch points. the device that provides the 4 to 20 mA signal.
Results: Repair the connection and/or the wire, when

proper connections. If you are troubleshooting a
“524-03 Desired Engine Speed Sensor short to STOP.
+batt” diagnostic code, proceed to Test Step 2. If
you are troubleshooting a “524-04 Desired Engine Test Step 3. Check for a Short Circuit to
Speed Sensor short to ground” diagnostic code, the +Battery at Terminal P1-36
proceed to Test Step 5.
mode and that the 35 amp circuit breaker is OFF.
improper. B. Make sure that there is no electrical power to the
device that provides the 4 to 20 mA signal.
replace parts, if necessary. C. Use an ohmmeter to measure the resistance
between terminals P1-36 and P1-57 on the ECM
STOP. side of the P1 connector.
251
Expected Result: Locate the wire with the short circuit and replace
the wire. Verify that the problem is resolved.
STOP.
Results:
Test Step 5. Check for a Short Circuit to
• Yes – The resistance is greater than 20,000 the +Battery Side at Terminal P1-37
ohms. The wiring from terminal P1-36 is not
shorted to the +Battery side. Do not reconnect A. Verify that the engine control is in the OFF/RESET
any connectors. Proceed to Test Step 4. mode and that the 35 amp circuit breaker is OFF.
• No – The resistance is less than 20,000 ohms. B. Make sure that there is no electrical power to the
There is a problem with a connection and/or the device that provides the 4 to 20 mA signal.
wiring from terminal P1-36.
C. Remove the two wires (“+” and “-”) for the 4 to
Repair: The problem may be between the P1 20 mA signal from the device that supplies the
connector and the J6 connector. Alternatively, the 4 to 20 mA signal. Insulate the wire leads with
problem may be between the P6 connector and electrical tape in order to ensure that the leads
the device that provides the 4 to 20 mA signal. do not create a short circuit.
Repair the connection and/or the wire, when D. Disconnect the P1 connector from the master
possible. Replace parts, if necessary. Verify that ECM.
E. Use an ohmmeter to measure the resistance
STOP. between terminals P1-37 and P1-57.
Test Step 4. Check for a Short to Ground Expected Result:

at Terminal P1-37
mode and that the 35 amp circuit breaker is OFF. Results:
B. Make sure that the leads of the wires for the 4 to • Yes – The resistance is greater than 20,000
20 mA signal do not create a short circuit. ohms. The wiring from terminal P1-37 is not
shorted to the +Battery side. Do not reconnect
C. Use an ohmmeter to measure the resistance any connectors. Proceed to Test Step 6.
between the ground strap for the master ECM
and terminal P1-37. • No – The resistance is less than 20,000 ohms.
There is a problem with a connection and/or the
Expected Result: wiring from terminal P1-37.
The resistance is greater than 20,000 ohms. Repair: The problem may be between the P1
connector and the J6 connector. Alternatively, the
Results: problem may be between the J6 connector and
the device that provides the 4 to 20 mA signal.
• Yes – The resistance is greater than 20,000 ohms.
The wiring from terminal P1-37 appears to be OK. Repair the connection and/or the wire, when
Repair: Reconnect the P1 connector. Reconnect the problem is resolved.
the two wires (“+” and “-”) for the 4 to 20 mA
signal to the device that supplies the 4 to 20 mA STOP.
signal.
Test Step 6. Check for a Short Circuit to
Proceed to Test Step 7. Ground at Terminal P1-36
• No – The resistance is less than 20,000 ohms. A. Verify that the engine control is in the OFF/RESET
There is a problem with a connection and/or the mode and that the 35 amp circuit breaker is OFF.
wiring that is connected to P1-37.
B. Make sure that the ends of the wires for the 4 to
Repair: The problem may be between the P1 20 mA signal do not create a short circuit.
problem may be between the P6 connector and C. Use an ohmmeter to measure the resistance
the device that provides the 4 to 20 mA signal. between ground strap (2) and terminal P1-36.
252
Expected Result: Repair: Service the device that provides the 4 to

20 mA according to the literature that is provided
The resistance is greater than 20,000 ohms. by the OEM of the device. Verify that the problem
is resolved.
Results:
STOP.
• Yes – The resistance is greater than 20,000
ohms. The wiring from terminal P1-36 appears
i01821182
to be OK. Do not reconnect any connectors.
Proceed to Test Step 7. Detonation Sensors
• No – The resistance is less than 20,000 ohms. SMCS Code: 1559-038
There is a problem with a connection and/or the
wiring from terminal P1-36. System Operation Description:
Repair: The problem may be between the P1 Detonation sensors are located on the upper
connector and the J9 connector. Alternatively, the cylinder block between every two cylinders.
problem may be between the P9 connector and Each sensor monitors two adjacent cylinders. For
the device that provides the 4 to 20 mA signal. example, one sensor monitors cylinders 1 and 3
and one sensor monitors cylinders 2 and 4.
STOP.
Test Step 7. Check the Device that

Provides the 4 to 20 mA Signal
Measure the 4 to 20 mA signal according to the
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 master ECM.
Verify the correct 4 to 20 mA signal at terminals

P1-36 and P1-37. Illustration 68 g00951975
Arrangement of the detonation sensors

Expected Result:
The master Electronic Control Module (ECM) and
The correct 4 to 20 mA signal is provided to the the slave ECM supply 8 VDC in order to power the
master ECM. sensors. The detonation sensors provide electrical
signals to the modules that indicate mechanical
Results: engine vibrations. Each sensor outputs an electrical
signal. The signal is amplified and the signal is
• Yes – The correct 4 to 20 mA signal is provided filtered. The frequency of the signal corresponds
to the master ECM. However, the master ECM is to the mechanical frequency of the vibrations.
not responding correctly to the signal. There may The amplitude of the signal is proportional to the
be a problem with the master ECM. intensity of the vibrations.
Repair: It is unlikely that the master ECM is faulty.
Exit this procedure and perform this procedure
again. If the problem is not resolved, replace
the master ECM according to Troubleshooting,
“Replacing the ECM”. Verify that the problem is
resolved.
STOP.
• No – The master ECM is not receiving the correct

4 to 20 mA signal. There is probably a problem
with the device that provides the 4 to 20 mA.
253
The master ECM monitors the detonation sensors The troubleshooting procedure may generate
on the left side of the engine. The slave ECM additional diagnostic codes. Keep your mind on
monitors the detonation sensors on the right side of correcting the cause of the original diagnostic code.
the engine. Each ECM monitors the signals in order Clear the diagnostic codes after the problem is
to determine the presence and the severity of the resolved.
detonation. The master ECM can retard the timing
of the cylinders on the left side of the engine in
order to limit detonation levels. The slave ECM can
retard the timing of the cylinders on the right side
of the engine in order to limit detonation levels. The
timing may be retarded for a single cylinder or for
more than one cylinder. The timing may be retarded
for all of the cylinders, if necessary. If retardation of
the timing does not sufficiently limit the detonation,
the master ECM will shut down the engine.
An 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 BTC (five degrees BTC
for propane operation). 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 proportional timing
advance is one degree per minute.
Each ECM will diagnose the detonation sensors

for a signal that is shorted to the −Battery side,
to the +Battery side, or for an open circuit. To
avoid detecting vibrations that are not related to
detonation, each ECM only monitors a detonation
sensor when one of the pistons that is monitored by
that sensor is between top center and 40 degrees
after top center on the power stroke. Therefore,
the “Block Tap” method of testing the detonation
sensors does not work for the G3500C Engine.
An input from a detonation sensor that is diagnosed

by an ECM as “open/shorted to +battery” may
measure 0 VDC on a voltmeter. This is caused
by the lack of pull up resistors in the detonation
sensor’s circuits inside the ECM.
Each ECM also supports related event codes

when the levels of detonation warrant a reaction
from the ECM. If the timing has been retarded by
the maximum amount and the level of detonation
remains high, the master ECM will shut down the
engine. Detonation protection is disabled when the
engine speed is less than 250 rpm.

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 a sensor.
The least likely cause is a problem with an ECM.
254
g00929784
Illustration 69
Schematic for the detonation sensors
255

• Connectors for each of the detonation sensors
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 70
Junction box

position.
g00902243
Illustration 72
Note: For the following steps, refer to Harness side of the side of the master ECM P2 connector
(P2-36) Signal for cylinders 2 and 4
(P2-54) Return
(P2-55) Return
(P2-56) +8 V supply
(P2-57) +8 V supply
g00929785
Illustration 71
Terminal box
(3) J8/P8 connectors for the detonation sensors

connectors:
256
g00902243
Illustration 74
Harness side of the P4 connector for the slave ECM
g00929380 (P4-54) Return for the detonation sensors
Illustration 73
Harness side of the J8 connector (P4-56) 8 volt supply for the detonation sensors
(J8-1) 8 V Supply for the detonation sensor for cylinders 2 and 4 (P4-57) 8 volt supply for the detonation sensors
(J8-3) 8 V Supply for the detonation sensor for cylinders 10 and 12 c. Perform a 45 N (10 lb) pull test on each of the
(J8-5) 8 V Supply for the detonation sensor for cylinders 18 and 20 wires that are associated with the circuit for
(J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 the detonation sensors.
(J8-10) 8 V Supply for the detonation sensor for cylinders 17 and
19
(J8-24) Signal from the detonation sensor for cylinders 14 and 16 g00929792
Illustration 75
Detonation sensors
(J8-28) Signal from the detonation sensor for cylinders 9 and 11 d. Check the harness and wiring for abrasion
(J8-29) Signal from the detonation sensor for cylinders 13 and 15 and for pinch points from the detonation
(J8-30) Signal from the detonation sensor for cylinders 17 and 19 sensors to each ECM.
(J8-33) Shield for the detonation sensor for cylinders 10 and 12 e. Make sure that the detonation sensors are
(J8-34) Shield for the detonation sensor for cylinders 14 and 16 properly installed according to the torque in
(J8-35) Shield for the detonation sensor for cylinders 18 and 20 Specifications, “Detonation Sensors”.
(J8-38) Shield for the detonation sensor for cylinders 9 and 11 Expected Result:
(J8-40) Shield for the detonation sensor for cylinders 17 and 19 All connectors, pins, and sockets are connected
properly. The connectors and the wiring do not
have corrosion, abrasion, or pinch points. All of the
detonation sensors are properly installed.
257
Results: Test Step 3. Check for Active Diagnostic

Codes for the Detonation Sensors
proper connections. Proceed to Test Step 2. Note: The run relay and the crank terminate relay
must be energized before a diagnostic code for a
• Not OK – The components are not in good detonation sensor can be generated. Therefore, the
condition and/or at least one connection is engine must be running. The engine will shut down
improper. soon after the diagnostic code for the detonation
sensor is activated.
replace parts, if necessary. A. Start the engine and run the engine.
STOP. B. Allow a minimum of 30 seconds for any

diagnostic codes to become active. Observe the
Test Step 2. Check for Diagnostic Codes “Active Diagnostic” screen of Cat ET and look for
for the 8 Volt DC Supply the diagnostic codes that are listed in Table 23:

Tools”.

C. Observe the “Active Diagnostic” screen of Cat

ET. Wait at least 30 seconds so that any codes
• “41-03 8 Volt DC Supply short to +batt”

• “41-04 8 Volt DC Supply short to ground”
Expected Result:
Neither of the “8 Volt DC Supply” diagnostic codes

are active.
Results:
• OK – Neither of the “8 Volt DC Supply” diagnostic

codes are active. Proceed to Test Step 3.
• Not OK – At least one of the “8 Volt DC Supply”

diagnostic codes is active.
Repair: The “8 Volt DC Supply” diagnostic code

must be resolved before you can proceed with
this functional test.
Exit this procedure and refer to Troubleshooting,

“+8V Sensor Voltage Supply”.
If necessary, return to this functional test in order

to troubleshoot the detonation sensor after the
“8 Volt DC Supply” diagnostic code has been
resolved.
STOP.
258
Table 23 Results:
Code Description Cylinders
• OK (No active codes) – None of the above codes
1501-03 Cylinder #1 Detonation are active at this time. The problem seems to
Sensor short to +batt be resolved. The original diagnostic code was
1 and 3 probably caused by a poor electrical connection
1501-04 Cylinder #1 Detonation
Sensor short to ground in one of the harness connectors.
1502-03 Cylinder #2 Detonation Repair: If any of the above codes are logged
Sensor short to +batt and the engine is not running properly, refer
2 and 4
1502-04 Cylinder #2 Detonation to Troubleshooting, “Troubleshooting Without a
Sensor short to ground Diagnostic Code”.
1505-03 Cylinder #5 Detonation If any of the above codes are logged and the
Sensor short to +batt
5 and 7 engine is running properly, there may be an
1505-04 Cylinder #5 Detonation intermittent problem in a connector or a wiring
Sensor short to ground harness. Refer to Troubleshooting, “Inspecting
6 and 8 STOP.
Sensor short to ground • Not OK (Active Code) – A “short to +batt” or
1509-03 Cylinder #9 Detonation “short to ground” diagnostic code was activated.
9 and 11 Repair: Note the diagnostic code and note the
1509-04 Cylinder #9 Detonation location of the suspect detonation sensor.
1510-03 Cylinder #10 Detonation Proceed to Test Step 4.
10 and 12 Test Step 4. Verify the Presence of the
Supply Voltage at the Sensor
1513-03 Cylinder #13 Detonation A. Set the engine control to the OFF/RESET mode.
Sensor short to +batt Switch the 35 amp circuit breaker OFF.
13 and 15
Sensor short to ground B. Disconnect the detonation sensor with the
diagnostic code.
Sensor short to +batt C. Switch the 35 amp circuit breaker ON. Set the
14 and 16
1514-04 Cylinder #14 Detonation engine control to the STOP mode.
17 and 19
18 and 20 g00890518
Illustration 76
Sensor short to ground Harness connector for the detonation sensors
(A) 8 volt supply
(B) Return
Note: A “short to ground” diagnostic code can (C) Signal
indicate either an actual short to ground or an open
circuit. D. Measure the voltage between terminals A and B
on the harness connector for the sensor.
Expected Result:
Expected Result:
None of the above diagnostic codes are active.
259
Results: • No – The voltage is not between 0.4 VDC and

0.6 VDC. If the voltage is less than 0.4 VDC,
• OK – The voltage is between 7.6 VDC and 8.4 there is probably a short to ground or an open
VDC. The correct voltage is available to the circuit between the connector for the detonation
sensor. Do not reconnect the sensor. Proceed to sensor and the ECM. If the voltage is greater
Test Step 5. than 4.8 VDC, there is probably a short circuit
to a +Battery source between the connector
• Not OK – The voltage is not between 7.6 VDC for the detonation sensor and the ECM. If you
and 8.4 VDC. The correct voltage is not available are troubleshooting a detonation sensor for the
to the sensor. There is probably an open circuit in master ECM, proceed to Test Step 6. If you are
the 8 volt supply or in the return for the sensor. troubleshooting a detonation sensor for the slave
ECM, proceed to Test Step 7.
Repair: The open circuit may be caused by a poor
electrical connection or a wiring problem between Test Step 6. Check the Operation of the
the ECM and the connector for the sensor. Master ECM
Repair the electrical connection and/or the wiring, A. Set the engine control to the OFF/RESET mode.
when possible. Replace the harness, if necessary. Switch the 35 amp circuit breaker OFF.
STOP. B. Use a 151-6320 Wire Removal Tool to remove

the signal wire for the suspect sensor from the
Test Step 5. Measure the Voltage of the P2 connector. This will replace the sensor circuit
Signal Wire at the Sensor with an open circuit.

Note: The run relay and the crank terminate relay

must be energized before a diagnostic code for a
detonation sensor can be generated. Therefore, the
engine must be running. The engine will shut down
Illustration 77 g00890518 soon after the diagnostic code for the detonation
sensor is activated.
Harness connector for the detonation sensors
(A) 8 volt supply D. Start the engine. Observe the “Active Diagnostic”
(B) Return
(C) Signal
screen on Cat ET. Allow a minimum of 30
seconds for any codes to activate.
A. Measure the voltage between terminals B and C
on the harness connector for the suspect sensor. An active “open/short to +batt” diagnostic code
is generated for the sensor.
Expected Result:
E. Set the engine control to the OFF/RESET mode.
Results:
• Yes – The voltage is between 0.4 VDC and 0.6

VDC.
Repair: Reconnect the suspect sensor. Start the

engine again and check for the diagnostic code.
If the diagnostic code recurs, replace the

detonation sensor with a known good detonation
sensor. Tighten the detonation sensor according
to the torque in Specifications, “Detonation
Sensor”. Verify that the problem is resolved.
STOP.
260
Repair: Remove the jumper wire. Insert the

terminal that was removed from the P2 connector.
Pull on the wire in order to verify that the terminal
is fully inserted into the connector. Repair the
harness, when possible. Replace the harness, if
necessary.
STOP.
• Not OK – No active “open/short to +batt”

and “short to ground” diagnostic codes were
generated. The master ECM is not operating
correctly.
Repair: It is unlikely that the master ECM has

failed. Exit this procedure and perform this
procedure again. If the problem is not resolved,
perform the following steps:

g00929856
Illustration 78
Master ECM with jumper wire
If the problem is resolved with the new ECM,
(1) P2 connector for the master ECM
(2) P1 connector for the master ECM
problem returns. If the new ECM operates
(3) Jumper wire correctly and the original ECM does not operate
correctly, replace the original ECM. Refer to
F. Fabricate a jumper wire that is long enough to Troubleshooting, “Replacing the ECM”.
reach between the P1 connector and the P2
connector. Install Deutsch terminals on the ends. STOP.
Install one end of jumper wire (3) into the terminal
for the signal wire that was removed from the P2 Test Step 7. Check the Operation of the
connector (1). Install the other end of the jumper Slave ECM
wire into terminal 19 of the P1 connector (2).
This will replace the sensor circuit with a short A. Set the engine control to the OFF/RESET mode.
circuit to ground. Switch the 35 amp circuit breaker OFF.
G. Start the engine. Observe the “Active Diagnostic” B. Use a 151-6320 Wire Removal Tool to remove
screen on Cat ET. Allow a minimum of 30 the signal wire for the suspect sensor from the
seconds for any codes to activate. P4 connector. This will replace the sensor circuit
An active “short to ground” diagnostic code is
generated for the sensor. C. Switch the 35 amp circuit breaker ON. Set the
Expected Result:
Note: The run relay and the crank terminate relay
Active “open/short to +batt” and “short to ground” must be energized before a diagnostic code for a
diagnostic codes are generated according to the detonation sensor can be generated. Therefore, the
above steps. engine must be running. The engine will shut down
soon after the diagnostic code for the detonation
Results: sensor is activated.
• OK – Active “open/short to +batt” and “short D. Start the engine. Observe the “Active Diagnostic”
to ground” diagnostic codes are generated screen on Cat ET. Allow a minimum of 30
according to the above steps. The master ECM seconds for any codes to activate.
is operating correctly. There is probably an open
circuit in a harness between the master ECM and An active “open/short to +batt” diagnostic code
the connector for the sensor. is generated for the sensor.
E. Set the engine control to the OFF/RESET mode.

261
Repair: Remove the jumper wire. Insert the

Pull on the wire in order to verify that the terminal
is fully inserted into the connector. Repair the
necessary.
STOP.
• Not OK – No active “open/short to +batt”

and “short to ground” diagnostic codes were
generated. The slave ECM is not operating
correctly.
Repair: It is unlikely that the slave ECM has failed.

again. If the problem is not resolved, perform the
following steps:
Temporarily install a new slave ECM. Refer to

g00929892
Illustration 79
Slave ECM with jumper wire
(1) P4 connector for the slave ECM
(2) P3 connector for the slave ECM
(3) Jumper wire correctly and the original ECM does not operate
F. Fabricate a jumper wire that is long enough to Troubleshooting, “Replacing the ECM”.
reach between the P4 connector and the P3
connector. Install Deutsch terminals on the ends. STOP.
Install one end of jumper wire (3) into the terminal
for the signal wire that was removed from the P4 i01821451
connector (1). Install the other end of the jumper
wire into terminal 19 of the P3 connector (2). ECM Output Circuit (Fuel
This will replace the sensor circuit with a short
circuit to ground. Control)
G. Start the engine. Observe the “Active Diagnostic” SMCS Code: 1901-038
screen on Cat ET. Allow a minimum of 30
seconds for any codes to activate. System Operation Description:
An active “short to ground” diagnostic code is The master Electronic Control Module (ECM)
generated for the sensor. contains the logic and the outputs for starting and
stopping the engine. The logic for starting and
Expected Result: stopping is customer programmable. The logic
responds to inputs from the following components:
Active “open/short to +batt” and “short to ground” engine control switch, emergency stop switch,
diagnostic codes are generated according to the remote start switch, data link, and other inputs.
above steps.
The fuel control relay is energize-to-run. To enable
Results: fuel flow to the engine, the relay for the Gas Shutoff
Valve (GSOV) must be energized. The master ECM
provides +Battery voltage to the relay for the GSOV
• OK – Active “open/short to +batt” and “short when the logic determines that fuel is required for
to ground” diagnostic codes are generated
according to the above steps. The slave ECM is engine operation. For engine shutdown, the master
operating correctly. There is probably an open ECM removes the voltage from the fuel control relay.
circuit in the harness between the slave ECM and This stops the fuel flow.
the connector for the sensor.
262
The output circuit for the relay for the GSOV

includes the J6 connector. If the J6 connector is not
used, a jumper wire must be connected between
terminals 21 and 31. The voltage will be removed
from the fuel control relay if the jumper wire is not
connected. The jumper wire must be connected in
order for the engine to start. The jumper wire must
remain connected in order for the engine to run.
Refer to Illustration 80 for the schematic diagram.


poor electrical connection or a problem in a wiring
the GSOV. The least likely cause is a problem with
the master ECM.

resolved.
Connections for the Fuel Control Relay
The fuel control relay may be connected to either of

the following connectors:
• P6 via wiring that is provided by the customer

• P7 via the engine harness
If the fuel control relay is connected to P6, terminals
P6-21 and P6-24 are used.
If the fuel control relay is connected to P7, a jumper

wire must be connected between terminals P6-21
and P6-31.
This procedure may be used to troubleshoot either

configuration.
263
g00955596
Illustration 80
Optional connections for the fuel control relay
Test Step 1. Inspect the Electrical A. Switch 35 amp circuit breaker (1) to the OFF
Connectors and Wiring position.
g00931487
Illustration 81
Junction box
264
g00930126
Illustration 83
(P2-11) Circuit driver for the fuel control relay
(P2-21) Return
g00929934
Illustration 82
Terminal box
(3) J6/P6 connector for the customer
(4) J7/P7 connectors for the harness from the fuel control relay
B. Set the engine control to the OFF/RESET mode.

C. Thoroughly inspect the following connectors and

the wiring harnesses for the connectors:

box
g00952066
• Connectors for the fuel control relay Illustration 84
a. Check the torque of the Allen head screw for (J6-21) Circuit driver for the fuel control relay
the ECM connectors. The proper torque is (J6-24) Return
6 ± 1 N·m (55 ± 9 lb in). (J6-31) Circuit for the fuel control relay

265
Results:


improper.
Repair: Perform the necessary repairs, when

possible. Replace parts, if necessary.
STOP.

Tools”.

C. Wait for 30 seconds and use Cat ET to check for

an active “17-05 Fuel Shutoff Valve open circuit”
diagnostic code.
If there is an active “17-05 Fuel Shutoff Valve

g00929957
Illustration 85 open circuit” diagnostic code, proceed to the
Harness side of the J7 connector “Results” for this Test Step. Otherwise, continue
(J7-50) Circuit driver for the fuel control relay this procedure.
(J7-64) Return
Note: The “17-05 Fuel Shutoff Valve open circuit”
c. Perform a 45 N (10 lb) pull test on each of diagnostic code cannot be detected when the
the wires that are associated with the fuel output for the fuel control relay is ON. The output is
control relay. ON when the engine control is in the START mode
and the engine speed is not zero.
D. Use Cat ET to check the logged diagnostic

codes. If there is a “17-06 Fuel Shutoff Valve
short to ground” or a “17-12 Fuel Shutoff Valve
malfunction” diagnostic code, clear the code.

by the master ECM when the output for the fuel
control relay is OFF. The output is OFF when the
engine control is in the STOP mode.
E. To prevent the engine from starting, shut the gas

supply OFF.
g00869737
Illustration 86 Note: To provide the output for the fuel control relay,
Typical fuel control relay the sequence for engine start-up must be initiated.
Otherwise, a “17-06 Fuel Shutoff Valve short to
d. Check the harness and wiring for abrasion ground” or a “17-12 Fuel Shutoff Valve malfunction”
and pinch points from the fuel control relay to diagnostic code cannot be generated.
the master ECM.
F. Set the engine control to the START mode for at
Expected Result: least 30 seconds. Then set the engine control to
the STOP mode.
266
G. Use Cat ET to look for a logged “17-06 Fuel Test Step 3. Check for a Short Circuit to
Shutoff Valve short to ground” or a “17-12 Fuel the +Battery Side
Shutoff Valve malfunction” diagnostic code again.
Expected Result:
When the engine control was in the STOP mode, Gaseous fuel is present. Personal Injury or Death
there was no active “17-05 Fuel Shutoff Valve open can result from an open flame or spark igniting the
circuit” diagnostic code. gaseous fuel causing an explosion and/or fire. Al-
ways use a gas detector to determine the presence
After the engine was cranked, there was no logged of gaseous fuel when maintaining and servicing.
“17-06 Fuel Shutoff Valve short to ground” or “17-12 Contact you local gas provider immediately for as-
Fuel Shutoff Valve malfunction” diagnostic code. sistance in the event of a leak.
Results: Note: Open sparks can be generated during this

test.
• OK – No diagnostic codes were generated. The
output for the fuel control relay seems to be OK at A. Make sure that no combustible gas is present in
this time. The initial diagnostic code was probably the surrounding atmosphere.
caused by a poor electrical connection.
B. Verify that the engine control is in the STOP
Repair: If there is an intermittent problem mode.
that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical C. Disconnect the connector from the fuel control
Connectors”. relay. Then reconnect the connector. Listen for
an audible click from the relay.
STOP.
If the ambient noise is too loud, touch the relay
• Not OK (“17-05 Fuel Shutoff Valve open circuit” when the relay is reconnected in order to feel the
diagnostic code) – A “17-05 Fuel Shutoff Valve vibration. The relay will vibrate when the relay is
open circuit” diagnostic code was activated. This de-energized and energized.
can be caused by an actual open circuit or by a
short circuit to the +Battery side. Proceed to Test Expected Result:
Step 3.
There is no audible click and/or vibration when the
• Not OK (“17-06 Fuel Shutoff Valve short to ground” relay is disconnected and reconnected. The relay
diagnostic code) – After the engine was cranked, is not energized when the engine control is in the
a “17-06 Fuel Shutoff Valve short to ground” STOP mode.
diagnostic code was generated. Proceed to Test
Step 7. Results:
• Not OK (“17-12 Fuel Shutoff Valve malfunction” • OK – There is no audible click and/or vibration
diagnostic code) – After the engine was cranked, when the relay is disconnected and connected.
a “17-12 Fuel Shutoff Valve malfunction” There is no short circuit to the +Battery side.
diagnostic code was generated. The master ECM There is an open circuit. Proceed to Test Step 5.
disabled the ignition.
• Not OK – There is an audible click and/or
Repair: Set the engine control to the OFF/RESET vibration when the relay is disconnected and
mode. Switch the 35 amp circuit breaker OFF. connected. The relay is receiving power when
the engine control is in the STOP mode. There is
Replace the fuel control relay. probably a short circuit to the +Battery side in a
connector or a wiring harness. Proceed to Test
STOP. Step 4.
267
Test Step 4. Determine the Cause of the 4. Disconnect the connector from the fuel control
Energized Relay relay. Then reconnect the connector. Listen for
an audible click from the relay.
If the ambient noise is too loud, touch the relay

when the relay is reconnected in order to feel
Gaseous fuel is present. Personal Injury or Death the vibration. The relay will vibrate when the
can result from an open flame or spark igniting the relay is de-energized and energized.
gaseous fuel causing an explosion and/or fire. Al-
ways use a gas detector to determine the presence If the relay is not energized, there is an
of gaseous fuel when maintaining and servicing. intermittent problem with a connector
Contact you local gas provider immediately for as- and/or the wiring. Refer to Troubleshooting,
sistance in the event of a leak. “Inspecting Electrical Connectors”.
Note: Open sparks can be generated during this If the relay is energized, there may be a
test. problem with the master ECM.
A. Set the engine control to the OFF/RESET mode. It is unlikely that the master ECM has failed.
Switch the 35 amp circuit breaker OFF. Exit this procedure and perform this procedure
again. If the problem is not resolved, perform
B. Use a 151-6320 Wire Removal Tool to remove the following steps:
terminals (P2-11) and (P2-21).
C. Switch the 35 amp circuit breaker ON. Set the Troubleshooting, “Replacing the ECM”.
D. Disconnect the connector from the fuel control install the original ECM and verify that the
relay. Then reconnect the connector. Listen for problem returns. If the new ECM operates
an audible click from the relay. correctly and the original ECM does not
operate correctly, replace the original ECM.
If the ambient noise is too loud, touch the relay Refer to Troubleshooting, “Replacing the ECM”.
when the relay is reconnected in order to feel the
vibration. The relay will vibrate when the relay is STOP.
de-energized and energized.
• Not OK – There is an audible click and/or
Expected Result: vibration when the relay is disconnected and
reconnected. The relay is energized when the
There is no audible click and/or vibration when the wiring is removed from the P2 connector. There is
relay is disconnected and reconnected. The relay a short circuit to the +Battery side in a harness.
is not energized when the wiring is removed from
the P2 connector. Repair: Repair the wiring and/or the connector,
Results:
STOP.
• OK – There is no audible click and/or vibration
when the solenoid is disconnected and Test Step 5. Create a Short Circuit in
reconnected. The relay is not energized when the order to Check for an Open Circuit
wiring is removed from the P2 connector.
Repair: Use the following procedure to determine Switch the 35 amp circuit breaker OFF.
whether the circuit driver for the relay is faulty:
B. Disconnect the fuel control relay’s connector.
1. Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF.
2. Reinstall terminals P2-11 and P2-21. Pull on

the wires in order to verify proper installation
of the terminals.

