Beruflich Dokumente
Kultur Dokumente
October 2010
Troubleshooting
G3600 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
BEN1-Up (Engine)
4ZS1-Up (Engine)
SAFETY.CAT.COM
i03991620
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identied by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identied by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without rst
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specic rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this
product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
cations including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5910-06 3
Table of Contents
Table of Contents
Troubleshooting Section
Introduction
General Information ................................................ 4
Welding Precaution ................................................. 4
Electronic Service Tools .......................................... 4
Troubleshooting Data Sheet ................................... 8
Electronic System Overview
System Overview ................................................... 11
Component Location ............................................. 18
Engine Monitoring System .................................... 24
Diagnostic Capabilities ......................................... 25
Programmable Parameters ................................... 25
Electrical Connectors ............................................ 26
Conguration Parameters
Conguration Parameters ..................................... 30
Diagnostic Trouble Codes
Diagnostic Trouble Codes ..................................... 39
Event Codes
Event Codes ........................................................ 51
Symptom Troubleshooting
Symptom Troubleshooting .................................... 67
Air Starting Motor Problem ................................... 67
Coolant Flow Is Low ............................................. 68
Coolant Level Is Low ............................................ 69
Coolant Pressure Is High ...................................... 69
Coolant Pressure Is Low ....................................... 70
Coolant Temperature Is High ................................ 71
Coolant Temperature Is Low ................................. 73
Crankcase Pressure Is High ................................. 74
Cylinder Is Noisy ................................................... 75
Detonation Occurrence ......................................... 76
Electrohydraulic System Oil Pressure Is Low ....... 78
Engine Cranks but Does Not Start ........................ 80
Engine Has Mechanical Noise (Knock) ................ 82
Engine Misres, Runs Rough or Is Unstable ........ 83
Engine Overcrank Occurrence ............................. 87
Engine Overloads ................................................. 88
Engine Overspeeds .............................................. 89
Engine Shutdown Is Intermittent ........................... 90
Engine Shutdown Occurrence .............................. 91
Engine Shutdown or Start Inhibit Initiated by Driven
Equipment ........................................................... 92
Engine Stalls Immediately After Starting .............. 93
Engine Vibration Is Excessive .............................. 93
Exhaust Emission and Fuel Consumption Are
High ..................................................................... 94
Exhaust Temperature Is High ............................... 95
Exhaust Temperature Is Low .............................. 100
Fuel Energy Content Problem ............................ 103
Fuel Pressure Problem ....................................... 105
Fuel Temperature Is High ................................... 106
Inlet Air Is Restricted ........................................... 107
Inlet Air Temperature Is High .............................. 108
Oil Consumption Is Excessive ............................. 110
Oil Filter Differential Pressure Problem ............... 111
Oil Level Is Low ................................................... 111
Oil Pressure Is High ............................................. 112
Oil Pressure Is Low .............................................. 113
Oil Temperature Is High ....................................... 114
Prelubrication Pressure Is Low ............................ 115
Spark Plug Life Is Short ....................................... 116
Temperature Ratio of Coolant to Oil Is Low ......... 116
Turbocharger Turbine Temperature Is High ......... 117
Circuit Tests
Air/Fuel Pressure Module - Test .......................... 119
Choke Actuator - Test ......................................... 127
Cylinder Combustion - Test ................................. 134
Cylinder Firing Signal - Test ................................ 142
Detonation - Test ................................................. 158
Electrical Power Supply - Test ............................ 174
Exhaust Temperature - Test ................................ 181
Fuel Actuator - Test ............................................. 193
Fuel Control - Test .............................................. 200
Ignition Primary - Test ......................................... 215
Ignition Secondary - Test .................................... 230
Indicator Lamp - Test .......................................... 237
Integrated Combustion Sensing Module - Test ... 245
Prelubrication - Test ............................................ 253
Sensor Signal (Analog, Active) - Test ................. 274
Sensor Signal (Analog, Passive) - Test .............. 284
Sensor Signal (PWM) - Test ............................... 289
Sensor Supply - Test ........................................... 299
Speed Control (Switch) - Test ............................. 313
Speed/Timing - Test ............................................ 318
Starting - Test ...................................................... 325
Wastegate - Test ................................................. 339
Service
Customer Passwords .......................................... 348
Factory Passwords ............................................. 348
ECM Will Not Accept Factory Passwords ........... 349
Electronic Service Tool Does Not Communicate .. 349
ECM Software - Install ........................................ 351
ECM - Replace ................................................... 352
Control Module - Replace (ICSM) ....................... 354
Electrical Connectors - Inspect ........................... 356
Unburned Gas - Purge ........................................ 359
Air/Fuel Pressure Module - Calibrate .................. 360
Index Section
Index ................................................................... 362
4 RENR5910-06
Troubleshooting Section
Troubleshooting Section
Introduction
i02725485
General Information
SMCS Code: 1000
As a reference, simplied schematics for each of the
engine's subsystems are included with each of the
circuit tests that are in this manual. For an accurate
representation of the entire electrical schematic that
is for your application, refer to the Electrical System
Schematic.
During troubleshooting, inspect all harness
connections before any component is replaced. If
these connections are not clean and tight, continuous
electrical problems or intermittent electrical problems
can result. Check that the wires are pushed into
the connectors completely. Make sure that the
connections are tight before other tests are made.