268
If the problem is not resolved, replace the fuel

control relay.
STOP.
• Not OK – A “17-05 Fuel Shutoff Valve open

circuit” diagnostic code was generated when the
jumper wire was installed. There may be an open
circuit in a harness. Proceed to Test Step 6.
Test Step 6. Check the Master ECM

g00891959
Illustration 87 B. Use the 151-6320 Wire Removal Tool to remove
(1) Connector for the fuel control relay terminals P2-11 and P2-21.
(2) Jumper wire
C. Install a jumper wire (2) into the two terminals of

the relay’s connector (1) on the engine harness.

Note: The “17-05 Fuel Shutoff Valve open circuit”

diagnostic code can only be detected when the
output for the fuel control relay is OFF. The output is
OFF when the engine control is in the STOP mode
and the engine is not running.
E. Wait for 30 seconds and use the “Active

Diagnostic” screen of Cat ET to look for a “17-05
Fuel Shutoff Valve open circuit” diagnostic code.
Expected Result:
A “17-05 Fuel Shutoff Valve open circuit” diagnostic

code was not generated when the jumper wire was g00930030
Illustration 88
installed.
Master ECM P2 connector with jumper wire
Results: (1) Jumper wire
(2) P2 connector
• OK – A “17-05 Fuel Shutoff Valve open circuit”
diagnostic code was not generated when the C. Install a jumper wire (1) into terminals P2-11 and
jumper wire was installed. The harness and the P2-21. Pull on the jumper wire in order to verify
ECM are OK. There is a problem with the relay. proper installation.
Repair: Perform the following procedure: D. Switch the 35 amp circuit breaker ON. Set the
mode. Switch the 35 amp circuit breaker OFF. Note: The “17-05 Fuel Shutoff Valve open circuit”
2. Remove the jumper wire from the relay’s output for the fuel control relay is OFF. The output is
connector on the engine harness. OFF when the engine control is in the STOP mode
and the engine is not running.
3. Inspect the relay’s connector for damage, for
moisture, and for corrosion. E. Wait for 30 seconds and use the “Active
Diagnostic” screen of Cat ET to look for an
4. Make repairs, as needed. active “17-05 Fuel Shutoff Valve open circuit”
diagnostic code.
269
Expected Result: Test Step 7. Create an Open Circuit in

order to Check for a Short Circuit to
There is no active “17-05 Fuel Shutoff Valve open Ground
circuit” diagnostic code.
Results:
• OK – When the jumper wire was installed, there

was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. The master ECM detects
the jumper wire at the P2 connector. However,
the master ECM did not detect the jumper wire
at the connector for the fuel control relay. There
is a problem between the P2 connector and the
connector for the fuel control relay.

g00891892
Illustration 89
2. Use a 151-6320 Wire Removal Tool to remove Typical fuel control relay
the jumper wire from the P2 connector. (1) Connector for the fuel control relay
(2) Relay
3. Reinstall the terminals into P2-11 and P2-21.
Pull on the wires in order to verify proper B. Disconnect connector (1) from relay (2).
installation of the terminals.
C. Set the engine control to the STOP mode.
4. Thoroughly inspect the J6/P6 and J7/P7
connectors. Inspect the wiring that is D. Use Cat ET to clear the logged “17-06 Fuel
connected to terminals J6-21 and J6-31. Shutoff Valve short to ground” diagnostic code.
5. Make repairs, if necessary. E. To prevent the engine from starting, shut OFF the
main gas supply.
STOP.
Note: To provide the output for the fuel control relay,
• Not OK – When the jumper wire was installed, a the sequence for engine start-up must be initiated.
“17-05 Fuel Shutoff Valve open circuit” diagnostic Otherwise, a “17-06 Fuel Shutoff Valve short to
code was activated. The master ECM did not ground” diagnostic code cannot be generated.
detect the jumper wire. There is a problem with
the master ECM. F. Set the engine control to the START mode for at
least 30 seconds. Then set the engine control to
Repair: Perform the following procedure: the STOP mode.
1. Set the engine control to the OFF/RESET G. Use Cat ET to look for a logged “17-06 Fuel
mode. Switch the 35 amp circuit breaker OFF. Shutoff Valve short to ground” diagnostic code
again.
2. Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P2 connector. Expected Result:
3. Reinstall the terminals into P2-11 and P2-21. A “17-06 Fuel Shutoff Valve short to ground” was
Pull on the wires in order to verify proper not generated.
installation of the terminals.
Results:
4. Replace the master ECM according to
Troubleshooting, “Replacing the ECM”. Verify • OK – When the relay was connected, a “short
that the problem is resolved. to ground” diagnostic code was generated.
When the relay was disconnected, no “short to
STOP. ground” diagnostic code was generated. There is
a problem with the relay.

270
1. Set the engine control to the OFF/RESET Results:

• OK – When the output to the relay was
2. Inspect the relay’s connectors for damage disconnected from the P2 connector, the “17-06
and/or for corrosion. Fuel Shutoff Valve short to ground” diagnostic
code was not generated. However, a “short to
3. Make repairs, as needed. ground” diagnostic code was generated when
the connector was disconnected from the fuel
If the problem is not resolved, replace the relay. control relay. There is a problem in the wiring
between the P2 connector and the connector for
STOP. the fuel control relay.
• Not OK – A “short to ground” diagnostic code Repair: Perform the following procedure:
was generated when the relay was disconnected.
There is a problem with the wiring or with the 1. Set the engine control to the OFF/RESET
ECM. Proceed to Test Step 8. mode. Switch the 35 amp circuit breaker OFF.
Test Step 8. Check the Master ECM 2. Reinstall the terminal that was removed from
P2-11. Pull on the wire in order to verify proper
A. Set the engine control to the OFF/RESET mode. installation of the terminal.
3. Repair the harness, when possible. Replace
B. Use the 151-6320 Wire Removal Tool to remove the harness, if necessary.
terminal P2-11.
STOP.
engine control to the STOP mode. • Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when
D. Use Cat ET to clear the logged “17-06 Fuel the output to the relay was disconnected from
Shutoff Valve short to ground” diagnostic code. the P2 connector. There may be a problem with
the master ECM.
E. To prevent the engine from starting, shut OFF the
main gas supply. Repair: Perform the following procedure:
Note: To provide the output for the fuel control relay, 1. Set the engine control to the OFF/RESET
the sequence for engine start-up must be initiated. mode. Switch the 35 amp circuit breaker OFF.
Otherwise, a “17-06 Fuel Shutoff Valve short to
ground” diagnostic code cannot be generated. 2. Reinstall the terminal that was removed from
P2-11. Pull on the wire in order to verify proper
F. Set the engine control to the START mode for at installation of the terminal.
least 30 seconds. Then set the engine control to
the STOP mode. 3. It is unlikely that the master ECM has failed.
G. Use Cat ET to look for a logged “17-06 Fuel again. If the problem is not resolved, perform
Shutoff Valve short to ground” diagnostic code the following steps:
again.
Expected Result: Troubleshooting, “Replacing the ECM”.
The “17-06 Fuel Shutoff Valve short to ground” If the problem is resolved with the new ECM,
diagnostic code was not generated. install the original ECM and verify that the
correctly and the original ECM does not
operate correctly, replace the original ECM.
Refer to Troubleshooting, “Replacing the ECM”.
STOP.
271
i01822452
ECM Output Circuit (Starting

Motor)
SMCS Code: 1901-038

contains the logic and the outputs for starting
the engine. The logic for starting 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.


a magnetic switch or with a relay. The least likely
cause is a problem with the master ECM.

resolved.
Electric Start
The master ECM supplies +Battery voltage to two

magnetic switches when the logic determines that
it is necessary. Each magnetic switch provides
+Battery voltage to a solenoid on an electric starting
motor.
The master ECM removes the voltage when the

crank terminate relay is energized. The voltage
is also removed if the customer programmable
“Overcrank Time” has expired.
Air Start
The master ECM supplies +Battery voltage to the

air start relay when the logic determines that it is
necessary. The master ECM removes the voltage
when the crank terminate relay is energized.
The voltage is also removed if the customer
programmable “Overcrank Time” has expired.
272
g00952093
Illustration 90
Schematic for the electric starting system
g00952094
Illustration 91
Schematic for the air starting system
273
Test Step 1. Inspect the Electrical • J7/P7 connectors on the terminal box
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 92 Illustration 94 g00892365
Junction box Harness side of the master ECM P2 connector
(P2-10) Start command
A. Set the engine control to the OFF/RESET mode. (P2-20) Return for the start command
position.

g00931023
Illustration 93
Terminal box for the master ECM g00931050
Illustration 95
(3) J7/P7 connectors for the wiring from the starting system Harness side of the J7 connector
(J7-28) Start command
B. Thoroughly inspect the following connectors and (J7-56) Return for the start command
the wiring harnesses for the connectors:

274
c. Perform a 45 N (10 lb) pull test on each of the Note: The “444-06 Start Relay short to ground”
wires that are associated with the circuit for diagnostic code can only be detected when the
the starter motor relay. output for the start command is ON. The output is
normally ON when the engine control is set from the
d. Check the harness and wiring for abrasion STOP mode to the START mode. The output remains
and for pinch points from the starter motor ON until the crank terminate relay is energized.
relay to the master ECM.
F. Set the engine control to the START mode for at
Expected Result: least six seconds. Then set the engine control to
the STOP mode.
properly. The connectors and the wiring do not have G. Use Cat ET to look for a logged “444-06 Start
corrosion, abrasion, or pinch points. Relay short to ground” diagnostic code again.
• OK – The components are in good condition with When the engine control was in the STOP mode,
proper connections. Proceed to Test Step 2. there was no active “444-05 Start Relay open
condition and/or at least one connection is After the engine was cranked, there was no logged
improper. “444-06 Start Relay short to ground” diagnostic
code.
Repair: Perform the necessary repairs, when
possible. Replace parts, if necessary. Results:
STOP. • OK – No diagnostic codes were activated. The

output for the start command seems to be OK at
Test Step 2. Check for Diagnostic Codes this time. The initial diagnostic code was probably
Refer to Troubleshooting, “Electronic Service Repair: If there is an intermittent problem
Tools”. that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical
B. Switch the 35 amp circuit breaker ON. Set the Connectors”.
STOP.
Note: The “444-05 Start Relay open circuit”
diagnostic code can only be detected when the • Not OK (“444-05 Start Relay open circuit”
output for the start command is OFF. The output diagnostic code) – A “444-05 Start Relay open
is normally OFF when the engine control is in the circuit” diagnostic code was activated. This can
STOP mode or when the crank terminate relay is be caused by an actual open circuit or by a
energized. short circuit to the +Battery side. If the engine is
equipped with an air starting system, proceed
C. Wait for 30 seconds and use Cat ET to check to Test Step 3. If the engine is equipped with an
for an active “444-05 Start Relay open circuit” electric starting system, proceed to Test Step 9.
diagnostic code.
• Not OK (“444-06 Start Relay short to ground”
If there is an active “444-05 Start Relay open diagnostic code) – After the engine was cranked,
circuit” diagnostic code, proceed to the “Results” a “444-06 Start Relay short to ground” diagnostic
for this Test Step. Otherwise, continue this code was activated. If the engine is equipped
procedure. with an air starting system, proceed to Test Step
7. If the engine is equipped with an electric
D. Use Cat ET to check the logged diagnostic starting system, proceed to Test Step 10.
codes. If there is a logged “444-06 Start Relay
short to ground” diagnostic code, clear the code.
E. To prevent the engine from starting, shut the gas

supply OFF.
275
Test Step 3. Check for a Short Circuit to C. Install a jumper wire into the two terminals of the
the +Battery Side harness connector for the air start relay.

Gaseous fuel is present. Personal Injury or Death E. Wait for 30 seconds and use the “Active
can result from an open flame or spark igniting the Diagnostic” screen of Cat ET to look for a “444-05
gaseous fuel causing an explosion and/or fire. Al- Start Relay open circuit” diagnostic code.
ways use a gas detector to determine the presence
of gaseous fuel when maintaining and servicing. Expected Result:
Contact you local gas provider immediately for as-
sistance in the event of a leak. A “444-05 Start Relay open circuit” diagnostic
code was not activated when the jumper wire was
Note: Open sparks can be generated during this installed.
test.
Results:
A. Make sure that no combustible gas is present in
the surrounding atmosphere. • OK – A “444-05 Start Relay open circuit”
diagnostic code was not activated when the
B. Ensure that the engine control is in the STOP jumper wire was installed. The master ECM
mode. detected the short circuit. The harness and the
master ECM are OK. There is a problem with the
C. Disconnect the connector from the air start relay. air start relay.
Then reconnect the connector. Listen for an
audible click from the relay. Repair: Perform the following procedure:
If the ambient noise is too loud, touch the air 1. Set the engine control to the OFF/RESET
start relay when the relay is reconnected in order mode. Switch the 35 amp circuit breaker OFF.
to feel the vibration. The relay will vibrate when
the relay is de-energized and energized. 2. Remove the jumper wire from the harness
connector.
Expected Result:
3. Inspect the relay’s connector and the harness
There is no audible click and/or vibration when the connector for the relay. Check for damage, for
air start relay is disconnected and reconnected. moisture, and for corrosion.
The relay is not energized when the engine control
is in the STOP mode. 4. Make repairs, as needed.
Results: If the problem is not resolved, replace the air

start relay.
• OK – There is no audible click and/or vibration
when the air start relay is disconnected and STOP.
connected. There is no short circuit to the
+Battery side. There is an open circuit. Proceed • Not OK – A “444-05 Start Relay open circuit”
to Test Step 4. diagnostic code was activated when the jumper
wire was installed. The master ECM did not detect
• Not OK – There is an audible click and/or the short circuit. Proceed to Test Step 5.
vibration when the air start relay is disconnected
and connected. The relay is receiving power Test Step 5. Check the Master ECM
when the engine control is in the STOP mode.
Proceed to Test Step 6. A. Ensure that the engine control is in the
OFF/RESET mode and that the 35 amp circuit
Test Step 4. Create a Short Circuit in breaker is OFF.
order to Check for an Open Circuit
B. Use a 151-6320 Wire Removal Tool to remove
A. Set the engine control to the OFF/RESET mode. terminals P2-10 and P2-20.
C. Install a jumper wire into terminals P2-10 and
B. Disconnect the harness connector from the air P2-20. Pull on the jumper wire in order to verify
start relay. proper installation.
276
D. Switch the 35 amp circuit breaker ON. Set the 3. Reinstall terminals P2-10 and P2-20. Pull on
engine control to the STOP mode. the wires in order to verify proper installation
of the terminals.
E. Wait for 30 seconds and use the “Active
Diagnostic” screen of Cat ET to look for an active It is unlikely that the master ECM has failed.
“444-05 Start Relay open circuit” diagnostic Exit this procedure and perform this procedure
code. again. If the problem is not resolved, perform the
following steps:
Expected Result:
There is no active “444-05 Start Relay open circuit” Troubleshooting, “Replacing the ECM”.
diagnostic code.
Results: install the original ECM and verify that the
• OK – When the jumper wire was installed, correctly and the original ECM does not operate
there was no active “444-05 Start Relay open correctly, replace the original ECM. Refer to
circuit” diagnostic code. The master ECM Troubleshooting, “Replacing the ECM”.
detects the jumper wire at the P2 connector.
However, the master ECM did not detect the STOP.
jumper wire at the relay’s connector. There
is a problem with the wiring. Test Step 6. Create an Open Circuit in
order to Check for a Short Circuit
The problem could be between
the P2 connector and the J7 connector. A. Set the engine control to the OFF/RESET mode.
Alternatively, the problem could be in the P7 Switch the 35 amp circuit breaker OFF.
connector or the wiring that is connected to
the P7 connector. B. Use a 151-6320 Wire Removal Tool to remove
terminals P2-10 and P2-20.
1. Set the engine control to the OFF/RESET engine control to the STOP mode.
D. To prevent the engine from starting, shut OFF the
2. Use a 151-6320 Wire Removal Tool to remove main gas supply.
the jumper wire from the P2 connector.
E. Set the engine control to the START mode for at
3. Reinstall terminals P2-10 and P2-20. Pull on least six seconds. Then set the engine control to
the wires in order to verify proper installation the STOP mode.
of the terminals.
Expected Result:
the harness, if necessary. There is no audible click and/or vibration when the
relay is disconnected and reconnected. The relay
STOP. is not energized when the engine control is in the
STOP mode.
• No – When the jumper wire was installed, a
“444-05 Start Relay open circuit” diagnostic code Results:
was activated. The master ECM did not detect
the jumper wire. There is a problem with the • OK – When the master ECM was connected, the
master ECM. relay was receiving power. When the master ECM
was not connected, the relay was not receiving
Repair: Perform the following procedure: power. There may be a problem with the master
ECM.
mode. Switch the 35 amp circuit breaker OFF. Repair: Perform the following procedure:
2. Use a 151-6320 Wire Removal Tool to remove 1. Set the engine control to the OFF/RESET
the jumper wire from the P2 connector. mode. Switch the 35 amp circuit breaker OFF.
277
2. Reinstall terminals P2-10 and P2-20. Pull on F. Use Cat ET to look for a logged “444-06 Start
the wires in order to verify proper installation Relay short to ground” diagnostic code again.
of the terminals.
Expected Result:
It is unlikely that the master ECM has failed.
Exit this procedure and perform this procedure A “444-06 Start Relay short to ground” was not
again. If the problem is not resolved, perform the activated.
following steps:
Results:
Troubleshooting, “Replacing the ECM”. • OK – A “444-06 Start Relay short to ground”
diagnostic code was not activated when the air
If the problem is resolved with the new ECM, start relay was disconnected. There is a problem
install the original ECM and verify that the with the air start relay.
correctly and the original ECM does not operate Repair: Perform the following procedure:
Troubleshooting, “Replacing the ECM”. 1. Set the engine control to the OFF/RESET
STOP.
2. Remove the jumper wire from the connector.
• Not OK – When the master ECM was
connected, the relay was receiving power. 3. Inspect the connectors for the air start relay.
When the master ECM was not connected, Check for damage, for moisture, and for
the relay was still receiving power. There corrosion.
is a problem with the wiring.
4. Make repairs, as needed.
The problem could be between
the P2 connector and the J7 connector. If the problem is not resolved, replace the air
Alternatively, the problem could be in the P7 start relay.
connector or the wiring that is connected to
the P7 connector. STOP.
Repair: Repair the harness, when possible. • Not OK – A “444-06 Start Relay short to ground”
Replace the harness, if necessary. diagnostic code was activated when the air start
relay was disconnected. The air start relay is OK.
STOP. Proceed to Test Step 8.
Test Step 7. Create an Open Circuit at the Test Step 8. Check the Master ECM
Air Start Relay
A. Set the engine control to the OFF/RESET mode. Switch the 35 amp circuit breaker OFF.
B. Use the 151-6320 Wire Removal Tool to remove
B. Disconnect the harness connector from the air terminals P2-10 and P2-20.
start relay.
C. Switch the 35 amp circuit breaker ON. Set the engine control to the STOP mode.
D. To prevent the engine from starting, shut OFF the
D. To prevent the engine from starting, shut OFF the main gas supply.
main gas supply.
Note: The “444-06 Start Relay short to ground”
Note: The “444-06 Start Relay short to ground” diagnostic code can only be detected when the
diagnostic code can only be detected when the output for the start command is ON. The output is
output for the start command is ON. The output is normally ON when the engine control is set from the
normally ON when the engine control is set from the STOP mode to the START mode. The output remains
STOP mode to the START mode. The output remains ON until the crank terminate relay is energized.
ON until the crank terminate relay is energized.
E. Set the engine control to the START mode for at
E. Set the engine control to the START mode for at least six seconds. Then set the engine control to
least six seconds. Then set the engine control to the STOP mode.
the STOP mode.
278
F. Use Cat ET to look for a logged “444-06 Start If the problem is resolved with the new ECM,
Relay short to ground” diagnostic code again. install the original ECM and verify that the
Expected Result: correctly and the original ECM does not operate
The “444-06 Start Relay short to ground” diagnostic Troubleshooting, “Replacing the ECM”.
code was not activated.
STOP.
Results:
Test Step 9. Check the “SM” Circuit
• OK – When the wiring was disconnected from Breaker
the master ECM, a “444-06 Start Relay short
to ground” diagnostic code was not activated.
There is a problem with the wiring. The problem
could be between the P2 connector and the J7
connector. Alternatively, the problem could be in
the P7 connector or the wiring that is connected
to the P7 connector.


the wires in order to verify proper installation
of the terminals.

the harness, if necessary.
STOP.
g00931258
Illustration 96
• Not OK – When the wiring was disconnected Junction box
from the master ECM, a “444-06 Start Relay short
to ground” diagnostic code was activated. There (1) “SM” circuit breaker (2.5 amp)
seems to be a problem with the master ECM.
A. Verify that the “SM” circuit breaker is in the ON
Repair: Perform the following procedure: position.
1. Set the engine control to the OFF/RESET Expected Result:

The “SM” circuit breaker is in the ON position.
the wires in order to verify proper installation Results:
of the terminals.
• OK – The “SM” circuit breaker is in the ON
It is unlikely that the master ECM has failed. position. Proceed to Test Step 10.
again. If the problem is not resolved, perform the • Not OK – The “SM” circuit breaker is not in the
following steps: ON position.
Temporarily install a new master ECM. Refer to Repair: Switch the “SM” circuit breaker to the ON
Troubleshooting, “Replacing the ECM”. position.
If the circuit breaker remains in the ON position,

the problem may be resolved. Perform the
following procedure:
1. Verify that the 35 amp circuit breaker is ON.

Set the engine control to the STOP mode.
279
Note: The “444-05 Start Relay open circuit”

output for the start command is OFF. The output
is normally OFF when the engine control is in the
STOP mode or when the crank terminate relay is
energized.
2. Wait for 30 seconds and use Cat ET to check

for an active “444-05 Start Relay open circuit”
diagnostic code.
If there is no active “444-05 Start

Relay open circuit” diagnostic code,
the problem appears to be resolved.
Resume normal operation.
If there is an active “444-05

Start Relay open circuit” diagnostic code,
Test Step 10. Inspect the Inside of the

Junction Box Illustration 98 g00931303
Fasteners for the junction box

A. Disconnect the +24 V power supply from the
engine. C. Remove seven bolts and nuts. Open the junction
box.
D. Inspect the inside of the junction box. Check

for moisture and for corrosion. Verify that each
electrical connection inside the junction box is
securely connected.
Expected Result:
The inside of the junction box does not have

moisture or corrosion. All of the electrical
connections inside the junction box are securely
connected.
Results:
• OK – The inside of the junction box does not

have moisture or corrosion. All of the electrical
connections inside the junction box are securely
connected. Proceed to Test Step 11.
g00931289
Illustration 97 • Not OK – The inside of the junction box has
Terminals on the junction box moisture or corrosion and/or there is a loose
electrical connection.
B. Verify that the power is disconnected by
checking for voltage at the “+” and “-” terminals Repair: Perform the necessary repairs, when
on the junction box. The voltage on the terminals possible. Replace parts, if necessary.
should be zero VDC.
STOP.

A. Use a 151-6320 Wire Removal Tool to remove
280
B. Use a multimeter to check for a short circuit

between the points that are listed in Table 25:
Note: Refer to Illustration 90, if necessary.

Table 25
Points to Check for a Short Circuit
Point Point
P2-10 The connection for the
“SM”circuit breaker that
is connected to wire
“P6B0A-RD”
One of the connections for The other connection for
Illustration 99 g00935305 the “SM” circuit breaker the “SM” circuit breaker
Side view of the junction box The connection for the The coil terminal of each
(1) Coil terminals on the magnetic switches “SM” circuit breaker that magnetic switch that
(2) Terminals on the “SM” circuit breaker is connected to wire is connected to wire
“P6B0B-RD” “C990-RD”
B. Use a multimeter to check for an open circuit The coil terminal of each P2-20
between the points that are listed in Table 24: magnetic switch that
is connected to wire
Table 24 “C991-BK”
Points to Check for an Open Circuit
Point Point Expected Result:
P2-20 “+” terminal on the junction All of the measurements are less than two ohms.
box
P2-10 “+” terminal on the junction Results:
box
Each coil terminal (1) on “+” terminal on the junction
• OK – All of the measurements are less than two
ohms. There is not an open circuit. Proceed to
each magnetic switch box
Test Step 13.
Each terminal (2) on the “+” terminal on the junction
“SM” circuit breaker box • Not OK – At least one measurement is more than
two ohms. There is a problem with the wiring or
Expected Result: with the “SM” circuit breaker.
All of the measurements are an open circuit. Repair: Repair the wiring and/or the connection,
Results:
STOP.
• OK – All of the measurements are an open Test Step 13. Check the Coils for the
circuit. There is not a short circuit to the +Battery.
Proceed to Test Step 12. Magnetic Switches
A. Use a multimeter to measure the resistance of
• Not OK – At least one measurement is not the coil for each magnetic switch.
an open circuit. There is a short circuit to the
+Battery.
Expected Result:
Repair: Repair the wiring and/or the connection,
when possible. Replace parts, if necessary. The resistance of each coil is between 16 and 20
ohms.
STOP.
Results:
Test Step 12. Check for a Short Circuit
• OK – The resistance of each coil is between 16
A. Verify that the “SM” circuit breaker is in the ON ohms and 20 ohms. The coil resistance for each
position. magnetic switch is correct.
281
Repair: Expected Result:
1. Install the seven bolts and nuts for the junction No diagnostic codes were activated.
box.
Results:
2. Reconnect the +24 V power supply to the
engine. • OK – No diagnostic codes were activated. The
initial diagnostic code was probably caused by a
Proceed to Test Step 14. poor electrical connection.
• Not – The resistance of a coil is not between 16 Repair: If there is an intermittent problem
ohms and 20 ohms. The resistance of a coil for that is causing the codes to be logged, refer
a magnetic switch is incorrect. to Troubleshooting, “Inspecting Electrical
Connectors”.
Repair: Replace the magnetic switch. Verify that
the original problem is resolved. STOP.
STOP. • Not OK – A diagnostic code was activated. There

may be a problem with the master ECM.
Test Step 14. Check the Operation of the
Master ECM Repair: It is unlikely that the master ECM has
A. Verify that terminals P2-10 and P2-20 are procedure again. If the problem is not resolved,
removed from the P2 connector. perform the following steps:
B. Verify that the 35 amp circuit breaker is ON. Temporarily install a new master ECM. Refer to
Verify that the “SM” circuit breaker is ON. Troubleshooting, “Replacing the ECM”.
Note: The “444-05 Start Relay open circuit” If the problem is resolved with the new ECM,
diagnostic code can only be detected when the install the original ECM and verify that the
output for the start command is OFF. The output problem returns. If the new ECM operates
is normally OFF when the engine control is in the correctly and the original ECM does not operate
STOP mode or when the crank terminate relay is correctly, replace the original ECM. Refer to
energized. Troubleshooting, “Replacing the ECM”.
C. Set the engine control to the STOP mode. STOP.
A “444-05 Start Relay open circuit” diagnostic

i01821791
code should not be activated.
D. Set the engine control to the OFF/RESET mode.

ECM Status Indicator Output
Switch the 35 amp circuit breaker OFF. SMCS Code: 7400-038-IND
E. Reinstall terminals P2-10 and P2-20. Pull on the System Operation Description:
wires in order to verify proper installation of the
terminals. The master Electronic Control Module (ECM) has
four outputs in order to indicate the status of engine
F. Switch the 35 amp circuit breaker ON. operation: “Run Relay”, “Crank Terminate Relay”,
“Engine Control Alarm Status”, and “Fault Relay”.
Note: The “444-06 Start Relay short to ground” These outputs can be used to energize indicator
diagnostic code can only be detected when the lamps or the outputs can be used to interface with
output for the start command is ON. The output is other controls.
normally ON when the engine control is set from the
STOP mode to the START mode. The output remains When the output is OFF, the circuit is open. The
ON until the crank terminate relay is energized. output provides a maximum current of 0.3 amperes
to the master ECM. The master ECM grounds the
G. Set the engine control to the START mode. current to the negative terminal of the battery in
Look for a “444-06 Start Relay short to ground” order to activate the appropriate output.
diagnostic code.
If any of the outputs have a short circuit to the
A “444-06 Start Relay short to ground” diagnostic +Battery side or excessive current, a diagnostic
code should not be activated. code is generated.
282
Note: These outputs do not provide enough current The most likely causes of a diagnostic code for a
for illumination of standard incandescent lights. If a status indicator is a poor electrical connection or a
lamp is burned out, replace the lamp with the lamp problem in a wiring harness. The next likely cause
that is specified in the engine’s Parts Manual. is a problem with an indicator. The least likely cause
is a problem with the master ECM.
“Run Relay” – This output indicates that the engine
is in the “Run” status. The engine will start soon or Logged diagnostic codes provide a historical
the engine is running. While this output is energized, record. Before you begin this procedure, use ET to
a short circuit to a positive voltage source or print the logged codes to a file.
excessive electrical current on the output will cause
a diagnostic code to become activated. The master The troubleshooting procedure may generate
ECM cannot diagnose this output while the output additional diagnostic codes. Keep your mind on
is OFF. correcting the cause of the original diagnostic code.
“Crank Terminate Relay” – This output indicates that resolved.
the engine rpm is greater than the programmed
engine speed that is required for disengagement of
the starting motor. While this output is energized,
a short circuit to a positive voltage source or
a diagnostic code to become Activated. The master
ECM cannot diagnose this output while the output
is OFF.
“Engine Control Alarm Status” – This is the alarm

output. This output indicates that the master ECM
has detected an electrical problem or an abnormal
operating condition. While this output is energized,
a short circuit to a positive voltage source or
a diagnostic code to become Activated. The master
ECM cannot diagnose this output while the output
is OFF.
“Fault Relay” – This is the shutdown output. This

output indicates that a potentially damaging
operating condition was detected by the master
ECM. The master ECM has shut down the engine.
While this output is energized, a short circuit to
a positive voltage source or excessive electrical
current on the output will cause a diagnostic code
to become Activated. The master ECM cannot
diagnose this output while the output is OFF.
A “323-03 Shutdown Lamp short to +batt” or

“324-03 Warning Lamp short to +batt” diagnostic
code can only be generated if a shutdown condition
or an alarm condition is active. Failure to correct
these serious conditions can result in engine
damage.

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”.
283
g00930181
Illustration 100
Schematic for the status indicators

g00930189
Illustration 102
Terminal box
g00931487
Illustration 101 (2) J2/P2 connectors for the master ECM
Junction box (3) J6/P6 connectors for the customer
A. Set the engine control to the OFF/RESET mode. B. Thoroughly inspect each of the following
Switch 35 amp circuit breaker (1) to the OFF connectors:
position.
Note: Some indicators may obtain the status of the
engine via a data link. If all of the status indicators • J6/P6 connectors on the terminal box
are not directly controlled by the master ECM, do
not proceed with this test. a. Check the torque of the Allen head screw for
6 ± 1 N·m (55 ± 9 lb in).

284
e. Check the harness and wiring for abrasion

and for pinch points from the customer’s
equipment to the master ECM.
Expected Result:

Results:

g00930205
Illustration 103
Harness side of the master ECM P2 connector condition and/or at least one connection is
(P2-28) Run Relay improper.
(P2-29) Crank Terminate Relay
(P2-30) Fault Relay Repair: Perform the necessary repairs and/or
(P2-31) Engine Control Alarm Status
STOP.

A. Connect Cat ET to the service tool connector
on the terminal box. Refer to Troubleshooting,
“Electronic Service Tools”.
B. Switch the 35 amp circuit breaker ON.
C. Attempt to start the engine and observe the

status indicators. Allow a minimum of 30 seconds
for any diagnostic codes to activate. Use the
“Active Diagnostic” screen on Cat ET to look for
the codes that are listed in Table 26:
Table 26
Diagnostic Codes and Descriptions with
Corresponding ECM Outputs
Illustration 104 g00930208 Code Description ECM Output

Harness side of the J6 connector 323-03 Shutdown Lamp short to “Fault Relay”
(J6-22) Run Relay +batt
(J6-23) Fault Relay
(J6-32) Crank Terminate Relay 324-03 Warning Lamp short to “Engine Control
(J6-33) Engine Control Alarm Status +batt Alarm Status”
443-03 Crank Terminate Relay “Crank
c. Perform a 45 N (10 lb) pull test on each of the short to +batt Terminate
wires that are associated with the circuit for Relay”
the status indicators.
445-03 Run Relay short to +batt “Run Relay”
Note: These outputs do not provide enough current
for illumination of standard incandescent lights. If a Expected Result:
lamp is burned out, replace the lamp with the lamp
that is specified in the engine’s Parts Manual. There are no active diagnostic codes. The “Engine
On” indicator and the “Crank Terminate” indicator (if
d. Inspect the wiring and the receptacles for the equipped) illuminated normally. The “Active Alarm”
status indicators. indicator and the “Engine Failure” indicator did not
illuminate.
285
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 STOP.
was started, the “Run Relay” indicator and the
“Crank Terminate Relay” indicator (if equipped) • Not OK (Active 443-03 or 445-03 Diagnostic
illuminated normally. The “Engine Control Alarm Code) – When the engine was started, the “Run
Status” indicator and the “Fault Relay” indicator Relay” indicator and/or the “Crank Terminate
did not illuminate. There are no active diagnostic Relay” indicator (if equipped) did not illuminate
codes. normally. The “Engine Control Alarm Status”
indicator and the “Fault Relay” indicator did not
Repair: The outputs for the status indicators seem illuminate. A 443-03 or 445-03 diagnostic code
to be operating correctly at this time. The original was activated. There is a problem with the output
diagnostic code was probably caused by a poor for the “Run Relay” indicator and/or the “Crank
electrical connection. Terminate Relay” indicator (if equipped). Proceed
to Test Step 4.
If there is an intermittent problem that is causing
the codes to be logged, refer to Troubleshooting, Test Step 3. Check for Proper Operation
“Inspecting Electrical Connectors”. of the Status Indicators for the Alarm and
Shutdown
STOP.
Note: All active diagnostic codes and active event
• Yes (Original 323-03 or 324-03 Diagnostic Code) – codes must be cleared in order for the “Engine
The original diagnostic code was “323-03 Control Alarm Status” indicator to be OFF.
Shutdown Lamp short to +batt” or “324-03
Warning Lamp short to +batt”. When the engine Allow the engine operation to continue for this
was started, the “Run Relay” indicator and the procedure. Operate the engine under low load.
“Crank Terminate Relay” indicator (if equipped)
illuminated normally. The “Engine Control Alarm
Status” indicator and the “Fault Relay” indicator
did not illuminate. There are no active diagnostic
codes.
Repair: The 323-03 and 324-03 diagnostic codes

can only be activated when the corresponding
indicator is activated. There may still be a
problem with the output for the alarm indicator
or the shutdown indicator. The alarm and/or the
shutdown must be activated.
Allow the engine operation to continue. Proceed

to Test Step 3.
• Not OK (Active 323-03 or 324-03 Diagnostic

Code) – There is an active “323-03 Shutdown
Lamp short to +batt” or “324-03 Warning Lamp
short to +batt”. There must be a shutdown
condition before a 323-03 diagnostic code
can be generated. There must be an alarm g00930223
Illustration 105
condition before a 324-03 diagnostic code can be
generated. Both of these conditions are serious. (1) Unfiltered engine oil pressure sensor
(2) Filtered engine oil pressure sensor
Repair: Use Cat ET to determine the event code

A. During engine operation, disconnect the
or the diagnostic code that corresponds to the
connector for the unfiltered engine oil pressure
323-03 or 324-03 diagnostic code. Troubleshoot
sensor (1). Observe the “Engine Control
that event code or that diagnostic code
Alarm Status” indicator on the control panel (if
before you troubleshoot the 323-03 or 324-03
equipped).
diagnostic code. Refer to Troubleshooting,
“Troubleshooting with an Event Code” or
Troubleshooting, “Troubleshooting with a
Diagnostic Code”.
286
If you are only troubleshooting a “324-03 Warning Test Step 4. Measure the Voltage of the
Lamp short to +batt”, proceed to the “Expected Suspect Indicator at the P2 Connector
Result”.
Note: When the filtered engine oil pressure sensor

is disconnected, the engine will shut down.
B. Disconnect the connector for the filtered engine

oil pressure sensor (2). Observe the “Fault Relay”
indicator on the control panel (if equipped).
C. Use the “Diagnostics” screen on Cat ET to look

for active diagnostic codes.
Expected Result:
The “Engine Control Alarm Status” 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 “Fault Relay” 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.
Results:
• OK – The indicators, diagnostic codes, and Illustration 106 g00930238

shutdown were activated according to the Terminal box
“Expected Result”. The outputs for the status
(1) Ground strap for the master ECM
indicators seem to be operating correctly at this (P2-28) Run Relay
time. The original problem seems to be resolved. (P2-29) Crank Terminate Relay
(P2-30) Fault Relay
Repair: The original diagnostic code was probably (P2-31) Engine Control Alarm Status
If there is an intermittent problem that is causing Switch the 35 amp circuit breaker OFF.
the codes to be logged, refer to Troubleshooting,
“Inspecting Electrical Connectors”. B. Insert a 7X-1710 Multimeter Probe into the
suspect control terminal in the master ECM P2
STOP. connector.
• Not OK – The “Engine Control Alarm Status” C. Connect the positive lead of a voltmeter to the
indicator and/or the “Fault Relay” indicator did end of the 7X-1710 Multimeter Probe. Connect
not illuminate normally when the sensors were the voltmeter’s negative lead to ground strap (1).
disconnected. A “323-03 Shutdown Lamp short
to +batt” and/or a “324-03 Warning Lamp short to D. Switch the 35 amp circuit breaker ON. Set the
+batt” diagnostic code was generated. There is a engine control to the STOP mode.
problem with the output for the status indicators.
The “542-03” and the “100-03” diagnostic codes E. Note the voltage that is displayed on the
were generated. The engine was shut down. voltmeter.
F. Set the engine control to the OFF/RESET mode.
287
G. If the customer has equipment for the status B. Disconnect the voltmeter leads and remove
indicators, disconnect one wire from the suspect the 7X-1710 Multimeter Probe from the P2
indicator. Be sure to disconnect the wire that connector.
comes from the master ECM.
C. Use a 151-6320 Wire Removal Tool to remove
H. Insulate the end of the wire with electrical tape in the suspect terminal from the ECM P2 connector.
order to ensure that the wire does not create a
short circuit. D. Insulate the terminal with electrical tape in order
to ensure that the terminal does not create a
I. Switch the 35 amp circuit breaker ON. Set the short circuit.
E. Fabricate a jumper wire with Deutsch terminals
J. Note the voltage that is displayed on the on the ends. Insert one end of the jumper wire
voltmeter. into the open terminal of the P2 connector.
Expected Result: F. Connect a voltmeter lead to the end of the jumper

wire that is not inserted into the connector.
Before the suspect indicator was disconnected,
voltage was displayed on the voltmeter. After the G. Connect the other lead of the voltmeter to the
suspect indicator was disconnected, the voltmeter ground strap for the master ECM.
displayed approximately zero volts.
H. Switch the 35 amp circuit breaker ON. Set the
Results: engine control to the STOP mode. Observe the
voltage reading on the voltmeter.
• Yes – Before the suspect indicator was
disconnected, voltage was displayed on Expected Result:
the voltmeter. After the suspect indicator
was disconnected, the voltmeter displayed The voltmeter displays approximately zero volts.
approximately zero volts. There is a problem in
the customer’s equipment. Results:
Repair: The problem could be caused by a poor • The voltage is approximately zero – After the
electrical connection, a wire, or a component in suspect terminal was removed from connector P2,
the customer’s equipment. the reading on the voltmeter was approximately
zero. There is a problem with a connection and/or
Set the engine control to the OFF/RESET mode. the wiring between the customer’s equipment
Switch the 35 amp circuit breaker OFF. and the ECM.
Thoroughly inspect all wiring and all Repair: Perform the following procedure:
connectors in the customer’s equipment.
Refer to Troubleshooting, “Inspecting Electrical 1. Switch the 35 amp circuit breaker OFF. Set the
Connectors”. engine control to the OFF/RESET mode.
If you suspect that the indicator has an internal 2. Disconnect the voltmeter leads.
short circuit, temporarily install a known good
indicator for the suspect indicator. Test the 3. Use a 151-6320 Wire Removal Tool to remove
indicator. Verify that the problem is resolved. the jumper wire from the ECM P2 connector.
Make the necessary repairs, when possible. 4. Insert the terminal for the output wire into the
Replace parts, if necessary. P2 connector. Pull on the wire in order to
verify that the terminal is fully inserted into the
STOP. connector.
• No – Before the suspect indicator was Repair the connection and/or the wiring, when
disconnected, voltage was displayed on the possible. Replace parts, if necessary.
voltmeter. After the suspect indicator was
disconnected, the voltage was still displayed on STOP.
the voltmeter. Proceed to Test Step 5.
• The voltage remained – After the suspect terminal
Test Step 5. Check the Master ECM was removed from the P2 connector, voltage was
still displayed on the voltmeter. There may be a
A. Set the engine control to the OFF/RESET mode. problem with the master ECM.
288
Repair: It is unlikely that the master ECM has The master ECM input at terminal 70 of the P1
failed. Exit this procedure and perform this connector (“Switched +Battery”) receives battery
procedure again. If the problem is not resolved, voltage from the engine control when the control is
perform the following steps: in the START mode, in the STOP mode, or in the
AUTO mode. When the master ECM detects battery
Temporarily install a new master ECM. Refer to voltage at this input, the master ECM will power up.
Troubleshooting, “Replacing the ECM”. When battery voltage is removed from this input,
the master ECM will power down after the engine
If the problem is resolved with the new ECM, has shut down.
problem returns. If the new ECM operates For the slave ECM, the input at terminal 70 of the
correctly and the original ECM does not operate P3 connector (“Switched +Battery”) receives battery
correctly, replace the original ECM. Refer to voltage from the engine control when the control is
Troubleshooting, “Replacing the ECM”. in the START mode, in the STOP mode, or in the
AUTO mode. When the slave ECM detects battery
STOP. voltage at this input, the slave ECM will power up.
The “168-02” diagnostic code indicates that the

i01823658
voltage of the power supply is intermittent or low
Electrical Power Supply while the engine is running. If the supply voltage
drops to zero and stays at zero, neither ECM will
SMCS Code: 1408-038 log this code. The engine will shut down.
System Operation Description: The “336-02” diagnostic code indicates that the
master ECM has detected a problem with the circuit
Electrical power is supplied to the following for the engine control.
components:
• Master Electronic Control Module (ECM) Caterpillar Electronic Technician (ET) to print the
• Slave ECM
This procedure may generate additional diagnostic
• Integrated Temperature Sensing Module (ITSM) codes. Keep your mind on correcting the cause of
the original diagnostic code. Clear the diagnostic
• Fuel metering valve codes after the problem is resolved.
• Actuator for the throttle
• Actuator for the compressor bypass group
The cause of an intermittent power supply can
occur on either the positive side or the negative
side of the power supply.
The 24 VDC power supply for the engine can be

provided by a battery or by an electrical power
supply. If the power is provided by an electrical
power supply, the maximum allowable AC ripple is
150 mV AC peak to peak. The minimum requirement
for the power supply is 22 VDC at 30 amperes.
The wiring from the power supply to the ECM must
provide a maximum voltage drop of 1.0 VDC.
289
g00952101
Illustration 107
Schematic for the electrical power
290

g00931678
Illustration 109
Terminal box
g00931669
Illustration 108 (5) J5 connector for the service tool
Junction box (6) J1/P1 connectors for the master ECM
(1) Circuit breaker for the engine control (2.5 ampere) (8) J7/P7 connectors for the harness for electrical power
(2) Circuit breaker for the customer (10 ampere) (9) J3/P3 connectors for the slave ECM
(3) Circuit breaker for the engine (35 ampere)
(4) Circuit breaker for the master ECM output for the electrical
starting motor (2.5 ampere) B. Thoroughly inspect each of the following
connectors:
Switch 35 amp circuit breaker (3) to the OFF • Master ECM J1/P1 connectors
position.
• Slave ECM J3/P3 connectors
Troubleshooting, “Inspecting Electrical Connectors”. • J5, J6/P6 and J7/P7 connectors on the terminal
box
• Connectors for the 24 VDC power supply

• Connectors for the engine control
6 ± 1 N·m (55 ± 9 lb in).

291
g00952118
Illustration 110
Harness side of ECM connectors P1 and P3
(31) Digital return
(52) Unswitched +Battery
(61) Stop (Master ECM)
(62) Start (Master ECM)
(63) -Battery
(64) Auto (Master ECM)
(65) -Battery
(67) -Battery
(69) -Battery
(70) Switched +Battery
g00931545
Illustration 112
(J7-57) Unswitched +Battery
(J7-58) Unswitched +Battery
(J7-60) Power for the engine control
(J7-61) Switched +Battery
(J7-65) Power for the customer
(J7-70) -Battery

wires that are associated with the electrical
power supply.

and for pinch points from the power supply to
the master ECM and from the engine control
to the master ECM.
Expected Result:
The connectors, pins, and sockets are connected

Illustration 111 g00952120 properly. The connectors and the wiring do not have
(P6-1) +Battery for the customer (10 amperes)
(P6-4) Power for the engine control
Results:
(P6-14) Switched +Battery
(P6-19) Stop command • OK – The components are in good condition with
(P6-29) Start command proper connections. Proceed to Test Step 2.
(P6-36) Digital return
(P6-39) Auto command
improper.
292
Repair: Perform the necessary repairs and/or Expected Result:

replace parts, if necessary. Ensure that all of the
seals are properly installed. Make sure that the The voltage that is measured at the terminals for
connectors are properly fastened. Verify that the the power supply is at least 22 VDC. The voltage
repair has eliminated the problem. that is measured at the P1 connector and at the P3
connector is within one volt of the voltage that was
STOP. measured at the terminals for the power supply. The
voltage measurements are constant.
Test Step 2. Check the Voltage at the
Power Supply, at the Master ECM, and at Results:
the Slave ECM
• OK – Each ECM is receiving the correct voltage.
A. Make sure that the engine will not crank during
this procedure. For an engine with an electric Repair: Perform the following procedure:
starting motor, make sure that the battery cables
are disconnected from the motor. For an engine Switch the 35 amp circuit breaker OFF.
with an air starting motor, make sure that the
pressurized air supply is OFF. Make sure that the Remove the probes from the P3 connector.
air is purged from the system.
Note: If a power supply is used instead of batteries,
the minimum voltage for the power supply is 22 • Not OK – An ECM is not receiving the correct
VDC. Troubleshoot the power supply if the voltage voltage.
is less than 22 VDC or more than 29 VDC.
B. Measure the voltage at the terminals for the
power supply. Record the measurement. 1. Switch the 35 amp circuit breaker OFF.
C. Insert two 7X-1710 Multimeter Probes into the 2. Remove the probes from the P3 connector.
harness side of the P1 connector. Insert the first
probe into terminal 52. Insert the second probe 3. Use a voltmeter to check the wiring. Refer to
into terminal 63. Connect a multimeter to the the schematic for the electrical system. Locate
probes. the source of the voltage drop.
D. Switch the 35 amp circuit breaker ON. 4. Make repairs, as needed.
E. Measure the power supply voltage at the P1 STOP.

connector. During the measurement, wiggle the
harness in order to check for an intermittent Test Step 3. Check the Engine Control
problem. Be sure to wiggle the harness near each Switch
of the connections. Record the measurement.
F. Switch the 35 amp circuit breaker OFF. Remove this procedure. For an engine with an electric
the probes from the P1 connector. starting motor, make sure that the battery cables
are disconnected from the motor. For an engine
G. Insert two 7X-1710 Multimeter Probes into the with an air starting motor, make sure that the
harness side of the P3 connector. Insert the first pressurized air supply is OFF. Make sure that the
probe into terminal 52. Insert the second probe air is purged from the system.
into terminal 63. Connect a multimeter to the
probes. B. Connect Cat ET to the service tool connector.
H. Switch the 35 amp circuit breaker ON. Tools”.
I. Measure the power supply voltage at the P3 C. Switch the 35 amp circuit breaker ON.
connector. During the measurement, wiggle the
harness in order to check for an intermittent Note: An “E225 Engine Overcrank” and/or an “E233
problem. Be sure to wiggle the harness near each Low Engine Prelube Pressure” event code may
of the connections. Record the measurement. be generated during this step. After you have
completed this step, clear the events from the
“Logged Events” screen of Cat ET.
293
D. Observe the “Active Diagnostic” screen on Cat E. Set the engine control to the STOP mode and
ET and set the engine control to the STOP mode, measure the voltage between terminals P1-31
the START mode, and the AUTO mode. Look for and P1-61. The correct voltage measurement is
an active “336-02 Incorrect ECS Switch inputs” less than one volt.
diagnostic code. Repeat this step several times.
F. Remove the probe from terminal 61 and insert
Expected Result: the probe into terminal 62.
A “336-02 Incorrect ECS Switch inputs” diagnostic G. Set the engine control to the START mode and
code was not activated when the engine control measure the voltage between terminals P1-31
was set to the STOP mode, the START mode, and and P1-62. The correct voltage measurement is
the AUTO mode. less than one volt.
Results: H. Remove the probe from terminal 62 and insert

the probe into terminal 64.
• OK – A “336-02 Incorrect ECS Switch inputs”
diagnostic code was not activated. The inputs I. Set the engine control to the AUTO mode and
from the engine control are correct. The problem measure the voltage between terminals P1-31
seems to be resolved. and P1-64. The correct voltage measurement is
less than one volt.
Repair: The problem may be intermittent.
Refer to Troubleshooting, “Inspecting Electrical J. Remove the probe from terminal 31 and insert the
Connectors”. probe into terminal 69. Remove the probe from
terminal 64 and insert the probe into terminal 70.
STOP.
K. Set the engine control to the STOP mode and
• Not OK – A “336-02 Incorrect ECS Switch inputs” measure the voltage between terminals P1-69
diagnostic code was activated. The master ECM and P1-70 connector. The correct voltage
has detected an invalid pattern of inputs from the measurement is at least 20 VDC.
engine control switch. Proceed to Test Step 4.
L. Set the engine control to the START mode and
Test Step 4. Check the Circuit of the measure the voltage between terminals P1-69
Engine Control Switch and P1-70. The correct voltage measurement is
at least +20 VDC.
this procedure. For an engine with an electric M. Set the engine control to the AUTO mode and
starting motor, make sure that the battery cables measure the voltage between terminals P1-69
are disconnected from the motor. For an engine and P1-70. The correct voltage measurement is
with an air starting motor, make sure that the at least 20 VDC.
pressurized air supply is OFF. Make sure that the
air is purged from the system. Expected Result:
B. Set the engine control to the OFF/RESET mode. The voltage checks are within the specifications.
Results:
C. Insert two 7X-1710 Multimeter Probes into the
harness side of the P1 connector. Insert the first • OK – The voltage checks are within the
probe into terminal 31. Insert the second probe specifications. Remove the probes from the P1
into terminal 61. Connect a multimeter to the connector. Start the engine and run the engine. If
probes. the original problem is not resolved, the master
ECM may have a problem.
D. Switch the 35 amp circuit breaker ON.
Repair: It is unlikely that the master ECM has
Note: An “E225 Engine Overcrank” and/or an “E233 failed. Perform the following procedure:
Low Engine Prelube Pressure” event code may be
generated during the test. After you have completed Temporarily install a new master ECM. Refer to
the test, clear the events from the “Logged Events” Troubleshooting, “Replacing the ECM”.
screen of Cat ET.
Note: During these measurements, wiggle the

harness in order to check for an intermittent
problem. Be sure to wiggle the harness near each
of the connections.
294

install the original ECM and verify that the problem
STOP.
• Not OK – The P1 connector does not have the

correct voltage.
Repair: Perform the following steps:

2. Disconnect the wires for the STOP, START,

and AUTO modes from the device that
provides engine control. The device may be a
mechanical switch or an electronic control.
3. If a mechanical switch provides engine control,

use an ohmmeter to check the contacts for the
switch. Set the switch to each position in order
to check the contacts. If an electronic control
provides engine control, check the control
according to the literature that is provided by
the OEM of the control. Verify that the correct
signals are generated by the electronic control.
4. If the engine control is faulty, replace the

control. If the problem is not resolved, repair
the harness, when possible. Replace the
harness, if necessary.
STOP.
295
i01824322
Engine Speed/Timing Sensor

SMCS Code: 1912-038
g00893441
Illustration 113
Speed/Timing sensor and timing ring
The speed/timing sensor provides information about The number one cylinder is at the top center
engine speed and the position of the crankshaft to position when the rising edge of the third narrow slot
the master Electronic Control Module (ECM) and the passes the center of the sliphead. All 24 teeth pass
slave ECM. The sensor is powered by the sensor the sliphead during one revolution of the camshaft
supply (12 VDC) from the master ECM. A magnetic or two revolutions of the crankshaft.
pickup is located in the plastic sliphead of the
sensor. The timing ring is mounted on the rear of With the information from the engine speed/timing
the left camshaft. As the teeth of the ring rotate past sensor, each ECM is able to calculate the positions
the sliphead of the sensor, the sensor generates a of the pistons in the cylinders. Each ECM determines
signal that matches the pattern of the teeth. the desired ignition timing according to the engine
speed and load. If detonation is detected in any
The timing ring has a special tooth pattern that of the cylinders, the appropriate ECM retards the
indicates the position of the camshaft and the timing of the affected cylinders. Each ECM sends
direction of rotation. The timing ring has 24 slots voltage pulses to the ignition transformers for firing
in the outer diameter. Twenty-one of the slots are the spark plugs according to the desired timing.
narrow. Three of the slots are about 2.5 times wider
than the rest of the slots. When the engine rotates in During engine operation, the master ECM will shut
the normal direction, the slots pass the speed/timing down the engine if either ECM detects a problem
sensor in the following order: with the signal from the speed/timing sensor. The
ECM that detected the problem with the signal will
• 1 wide slot activate the corresponding diagnostic code.
• 3 narrow slots If there is a problem with the engine speed/timing

sensor’s signal during start-up but no corresponding
• 2 wide slots diagnostic code is active, the master ECM will not
initiate the ignition. The engine will not start. The
• 18 narrow slots corresponding diagnostic code is not activated.
296

harness. The next likely cause is a problem with the
engine speed/timing sensor. The least likely cause
is a problem with an ECM.


resolved.
g00931711
Illustration 114
Schematic for the circuit of the speed/timing sensor
297
Test Step 1. Inspect the Electrical • J3/P3 connectors for the slave ECM
Connectors and Wiring.
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 115
A. Set the engine control to the OFF/RESET mode. Illustration 117 g00893339
position.
(P1-33) Signal
Note: For the following steps, refer to (P1-51) Return
g00931713
Illustration 118
Harness side of the slave ECM P3 connector
(P3-33) Signal
g00931631
Illustration 116
(3) J7/P7 connectors for the harness from the speed/timing sensor
B. Thoroughly inspect the following connections:

298
g00931736
Illustration 120
Speed/Timing sensor
(5) Speed/Timing sensor

and for pinch points from the speed/timing
Illustration 119 g00931722 sensor to each ECM.
Harness side of the P7 connector
Expected Result:
(P7-9) Signal
(P7-23) Return
(P7-37) Shield The connectors, pins, and sockets are connected
(P7-51) 12 volt supply properly. The connectors and the wiring do not have
wires that are associated with the circuit for Results:
the speed/timing sensor.

improper.

STOP.
Test Step 2. Check the Sensor

B. Remove the speed/timing sensor.

299
c. Coat the threads of the sensor with

4C-5597 Anti-Seize Compound.
d. Install the sensor. Tighten the sensor to

40 ± 5 N·m (30 ± 4 lb ft).

g00931748
Illustration 121 • Not OK – The plastic sliphead is damaged and/or
Plastic sliphead for the speed/timing sensor the tension of the sliphead is insufficient.
C. Inspect the condition of the plastic sliphead. Repair: Install a new sensor. Calibrate the sensor.
Look for signs of wear and for contaminants. Refer to Troubleshooting, “Engine Speed/Timing
Clean any debris from the plastic sliphead. Sensor - Calibrate”.
D. Check the tension of the plastic sliphead. Gently If the condition is not resolved, proceed to Test
extend the plastic sliphead for a minimum of Step 3.
4 mm (0.16 inch). Then push back the plastic
sliphead. Test Step 3. Check for Active Diagnostic
Codes for the 12 Volt Sensor Supply
Expected Result:
The sensor is in good condition. At least 22 N (5 lb) Refer to Troubleshooting, “Electronic Service
of force is required to push in the plastic sliphead Tools”.
from the extended position.
Results: engine control to the STOP mode.
• OK – The sensor is not damaged. The tension of C. Use the “Active Diagnostic” screen on Cat ET.
the plastic sliphead is correct. Look for the following codes:
Repair: Install the sensor. • 145-03 12 Volt DC Power Supply short to +batt
• 145-04 12 Volt DC Power Supply short to
NOTICE ground
The plastic sliphead must be fully extended when the
speed/timing sensor is installed so that the sensor Expected Result:
maintains the correct clearance with the timing ring.
If the correct clearance is not maintained, the signal None of the above codes are active.
from the sensor will not be generated.
Results:
Do not install the sensor’s plastic sliphead between
the teeth of the timing ring. Damage to the plasic slip- • No active codes – None of the above codes are
head will result. Before installing the sensor, ensure active. However, at least one of the codes is
that a tooth of the ring is visible in the mounting hole logged.
for the sensor.
Repair: Clear the logged codes.
1. Use the following steps to install the
speed/timing sensor: Proceed to Test Step 4.
a. Ensure that a tooth on the timing ring is • Active code – One of the above codes is active.
visible in the mounting hole for the sensor. Proceed to Test Step 5.
b. Fully extend the sliphead. Test Step 4. Use Cat ET to Check the
Engine RPM
Note: The plastic sliphead is designed to contact
the tooth of the timing ring during installation. As A. Use the “Status - Group 1” screen in order to
the timing ring begins to turn, the radial runout of observe “Engine Speed”. Observe the “Engine
the timing ring will push the plastic sliphead into Speed” parameter on the screen and set the
the sensor body slightly. This provides the plastic engine control to the START mode. Crank the
sliphead’s air gap with a self-adjusting function. The engine.
maximum allowable clearance between the sliphead
and a tooth on the timing ring is 0.5 mm (0.02 inch).
300
B. Continue to observe the screen and allow the Results:

engine rpm to stabilize at the normal cranking
speed. • OK – The sensor is receiving correct supply
voltage. A 145-03 diagnostic code or a 145-04
C. Set the engine control to the STOP mode. diagnostic code is not active. Leave the breakout
t connected. Proceed to Test Step 6.
Expected Result:
• Not OK – The sensor is not receiving correct
Before the engine is cranked, the engine speed is supply voltage or a 145-03 diagnostic code or a
“0”. The engine speed increases until the speed 145-04 diagnostic code is active. Remove the
stabilizes at the normal cranking speed. When the breakout t. Proceed to Test Step 7.
engine is stopped, the speed decreases back
to “0”. A 320-03 diagnostic code or a 320-08 Test Step 6. Isolate the Signal Voltage at
diagnostic code is not activated. the Sensor
Results: A. Set the engine control to the OFF/RESET mode.
• OK – The engine started and the engine B. Ensure that the breakout t is connected in series
ran properly. A 320-03 diagnostic code or a with the connectors for the speed/timing sensor.
320-08 diagnostic code was not activated. The
speed/timing sensor is operating properly. STOP. C. Remove the wire from terminal C of the breakout
t in order to isolate the sensor signal wire.
• Not OK – The engine cranked. However, Cat
ET did not display the correct engine speed D. Set the engine control to the STOP mode.
or a 320-03 or a 320-08 diagnostic code was Measure the signal voltage between terminals B
activated. Proceed to Test Step 5. and C.
• Not OK – The engine cranked but the engine did E. Set the engine control to the START mode. Crank
not start. Cat ET displayed the correct engine the engine and measure the signal voltage
speed. A 320-03 diagnostic code or a 320-08 between terminals B and C.
diagnostic code was not activated. Each ECM is
receiving a valid signal. Expected Result:
Repair: Refer to Troubleshooting, “Engine Cranks When the engine control is in the STOP mode,
But Will Not Start”. Make repairs, as needed. the voltage is less than 3.0 VDC or the voltage is
greater than 10.0 VDC.
STOP.
The voltage varied between 2.0 VDC and 4.0 VDC
Test Step 5. Measure the Sensor Supply during cranking.
Voltage at the Sensor
Results:
A. Set the engine control to the OFF mode.
• OK – The sensor is producing the correct output
B. Install a 8T-8726 Adapter Cable As (Three-Pin signal.
Breakout) in series with the connectors for the
speed/timing sensor. Repair: Remove the breakout t from the
connectors for the speed/timing sensor.
C. Set the engine control to the STOP mode. Reconnect the connectors for the speed/timing
Measure the supply voltage between terminals A sensor.
and B of the breakout t.
If you are troubleshooting the speed/timing
Expected Result: sensor’s signal for the master ECM, proceed
to Test Step 8. If you are troubleshooting the
The voltage is between 11.5 VDC and 13.5 VDC. speed/timing sensor’s signal for the slave ECM,
A 145-03 diagnostic code or a 145-04 diagnostic proceed to Test Step 9.
code is not active.
• Not OK – The sensor is not producing the correct
output signal.
Repair: Set the engine control to the OFF/RESET

301
Remove the breakout t from the connectors for If the problem is resolved with the new ECM,
the speed/timing sensor. install the original ECM and verify that the problem
Install a new speed/timing sensor. Calibrate the original ECM does not operate correctly,
the sensor. Refer to Troubleshooting, “Engine replace the ECM. Refer to Troubleshooting,
Speed/Timing Sensor - Calibrate”. “Replacing the ECM”.
STOP. STOP.
Test Step 7. Measure the Sensor Supply Test Step 8. Isolate the Sensor Signal at
Voltage at the Master ECM the Master ECM and Measure the Sensor
Signal Voltage at the Master ECM
B. Use two 7X-1710 Multimeter Probes. Insert the
probes into terminals P1-33 and P1-51. B. Use a 151-6320 Wire Removal Tool to remove
C. Set the engine control to the STOP mode.
Measure the supply voltage at the master ECM. C. Connect the leads of a multimeter to the terminals
that were removed from the P1 connector.
Expected Result:
D. Set the engine control to the STOP mode.
The voltage is between 11.5 VDC and 13.5 VDC. Measure the signal voltage between the
A 145-03 diagnostic code or a 145-04 diagnostic terminals. Record the measurement.
code is not active.
E. Set the engine control to the START mode.
Results: Crank the engine and measure the signal
voltage between the terminals again. Record the
• Yes – The sensor supply voltage at the ECM measurement.
is between 11.5 VDC and 13.5 VDC. A 145-03
diagnostic code or a 145-04 diagnostic code Expected Result:
is not active. The wiring and/or the connectors
between the sensor and the master ECM has When the engine control is in the STOP mode,
an open circuit or the circuit has excessive the voltage is less than 3.0 VDC or the voltage is
resistance. greater than 10.0 VDC.
Repair: Set the engine control to the OFF/RESET The voltage varied between 2.0 VDC and 4.0 VDC
mode. Switch the 35 amp circuit breaker OFF. during cranking.
Make the necessary repairs to the harness and/or
connectors. Results:
STOP. • OK – Both of the measurements are correct.

However, the master ECM is not reading the
• No – The master ECM is not producing the signal. There may be a problem with the master
correct sensor supply voltage or a 145-03 or a ECM.
145-04 diagnostic code is active. There may be a
problem with the master ECM. Repair: It is unlikely that the master ECM has
Repair: It is unlikely that the master ECM has procedure again. If the condition is not resolved,
failed. Exit this procedure and perform this perform the following steps:
procedure again. If the condition is not resolved,
perform the following steps: Temporarily install a new master ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the problem is resolved with the new ECM,
install the original ECM and verify that the problem
STOP.
302
• Not OK – The signal voltage is not correct. There If the problem is resolved with the new ECM,
is an intermittent problem in the circuit for the install the original ECM and verify that the problem
speed/timing sensor. returns. If the new ECM operates correctly and
Repair: Refer to Troubleshooting, “Inspecting replace the ECM. Refer to Troubleshooting,
Electrical Connectors”. Make repairs, as needed. “Replacing the ECM”.
STOP. STOP.
Test Step 9. Isolate the Sensor Signal at • Not OK – The signal voltage is not correct. There
the Slave ECM and Measure the Sensor is an intermittent problem in the circuit for the
Signal Voltage at the Slave ECM speed/timing sensor.
A. Set the engine control to the OFF/RESET mode. Repair: Refer to Troubleshooting, “Inspecting
Electrical Connectors”. Make repairs, as needed.
terminal 33 from the P3 connector on the slave STOP.
ECM. Remove terminal 51 from the P1 connector
from the master ECM.
i01826022
C. Connect one lead of a multimeter to the terminal

that was removed from the P3 connector.
Fuel Metering Valve
Connect the other lead of the multimeter to the SMCS Code: 1741-038
Measure the signal voltage between the The fuel metering valve is an electronic gas valve
terminals. Record the measurement. that controls the flow of fuel to the engine. The valve
works with the master Electronic Control Module
E. Set the engine control to the START mode. (ECM) in order to ensure the correct flow of gas in
Crank the engine and measure the signal all conditions of engine operation.
voltage between the terminals again. Record the
measurement. The master ECM sends a command signal for
the flow of fuel and information about the specific
Expected Result: gravity of the gas to the fuel metering valve.
The valve converts the command signal and
When the engine control is in the STOP mode, the information into a valve position that directly
the voltage is less than 3.0 VDC or the voltage is corresponds to the desired gas flow. The position
greater than 10.0 VDC. of the valve is compensated by these additional
factors that are internal to the valve: a signal for
The voltage varied between 2.0 VDC and 4.0 VDC absolute fuel pressure, differential pressure of the
during cranking. valve, and fuel temperature.
Results: The following procedure tests whether the command
signal for the flow of fuel and the information about
• OK – Both of the measurements are correct. the specific gravity of the gas is properly sent
However, the slave ECM is not reading the signal. to the fuel metering valve by the master ECM.
There may be a problem with the slave ECM. The command signal is a 180 hertz PWM signal.
Information about the specific gravity of the gas is
Repair: It is unlikely that the slave ECM has failed. sent to the fuel metering valve via the CAN Data
Exit this procedure and perform this procedure Link.
again. If the condition is not resolved, perform
the following steps: The fuel metering valve sends information to the
master ECM via the CAN Data Link. This procedure
Temporarily install a new slave ECM. Refer to also tests whether the following information is
Troubleshooting, “Replacing the ECM”. properly sent to the master ECM by the fuel
metering valve: position of the fuel valve, absolute
fuel pressure, differential pressure of the valve, and
fuel temperature.
303
g00952248
Illustration 122
Schematic for the circuit of the fuel metering valve
304

• J6/P6, J7/P7, and J9/P9 connectors on the
terminal box
• Connectors on the fuel metering valve

6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 123

position.

g00931867
Illustration 125
(P1-34) CAN Data Link −
(P1-42) CAN shield
(P1-50) CAN Data Link +
(P1-58) Signal for the fuel flow
(P1-60) Return for the signal for the fuel flow
g00931792
Illustration 124
Terminal box
(2) Ground strap
(5) J7/P7 connectors for the harness from the fuel metering valve
(6) J9/P9 connectors for the harness for the CAN data link
data link
305
g00931879
Illustration 126
(J7-11) Signal for the fuel flow
(J7-25) Return for the signal for the fuel flow
(J7-39) Shield
g00931976
Illustration 128
Top view of the engine. The 60 Hz configuration is shown. The
50 Hz configuration is similar.
(8) Fuel metering valve
(9) P24/J24 connectors for the fuel metering valve
d. Check the wiring for abrasion and for pinch

points from the fuel metering valve to the
master ECM.
Expected Result:
All of the connectors, pins, and sockets are

g00952267 do not have corrosion, abrasion, or pinch points.
Illustration 127
Harness side of the P24 connector for the fuel metering valve
Results:
(P24-C) CAN Data Link +
(P24-D) CAN Data Link + to the throttle actuator
(P24-E) CAN Data Link − to the throttle actuator • OK – The components are in good condition with
(P24-F) CAN Data Link − proper connections. Proceed to Test Step 2.
(P24-K) Unswitched +Battery
(P24-L) −Battery
(P24-M) Switched +Battery • Not OK – The components are not in good
(P24-S) Signal for the fuel flow condition and/or at least one connection is
(P24-T) Return for the signal for the fuel flow improper.

the wires that are associated with the fuel
metering valve.
306
Repair: Perform the necessary repairs and/or • Not OK (Active 1446-09) – The master ECM has
replace parts, if necessary. Ensure that all of detected an open circuit or a short circuit for the
the seals are properly installed. Ensure that the circuit of the CAN Data Link between the master
connectors are properly engaged. Verify that the ECM and the fuel metering valve. Proceed to Test
repair has eliminated the original problem. Step 4.
STOP. • Not OK (Active 1446-12) – The fuel metering

valve has detected an internal malfunction.
Repair: Refer to Installation and Operation
A. Connect the Caterpillar Electronic Technician Manual, SEBU7630, “Raptor Gas Regulation and
(ET) to the service tool connector on the terminal Metering Valve/Actuator System for Caterpillar”.
box.
STOP.
engine control to the STOP mode. • Not OK (Active 1446-13) – The fuel metering
valve requires calibration.
C. Use Cat ET to determine if any of the following
diagnostic codes are active: Repair: Refer to Installation and Operation
Manual, SEBU7630, “Raptor Gas Regulation and
• 1446-05 “Fuel Metering Module open circuit” Metering Valve/Actuator System for Caterpillar”.
• 1446-09 “Unable to communicate with Fuel STOP.

Metering Module”
• Not OK (Active 1447-12) – There is a malfunction
• 1446-12 “Fuel Metering Module malfunction” of the sensor module in the fuel metering valve.
• 1446-13 “Fuel Metering Module calibration Repair: Refer to Installation and Operation
required” Manual, SEBU7630, “Raptor Gas Regulation and
Metering Valve/Actuator System for Caterpillar”.
• 1447-12 “Fuel Metering Sensor Module
malfunction” STOP.
Expected Result: Test Step 3. Check the Signal for the Fuel
Flow
There are no active diagnostic codes.
Results: Switch the 35 amp circuit breaker OFF.
• OK – There are no active diagnostic codes. B. Insert two 7X-1710 Multimeter Probes into the
The signal and the communication between the harness side of the P1 connector. Insert the first
master ECM and the fuel metering valve appear probe into terminal 58. Insert the second probe
to be OK at this time. However, diagnostic codes into terminal 60. Use a multimeter that is capable
may be logged. of measuring the frequency and the duty cycle.
Connect the multimeter to the probes.
problem, refer to Troubleshooting, “Inspecting C. Switch the 35 amp circuit breaker ON. Set the
Electrical Connectors”. engine control to the STOP mode.
STOP. D. Measure the DC voltage, the duty cycle, and the

frequency of the signal for the fuel flow.
• Not OK (Active 1446-05) – The master ECM has
detected an open circuit or a short circuit for the Expected Result:
circuit of the fuel flow signal between the ECM
and the fuel metering valve. Proceed to Test Step The DC voltage is between 13.7 and 15.7.
3.
The duty cycle is between 92 and 98 percent.
The frequency is between 175 and 185 hertz.

307
• OK – The voltage, the duty cycle, and the The continuity of the circuits between the terminals
frequency of the signal for the fuel flow is correct is good.
at the master ECM P1 connector. There is a
problem with the fuel metering valve. The continuity between the terminals and the
ground strap is open.
Repair: Replace the fuel metering valve. Verify
that the repair has eliminated the original problem. Results:
STOP. • OK – The continuity of the circuits is good. The

continuity of the circuit between the master ECM
• Not OK – The voltage, the duty cycle, and/or the and the ground strap is open.
frequency of the signal for the fuel flow is not
correct at the master ECM P1 connector. Proceed Repair: Perform the following steps:
to Test Step 5.
Test Step 4. Check the Continuity of the engine control to the STOP mode.
Wiring Harness for the CAN Data Link
2. Observe the “Active Diagnostic Codes” screen
A. Set the engine control to the OFF/RESET mode. of Cat ET.
If a “1446-09 Unable to communicate with Fuel
B. Disconnect the master ECM J1/P1 connectors. Metering Module” diagnostic code is activated,
Disconnect the harness connector for the fuel troubleshoot the CAN data link. Refer to the
metering valve. engine’s schematic diagram.
If a 1446-09 diagnostic code is not activated,

• Not OK – At least one of the following conditions

is found: There is an open circuit between the
plug for the master ECM and the plug for the fuel
metering valve. There is a short circuit between
the plug for the master ECM and a component
that is at ground potential.
Repair: Perform the necessary repairs to the

wiring and/or connectors. Replace parts, if
necessary. Ensure that all of the seals are properly
installed. Ensure that the connectors are properly
g00952177
Illustration 129 engaged. Verify that the repair has eliminated the
(P1) Connector for the ECM original problem.
(P24) Connector for the fuel metering valve
(P1-34) CAN Data Link − STOP.
(P1-50) CAN Data Link +
(P24-F) CAN Data Link −
(P24-C) CAN Data Link + Test Step 5. Check the Continuity of the
Circuit for the Fuel Flow
C. Use a multimeter to check for continuity between
the points that are listed in Table 27. A. Set the engine control to the OFF/RESET mode.
Table 27
B. Disconnect the J1/P1 connector.
Connector and Terminal Connector and Terminal C. Disconnect the fuel metering valve J24/P24
connector.
P1-34 P24-F
P1-50 P24-C
P1-34 Ground strap for the ECM
P1-50 Ground strap for the ECM
308
Test Step 6. Check the Resistance of the

Internal Circuit of the Fuel Metering Valve
A. Ensure the following conditions:
• The engine control is in the OFF/RESET mode.

• The 35 amp circuit breaker in the terminal box
is OFF.
• The fuel metering valve J24/P24 connectors

are disconnected.
g00952182
Illustration 130
(P1) Connector for the ECM
(P24) Connector for the fuel metering valve
(P1-58) Signal for the fuel flow
(P1-60) Return for the signal for the fuel flow
(P24-S) Signal for the fuel flow
(P24-T) Return for the signal for the fuel flow
D. Use a multimeter to check the continuity of the

following circuits:
• P1-58 and P24-S

g00952241
• P1-58 and the ground strap for the ECM Illustration 131
J24 connector on the fuel metering valve
• P1-60 and P24-T (J24-S) Signal for the fuel flow
(J24-T) Return for the signal for the fuel flow
Expected Result:
B. Measure the resistance between terminals J24-S
The continuity of the circuits between the terminals and J24-T.
is good.
Expected Result:
The continuity between the terminal and the ground
strap is open. The resistance is between 315,000 ohms and
325,000 ohms.
Results:
Results:
• OK – The continuity of the circuit between the
master ECM and the fuel metering valve is good. • OK – The resistance is between 315,000 ohms
The continuity of the circuit between the master and 325,000 ohms. Proceed to Test Step 7.
ECM and the ground strap is open. Proceed to
Test Step 6. • Not OK – The resistance is not between 315,000
ohms and 325,000 ohms.
• Not OK – One or both of the following conditions
is found: There is an open circuit between the Repair: Replace the fuel metering valve. Verify
master ECM and the fuel metering valve. There that the repair has eliminated the original problem.
is a short circuit between the master ECM and a
component that is at ground potential. STOP.
Repair: Repair the wiring and/or connectors. Test Step 7. Check the Supply Voltage to
Replace parts, if necessary. Ensure that all of the Fuel Metering Valve
the seals are properly installed. Ensure that the
connectors are properly engaged. Verify that the A. Ensure the following conditions:
repair has eliminated the original problem.
• The engine control is in the OFF/RESET mode.
STOP.
309
• The 35 amp circuit breaker in the terminal box • Not OK – The voltage is not correct at the P24
is OFF. plug for the fuel metering valve. There is an open
circuit or a short circuit in the harness to the fuel
• The fuel metering valve J24/P24 connectors metering valve.
are disconnected.
Repair: Perform the necessary repairs for the
B. Switch the 35 amp circuit breaker ON. Set the wiring and/or the connectors. Replace parts,
engine control to the STOP mode. if necessary. Ensure that all of the seals are
properly installed. Ensure that the connectors
Note: The “1446-05 Fuel Metering Module open are properly engaged. Verify that the repair has
circuit” and “1446-09 Unable to communicate with eliminated the original problem.
Fuel Metering Module” diagnostic codes will be
activated. STOP.
i01829123
Generator Output Power

Sensor

provides control of the air/fuel ratio for performance
and for efficiency at low emission levels. To
accurately control the air/fuel ratio, the master ECM
g00952242
Illustration 132 requires information on the engine load. Information
P24 plug on the harness for the fuel metering valve on the engine load may be provided by the EMCP
(P24-K) Unswitched +Battery II + system or by a generator output power sensor.
(P24-L) −Battery
(P24-M) Switched +Battery EMCP II +
C. Use a multimeter to measure the voltage between If the generator is equipped with the EMCP II +
the following terminals of the harness connector system, information on the engine load is provided
for the fuel metering valve: via the CAT data link. If the master ECM determines
that the information is bad, a 1719-12 diagnostic
• P24-M and P24-L code will be activated. If the master ECM does not
receive any information from EMCP II +, a 1719-03
• P24-K and P24-L diagnostic code will be activated.
Expected Result: If either code is activated below 25 percent load,

the engine will continue to run. The code remains
The voltage between terminals P24-M and P24-L is active until the engine control is set to the STOP
between 22.0 VDC and 24.0 VDC. mode.
The voltage between terminals P24-K and P24-L If either code is activated above 25 percent load,
terminals is 22.0 VDC and 24.0 VDC. the master ECM cannot accurately control the
air/fuel ratio. The code is logged and the engine
Results: is shut down.
• OK – The voltage is correct at the P24 plug for the Generator Output Power Sensor
fuel metering valve. However, the fuel metering
valve is not communicating with the master ECM.
Repair: Replace the fuel metering valve. Verify

that the repair has eliminated the original problem.
STOP.
310
If the generator is not equipped with the EMCP II +

system, information on the engine load is provided
by a generator output power sensor. The generator
output power sensor sends a variable DC signal
to the master ECM that indicates the total real
power that is being developed by the generator.
The signal voltage from the generator output power
sensor can vary between 0.2 VDC and 4.8 VDC.
A voltage that is near 0.2 VDC indicates that the
generator has a low power output. A voltage that is
near 4.8 VDC indicates that the generator has a
high power output.
If the voltage is greater than 4.8 VDC, the input is

assumed to have a short circuit to a positive voltage
source or an open circuit and the master ECM will
activate a 1719-03 diagnostic code. If the signal
voltage is less than 0.2 VDC, the input is assumed
to have a short circuit to ground and the master
ECM will activate a 1719-04 diagnostic code.
If either code is activated below 25 percent load,

the engine will continue to run. The code remains
active until the engine control is set to the STOP
mode.
If either code is activated above 25 percent load,

the master ECM cannot accurately control the
air/fuel mixture. The code is logged and the engine
is shut down.
g00952304
Illustration 133
Schematic of the generator output power sensor input with EMCP II +
For the actual wiring, refer to the generator’s schematic diagram.
311
g00952309
Illustration 136
Terminal box
(3) J6/P6 connectors for the wiring from the generator output
power sensor
(4) J9/P9 connectors for the harness from the Integrated
Temperature Sensing Module
g00952306
Illustration 134
Schematic of the generator output power sensor input with the B. Thoroughly inspect the following components:
generator output power sensor
Connectors and Wiring • J6/P6 connectors on the terminal box
• The wiring and the connections between the
master ECM and the generator output power
sensor (if equipped)
• The wiring and the connections between the

master ECM and the EMCP II + system (if
equipped)

6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 135

position.

312
g00934823
Illustration 137
(P1-9) CAT data link −
(P1-19) Return for the generator output power sensor
(P1-25) Generator output power sensor input
g00934828
Illustration 139
(J9-1) CAT data link +
(J9-7) CAT data link −

wires that are associated with the circuit for
the generator output power sensor.

and for pinch points between the generator
output power sensor and the master ECM.
Expected Result:

Results:
g00952302
Illustration 138
Harness side of the J6 connector proper connections. Proceed to Test Step 2.
(J6-3) Generator output power sensor input
(J6-7) CAT data link +
(J6-13) Return for the generator output power sensor
(J6-17) CAT data link − condition and/or at least one connection is
improper.

STOP.
Test Step 2. Check for a Diagnostic Code

A. Connect the Cat Electronic Technician (ET) to the
service tool connector. Refer to Troubleshooting,
“Electronic Service Tools”.
313
B. Start the engine and run the engine. If the E. Use an ohmmeter to check for continuity between
generator is equipped with EMCP II +, activate terminals P1-19 and P1-25.
the EMCP II + system.
Expected Result:
C. Observe the “Active Diagnostic” screen on ET.
Allow a minimum of 30 seconds for any codes to The continuity check indicates a short circuit.
activate. Look for these codes:
Results:
• 1719-03
• OK – The continuity check indicates a short
• 1719-04 circuit. The circuit is not open. Proceed to Test
Step 4.
• 1719-12
• Not OK – The continuity check indicates an open
D. Stop the engine. circuit. There is an open circuit in a wire or in a
connector.
Expected Result:
Repair: The open circuit may be between the P1
There are no active codes for the generator output connector and the J6 connector. Alternatively, the
power sensor. open circuit may be between the J6 connector
and the generator output power sensor.
Results:
Repair the wire or the connection, when possible.
• No active codes – There are no active codes for Replace parts, if necessary. Verify that the
the generator output power sensor. There may be problem is resolved.
a logged code for the generator output power
sensor. STOP.
Repair: If there is a logged code for the Test Step 4. Check for a Short Circuit to
generator output power sensor, there may be a Positive Voltage Source
a problem with the wiring and/or a connector.
Refer to Troubleshooting, “Inspecting Electrical A. Disconnect the P2 connector from the master
Connectors”. ECM. Disconnect the P4 connector from the
slave ECM.
STOP.
B. Use an ohmmeter to check for continuity between
• Active 1719-03 code – If the generator is the terminals that are listed in Table 28.
equipped with EMCP II +, proceed to Test Step 7.
Otherwise, proceed to Test Step 3. Table 28
• Active 1719-04 code – There is an active 1719-04
code. Proceed to Test Step 5. P1-19 Return for the P1-2 (5 VDC)
generator output power
sensor input P1-18 (5 VDC)
• Active 1719-12 code – There is an active 1719-12
code. Proceed to Test Step 7. P1-4 (8 VDC)
P2-56 (8 VDC)
P2-57 (8 VDC)
A. Set the engine control to the OFF/RESET mode. P4-56 (8 VDC)
P4-57 (8 VDC)
B. Label the two output wires and remove the two P1-43 (12 VDC)
output wires from the generator output power
sensor. P1-57 (Unswitched
+Battery)
C. Install a jumper wire between the two wires that P1-70 (Switched +Battery)
were removed from the generator output power
sensor.
Expected Result:
D. Disconnect the P1 connector from the master
ECM. Each continuity check indicates an open circuit.
314
Results: • No – The continuity check indicates a short

circuit. There is a short circuit to ground in a
• Yes – Each continuity check indicates an open harness or in a connector.
circuit. The wiring is not shorted to a positive
voltage source. Repair: The problem may be between the P1
Repair: Perform the following procedure: problem may be between the J6 connector and
1. Remove the jumper wire from the two output
wires for the generator output power sensor. Repair the harness or the connection, when
2. Reconnect the two output wires to the the problem is resolved.
generator output power sensor. Be sure to
connect each wire to the correct terminal. STOP.
3. Reconnect the P1 connector, the P2 connector, Test Step 6. Check the Generator Output
and the P4 connector. Power Sensor
Proceed to Test Step 6. A. Measure the output of the generator output
power sensor according to the literature that is
• No – At least one continuity check indicates a provided by the OEM of the sensor. Verify that
short circuit. There is a short circuit to a positive the correct signal is provided to the master ECM.
voltage source in a harness or in a connector.
B. Verify the correct signal at terminals P1-25 and
Repair: The problem may be between the P1 P1-19.
problem may be between the J6 connector and Expected Result:
The correct signal is provided to the master ECM.
Repair the harness or the connection, when
possible. Replace parts, if necessary. Verify that Results:
• Yes – The correct signal is provided to the master
STOP. ECM. However, the master ECM is not responding
correctly to the signal. There may be a problem
Test Step 5. Check for a Short to Ground with the master ECM.
A. Verify that the engine control is in the OFF/RESET Repair: It is unlikely that the master ECM
mode and that the 35 amp circuit breaker is OFF. has failed. Exit this procedure and perform
this procedure again. If the problem is not
B. Disconnect the P1 connector from the master resolved, replace the master ECM according to
ECM. Troubleshooting, “Replacing the ECM”. Verify that
C. Use an ohmmeter to check for continuity between
P1-25 and the ECM ground strap. STOP.
Expected Result: • No – The master ECM is not receiving the correct

signal. There is probably a problem with the
The continuity check indicates an open circuit. generator output power sensor.
Results: Repair: Service the generator output power

sensor according to the literature that is provided
• Yes – The continuity check indicates an open by the OEM of the device. Verify that the problem
circuit. The wiring is not shorted to ground. is resolved.
Repair: Reconnect the P1 connector. STOP.

315
Test Step 7. Check the Wiring for the CAT • Not OK – At least one check of the resistance for
Data Link the CAT data link is incorrect. There is a problem
with the wiring for the CAT data link.
Switch the 35 amp circuit breaker OFF. Repair: Repair the connection and/or the wire,
when possible. Replace parts, if necessary. Verify
B. Disconnect Cat ET from the service tool that the problem is resolved.
connector.
STOP.
C. Label the wiring for the CAT data link at the
EMCP II + system. Disconnect the wiring for the Test Step 8. Check the EMCP II + System
CAT data link from the EMCP II + system.
A. Check the EMCP II + system according to the
D. Disconnect the P1 connector from the master applicable literature. Verify that the EMCP II +
ECM. system is operating properly.
E. Measure the resistance between the points that Expected Result:

are listed in Table 29. During each measurement,
wiggle the wires in the harness in order to check The EMCP II + system is operating properly.
for an intermittent problem. Be sure to wiggle the
wires near each of the connectors. Results:
Table 29 • OK – The EMCP II + system is operating properly.

Resistance Measurements for the CAT Data Link
Repair: Start the engine and run the engine again.
Connector and Terminal Connector and Terminal If the diagnostic code persists, there may be a
P1-8 The wire for CAT data link problem with the master ECM.
+ at the EMCP II + system
It is unlikely that the ECM has failed. Exit this
P1-9 The wire for CAT data link procedure and perform this procedure again. If
− at the EMCP II + system the problem is not resolved, perform the following
P1-8 Ground strap for the master steps:
ECM
Temporarily install a new ECM. Refer to
P1-9 Ground strap for the master
ECM
Expected Result: install the original ECM and verify that the
Each check of the resistance between the correctly and the original ECM does not operate
connectors is less than 5 ohms. correctly, replace the original ECM. Refer to
Each check of the resistance between the connector
and the ground strap is greater than 20,000 ohms. STOP.
Results: • Not OK – There is a problem with the EMCP II

+ system.
• OK – Each check of the resistance for the CAT
data link is within the specification. The wiring for Repair: Service the EMCP II + system. Verify that
the CAT data link appears to be OK. the original problem is resolved.
Repair: Perform the following procedure: STOP.
1. Connect all of the electrical connectors.
2. Reconnect the wiring for the CAT data link to

the EMCP II + system. Be sure to connect
each wire to the correct terminal.

316
i01827541 For the combinations of cylinders that can be

affected by a condition, refer to Table 30.
Ignition Transformers Primary
Circuit Table 30
Diagnostic Conditions and the Combinations
SMCS Code: 1561-038 of Cylinders that are Affected
Condition Cylinders
Circuit driver’s side open Only one cylinder
The master Electronic Control Module (ECM) has is affected.
Return side open
internal circuit drivers for the ignition transformers
on the left side of the engine. Each circuit driver Return side short to ground
creates a signal of +108 volts. The signal goes to
Circuit driver’s side short to
the high side of the primary circuits of the ignition +Battery for cylinders 1, 2, 7, 8,
transformers. The transformers deliver high voltage 9, 10, 11, 12, 17, 18, 19, or 20
(8000 to 37,000 volts) to the spark plugs. The
ignition wiring is continuous from the master ECM Circuit driver’s side short to
P2 connector to the individual transformers for the ground for cylinders 1, 2, 7, 8, 9,
cylinders with an even number. 10, 11, 12, 17, 18, 19, or 20
Return side short to +Battery for
The slave ECM has internal circuit drivers for the cylinders 5, 6, 13, or 14
ignition transformers on the right side of the engine.
Cylinder 3 or 5 3 and 5
Each circuit driver creates a signal of +108 volts.
The signal goes to the high side of the primary +Battery
circuits of the ignition transformers. The transformers
deliver high voltage (8000 to 37,000 volts) to the Cylinder 4 or 6 4 and 6
spark plugs. The ignition wiring is continuous from Circuit driver’s side short to
the P4 connector on the slave ECM to the individual +Battery
transformers for the cylinders with an odd number. Cylinder 13 or 15 13 and 15
Some circuit drivers and returns are shared. +Battery
Therefore, a single problem will activate either only
Cylinder 14 or 16 14 and 16
one diagnostic code or multiple codes.
+Battery
Circuit Drivers
Return side short to +Battery 1, 3, 7, and 9
Some circuit drivers send signals to a single 11, 15, 17, and 19
cylinder. A high side short circuit will affect only that
cylinder. 2, 4, 8, and 10
12, 16, 18, and 20
Some circuit drivers send signals to more than one
cylinder. For this reason, a high side short circuit
will affect more than one cylinder. Because the circuits are in pairs or groups,
multiple diagnostic codes can be activated for a
Return Side single problem. If multiple diagnostic codes are
active for the primary ignition, troubleshooting the
The master ECM has internal returns for the ignition circuits one at a time is an effective way to find the
transformers on the left side of the engine. Some of root cause.
the returns consist of groups of terminals that are
connected via diodes inside the master ECM. This Logged diagnostic codes provide a historical
means that a return short circuit to the +Battery will record. Before you begin this procedure, use the
simultaneously affect all of the cylinders that are Caterpillar Electronic Technician (ET) to print the
grouped. logged codes to a file.
The slave ECM has internal returns for the ignition The most likely causes of the diagnostic code are a
transformers on the right side of the engine. Some poor electrical connection or a problem in a wiring
of the returns consist of groups of terminals that are harness. The next likely cause is a problem with
connected via diodes inside the slave ECM. This an ignition transformer. The least likely cause is a
means that a return short circuit to the +Battery will problem with an ECM.
simultaneously affect all of the cylinders that are
grouped.
317
g00952375
Illustration 140
Schematic for the primary ignition on the left side of the engine
318
g00932515
Illustration 141
Schematic for the primary ignition on the right side of the engine
319

• Slave ECM J4/P4 connectors
6 ± 1 N·m (55 ± 9 lb in).
g00903979
Illustration 144
g00931487 Harness side of the master ECM P2 connector
Illustration 142
(P2-1) Number 2 transformer’s circuit driver
(P2-2) Number 2 transformer’s return
A. Set the engine control to the OFF/RESET mode. (P2-3) Number 12 transformer’s circuit driver
Switch 35 amp circuit breaker (1) to the OFF (P2-4) Number 12 transformer’s return
position. (P2-14) Number 4 transformer’s circuit driver
Note: For the following steps, refer to (P2-17) Number 16 transformer’s return
Troubleshooting, “Inspecting Electrical Connectors”. (P2-24) Number 8 transformer’s circuit driver
g00932124
Illustration 143
Terminal box
(2) Harness for the primary ignition from the master ECM to the
left bank
(5) Harness for the primary ignition from the slave ECM to the
right bank
B. Thoroughly inspect the following connectors:

320

STOP.

for the Primary Circuit
Tools”.
B. Switch the 35 amp circuit breaker ON.
g00903979 C. Attempt to start the engine. Use Cat ET in order

Illustration 145 to determine if the following codes are active or
Harness side of the P4 connector for the slave ECM logged:
(P4-2) Number 1 transformer’s return • 301-05 Ignition Transformer Primary #1 open
circuit through 316-05 Ignition Transformer
(P4-14) Number 3 transformer’s circuit driver Primary #16 open circuit
(P4-16) Number 15 transformer’s circuit driver • 1752-05 Ignition Transformer Primary #17 open
(P4-17) Number 15 transformer’s return circuit through 1755-05 Ignition Transformer
(P4-25) Number 7 transformer’s return Primary #20 open circuit
(P4-27) Number 19 transformer’s return • 301-06 Ignition Transformer Primary #1 short
(P4-32) Number 9 transformer’s circuit driver through 316-06 Ignition Transformer Primary
(P4-33) Number 9 transformer’s return #16 short
(P4-48) Number 5 transformer’s circuit driver • 1752-06 Ignition Transformer Primary #17 short
(P4-49) Number 5 transformer’s return through 1755-06 Ignition Transformer Primary
(P4-50) Number 13 transformer’s circuit driver #20 short
Note: If a diagnostic code for the primary circuit is

b. Perform a 45 N (10 lb) pull test on each of
logged but not currently active, attempt to repeat
the condition that activated the code. Run the
of the ignition system. engine to full operating temperature.
C. Check the ignition harnesses and wiring for
Expected Result:
abrasion and for pinch points from each ignition
transformer to each ECM.
None of the above diagnostic codes are active.
Expected Result:
Results:
properly. The connectors and the wiring do not have • Active “open circuit” – There is an open in the
primary circuit. Proceed to Test Step 6.
Results: • Active “short” – There is a short in the primary

circuit. Proceed to Test Step 3.
• OK – The components are in good condition with • Logged only – There may be an intermittent
problem in the ignition harness.
• Not OK – The components are not in good Repair: Perform the following steps:
improper.
321
Test Step 3. Check the Transformer’s

Primary Circuit and the Secondary Circuit
Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when Avoid contacting the ignition system components
the engine is operating. The transformers are and wiring.
grounded to the valve covers. Personal injury or
death may result and the ignition system will be Do not attempt to remove the valve covers when
damaged if the valve covers are removed during the engine is operating. The transformers are
engine operation. The engine will not operate grounded to the valve covers. Personal injury or
without the valve covers. death may result and the ignition system will be
damaged if the valve covers are removed during
1. Set the engine control to the OFF/RESET engine operation. The engine will not operate
mode. Switch the 35 amp circuit breaker OFF. without the valve covers.

g00932886
Illustration 146
(1) Cover
(2) Transformer
(3) 3-pin connector g00932886
Illustration 147
(1) Cover
2. Remove cover (1) for the suspect cylinder. (2) Transformer
Inspect the harness and 3-pin connector (3) (3) 3-pin connector
of transformer (2). Check for corrosion, for
abrasion, and for pinch points. B. Remove cover (1) for the suspect cylinder.
3. Reconnect the connectors, and reinstall the C. Disconnect 3-pin connector (3). Visually inspect
cover. the 3-pin connectors for corrosion and/or for
damage.
If the problem persists, refer to Troubleshooting,
“Inspecting Electrical Connectors”. D. Remove transformer (2) from the cylinder head.
STOP.
322
g00954719
Illustration 149
(A) + Terminal
(B) - Terminal
(13) Mounting flange
(14) Connector for the spark plug
a. Set the multimeter to the diode scale. Connect

g00954718
Illustration 148 the multimeter leads to terminals (A) and (B) of
Schematic for the primary circuit and for the secondary circuit the 3-pin connector. The polarity of the leads
(4) 3-pin connector for the transformer is not important. Measure the voltage between
(5) Terminal A the terminals. Record the measurement.
(6) Terminal B
(7) Blocking diode b. Reverse the multimeter leads. Measure the
(8) Flyback diode
(9) Primary coil of the transformer
voltage between the terminals again. Record
(10) Secondary coil of the transformer the measurement.
(11) Resistor
(12) Spark plug gap F. Measure the resistance of the secondary circuit.
E. Measure the primary circuit by checking the Note: The resistance of the secondary coil will vary
voltage of the blocking diode. with the temperature. Illustration 150 demonstrates
the relationship between the secondary coil’s
resistance and the temperature. A reading that is
within 1000 ohms is acceptable. For example, if the
transformer’s temperature is 60 C (140 F), the
correct resistance is between 21,000 and 23,000
ohms.
323
• Not OK – At least one of the three measurements

is incorrect.
Repair: Replace the ignition transformer. Make

sure that you use the correct transformer for
the G3520C Engine.
STOP.
Test Step 4. Check for a Short Circuit

Between the ECM and the Transformer
Illustration 150 g00863850 There is a strong electrical shock hazard when the
Resistance versus temperature
crankshaft is rotating.
(Y) Resistance in ohms
(X) Temperature in degrees celsius (degrees fahrenheit)
Do not touch the wires that are associated with
the ignition system when the engine is cranking
a. Set the multimeter to the 40,000 ohm scale. or when the engine is running.
Measure the resistance between mounting
flange (13) and the extension’s internal NOTICE
terminal (14) for the spark plug. The air inlet, the cylinders, and the exhaust system
can be filled with fuel when the gas supply is ON, the
Expected Result: ignition system is disabled, and the engine is cranked.
The unburned fuel can ignite unexpectedly and cause
For the primary circuit, one of the voltage damage.
measurements is approximately 0.450 VDC. The
other voltage measurement indicates an open Turn OFF the gas supply before you perform this step.
circuit.
For the secondary circuit, the resistance between A. Shut OFF the fuel supply. Set the engine control
the screw for the ground spring and the connector to the OFF mode.
for the spark plug is within the acceptable tolerance.
B. Disconnect the 3-pin connector for the suspect
Results: transformer.
• OK – All three of the measurements are correct. C. Set the engine control to the START mode and
observe the “Active Diagnostic” screen of Cat ET
Repair: Perform the following steps: while you crank the engine.
1. Install the spark plug according to the Expected Result:

instructions in Operation and Maintenance
Manual, “Ignition System Spark Plugs - The “short” code is active when the transformer’s
Check/Adjust/Replace”. connector is disconnected.
2. Switch the suspect transformer with a Results:

transformer from a different cylinder that is
known to be good. Install the transformers. • Yes – The “short” code was activated after
Install the valve covers. the transformer’s connector was disconnected.
3. Reset the control system. Restart the engine.
Clear any logged codes. • No – The original “short” code was not
activated after the transformer’s connector was
4. Operate the engine. Check for a recurrence of disconnected.
the problem.
If the problem stays with the suspect transformer,
replace the transformer. 1. Connect the ignition harness to the transformer.
If the problem stays with the suspect cylinder,

324
2. Set the engine control to the START mode B. Use a 151-6320 Wire Removal Tool to
and observe the “Active Diagnostic” screen of remove the terminal for the circuit driver of the
Cat ET while you crank the engine. Look for suspect cylinder from the ECM connector. For
a “short circuit” code. identification of the appropriate terminal, refer to
Illustration 151 and Table 31.
Replace the transformer if the original “short
circuit” code is activated. Table 31
Cylinder and Corresponding Terminal of the ECM
If the original “short circuit” code does not Connector for the Ignition Harness
return, the problem appears to be resolved.
Resume normal operation. Cylinder Terminal for the Circuit
Driver
STOP. 1 P4-1
Test Step 5. Disconnect the Wiring From 2 P2-1

the ECM and Check for a Short Circuit 3 P4-14
4 P2-14
5 P4-48
There is a strong electrical shock hazard when the 6 P2-48
crankshaft is rotating.
7 P4-24
Do not touch the wires that are associated with 8 P2-24
the ignition system when the engine is cranking
or when the engine is running. 9 P4-32
10 P2-32
NOTICE 11 P4-3
The air inlet, the cylinders, and the exhaust system
12 P2-3
can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked. 13 P4-50
14 P2-50
damage.
15 P4-16
Turn OFF the gas supply before you perform this step.
16 P2-16
17 P4-34
Switch the 35 amp circuit breaker OFF. 18 P2-34
19 P4-26
20 P2-26

D. Set the engine control to the START mode and

observe the “Active Diagnostic” screen of Cat ET
while you crank the engine.
Expected Result:
An “open circuit” diagnostic code is activated for

Illustration 151 g00932479 the circuit after removal of the wire for the circuit
driver.
ECM P2 or P4 connector
325
Results: D. Install a jumper wire into terminals A and B of the

3-pin connector on the ignition harness.
• Yes – The ECM detected an open circuit after the
wire was disconnected from the ECM. There is a E. Set the engine control to the START mode and
short circuit in the wiring. observe the “Active Diagnostic” screen of Cat ET
while you crank the engine. Look for the original
Repair: Set the engine control to the OFF/RESET “open circuit” code.
Repair the harness, when possible. Replace the Expected Result:
The original “open circuit” code is active.
STOP.
Results:
• No – The ECM continued to activate a “short
circuit” diagnostic code after the wire was • Yes – The original “open circuit” code was
disconnected from the ECM. There is a problem activated after a short circuit was created in the
with the ECM. ignition harness. The ECM did not detect the
jumper wire. Reconnect the ignition harness to
Repair: Replace the ECM that is appropriate for the transformer. Proceed to Test Step 7.
the suspect cylinder. Follow the instructions in
Troubleshooting, “Replacing the ECM”. • No – Cat ET displayed an active “short”
diagnostic code after a short circuit was created
STOP. in the ignition harness. The harness and the ECM
are OK.
Test Step 6. Create a Short Circuit in the
Ignition Harness Repair: Perform the following steps:
Ignition systems can cause electrical shocks. There is a strong electrical shock hazard when the
Avoid contacting the ignition system components crankshaft is rotating.
and wiring.
Do not attempt to remove the valve covers when the ignition system when the engine is cranking
the engine is operating. The transformers are or when the engine is running.
death may result and the ignition system will be
damaged if the valve covers are removed during NOTICE
engine operation. The engine will not operate The air inlet, the cylinders, and the exhaust system
without the valve covers. can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked.
NOTICE damage.
can be filled with fuel when the gas supply is ON, the Turn OFF the gas supply before you perform this step.
damage.
2. Remove the jumper wire from the 3-pin
connector of the ignition harness.
A. Shut OFF the fuel supply. Set the engine control
to the OFF/RESET mode. 3. Reconnect the ignition harness to the
transformer.
B. Remove the valve cover for the suspect cylinder.
4. Set the engine control to the START mode and
C. Disconnect the 3-pin connector for the observe the “Active Diagnostic” screen of Cat
transformer. Inspect the connectors. Verify that ET while you crank the engine. Look for the
the connectors do not have damage or corrosion. original “open circuit” code.
Inspect the harness. Verify that the harness does
not have damage or corrosion.
326
5. If the original “open circuit” code is activated, Table 32

set the engine control to the OFF/RESET mode. Cylinders and Corresponding Terminals of the ECM
Switch the 35 amp circuit breaker OFF. Connectors for the Ignition Harnesses
6. Replace the transformer. Make sure that you Cylinder Terminals for the
use the correct transformer for the G3520C Cylinder
Engine. 1 P4-1 and P4-2
7. Clear all of the logged diagnostic codes. 2 P2-1 and P2-2

3 P4-14 and P4-15
STOP.
4 P2-14 and P2-15
Test Step 7. Check the Engine Harness 5 P4-48 and P4-49
for an Open Circuit
6 P2-48 and P2-49
7 P4-24 and P4-25
8 P2-24 and P2-25
There is a strong electrical shock hazard when the
crankshaft is rotating. 9 P4-32 and P4-33
10 P2-32 and P2-33
the ignition system when the engine is cranking 11 P4-3 and P4-4
or when the engine is running. 12 P2-3 and P2-4
13 P4-50 and P4-51
NOTICE
14 P2-50 and P2-51
can be filled with fuel when the gas supply is ON, the 15 P4-16 and P4-17
16 P2-16 and P2-17
damage. 17 P4-34 and P4-35
18 P2-34 and P2-35
19 P4-26 and P4-27
A. Shut OFF the fuel supply. Set the engine control 20 P2-26 and P2-27
to the OFF/RESET mode. Switch the 35 amp
circuit breaker to the OFF position.
C. Install the ends of a jumper wire into the terminals
for the removed wires. This will replace the wiring
D. Set the engine control to the START mode. Switch

the 35 amp circuit breaker to the ON position.
E. Observe the “Active Diagnostic” screen of Cat

ET while you crank the engine. Look for a “short
Expected Result:
A “short circuit” diagnostic code is activated for

the suspect cylinder. The original “open circuit”
g00903979 diagnostic code is not active.
Illustration 152
ECM P2 or P4 connector

two terminals for the circuit driver of the
suspect cylinder from the ECM connector. For
identification of the appropriate terminals, refer
to Illustration 152 and Table 32.
327
Results:
• Yes – When the jumper wire was installed into the

connector, a “short circuit” diagnostic code was
activated for the suspect cylinder. The original
“open circuit” diagnostic code was not active.
There is an open circuit in the wiring harness for
the suspect cylinder.

2. Remove the jumper wire and reinstall the

terminals that were removed from the
connector. Pull on the wires in order to verify
that the terminals are fully inserted into the
connector.

the harness, if necessary.
STOP.
• No – When the jumper wire was installed into the

connector, a “Short circuit” diagnostic code was
not activated. The ECM did not detect the jumper
wire. There is a problem with the ECM.
Repair: Replace the ECM that is appropriate for

the suspect cylinder. Follow the instructions in
STOP. Illustration 153 g00932782
Ignition transformer and spark plug

i01828264 (1) Mounting flange
(2) 3-pin connector
Ignition Transformers (3) Transformer
(4) Extension
Secondary Circuit and Spark (5) Secondary spark plug terminal
(6) O-ring seal
Plugs (7) Hole in the spark plug’s precombustion chamber
SMCS Code: 1555-038; 1561-038 The secondary circuit of the transformer provides an
initial 8,000 to 37,000 volts to the spark plug. This
System Operation Description: voltage ionizes the spark plug gap. This voltage is
then reduced to about 1000 volts. The total duration
The ignition transformers initiate combustion by of the spark is approximately 400 microseconds.
providing high voltage to the spark plugs. The
positive output from the secondary circuit of the Each Electronic Control Module (ECM) can diagnose
transformer is at the connection for the terminal the primary circuit of the ignition transformers for
of the transformer and the terminal of the spark open circuits and/or for short circuits. Secondary
plug. The transformers are located underneath open circuits and short circuits will not directly
covers at the top of each cylinder. Each transformer shut down the engine. However, these conditions
is grounded to the cylinder head via a mounting may lead to misfire which can cause lugging of
flange. the engine. Lugging of the engine can cause a
shutdown.

328
Note: Ignition transformers from Electronic Ignition Table 33

Systems (EIS) are not interchangeable with the Parameters for the Status Screens on Cat ET
transformers in this engine.
Screen 1 Screen 2
Caterpillar spark plugs are high voltage devices Group 8 Group 9
with internal resistors. The spark plugs operate at a “Cylinder #1 Transformer “Cylinder #2 Transformer
voltage that is greater than 5,000 volts. Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage”
Most ignition systems are not affected by resistance
in the secondary circuit. If a measurement of the “Cylinder #3 Transformer “Cylinder #4 Transformer
resistance is desired, a megohmmeter must be Secondary Output Voltage Secondary Output Voltage
used. A low voltage multimeter will not provide a
reliable reading of the resistance because oxidation “Cylinder #5 Transformer “Cylinder #6 Transformer
of the spark plug’s internal components will affect Secondary Output Voltage Secondary Output Voltage
the readings of those meters. Percentage” Percentage”
“Cylinder #7 Transformer “Cylinder #8 Transformer
Test Step 1. Check the Status Screen of Secondary Output Voltage Secondary Output Voltage
Cat ET for the Output of the Secondary Percentage” Percentage”
Circuits of the Transformers
Secondary Output Voltage Secondary Output Voltage
g00931487 E. Start the engine. Apply the normal load at rated

Illustration 154 speed. Allow the engine to warm up to normal
operating temperature.
Switch 35 amp circuit breaker (1) to the OFF F. Observe the value of the output for the secondary
position. circuit of each transformer.
B. Connect Cat ET to the service tool connector. Expected Result:
Tools”. The displayed value of the output for the secondary
circuit of each transformer is between 1 and 90
C. Switch the 35 amp circuit breaker ON. Set the percent.
Results:
D. Set up two status screens for Cat ET. Use eight
of the following labels for parameters on each • OK – The displayed value of the output for
status screen: the secondary circuit of each transformer is
between 1 and 90 percent. The ignition system
components are operating properly.
329
Repair: Investigate other possible root causes of

the problem. Troubleshoot the symptom. Refer NOTICE
to Troubleshooting, “Troubleshooting Without A Pulling on the wiring harness may break the wires. Do
Diagnostic Code”. not pull on the wiring harness.
STOP.
C. Disconnect the ignition harness from 3-pin
• Not OK – At least one of the outputs displayed connector (3). Remove transformer (2) from the
a value of 0 percent or a value that is greater engine.
than 90 percent. The ignition system components
require maintenance. Proceed to Test Step 2.
Test Step 2. Inspect the Transformer

Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when

the engine is operating. The transformers are
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.

g00932907
Illustration 156
(4) Transformer
(5) Extension
(6) Secondary terminal for the spark plug
(7) O-ring seal
D. Inspect the body of transformer (4) and extension

(5) for corrosion and/or for damage.
g00932886 E. Inspect internal O-ring seal (7) for damage.

Illustration 155
(1) Cover F. The extension has an internal terminal for the
(2) Transformer
(3) 3-pin connector
spark plug. Inspect the terminal for looseness,
for corrosion, and/or for damage. Insert a spark
B. Remove cover (1) for the suspect cylinder. plug into the extension and check the terminal
for spring pressure.
330
Test Step 3. Check the Primary Circuit

NOTICE and the Secondary Circuit
The extension can be scratched and damaged with a
wire brush. Do not use a wire brush on the extension.
G. Clean any deposits from the inside of the

extension. Use a 6V-7093 Brush with isopropyl
alcohol.
Expected Result:
The transformer is in good condition.
Results:
• OK – The transformer appears to be in good

condition. Proceed to Test Step 3.
• Not OK – An inspection found a problem with the

transformer.
Repair: Repair the transformer, when possible.

Replace the transformer, if necessary. Be sure
to use the correct transformer for the G3520C
Engine.
Reset the control system. Restart the engine.

Clear the logged codes.
STOP. g00932912
Illustration 157
Schematic for the primary circuit and for the secondary circuit
(1) 3-pin connector for the transformer
(2) Terminal A
(3) Terminal B
(4) Blocking diode
(5) Flyback diode
(6) Primary coil of the transformer
(7) Secondary coil of the transformer
(8) Resistor
(9) Spark plug gap
A. Measure the primary circuit by checking the

voltage of the blocking diode.
331
g00863850
Illustration 159
Resistance versus temperature
(Y) Resistance in ohms
(X) Temperature in degrees celsius (degrees fahrenheit)
a. Set the multimeter to the 40,000 ohm scale.

Illustration 158 g00932916 Measure the resistance between mounting
flange (10) and the extension’s internal
(A) + Terminal
(B) - Terminal
terminal (11) for the spark plug.
(10) Mounting flange
(11) Connector for the spark plug Expected Result:
a. Set the multimeter to the diode scale. Connect For the primary circuit, one of the voltage
the multimeter leads to the terminal (A) and measurements is approximately 0.450 VDC. The
terminal (B) of the 3-pin connector. The other voltage measurement indicates an open
polarity of the leads is not important. Measure circuit.
the voltage between the terminals. Record
the measurement. For the secondary circuit, the resistance between
the mounting flange and the secondary terminal for
b. Reverse the multimeter leads. Measure the the spark plug is within the acceptable tolerance.
voltage between the terminals again. Record
the measurement. Results:
B. Measure the resistance of the secondary circuit. • OK – All three of the measurements are correct.
Note: The resistance of the secondary coil will vary
with the temperature. Illustration 159 demonstrates • Not OK – At least one of the measurements is
the relationship between the secondary coil’s incorrect.
resistance and the temperature. A reading that is
within 1000 ohms is acceptable. For example, if the Repair: Make sure that the engine control is in
transformer’s temperature is 60 C (140 F), the the OFF/RESET mode and that the 35 amp circuit
correct resistance is between 21,000 and 23,000 breaker is OFF. Replace the ignition transformer.
ohms. Make sure that you use the correct transformer
for the G3520C Engine.
STOP.
Test Step 4. Check the Spark Plug

A. Switch the 35 amp circuit breaker OFF.
332
C. Reset the control system. Clear any logged

diagnostic codes.
D. Start the engine and operate the engine in order

to generate the diagnostic code again.
Expected Result:
g00837850 A diagnostic code is not generated.
Illustration 160
Spark plug that has a precombustion chamber
Results:
B. Perform the following procedures according to
the instructions in the engine’s Operation and • OK – A diagnostic code is not generated.
Maintenance Manual. Proceed with normal operation. STOP.
a. Remove the spark plug from the cylinder • Not OK – A diagnostic code is generated.
head. Proceed to Test Step 6.
b. Inspect the spark plug. Test Step 6. Isolate the Spark Plug and
the Transformer
c. Clean the spark plug.
A. Switch the suspect transformer with a transformer
Note: For a spark plug with a precombustion from a different cylinder that is known to be
chamber, the resistance cannot be measured. good. Install the transformers. Install the covers.
The minimum service life of a spark plug with a
precombustion chamber is approximately 3000 B. Reset the control system. Clear any logged
service hours. The spark plug may be good diagnostic codes.
for a considerable period beyond 3000 service
hours. Experience at the particular site will help to C. Start the engine and operate the engine in order
determine the proper interval for replacement of the to generate the diagnostic code again.
spark plug.
Expected Result:
Expected Result:
The diagnostic code is generated for the suspect
The spark plug is in good condition. transformer.
Results: Results:
• OK – The spark plug is in good condition. • Yes – The diagnostic code is generated for the
Proceed to Test Step 5. suspect transformer.
• Not OK – The spark plug is not in good condition. Repair: Make sure that the engine control is in
the OFF/RESET mode and that the 35 amp circuit
Repair: Discard the spark plug. Install a new breaker is OFF. Replace the faulty transformer.
spark plug according to the instructions in the Make sure that you use the correct transformer
engine’s Operation and Maintenance Manual. for the G3520C Engine. Reset the control system.
Clear any logged diagnostic codes.
Reset the control system. Restart the engine.
Clear the logged codes. STOP.
STOP. • No – The diagnostic code is generated for the

original cylinder.
Test Step 5. Operate the Engine
A. Install the spark plug according to the instructions
in the engine’s Operation and Maintenance
Manual.
B. Install the transformer and the cover.

333
Repair: Make sure that the engine control is The MS connectors have a metal housing. The pins
in the OFF/RESET mode and that the 35 amp and the sockets are soldered to the electrical wires.
circuit breaker is OFF. Install a new spark plug The solder connections are usually protected by
according to the instructions in Operation and a chemical potting which prevents access to the
Maintenance Manual, “Ignition System Spark solder point.
Plugs - Check/Adjust/Replace”. Reset the control
system. Clear any logged diagnostic codes.
STOP.
i01811734
Inspecting Electrical
Connectors
SMCS Code: 7553-040-WW
Many of the troubleshooting procedures direct you

to a specific electrical connector. Use the following
test steps to help determine whether the connector
is the cause of the problem. If a problem is found
in a connector, repair the connector and verify that
the problem is corrected.
g00700064
Illustration 162
Intermittent electrical problems are often caused
by poor connections. Always check for an active
diagnostic code before you open any connection. Deutsch connectors have a plastic housing. The
Immediately after you reconnect the connector, pins and the sockets are crimped onto the electrical
check for codes again. Sometimes, simply wires. The connector has a locking mechanism
disconnecting a connector and then reconnecting in order to hold the pins and the sockets. These
the connector can solve a problem. If this occurs, connectors are repairable without cutting the wires.
the following conditions are likely causes:
• Loose terminals
• Bent terminals
• Improperly crimped terminals
• Improperly mated connectors
• Moisture
• Corrosion
g00700045
Illustration 161
334
g00928006
Illustration 163
Use the following test steps in order to thoroughly • Not OK

inspect the connectors and determine if the
connectors are the cause of the problem. Repair: Repair the connectors and/or replace the
connectors. Reconnect all of the connectors.
Test Step 1. Check the Connectors.
STOP.
A. Always set the engine control to the OFF/RESET
mode before you inspect electrical conductors. Test Step 2. Check the Allen Head Screw
Switch the 35 amp circuit breaker OFF. on the Rectangular Connectors
B. For the MS connectors, make sure that the A. Ensure that each allen head screw is properly
receptacle is turned fully in the clockwise tightened. Be careful not to overtighten the screw
direction. Check that the threading is properly and break the screw.
aligned and securely mated.
B. When you connect a 70-pin connector to an
C. For the Deutsch HD connectors, make sure Electronic Control Module (ECM), do not exceed
that the plug and the receptacle are aligned 6 ± 1 N·m (55 ± 9 lb in) of torque on the screw.
properly with the index markings. Make sure that
the receptacle is turned fully in the clockwise C. When you connect a rectangular connector to
direction. Verify that the receptacle is clicked the terminal box, do not exceed 2.25 ± 0.25 N·m
into the locked position. Make sure that the two (20 ± 2 lb in) of torque on the screw.
halves cannot be pulled apart.
Expected Result:
D. For the Deutsch DT style, make sure that the
orange wedge is used in order to lock the pins. Each rectangular connector is secure and the allen
Check that the receptacle has clicked into the head screw is properly torqued.
locked position. Make sure that the two halves
cannot be pulled apart. Results:
Expected Result: • OK – Proceed to Test Step 3.

All connectors are properly mated and free of • Not OK
damage.
Repair: Repair the connector or replace the
Results: connector, as required.
• OK – Proceed to Test Step 2.

335
Verify that the repair eliminates the problem. c. Switch the 35 amp circuit breaker ON. Set
the engine control to the STOP mode. Then
STOP. start the engine. Run the engine under normal
operating conditions.
Test Step 3. Perform a Pull Test on Each
Wire Connection. d. Monitor the “Active Diagnostic Code” screen
on Cat ET while you pull on all harnesses and
A. Each terminal and each connector should easily connectors for the circuit with the active code.
withstand 45 N (10 lb) of pull and each wire
should remain in the connector body. This test If the harness is being pulled and the active
checks whether the wire was properly crimped diagnostic code disappears, there is a
in the terminal and whether the terminal was problem in the wiring or the connector.
properly inserted into the connector.
B. If there are no active diagnostic codes that
B. The DT connectors use an orange wedge to lock pertain to the circuit, perform the following test:
the terminals in place. Ensure that the orange
wedge is not missing and that the orange wedge a. Run the engine under normal operating
is installed properly on the DT connectors. conditions.
Note: Terminals should ALWAYS be crimped onto b. Monitor the “Display Status” screen on Cat
the wires with a crimp tool. Do not solder terminals. ET while you pull on all harnesses and
Use the 1U-5804 Crimp Tool. connectors for the circuit.
Expected Result: If the harness is being pulled and the reading

changes erratically, there is a problem in the
Each terminal and each connector easily withstands wiring or the connector.
45 N (10 lb) of pull and each wire remains in the
connector body. C. If there are no active diagnostic codes and there
are complaints about intermittent changes in
Results: speed or power cutouts, perform the following
test:
a. Run the engine under normal operating
• Not OK conditions.
Repair: Repair the circuit. b. Listen for speed burps or power cutouts while
the wiring and/or the connectors are pulled.
Verify that the repair eliminates the problem.
If the harness is being pulled and the engine
STOP. has a speed burp or a power cutout, there
could be a problem in the wiring or the
Test Step 4. Monitor the Electronic connector.
Service Tool While the Wiring and the
Connectors Are Being Pulled. Expected Result:
The problem appears to be external to the

harnesses and connectors. Pulling on the harness
and on the connectors does not affect the active
There is a strong electrical shock hazard when diagnostic code, component status, or engine
the crankshaft is rotating. Do not touch wires that performance.
are associated with the ignition transformer circuit
when the engine is cranking or running. Results:
A. If there is an active diagnostic code that pertains • OK – Proceed to Test Step 5.

to the circuit, perform the following steps:
• Not OK
a. Set the engine control to the OFF/RESET
mode. Switch the 35 amp circuit breaker OFF. Repair: Set the engine control to the OFF/RESET
b. Connect the Caterpillar Electronic Technician Repair the circuit.
(ET) to the service tool connector on the
terminal box.
336
Verify that the repair eliminates the problem. Test Step 6. Check the Connectors for
Moisture or Corrosion.
STOP.
Test Step 5. Check Wires for Nicks or

Abrasion in the Insulation.
A. Set the engine control to the STOP mode. Allow
the engine to coast to a stop.
B. Set the engine control to the OFF/RESET mode.

C. Carefully inspect each wire for signs of abrasion,

of nicks, or of cuts.
The following areas are likely locations:
• Places with exposed insulation

• Points with wiring that rubs against the engine
• Places with wiring that rubs against a sharp
point Illustration 164 g00690571
D. Check all of the hold down clamps for the A. Ensure that the connector seals and the white
harness in order to verify that the harness is sealing plugs are in place. If any of the seals or
properly clamped. Also, check all of the hold plugs are missing, replace the seal or plug. If
down clamps in order to verify that the harness necessary, replace the connector.
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 do not have abrasion, nicks, or cuts and

the harness is properly clamped.
Results:

• Not OK
Repair: Repair the wires or replace the wires, as
required.
STOP.
g00690568
Illustration 165
B. Check all of the wiring harnesses in order to

verify that the harness does not make a sharp
bend out of a connector. This will deform the
connector seal and this will create a path for the
entrance of moisture.
Thoroughly inspect each ECM connector for

evidence of moisture entry.
337
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 an ECM connector. If moisture
is found in an ECM connector, thoroughly check all Verify that the repair eliminates the problem.
connectors and wires on the harness that connects
to the ECM. The ECM is not the source of the STOP.
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 does not have corrosion, abrasion,
or pinch points.
Results:

• Not OK
Repair: Repair the circuit. Ensure that all of the
seals are properly in place and ensure that the Illustration 166 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.
338
Expected Result: This troubleshooting procedure may generate

Each socket firmly grips each pin. correcting the cause of the original diagnostic code.
Results: resolved.
• OK – The pins and sockets mate properly. STOP.

• Not OK – The pins and sockets do not mate
properly.
Repair: Repair any bad pins and sockets.

Replace the connectors, if necessary. Replace
the wiring, if necessary.
STOP.
i01828672
Integrated Temperature
Sensing Module (ITSM)
SMCS Code: 1901-038

monitors K type thermocouples at each cylinder
exhaust port and at the inlets and outlets for
both turbochargers. The ITSM can also calculate
the average temperature for each cylinder bank
(left and right). Temperature readings of the
thermocouples are available over the CAT Data
Link for use by each Electronic Control Module
(ECM) and other modules. The temperatures can be
viewed on the Caterpillar Electronic Technician (ET).
The ITSM generates event codes for each of the

following programmable conditions:
• High exhaust temperature

• High deviation of an exhaust port temperature
• Low deviation of an exhaust port temperature
• High inlet temperature to the turbocharger turbine
• High outlet temperature from the turbocharger
turbine
A diagnostic code is generated by the ITSM for the

circuit of any thermocouple that is shorted to the
+Battery side, shorted to ground, or open.

record. Before you begin this procedure, use Cat
ET to print the logged codes to a file.
339
g00952421
Illustration 167
Schematic for the circuit of the ITSM for 1500 RPM engines
340
For the actual wiring, refer to the schematic for the engine electrical system.
341
g00952422
Illustration 168
Schematic for the circuit of the ITSM for 1800 RPM engines
342
For the actual wiring, refer to the schematic for the engine electrical system.

• J7/P7 and J9/P9 connectors on the terminal
box

6 ± 1 N·m (53 ± 9 lb in).

g00931487
Illustration 169

position.

g00894447
Illustration 171
(P1-9) CAT data link −

for the ITSM.
g00932985
Illustration 170
Terminal box
(2) J1/P1 connectors for the master EM
(3) J7/P7 connectors for the harness from the ITSM
(4) J9/P9 connectors for the CAT Data Link
343
g00932996
Illustration 172
Thermocouples
(6) Thermocouple for the temperature of a (8) Thermocouples for the temperature of
cylinder exhaust port the turbocharger exhaust outlets
(7) Thermocouple for the temperature of the (9) Thermocouple for the temperature of the
exhaust inlet to the turbocharger turbine turbocharger exhaust outlet
d. Carefully inspect the connectors for each of

the thermocouples. Check the harnesses and
wiring for abrasion and for pinch points from
each thermocouple to the ITSM.
g00933003
Illustration 173
ITSM
(10) 54-pin connectors for the harness to the thermocouples
(11) ITSM
(12) 14-pin connectors for the harness to the terminal box for the
master ECM
344
e. Thoroughly inspect 54-pin connectors (10) Repair: If any of the codes are logged, there
and 14-pin connectors (12) for ITSM (11). may be an intermittent condition that is causing
Check the harnesses and wiring for abrasion the codes to be generated. If the engine is
and for pinch points from the ITSM to the not running properly, refer to Troubleshooting,
master ECM. “Troubleshooting Without a Diagnostic Code”.
Expected Result: STOP.
All of the connectors, pins, and sockets are • Active “short to ground” or “short to +batt” – At
connected properly. The connectors and the wiring least one “short to ground” or “short to +batt”
do not have corrosion, abrasion, or pinch points. diagnostic code is active. Proceed to Test Step 3.
Results: • Active “open circuit” – At least one “open circuit”

diagnostic code is active. Proceed to Test Step 4.
proper connections. Proceed to Test Step 2. Test Step 3. Create an Open Circuit
• Not OK – The components are not in good A. Set the engine control to the OFF/RESET mode.
condition and/or at least one connection is Switch the 35 amp circuit breaker OFF.
improper.
B. Disconnect the connector for the thermocouple
Repair: Perform the necessary repairs and/or with the short circuit diagnostic code.
replace parts, if necessary. Note that all of the
wiring for the thermocouples must be K type. C. Switch the 35 amp circuit breaker ON. Set the
STOP.
D. Access the “Active Diagnostic” screen for the
Test Step 2. Verify the Active Diagnostic ITSM on Cat ET. Allow a minimum of 30 seconds
Codes for any diagnostic codes to be generated.
A. Access the “Active Diagnostic” screen for the Expected Result:

ITSM on Cat ET. Determine if any of the following
diagnostic codes for the thermocouples are There is an active “open circuit” diagnostic code for
active: the disconnected thermocouple.
• 1489-03 through 1492-03 (“short to +batt”) Results:
• 1489-04 through 1492-04 (“short to ground”) • Yes – There is an active “open circuit” diagnostic
code for the disconnected thermocouple. The
• 1489-05 through 1492-05 (“open circuit”) ITSM and the harness are OK.
• 1531-03 through 1550-03 (“short to +batt”) Repair: Perform the following procedure:
• 1531-04 through 1550-04 (“short to ground”) 1. Thoroughly inspect the thermocouple’s

connectors. Ensure that the connectors and
• 1531-05 through 1550-05 (“open circuit”) the seals are in good condition.
Expected Result: 2. Reconnect the thermocouple’s connectors and

check for an active short circuit diagnostic
None of the above diagnostic codes for the code.
thermocouples are active.
If the short circuit diagnostic code becomes
Results: active again, there is a problem with the
thermocouple.
• No Active Codes – None of the above diagnostic
codes for the thermocouples are active. 3. Disconnect the suspect thermocouple and
connect a thermocouple that is known to be
good. Do not install the thermocouple into the
engine yet.
345
4. Check for an active short circuit diagnostic 2. Reconnect the thermocouple’s connectors and
code. check for an active open circuit diagnostic
code.
If the diagnostic code is not generated with
the good thermocouple, remove the suspect If the open circuit diagnostic code becomes
thermocouple from the engine. Install the good active again, there is a problem with the
thermocouple. thermocouple.
5. Clear the logged diagnostic codes. 3. Disconnect the suspect thermocouple and
connect a thermocouple that is known to be
STOP. good. Do not install the good thermocouple
into the engine yet.
• No – There is not an active “open circuit”
diagnostic code for the disconnected 4. Check for an active open circuit diagnostic
thermocouple. There is a short circuit between code.
the harness for the thermocouple and the ITSM.
Proceed to Test Step 5. If the diagnostic code is not generated with
the good thermocouple, remove the suspect
Test Step 4. Create a Short Circuit thermocouple from the engine. Install the good
thermocouple.
Switch the 35 amp circuit breaker OFF. 5. Clear the logged diagnostic codes.
B. Disconnect the connector for the thermocouple STOP.

with the open circuit diagnostic code.
• No – When the jumper wire was installed, the
C. Install a jumper wire into terminals A and B on the “open circuit” diagnostic code recurred. There is
harness connector for the suspect thermocouple. probably an open circuit in the harness between
the ITSM and the connector for the thermocouple.
engine control to the STOP mode. Repair: Remove the jumper wire.
E. Access the “Active Diagnostic” screen for the Proceed to Test Step 5.
ITSM on Cat ET. Allow a minimum of 30 seconds
for any diagnostic codes to be generated. Test Step 5. Check the ITSM
Observe the “Active Diagnostic” screen.
F. Remove the jumper wire and observe the Switch the 35 amp circuit breaker OFF.
“Active Diagnostic” screen. Allow a minimum
of 30 seconds for any diagnostic codes to be B. Disconnect the 54-pin connector from the ITSM.
generated. Thoroughly inspect the 54-pin connectors.
Ensure that the connectors are in good condition.
Expected Result:
When the jumper wire was installed, a “short circuit” engine control to the STOP mode.
diagnostic code was generated. When the jumper
wire was removed, the “open circuit” diagnostic Note: When the 54-pin connectors are disconnected,
code recurred. an active “open circuit” diagnostic code will be
generated for all of the thermocouples. This is
Results: normal. Only pay attention to the diagnostic codes
for the suspect thermocouple.
• Yes – When the jumper wire was installed, a
“short circuit” diagnostic code was generated. D. Access the “Active Diagnostic” screen for the
When the jumper wire was removed, the “open ITSM on Cat ET. Allow a minimum of 30 seconds
circuit” diagnostic code recurred. The ITSM and for any diagnostic codes to be generated.
the harness are OK. Observe the “Active Diagnostic” screen.
Repair: Perform the following procedure: E. Set the engine control to the OFF/RESET mode.
1. Thoroughly inspect the thermocouple’s
connectors. Ensure that the connectors and
the seals are in good condition.
346
F. Install a jumper wire into the terminals for the 4. If the problem is resolved with the new ITSM,
suspect sensor on the 54-pin connector on the install the original ITSM and verify that the
ITSM. For identification of the terminals, refer to problem returns. If the new ITSM operates
Illustration 167 or 168. correctly and the original ITSM does not
operate correctly, replace the original ITSM.
G. Switch the 35 amp circuit breaker ON. Set the Refer to Troubleshooting, “Replacing the
engine control to the STOP mode. Observe the ITSM”.
“Active Diagnostic” screen. Allow a minimum
of 30 seconds for any diagnostic codes to be STOP.
generated.
i01828783
Expected Result:
When the 54-pin connectors were disconnected,

PWM Sensor
an “open circuit” diagnostic code was generated SMCS Code: 5574-038
for the suspect sensor. When the jumper wire was
installed, a “short circuit” diagnostic code was System Operation Description:
generated.
The engine contains the following Pulse Width
Results: Modulated sensors (PWM):
• Yes – When the 54-pin connectors were • Engine coolant pressure (outlet)
disconnected, an “open circuit” diagnostic code
was generated for the suspect sensor. When
the jumper wire was installed, a “short circuit”
• Inlet manifold air pressure
diagnostic code was generated. The ITSM is A PWM sensor produces a digital signal. In a digital
OK. There is a problem in the harness between signal, the duty cycle varies as the input condition
the ITSM and the connector for the suspect changes. The frequency remains constant. Refer
thermocouple. to Illustration 174.
Repair: Remove the jumper wire. Repair the
necessary. Clear the logged diagnostic codes
and verify that the problem is resolved.
STOP.
• No – Either of the following results or both of the

results occurred: When the 54-pin connectors
were disconnected, an “open circuit” diagnostic
code was not generated for the suspect sensor.
When the jumper wire was installed, a “short
circuit” diagnostic code was not generated. There
may be a problem with the ITSM.
Repair: It is unlikely that the ITSM has failed.

again. If the problem is not resolved, perform the
following steps:

2. Remove the jumper wire from the connector

on the ITSM.
3. Temporarily install a new ITSM. Refer to

Troubleshooting, “Replacing the ITSM”. Illustration 174 g00852792
Sample duty cycles that are low, medium, and high.

347

supplies 8.0 ± 0.8 VDC to each PWM sensor.
Note: Excessive pressure can generate false “noisy

signal” diagnostic codes.
If the actual inlet manifold air pressure is greater

than approximately 338 kPa (49 psi), a “106-08 Air
Inlet Pressure Sensor noisy signal” diagnostic code
will be generated. Although there is not a problem
with the sensor, the code will be generated.
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 “106-08” or “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 activation of false
diagnostic codes.

record. Before you begin this procedure, print the

resolved.
g00933025
Illustration 175
Schematic for the PWM sensors
348

• J7/P7 connectors for the harness from the
PWM sensors
• The connectors for each PWM sensor

6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 176

position.

Troubleshooting, “Inspecting Electrical Connectors”. Illustration 178
g00933041

(P1-5) Return
(P1-10) Signal for inlet manifold air pressure
g00896241
Illustration 179
g00933033
Illustration 177 (P2-68) Signal for engine coolant pressure (outlet)
(4) J7/P7 connectors for the PWM sensors
B. Thoroughly inspect the following connectors:

349
g00933045
Illustration 180
Harness side of the P7 connector
(P7-1) Signal for inlet manifold air pressure
(P7-2) Signal for engine coolant pressure (outlet)
(P7-15) Return for inlet manifold air pressure
(P7-16) Return for engine coolant pressure (outlet)
(P7-29) Shield
(P7-30) Shield
(P7-43) 8 volt supply for the inlet manifold air pressure
(P7-44) 8 volt supply for the engine coolant pressure (outlet)

for the PWM sensors.
350
g00933079
Illustration 181
(5) Sensor for engine coolant pressure
(outlet)
(6) Sensor for inlet manifold air pressure
d. Check the harness and wiring for abrasion C. Observe the “Active Diagnostic” screen on Cat
and for pinch points from each of the PWM ET. Allow a minimum of thirty seconds for any
sensors to the master ECM. codes to activate. Look for these codes:
Expected Result: • 41-03 8 Volt DC Supply short to +batt

The connectors, pins, and sockets are connected • 41-04 8 Volt DC Supply short to ground
corrosion, abrasion, or pinch points. Expected Result:
Results: There are no active “8 Volt DC Supply” diagnostic

codes.
proper connections. Proceed to Test Step 2. Results:
• Not OK – The components are not in good • No codes – There are no active diagnostic codes
condition and/or at least one connection is for the power supplies. Proceed to Test Step 3.
improper.
• Active code – There is an active diagnostic code
Repair: Perform the necessary repairs and/or for the 8 volt power supply. This procedure will
replace parts, if necessary. not work when this type of code is active.
STOP. Repair: Refer to Troubleshooting, “+8 V Sensor

Voltage Supply”.
Test Step 2. Check for Active “8 Volt DC
Supply” Diagnostic Codes STOP.
A. Connect the Caterpillar Electronic Technician Test Step 3. Check for Active Diagnostic
(ET) to the service tool connector. Refer to Codes for the PWM Sensors
Troubleshooting, “Electronic Service Tools”.
A. Turn on the “Active Diagnostic” screen on Cat
B. Switch the 35 amp circuit breaker ON. Set the ET. Determine if any of these diagnostic codes
engine control to the STOP mode. are active:
351
• 106-03 Air Inlet Pressure Sensor open/short Expected Result:

to +batt
• 106-08 Air Inlet Pressure Sensor noisy signal
Results:
• 109-03 Engine Coolant Outlet Pressure
open/short to +batt • OK – The voltage is within the specification. The
correct voltage is present at the sensor connector.
• 109-08 Engine Coolant Outlet Pressure noisy Proceed to Test Step 5.
signal
• Not OK – The voltage is not within the
Expected Result: specification. The correct voltage is not present
at the sensor connector. The correct voltage must
One of the above codes is active. be present at the sensor connector in order to
continue this procedure.
Results:
Repair: Verify that the wiring and/or connectors
• Yes – At least one of the above diagnostic codes are OK. Repair any faulty wiring and/or
is active. Proceed to Test Step 4. connectors, when possible. Replace any
faulty wiring and/or connectors, if necessary.
• No – None of the above codes are active. Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
and the engine is not running properly, refer STOP.
to Troubleshooting, “Troubleshooting Without a
Diagnostic Code”. Test Step 5. Verify that +Battery Voltage
is Not Present in the Signal Wire
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.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
STOP.
Test Step 4. Verify the Supply Voltage to Illustration 183 g00896299

the Sensor
Harness connector for the PWM sensors
A. Set the engine control to the OFF/RESET mode. (B) Return
(C) Signal
B. Disconnect the suspect sensor.
A. At the harness connector for the suspect sensor,
C. Set the engine control to the STOP mode. measure the voltage between terminal (B) and
terminal (C).
Expected Result:
Results:
g00896288 • OK – The voltage is between 7.0 VDC and 8.0

Illustration 182 VDC. The battery voltage is not present in the
Harness connector for the PWM sensors signal wire. Proceed to Test Step 6.
(A) 8 volt supply
(B) Return • Not OK – The voltage is approximately equal to
the battery voltage. The signal wire is probably
D. At the harness connector for the suspect sensor, shorted to the battery between the sensor and
measure the voltage between terminals (A) and the master ECM.
(B).
352
Repair: Set the engine control to the OFF/RESET 2. Check the duty cycle and the frequency of the
mode. Switch the 35 amp circuit breaker OFF. sensor signal again.
Repair the harness, when possible. Replace the
harness, if necessary. 3. If the duty cycle and the frequency of the
sensor signal are incorrect, set the engine
STOP. control to the OFF/RESET mode.
• Not OK – The voltage is approximately 0 volts. 4. Disconnect the sensor. Connect a sensor that
The signal wire is probably shorted to ground is known to be good. Do not install the new
between the sensor and the master ECM. sensor into the engine yet.
Repair: Set the engine control to the OFF/RESET 5. Set the engine control to the STOP mode.
mode. Switch the 35 amp circuit breaker OFF. Allow a minimum of 30 seconds for any codes
Repair the harness, when possible. Replace the to activate.
6. Check for an active diagnostic code. If the
STOP. code is not active for the new sensor, install
the sensor into the engine. Clear any logged
Test Step 6. Check the Signal at the diagnostic codes.
Sensor
STOP.
Test Step 7. Check the Signal at the
B. Install a 8T-8726 Adapter Cable As (Three-Pin Master ECM
Breakout) at the harness connector for the
suspect sensor. A. Set the engine control to the OFF/RESET mode.
C. Use a multimeter that is capable of measuring
both the duty cycle and the frequency. Connect B. Insert two 7X-1710 Multimeter Probes into the
the multimeter to terminal B and terminal C of terminals that are appropriate for the suspect
the breakout t. sensor.
D. Set the engine control to the STOP mode. The terminals for the connection of the probes
are identified in Table 34.
E. Measure the duty cycle and the frequency of the
suspect sensor. Table 34
Terminals for the Connection of the Probes
Expected Result:
Suspect Sensor Connector and Terminals
The duty cycle is between 5 percent and 95 Engine coolant pressure J2-68 and J1-5
percent. (outlet)
The frequency is between 400 and 600 Hz. Inlet manifold air pressure J1-10 and J1-5
Results: C. Use a multimeter that is capable of measuring

both the duty cycle and the frequency. Connect
• OK – The duty cycle is between 5 percent and the multimeter to the probes.
95 percent. The frequency is between 400 and
600 Hz. A valid signal is produced by the sensor. D. Switch the 35 amp circuit breaker ON. Set the
Proceed to Test Step 7. engine control to the STOP mode.
• Not OK – The duty cycle or the frequency is E. Measure the duty cycle and the frequency of the
incorrect. The sensor is receiving the correct suspect sensor.
supply voltage but the sensor is not producing
a valid signal. Expected Result:
Repair: Perform the following steps: The duty cycle is between 5 percent and 95
percent.
1. Thoroughly inspect the connector for
the sensor according to Troubleshooting, The frequency is between 400 and 600 Hz.
353
Results: i01829566
• OK – The duty cycle is between 5 percent and Throttle Actuator

95 percent. The frequency is between 400 and
600 Hz. The ECM is receiving a valid signal from SMCS Code: 1716-038
the sensor.
The throttle actuator is an electronic actuator that
1. Set the engine control to the OFF/RESET works with the master Electronic Control Module
mode. Switch the 35 amp circuit breaker OFF. (ECM) in order to ensure the correct throttle position
in all conditions of engine operation.
engine control to the STOP mode. The master ECM and the throttle actuator
communicate via the CAN data link. The master
3. Check “Status Screen Group 2” on Cat ET. ECM sends a command signal to the actuator.
Look for a valid signal. The actuator sends the following information to the
master ECM: actuator position, CCM heartbeat,
It is possible that the actual air inlet pressure is software version, and internal fault diagnosis.
less than the pressure that can be measured by
the sensor during low idle operation (26.7 kPa If the master ECM cannot communicate with the
(3.87 psi)). This causes the master ECM to set throttle actuator, the master ECM activates a
the 106-03 diagnostic code although there is no 1440-09 diagnostic code and the engine is shut
short circuit to the +Battery side. In this case, down. A 1440-09 diagnostic code is probably
adjust the derivative gain and the fuel quality in caused by a problem with an electrical connector
order to make the engine more stable at low idle. or a harness. The next likely cause is a problem
Refer to Troubleshooting, “System Configuration with the actuator. The least likely cause is a problem
Parameters”. with the master ECM.
Otherwise, verify that the master ECM is receiving Terminating resistors must be connected to each
the correct voltage. Refer to Troubleshooting, end of the CAN data link. The terminating resistors
“Electrical Power Supply”. improve the communication between the devices. If
there is an intermittent diagnostic code for any of
If the condition is not resolved, temporarily install the devices that are connected to the CAN data
a new master ECM. Refer to Troubleshooting, link, be sure to check the terminating resistor that is
“Replacing the ECM”. inside the terminal box. Also check the jumper wire
that is connected between terminals J and K on the
If the problem is resolved with the new ECM, actuator for the bypass valve. Make repairs, when
install the original ECM and verify that the possible. Replace parts, if necessary.
correctly and the original ECM does not operate Logged diagnostic codes provide a historical
correctly, replace the original ECM. Refer to record. Before you begin this procedure, use the
Troubleshooting, “Replacing the ECM”. Caterpillar Electronic Technician (ET) to print the
STOP.
• Not OK – The duty cycle or the frequency is additional diagnostic codes. Keep your mind on
incorrect. The sensor is producing a valid signal correcting the cause of the original diagnostic code.
but the signal does not reach the master ECM. Clear the diagnostic codes after the problem is
There is a problem in the harness between the resolved.
sensor and the master ECM.
Repair: Repair the harness, when possible.

Replace the harness, if necessary.
STOP.
354
g00934101
Illustration 184
Schematic for the circuit of the throttle actuator
355

• Connectors on the throttle actuator
6 ± 1 N·m (55 ± 9 lb in).

g00931487
Illustration 185
Junction box
A. Set the engine control to the OFF/RESET position.

position.
Note: For the following steps, refer to g00933941

Illustration 187
Troubleshooting, “Inspecting Electrical Connectors”. Harness side of the ECM P1 connector
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
g00933933
Illustration 186
Terminal box
(2) Ground strap
g00934039
(3) J1/P1 connectors for the master ECM Illustration 188
(4) J9/P9 connectors for the CAN data link Harness side of the ECM J9 connector
data link (J9-6) CAN data link +
(J9-12) CAN data link −
(J9-18) CAN shield
356
c. Perform a 45 N (10 lb) pull test on each of B. Switch the 35 amp circuit breaker ON. Set the
the wires that are associated with the throttle engine control to the STOP mode.
actuator.
C. Use Cat ET in order to determine if a 1440-09
diagnostic code is active.
Expected Result:
The 1440-09 code is not active.
Results:
• OK – The 1440-09 code is not active. The

communication between the master ECM and the
throttle actuator appears to be OK at this time.
However, diagnostic codes may be logged.

problem, refer to Troubleshooting, “Inspecting
Terminating resistors must be connected to

each end of the CAN data link. The terminating
resistors improve the communication between the
Illustration 189
g00935524 devices. If there is an intermittent diagnostic code
for any of the devices that are connected to the
The right side of the engine with the throttle actuator
CAN data link, be sure to check the terminating
resistor that is inside the terminal box. Also
d. Check the wiring for abrasion and for pinch
check the jumper wire that is connected between
points from the throttle actuator to the master
terminals J and K on the actuator for the bypass
ECM.
valve. Make repairs, when possible. Replace
parts, if necessary.
Expected Result:
STOP.
All of the connectors, pins, and sockets are
do not have corrosion, abrasion, or pinch points. • Not OK (Active 1440-09) – The master ECM has
detected a problem with the communication
between the master ECM and the throttle actuator.
Results:
• OK – The components are in good condition with Test Step 3. Check the CAN Data Link for
Continuity Between the Throttle Actuator
• Not OK – The components are not in good and the Master ECM
improper. A. Set the engine control to the OFF/RESET mode.
replace parts, if necessary. Ensure that all of B. Disconnect the P1 connector. Disconnect the
the seals are properly installed. Ensure that the connector for the throttle actuator.
connectors are properly engaged. Verify that the
repair has eliminated the original problem. C. Use a multimeter to check for continuity between
STOP. each measurement, wiggle the harnesses in
Test Step 2. Check for Diagnostic Codes the harness. Be sure to wiggle the harness near
each of the connectors. Be sure to wiggle the
A. Connect the Caterpillar Electronic Technician harness near the fuel metering valve.
(ET) to the service tool connector on the terminal
box.
357
Table 35 Table 36
Points to Check for Continuity Points to Check for Continuity
Connector and Harness Connector for the Connector and Terminal Connector and Terminal
Terminal Throttle Actuator
P1-34 (CAN Data Link −) P1-50 (CAN Data Link +)
P1-34 Terminal B (CAN data link −) P1-42 (CAN Shield)
P1-52 (+ Battery)
P1-50 Terminal A (CAN data link +) Ground strap for the ECM
P1-42 Terminal M (CAN shield) P1-50 (CAN Data Link +) P1-42 (CAN Shield)
P1-52 (+ Battery)
Expected Result: Ground strap for the ECM
P1-42 (CAN Shield) P1-52 (+ Battery)
The continuity of the circuits between the terminals Ground strap for the ECM
is good.
All of the measurements indicate an open circuit.

• OK – The continuity of the circuits between the
terminals is good. Proceed to Test Step 4.
Results:
• Not OK – At least one of the continuity checks
indicates an open circuit. There is an open circuit • OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short
for the CAN data link between the throttle actuator
circuit.
and the master ECM.
Repair: Reconnect the P1 connector. Reconnect
Repair: The open circuit could be caused by
the connector for the throttle actuator.
a poor electrical connection in a connector.
Alternatively, the open circuit could be caused by
one of the following components:
• The harness inside the terminal box • Not OK – At least one of the measurements
indicate a short circuit.
• The harness between the terminal box and the Repair: The short circuit could be caused by
fuel metering valve
a poor electrical connection in a connector.
Alternatively, the short circuit could be caused by
• The harness between the fuel metering valve one of the following components:
• The fuel metering valve • The harness inside the terminal box
Make repairs, when possible. Replace parts, if • The harness between the terminal box and the
fuel metering valve
necessary.
STOP. • The harness between the fuel metering valve

a Short Circuit • The fuel metering valve
Make repairs, when possible. Replace parts, if
necessary.
mode and that the 35 amp circuit breaker is OFF.
STOP.
B. Use a multimeter to check for continuity between
each measurement, wiggle the harnesses in
A. Switch the 35 amp circuit breaker ON. Set the
the harness. Be sure to wiggle the harness near
each of the connectors. Be sure to wiggle the
harness near the fuel metering valve.
B. Use Cat ET in order to determine if a 1440-09
diagnostic code is active.
358
Expected Result: 4. Temporarily install a new fuel metering valve. If

the new fuel metering valve operates correctly,
The 1440-09 code is not active. the problem is resolved. If the new fuel
metering valve does not operate correctly,
Results: install the original fuel metering valve. Refer
• OK – The 1440-09 code is not active. The Connectors”.
problem seems to be resolved. The initial
diagnostic code was probably caused by a poor STOP.
electrical connection.
Repair: If there is an intermittent problem

that is causing the code to be logged, refer
Connectors”.
STOP.
• Not OK – The 1440-09 code is active.

Repair: The active 1440-09 code could be caused
by one of the following components:
• The master ECM

• The actuator for the bypass valve
• The fuel metering valve
It is unlikely that any of the components that are
listed above have failed. Exit this procedure and
perform this procedure again. If the 1440-09 code
remains active, perform the following procedure:
1. Temporarily install a new master ECM. Refer to

problem is resolved with the new ECM, install
the original ECM and verify that the problem
returns. If the new ECM operates correctly
and the original ECM does not operate
problem is not resolved with a new ECM, install
the original ECM. Continue with this procedure.
2. Temporarily install a new throttle actuator. If

the new throttle actuator operates correctly,
the problem is resolved. If the new throttle
actuator does not operate correctly, install the
original throttle actuator and continue with this
procedure.
3. Temporarily install a new actuator for the

bypass valve. If the new actuator for the
bypass valve operates correctly, the problem
is resolved. If the new actuator for the bypass
valve does not operate correctly, install the
original actuator for the bypass valve and
continue with this procedure.
359
Calibration Procedures
i01828904
Engine Speed/Timing Sensor -

Calibrate
SMCS Code: 1912-524

the ability to calibrate the mechanical differences
between the Top Center (TC) of the flywheel and
the TC of the timing gear on the left rear camshaft
gear. A magnetic transducer signals the TC of
the flywheel to the master ECM when the TC hole
on the flywheel passes beneath the transducer.
The engine speed/timing sensor signals the TC
of the timing gear to the master ECM. Any offset
between the TC of the flywheel and the TC of the
timing gear is stored into memory. The master ECM
communicates the information from the calibration
to the slave ECM via the CAT data link.
Calibration of the timing is required only after the

following circumstances:
• The master ECM has been replaced.

• The speed/timing sensor has been replaced.
• The timing gear and/or the rear gear train have
been adjusted.
• The timing gear and/or the rear gear train have

been replaced.
Note: The “261-13 Engine Timing calibration

required” diagnostic code is generated only for a
master ECM that has never performed a timing
calibration.
The calibration procedure is initiated with the

Caterpillar Electronic Technician (ET).
360
Test Step 1. Install the Transducer
g00933152
Illustration 190
(1) Connector for the 7X-1695 cable (3) 6V-2197 Magnetic Transducer
(2) 7X-1695 Cable (4) 6V-3093 Transducer Adapter
A. Set the engine control to the OFF/RESET mode. E. Connect Cat ET to the service tool connector
Remove the timing calibration plug from either on the terminal box. For instructions, refer to
the left side or the right side of the flywheel Troubleshooting, “Electronic Service Tools”. Start
housing. Install 6V-3093 Transducer Adapter Cat ET.
(4) into the hole.
Continue to the next test step.
NOTICE
The timing hole in the flywheel must not be aligned Test Step 2. Calibration
with the hole for the transducer. The transducer will
be damaged on engine start-up if the transducer is Note: A two-step process is used to calibrate
installed through both holes. Rotate the flywheel for the signal for the speed/timing sensor. The new
more than 10 degrees before or after the TC position timing reference is calculated first. The reference is
in order to move the flywheel hole away from the hole based on the signals from the transducer and the
for the transducer. Always confirm that the holes are speed/timing sensor. Next, the new timing reference
not aligned. is programmed into the permanent memory of the
master ECM.
B. Make sure that the hole in the flywheel housing A. Start the engine. Operate the engine at the rated
for the transducer is not aligned with the timing speed and load.
hole in the flywheel. Remove the protective end
cap from 6V-2197 Magnetic Transducer (3). B. Select “Service” from the main menu on Cat
Insert the transducer into the adapter until the ET. Select “Calibrations” from the menu. Select
transducer contacts the surface of the flywheel. “Timing Calibration”.
Move the transducer 1 mm (0.04 inch) away from
the surface of the flywheel. Tighten the nut on C. Use either of the following methods in order
the adapter in order to secure the transducer to initiate the calculation of the new timing
in place. reference:
C. Connect the one end of 7X-1695 Cable (2) to • Press the space bar on the keyboard of the
the transducer. Connect the other end of the PC.
cable to connector (1) on the side of the engine.

361
• Click the left mouse button on the “Continue” Repair: Replace the master ECM according to
button in the lower left corner of the Cat ET the instructions in Troubleshooting, “Replacing
screen. the ECM”.
Cat ET will indicate “Please wait...Calculating the STOP.

new Timing Reference”. After a few moments,
Cat ET will display “The ECM has calculated the
Timing Reference” and “Choose the Continue
button to program the Timing Reference”.
D. Use either of the following methods in order to

program the new timing reference:
• Press the space bar on the keyboard of the

PC.
• Click the left mouse button on the “Continue”

button in the lower left corner of the Cat ET
screen.
Expected Result:
After a few moments, Cat ET will display

“CALIBRATION SUCCESSFUL”.
Results:
• OK – The timing calibration was successful.

Disconnect the transducer and the cable.
Remove the adapter and reinstall the timing
calibration plug. Replace the protective cover on
the transducer. STOP.
• Not OK – Cat ET displayed “COULD NOT

CALIBRATE”. The calibration was unsuccessful.
Repair: If the calibration failed in the first step,

verify that the engine rpm was stable during the
calibration (± 50 rpm). Verify that there are no
active diagnostic codes which can prevent the
calibration. Repeat the calibration procedure.
If the calibration is still unsuccessful, check the

installation of the tools and the operation of the
tools. Check the 7X-1695 Cable for continuity.
Verify that the transducer is not bent, open,
or shorted internally. Repeat the calibration
procedure.
Excessive backlash in the gear train will cause

inconsistent timing. Refer to Disassembly and
Assembly for identifying and repairing a gear
train problem.
STOP.
• Not OK – The calibration was completed

successfully. However, the “261-13 Engine Timing
calibration required” diagnostic code is still active.
362
Index Section
Index
Numerics E053 Low Fuel Pressure Warning....................... 166
E096 High Fuel Pressure .................................... 166
+5V Sensor Voltage Supply................................. 210 E100 Low Engine Oil Pressure Warning ............. 167
+8V Sensor Voltage Supply................................. 218 E127 Engine Oil Filter Diff Pressure Low
Warning ............................................................. 167
E128 Engine Oil Filter Diff Pressure Low
A Shutdown........................................................... 167
E129 Engine Oil Filter Diff Pressure High
Analog Sensor Signal.......................................... 226 Warning ............................................................. 167
E130 Engine Oil Filter Diff Pressure High
Shutdown........................................................... 168
B E135 Low Jacket Water Pressure Shutdown....... 168
E223 High Gas Temperature ............................... 168
Bypass Valve ....................................................... 235 E224 High Jacket Water Inlet Pressure ............... 169
E225 Engine Overcrank ...................................... 169
E226 Driven Equipment Not Ready..................... 169
C E229 Fuel Energy Content Setting Low .............. 169
E230 Fuel Energy Content Setting High.............. 170
Calibration Procedures ........................................ 359 E231 Fuel Quality Out of Range.......................... 170
CAT Data Link...................................................... 243 E242 Engine Overload ........................................ 170
Customer Passwords............................................. 29 E243 High Left Turbo Turbine Outlet
Temperature....................................................... 170
E244 High Right Turbo Turbine Outlet
D Temperature....................................................... 171
E245 High Right Turbo Turbine Inlet
Desired Speed Input (4 - 20 mA)......................... 248 Temperature....................................................... 171
Detonation ............................................................. 44 E246 High Left Turbo Turbine Inlet Temperature.. 172
Probable Causes ............................................... 44 E264 Emergency Stop Activated......................... 172
Recommended Repairs ..................................... 45 E268 Unexpected Engine Shutdown ................... 172
Detonation Sensors ............................................. 252 E269 Customer Shutdown Requested ................ 173
Diagnostic Codes .................................................. 72 E270 Driven Equipment Shutdown Requested ... 173
Active Diagnostic Codes .................................... 73 E337 High Engine Oil to Engine Coolant Diff
Logged Diagnostic Codes.................................. 73 Temp .................................................................. 173
Diagnostic Functional Tests................................. 210 E401 Cylinder #1 Detonation............................... 173
Driven Equipment .................................................. 46 E402 Cylinder #2 Detonation............................... 174
Probable Causes ............................................... 46 E403 Cylinder #3 Detonation............................... 174
Recommended Repairs ..................................... 46 E404 Cylinder #4 Detonation............................... 174
E405 Cylinder #5 Detonation............................... 174
E E407 Cylinder #7 Detonation............................... 175
E004 Engine Overspeed Shutdown .................... 162 E409 Cylinder #9 Detonation............................... 175
E015 High Engine Coolant Temperature Derate.. 162 E410 Cylinder #10 Detonation............................. 176
E016 High Engine Coolant Temperature E411 Cylinder #11 Detonation............................. 176
Shutdown........................................................... 163 E412 Cylinder #12 Detonation............................. 176
E017 High Engine Coolant Temperature E413 Cylinder #13 Detonation............................. 176
Warning ............................................................. 163 E414 Cylinder #14 Detonation............................. 177
E019 High Engine Oil Temperature Shutdown .... 163 E415 Cylinder #15 Detonation............................. 177
E020 High Engine Oil Temperature Warning....... 163 E416 Cylinder #16 Detonation............................. 177
E025 High Inlet Air Temperature Derate.............. 164 E417 Cylinder #17 Detonation............................. 177
E026 High Inlet Air Temperature Shutdown ........ 164 E418 Cylinder #18 Detonation............................. 178
E027 High Inlet Air Temperature Warning ........... 164 E419 Cylinder #19 Detonation............................. 178
E038 Low Engine Coolant Temperature E420 Cylinder #20 Detonation............................. 178
Warning ............................................................. 165 E421 Cylinder #1 Detonation Shutdown.............. 179
E040 Low Engine Oil Pressure Shutdown........... 165 E422 Cylinder #2 Detonation Shutdown.............. 179
E042 Low System Voltage Shutdown.................. 165 E423 Cylinder #3 Detonation Shutdown.............. 179
E043 Low System Voltage Warning .................... 165 E424 Cylinder #4 Detonation Shutdown.............. 179
E050 High System Voltage Warning ................... 166 E425 Cylinder #5 Detonation Shutdown.............. 180
363
Index Section
E426 Cylinder #6 Detonation Shutdown.............. 180 E839 Cyl #19 Exhaust Port Temp Deviating
E427 Cylinder #7 Detonation Shutdown.............. 180 High ................................................................... 199
E428 Cylinder #8 Detonation Shutdown.............. 181 E840 Cyl #20 Exhaust Port Temp Deviating
E429 Cylinder #9 Detonation Shutdown.............. 181 High ................................................................... 199
E430 Cylinder #10 Detonation Shutdown............ 181 E841 Cyl #1 Exhaust Port Temp Deviating Low .. 200
E439 Cylinder #19 Detonation Shutdown............ 184 E850 Cyl #10 Exhaust Port Temp Deviating Low.. 203
E440 Cylinder #20 Detonation Shutdown............ 184 E851 Cyl #11 Exhaust Port Temp Deviating Low.. 204
E801 Cylinder #1 High Exhaust Port Temp ......... 184 E852 Cyl #12 Exhaust Port Temp Deviating Low.. 204
E810 Cylinder #10 High Exhaust Port Temp ....... 188 E864 Low Gas Fuel Differential Pressure ........... 208
E811 Cylinder #11 High Exhaust Port Temp ....... 188 E865 High Gas Fuel Differential Pressure........... 208
E812 Cylinder #12 High Exhaust Port Temp ....... 188 E866 Low Gas Fuel Flow Rate............................ 208
E813 Cylinder #13 High Exhaust Port Temp ....... 189 E867 Improper Gas Flow Control Valve
E814 Cylinder #14 High Exhaust Port Temp ....... 189 Response........................................................... 209
E815 Cylinder #15 High Exhaust Port Temp ....... 190 E868 Gas Flow Control Valve Malfunction .......... 209
E816 Cylinder #16 High Exhaust Port Temp ....... 190 ECM Output Circuit (Fuel Control)....................... 261
E817 Cylinder #17 High Exhaust Port Temp ....... 190 ECM Output Circuit (Starting Motor) ................... 271
E818 Cylinder #18 High Exhaust Port Temp ....... 191 ECM Status Indicator Output............................... 281
E819 Cylinder #19 High Exhaust Port Temp ....... 191 ECM Will Not Accept Factory Passwords .............. 46
E820 Cylinder #20 High Exhaust Port Temp ....... 191 Probable Causes ............................................... 46
E821 Cyl #1 Exhaust Port Temp Deviating High.. 192 Recommended Repairs ..................................... 46
E822 Cyl #2 Exhaust Port Temp Deviating High.. 192 Electrical Connectors and Functions ..................... 11
E823 Cyl #3 Exhaust Port Temp Deviating High.. 193 Harness Wire Identification................................ 11
E824 Cyl #4 Exhaust Port Temp Deviating High.. 193 Junction Box ...................................................... 13
E825 Cyl #5 Exhaust Port Temp Deviating High.. 193 Sensors.............................................................. 13
E826 Cyl #6 Exhaust Port Temp Deviating High.. 194 Terminal Box ...................................................... 11
E827 Cyl #7 Exhaust Port Temp Deviating High.. 194 Electrical Power Supply ....................................... 288
E828 Cyl #8 Exhaust Port Temp Deviating High.. 195 Electronic Service Tool Will Not Communicate with
E829 Cyl #9 Exhaust Port Temp Deviating High.. 195 ECM (The Caterpillar Electronic Technician (ET)
E830 Cyl #10 Exhaust Port Temp Deviating Will Not Communicate With an Electronic Control
High ................................................................... 195 Module (ECM) and/or the Integrated Temperature
E831 Cyl #11 Exhaust Port Temp Deviating Sensing Module (ITSM))...................................... 47
High ................................................................... 196 Probable Causes ............................................... 47
E832 Cyl #12 Exhaust Port Temp Deviating Recommended Repairs ..................................... 47
High ................................................................... 196 Electronic Service Tools ........................................ 18
E833 Cyl #13 Exhaust Port Temp Deviating Caterpillar Electronic Technician (ET)................ 20
High ................................................................... 197 Electronic Troubleshooting ...................................... 9
E834 Cyl #14 Exhaust Port Temp Deviating Engine Coolant Temperature (High) ...................... 47
High ................................................................... 197 Engine Coolant Temperature (Low)....................... 49
E836 Cyl #16 Exhaust Port Temp Deviating Probable Causes ............................................... 49
High ................................................................... 198 Recommended Repairs ..................................... 49
E837 Cyl #17 Exhaust Port Temp Deviating Engine Cranks but Will Not Start ........................... 49
High ................................................................... 199
364
Index Section
Engine Misfires, Runs Rough or Is Unstable......... 50 Exhaust Port Temperature (Low) ........................... 62
Probable Causes ............................................... 50 Probable Causes ............................................... 62
Recommended Repairs ..................................... 50 Recommended Repairs ..................................... 62
Engine Monitoring System .................................... 22
Changing the Settings of the Monitoring
System ............................................................. 22 F
Default Settings of the Monitoring System......... 24
Engine Power Derating ...................................... 24 Factory Passwords ................................................ 30
Monitoring Parameters....................................... 22 Factory Passwords Worksheet .............................. 30
Programmable Parameters of the Integrated Flash Programming ............................................... 31
Temperature Sensing Module .......................... 27 Flash Programming............................................ 31
Engine Oil Filter Differential Pressure ................... 52 Fuel Energy Content.............................................. 63
Engine Oil Pressure (Low)..................................... 52 Fuel Metering Valve....................................... 63, 302
Engine Oil Temperature (High) .............................. 53 Fuel Pressure ........................................................ 63
Engine Overcrank.................................................. 54
Probable Causes ............................................... 54
Recommended Repairs ..................................... 54 G
Engine Overload.................................................... 55
Probable Causes ............................................... 55 Gas Fuel Differential Pressure (High).................... 63
Recommended Repairs ..................................... 55 Probable Causes ............................................... 63
Engine Overspeed................................................. 55 Recommended Repairs ..................................... 64
Probable Causes ............................................... 55 Gas Fuel Differential Pressure (Low) .................... 64
Engine Shutdown .................................................. 56 Recommended repairs....................................... 64
Probable Causes ............................................... 56 Gas Fuel Flow Rate (Low) ..................................... 64
Engine Shutdown (Unexpected)............................ 56 Recommended Repairs ..................................... 65
Probable Causes ............................................... 56 Gas Temperature (High) ........................................ 65
Recommended Repair ....................................... 57 Probable Causes ............................................... 65
Engine Shutdown without a Diagnostic Code........ 58 Recommended Repairs ..................................... 65
Probable Causes ............................................... 58 Generator Output Power Sensor ......................... 309
Recommended Repairs ..................................... 58
Engine Speed/Timing Sensor.............................. 295
Engine Speed/Timing Sensor - Calibrate ............ 359 I
Engine Starts but Stalls Immediately..................... 59
Probable Causes ............................................... 59 Ignition Transformers Primary Circuit .................. 316
Recommended Repairs ..................................... 59 Ignition Transformers Secondary Circuit and Spark
Engine Timing Does Not Match Programmed Plugs.................................................................. 327
Timing .................................................................. 59 Important Safety Information ................................... 2
Probable Causes ............................................... 59 Inlet Air Temperature (High) .................................. 66
Engine Will Not Crank ........................................... 60 Recommended Repairs ..................................... 66
Probable Causes ............................................... 60 Inspecting Electrical Connectors ......................... 333
Recommended Repairs ..................................... 60 Integrated Temperature Sensing Module
Event Codes ........................................................ 160 (ITSM)................................................................ 338
Active Event Codes.......................................... 161 Intermittent Engine Shutdown ............................... 66
Diagnostic Codes and Event Codes ................ 161 Probable Causes ............................................... 67
Logged Event Codes ....................................... 162 Recommended Repairs ..................................... 67
Operator Information........................................ 161
Other Symptoms .............................................. 161
Troubleshooting................................................ 161 J
Exhaust Port Temperature (High) .......................... 61
Probable Causes ............................................... 61 Jacket Water Inlet Pressure (High) ........................ 67
365
Index Section
Jacket Water Pressure (Low)................................. 68 MID 033 - CID 0405 - FMI 06 Ignition Transformer
Probable Causes ............................................... 68 Secondary #5 short to ground ............................. 83
Recommended Repairs ..................................... 68 MID 033 - CID 0407 - FMI 05 Ignition Transformer
Jacket Water to Engine Oil Differential Temperature Secondary #7 open circuit ................................... 84
(Low).................................................................... 68 MID 033 - CID 0407 - FMI 06 Ignition Transformer
Probable Causes ............................................... 68 Secondary #7 short to ground ............................. 84
Recommended Repairs ..................................... 68 MID 033 - CID 0409 - FMI 05 Ignition Transformer
Secondary #9 open circuit ................................... 84
M Secondary #9 short to ground ............................. 85
MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short Secondary #11 open circuit ................................. 85
to +batt................................................................. 73 MID 033 - CID 0411 - FMI 06 Ignition Transformer
MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short Secondary #11 short to ground ........................... 86
to ground.............................................................. 74 MID 033 - CID 0413 - FMI 05 Ignition Transformer
MID 033 - CID 0168 - FMI 02 System Voltage Secondary #13 open circuit ................................. 86
intermittent/erratic ................................................ 74 MID 033 - CID 0413 - FMI 06 Ignition Transformer
MID 033 - CID 0301 - FMI 05 Ignition Transformer Secondary #13 short to ground ........................... 87
Primary #1 open circuit........................................ 74 MID 033 - CID 0415 - FMI 05 Ignition Transformer
MID 033 - CID 0301 - FMI 06 Ignition Transformer Secondary #15 open circuit ................................. 87
Primary #1 short .................................................. 75 MID 033 - CID 0415 - FMI 06 Ignition Transformer
Primary #3 open circuit........................................ 75 MID 033 - CID 0590 - FMI 09 Unable to communicate
MID 033 - CID 0303 - FMI 06 Ignition Transformer with Engine ECM ................................................. 88
Primary #3 short .................................................. 75 MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation
MID 033 - CID 0305 - FMI 05 Ignition Transformer Sensor open/short to +batt .................................. 88
Primary #5 open circuit........................................ 76 MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation
MID 033 - CID 0305 - FMI 06 Ignition Transformer Sensor short to ground ........................................ 88
Primary #11 open circuit...................................... 78 MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation
Primary #11 short ................................................ 78 MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation
Primary #13 open circuit...................................... 79 MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation
Primary #13 short ................................................ 79 MID 033 - CID 1748 - FMI 05 Ignition Transformer
MID 033 - CID 0315 - FMI 05 Ignition Transformer Secondary #17 open circuit ................................. 91
Primary #15 open circuit...................................... 80 MID 033 - CID 1748 - FMI 06 Ignition Transformer
Primary #15 short ................................................ 80 MID 033 - CID 1750 - FMI 05 Ignition Transformer
MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor Secondary #19 open circuit ................................. 92
short to +batt ....................................................... 80 MID 033 - CID 1750 - FMI 06 Ignition Transformer
MID 033 - CID 0320 - FMI 08 Engine Speed/Timing Secondary #19 short to ground ........................... 93
signal abnormal ................................................... 81 MID 033 - CID 1752 - FMI 05 Ignition Transformer
MID 033 - CID 0401 - FMI 05 Ignition Transformer Primary #17 open circuit...................................... 93
Secondary #1 open circuit ................................... 81 MID 033 - CID 1752 - FMI 06 Ignition Transformer
MID 033 - CID 0401 - FMI 06 Ignition Transformer Primary #17 short to ground ................................ 93
Secondary #1 short to ground ............................. 82 MID 033 - CID 1754 - FMI 05 Ignition Transformer
MID 033 - CID 0403 - FMI 05 Ignition Transformer Primary #19 open circuit...................................... 94
Secondary #3 open circuit ................................... 82 MID 033 - CID 1754 - FMI 06 Ignition Transformer
MID 033 - CID 0403 - FMI 06 Ignition Transformer Primary #19 short to ground ................................ 94
Secondary #3 short to ground ............................. 82 MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
MID 033 - CID 0405 - FMI 05 Ignition Transformer circuit ................................................................... 94
Secondary #5 open circuit ................................... 83
366
Index Section
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short MID 036 - CID 0310 - FMI 05 Ignition Transformer
to ground.............................................................. 95 Primary #10 open circuit.................................... 106
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve MID 036 - CID 0310 - FMI 06 Ignition Transformer
malfunction .......................................................... 95 Primary #10 short .............................................. 107
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short MID 036 - CID 0312 - FMI 05 Ignition Transformer
to +batt................................................................. 96 Primary #12 open circuit.................................... 107
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short MID 036 - CID 0312 - FMI 06 Ignition Transformer
to ground.............................................................. 96 Primary #12 short .............................................. 107
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0314 - FMI 05 Ignition Transformer
open/short to +batt .............................................. 96 Primary #14 open circuit.................................... 108
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0314 - FMI 06 Ignition Transformer
short to ground .................................................... 97 Primary #14 short .............................................. 108
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure MID 036 - CID 0316 - FMI 05 Ignition Transformer
Sensor short to +batt ........................................... 97 Primary #16 open circuit.................................... 109
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure MID 036 - CID 0316 - FMI 06 Ignition Transformer
Sensor noisy signal.............................................. 98 Primary #16 short .............................................. 109
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor
open/short to +batt .............................................. 98 short to +batt ..................................................... 109
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet MID 036 - CID 0320 - FMI 08 Engine Speed/Timing
Pressure Sensor noisy signal .............................. 98 signal abnormal ................................................. 110
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Temperature open/short to +batt ......................... 99 to +batt............................................................... 110
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Temperature short to ground ............................... 99 +batt................................................................... 110
MID 036 - CID 0145 - FMI 03 12 Volt DC Power MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Supply short to +batt ........................................... 99 inputs ................................................................. 111
MID 036 - CID 0145 - FMI 04 12 Volt DC Power MID 036 - CID 0402 - FMI 05 Ignition Transformer
Supply short to ground ...................................... 100 Secondary #2 open circuit ................................. 111
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0402 - FMI 06 Ignition Transformer
intermittent/erratic .............................................. 100 Secondary #2 short to ground ........................... 111
MID 036 - CID 0172 - FMI 03 Intake Manifold Air MID 036 - CID 0404 - FMI 05 Ignition Transformer
Temp open/short to +batt................................... 100 Secondary #4 open circuit ................................. 112
MID 036 - CID 0172 - FMI 04 Intake Manifold Air MID 036 - CID 0404 - FMI 06 Ignition Transformer
Temp short to ground......................................... 101 Secondary #4 short to ground ........................... 112
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature MID 036 - CID 0406 - FMI 05 Ignition Transformer
open/short to +batt ............................................ 101 Secondary #6 open circuit ................................. 112
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature MID 036 - CID 0406 - FMI 06 Ignition Transformer
short to ground .................................................. 102 Secondary #6 short to ground ........................... 113
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0408 - FMI 05 Ignition Transformer
calibration required ............................................ 102 Secondary #8 open circuit ................................. 113
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC Power MID 036 - CID 0408 - FMI 06 Ignition Transformer
Supply short to +batt ......................................... 102 Secondary #8 short to ground ........................... 114
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC Power MID 036 - CID 0410 - FMI 05 Ignition Transformer
Supply short to ground ...................................... 103 Secondary #10 open circuit ............................... 114
Primary #2 open circuit...................................... 103 Secondary #10 short to ground ......................... 115
Primary #2 short ................................................ 104 Secondary #12 open circuit ............................... 115
MID 036 - CID 0308 - FMI 06 Ignition Transformer MID 036 - CID 0443 - FMI 03 Crank Terminate Relay
Primary #8 short ................................................ 106 short to +batt ..................................................... 117
367
Index Section
MID 036 - CID 0444 - FMI 05 Start Relay open MID 036 - CID 1751 - FMI 05 Ignition Transformer
circuit ................................................................. 118 Secondary #20 open circuit ............................... 128
MID 036 - CID 0444 - FMI 06 Start Relay short to MID 036 - CID 1751 - FMI 06 Ignition Transformer
ground................................................................ 118 Secondary #20 short to ground ......................... 129
MID 036 - CID 0445 - FMI 03 Run Relay short to MID 036 - CID 1753 - FMI 05 Ignition Transformer
+batt................................................................... 118 Primary #18 open circuit.................................... 129
MID 036 - CID 0524 - FMI 03 Desired Engine Speed MID 036 - CID 1753 - FMI 06 Ignition Transformer
Sensor short to +batt ......................................... 119 Primary #18 short to ground .............................. 129
MID 036 - CID 0524 - FMI 04 Desired Engine Speed MID 036 - CID 1755 - FMI 05 Ignition Transformer
Sensor short to ground ...................................... 119 Primary #20 open circuit.................................... 130
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil MID 036 - CID 1755 - FMI 06 Ignition Transformer
Pressure open/short to +batt ............................. 119 Primary #20 short to ground .............................. 130
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil MID 111 - CID 0591 - FMI 12 EEPROM checksum
Pressure short to ground ................................... 120 fault or ECM not programmed............................ 130
MID 036 - CID 1042 - FMI 09 Unable to communicate MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out
with ITSM........................................................... 120 Temp Sens short to +batt................................... 131
MID 036 - CID 1440 - FMI 09 Unable to communicate MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out
with Throttle Actuator Drv .................................. 121 Temp Sens short to ground ............................... 131
MID 036 - CID 1446 - FMI 05 Fuel Metering Module MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out
open circuit ........................................................ 121 Temp Sens open circuit ..................................... 131
MID 036 - CID 1446 - FMI 09 Unable to communicate MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out
with Fuel Metering Module ................................ 121 Temp Sens short to +batt................................... 132
MID 036 - CID 1446 - FMI 12 Fuel Metering Module MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out
malfunction ........................................................ 122 Temp Sens short to ground ............................... 132
MID 036 - CID 1446 - FMI 13 Fuel Metering Module MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out
calibration required ............................................ 122 Temp Sens open circuit ..................................... 132
MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In
Module malfunction............................................ 122 Temp Sens short to +batt................................... 133
MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In
Sensor open/short to +batt ................................ 122 Temp Sens short to ground ............................... 133
MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In
Sensor short to ground ...................................... 123 Temp Sens open circuit ..................................... 133
MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In
Sensor open/short to +batt ................................ 123 Temp Sens short to +batt................................... 134
Sensor short to ground ...................................... 123 Temp Sens short to ground ............................... 134
Sensor open/short to +batt ................................ 124 Temp Sens open circuit ..................................... 134
MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port
Sensor short to ground ...................................... 124 Temp Sensor short to +batt ............................... 135
Sensor open/short to +batt ................................ 124 Temp Sensor short to ground ............................ 135
Sensor short to ground ...................................... 125 Temp Sensor open circuit .................................. 136
Sensor open/short to +batt ................................ 125 Temp Sensor short to +batt ............................... 136
Sensor short to ground ...................................... 125 Temp Sensor short to ground ............................ 136
MID 036 - CID 1636 - FMI 09 Loss of Communication MID 111 - CID 1532 - FMI 05 Cyl #2 Exhaust Port
with Engine #2 (Slave) ....................................... 126 Temp Sensor open circuit .................................. 137
MID 036 - CID 1719 - FMI 03 Generator Output MID 111 - CID 1533 - FMI 03 Cyl #3 Exhaust Port
Power Sensor open/short to +batt ..................... 126 Temp Sensor short to +batt ............................... 137
Power Sensor short to ground ........................... 126 Temp Sensor short to ground ............................ 138
Power Sensor malfunction ................................. 127 Temp Sensor open circuit .................................. 138
MID 036 - CID 1720 - FMI 09 Unable to communicate MID 111 - CID 1534 - FMI 03 Cyl #4 Exhaust Port
with Turbo Compressor Bypass Valve Solenoid.. 127 Temp Sensor short to +batt ............................... 138
Secondary #18 open circuit ............................... 127 Temp Sensor short to ground ............................ 139
Secondary #18 short to ground ......................... 128 Temp Sensor open circuit .................................. 139
368
Index Section
Temp Sensor open circuit .................................. 140 Temp Sensor open circuit .................................. 152
MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port
Temp Sensor short to +batt ............................... 147
MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port P
Temp Sensor short to ground ............................ 147
MID 111 - CID 1541 - FMI 05 Cyl #11 Exhaust Port Programming Parameters...................................... 29
Temp Sensor open circuit .................................. 147 PWM Sensor ....................................................... 346
MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port R
MID 111 - CID 1542 - FMI 05 Cyl #12 Exhaust Port Replacing the ECM................................................ 38
Temp Sensor open circuit .................................. 149 Replacing the ITSM ............................................... 40
MID 111 - CID 1543 - FMI 04 Cyl #13 Exhaust Port S
MID 111 - CID 1543 - FMI 05 Cyl #13 Exhaust Port Self-Diagnostics..................................................... 10
Temp Sensor open circuit .................................. 150 Symptoms.............................................................. 44
MID 111 - CID 1544 - FMI 03 Cyl #14 Exhaust Port Diagnostic Codes and Event Codes .................. 44
Temp Sensor short to +batt ............................... 150 Operator Information.......................................... 44
MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port Other Symptoms ................................................ 44
Temp Sensor open circuit .................................. 151
369
Index Section
System Configuration Parameters......................... 31

Air/Fuel Ratio Control......................................... 33
Governing of the Air/Fuel Ratio Control and of the
Engine Speed................................................... 32
Information for the ECM..................................... 38
“Monitoring and Protection” ............................... 37
Override Parameters.......................................... 38
Power Monitoring ............................................... 37
Speed Control .................................................... 34
Start/Stop Control Parameters........................... 36
System Overview..................................................... 9
Air/Fuel Ratio Control........................................... 9
Engine Monitoring and Protection...................... 10
Engine Speed Governing..................................... 9
Ignition Control................................................... 10
Introduction .......................................................... 9
Start/Stop Sequencing......................................... 9
System Voltage...................................................... 69
Probable Causes ............................................... 69
Table of Contents..................................................... 3
Throttle Actuator .................................................. 353
Troubleshooting Data Sheet .................................. 42
Report the Service Information .......................... 43
Troubleshooting Section .......................................... 9
Troubleshooting with a Diagnostic Code ............... 72
Troubleshooting with an Event Code ................... 160
Troubleshooting without a Diagnostic Code .......... 44
Turbocharger Turbine Temperature (High)............. 69
Probable Causes ............................................... 69
Turbocharger Turbine Temperature (Low).............. 70
Probable Causes ............................................... 70
370
Index Section
371
Index Section
©2003 Caterpillar
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Troubleshooting JKK Caterpillar G3516B

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Troubleshooting JKK Caterpillar G3516B

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RENR5979

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

Troubleshooting Section Air/Fuel Ratio Control

• Air/Fuel ratio control Start/Stop Sequencing

Engine Monitoring and Protection • Diagnostic

Problems with the electronic system such as an • Active

i01816322 Terminal Box

Harness Wire Identification

RD Red Rear view of the engine

For example, a code of J011-RD on the schematic

The schematic also identifies the size of the wire.

The junction box contains all of the circuit breakers

The sensors also enable the activation of alarms, of

Pressure switch for the coolant pump (inlet) (4) – A

Engine coolant temperature sensor (5) – The

To convert kPa to psi, divide the kPa by 6.89. To

Inlet air temperature sensor (8) – A sensor for

Detonation sensors (9) – The detonation sensors

Speed/timing sensor (10) – The engine speed/timing

Integrated Temperature Sensing Module • Program parameters.

The Integrated Temperature Sensing Module

The ITSM also calculates the average temperature

• The average temperature is higher than the limit

• The average temperature is lower than the limit

• The temperature of a cylinder deviates

Electronic Service Tools

Caterpillar Electronic Service Tools are designed to

Note: Either the 171-4401 Communication Adapter

Caterpillar Electronic Technician

2. Connect cable (2) to the RS232 serial port of

3. Connect cable (2) to communication adapter (3).

4. Connect cable (4) to communication adapter (3).

5. Connect cable (4) to cable (5).

6. Connect cable (5) to the service tool connector

7. Set the engine control to the STOP mode.

If Cat ET displays “Duplicate Type on data link.

The harness inside the terminal box for the

Check the continuity between terminals J3-29

Connecting Cat ET with the 7X-1701

1. Set the engine control to the OFF/RESET mode.

2. Connect cable (2) to the RS232 serial port of

3. Connect cable (2) to communication adapter (4).

4. Connect cable (3) to communication adapter (4).

5. Connect cable (3) to cable (5).

6. Connect cable (5) to the service tool connector

7. Set the engine control to the ON mode. The

If Cat ET displays “Duplicate Type on data link.

Engine Monitoring System The new settings will be effective immediately.

SMCS Code: 7490 Monitoring Parameters

“High Engine Oil Temperature” “Low Gas Fuel Differential Pressure”

If one of these three deratings is activated, the

“Low System E043 (1) Warning 20 volts 20

“High Engine Oil E020 (1) Warning 102 C Customer 85 to 102 C

“High Inlet Air E027 (1) On 69 C 32 to 85 C

Separate timers are used in the master ECM for

For example, the warning for “High Engine Coolant

Conditions for Parameters

The conditions are designed to eliminate false

If the trip point for a shutdown is programmed to

Programmable Parameters of the

“High Engine Oil E020 (1) Warning 102 C Customer 85 to 102 C

“High Inlet Air E027 (1) On 69 C 32 to 85 C