Failure of an electrical component may cause the
failure of other components. Always attempt to
correct the cause of an electrical failure before you
replace a component. If wire insulation is punctured,
repair the damage. Seal the damaged wires with
8T-0065 Silicone Sealant. Cover the sealant with
two layers of 1P-0810 Electrical Tape.
i03245492
Welding Precaution
SMCS Code: 1000
Proper welding procedures are necessary in order
to avoid damage to the engine's Electronic Control
Module (ECM), to sensors, and to associated
components. Components that are for the driven
equipment should also be considered. Perform
welding on the engine according to the following
procedure:
1. Set the engine control to the STOP position.
2. Ensure that the fuel supply to the engine is turned
off.
3. Disconnect the negative terminal from the battery.
4. Disconnect all electronic components from the
wiring harnesses. This includes the following
components:
Sensors
Diagnostic tests
Calibrations
Flash programming
Parameters
Event codes
Diagnostic codes
Engine conguration
Always use the latest revision of Cat ET. The media
is available on CD and the media can also be
downloaded from various Caterpillar web sites.
Table 3
Software, JEBD3003, CATERPILLAR
ELECTRONIC TECHNICIAN
6 RENR5910-06
Troubleshooting Section
Once you have downloaded Cat ET onto your
PC, you will need a license from your Caterpillar
dealer in order to use the software. Various licenses
are available for different users with different
requirements. Consult your Caterpillar dealer.
Note: For more information regarding the use of
Cat ET and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
software.
Connecting Cat ET
Connecting the Communication Adapter
Table 4 lists the standard hardware that is required in
order to connect Cat ET.
Note: The 275-5120 Communication Adapter
Gp was canceled and replaced by the 317-7484
Communication Adapter Gp. However, the 275-5120
Communication Adapter Gp can still be used.
Table 4
Standard Hardware for the Use of Cat ET
Part Number Description
N/A Personal Computer (PC)
317-7484
Communication Adapter
Gp
Components of the 317-7484 Communication
Adapter Gp
317-7485
Communication Adapter
(3)
353-5083 Cable As (USB)
327-8981 Cable As (DATA LINK)
Tool Operating Manual & Software CD ROM,
NETG5057, Communication Adapter 3
Follow the instructions for the communication
adapter. Use the following procedure in order to
connect Cat ET and the communication adapter to
a PC.
1. Remove the electrical power from the ECM.
g02051513
Illustration 1
(1) PC
(2) 353-5083 Cable As (USB)
(3) 317-7485 Communication Adapter (3)
(4) 327-8981 Cable As (DATA LINK)
2. Connect cables (2) and (4) to communication
adapter (3).
Note: The communication adapter will power up
when the adapter is connected to a PC or to an ECM
that is powered up.
3. Connect cable (2) to the USB port of the PC.
4. Connect cable (4) to a service tool connector.
5. Restore electrical power to the ECM. Verify that
the POWER indicator on the communication
adapter is illuminated. Make sure that the PC is
powered up.
6. Establish communication between Cat ET and the
ECM. If Cat ET indicates that there is more than
one ECM, select the engine ECM.
7. If Cat ET and the communication adapter
do not communicate with the ECM, refer to
Troubleshooting, Electronic Service Tool Will Not
Communicate with ECM.
Refer to Troubleshooting, Electronic Service Tool
Does Not Communicate if any of the following
conditions exist:
Control of ignition
Start/stop control
Start-up
No feedback
Combustion feedback
Prechamber calibration
Error for the inlet manifold air pressure This
is the absolute difference between the actual inlet
manifold air pressure and the desired inlet manifold
air pressure.
In each of these modes, the air/fuel ratio is controlled
by either the air choke actuator or the wastegate
actuator: only one of the actuators operates at any
time. The active actuator is determined by the ability
to provide the desired inlet manifold air pressure.
Both of the actuators regulate the air ow. The
regulation is based on an error that is calculated for
the inlet manifold air pressure. Both of the actuators
are controlled by a map for the air/fuel ratio.
RENR5910-06 13
Troubleshooting Section
The software is also programmed to correct the
fuel ow according to the temperature of the jacket
water and the engine speed. This occurs when the
coolant temperature is not at the water temperature
regulator's rated temperature. If the temperature is
cooler than the rating, the fuel in the cylinder head is
also cooler and more dense. Because the denser
fuel provides an air/fuel mixture that is richer than
the desired mixture, the calculation of the fuel ow
is corrected for the lower temperature. This tends
to lean the actual air/fuel ratio. If the temperature is
warmer than the rating, the fuel in the cylinder head
is less dense. Because the warmer fuel provides a
leaner air/fuel mixture, the calculation of the fuel ow
is corrected for the higher temperature. This tends
to richen the air/fuel ratio.
Note: When the engine is operating in combustion
feedback, the temperature of the jacket water only
affects the fuel correction factor.
The relationship of the modes of operation to the
engine load and the transitions between the modes
are represented in Illustration 5. Illustration 5 is for
engines with the 1.9 and earlier versions of software.
g01648774
Illustration 5
Schematic of the modes of operation, of transitions, and of the engine load for version 1.9 software
14 RENR5910-06
Troubleshooting Section
The relationship of the modes of operation to the
engine load and the transitions between the modes
are represented in Illustration 6. Illustration 6 is for
engines with the 2.0 software version. The modes of
operation are explained in more detail below.
g01649253
Illustration 6
Schematic of the modes of operation, of transitions, and of the engine load for version 2.0 software
Note: Control of the inlet manifold air pressure is not
determined directly by the engine load. The active
actuator is determined by the ability to provide the
desired inlet manifold air pressure.
At loads that are approximately less than 40 percent,
the air/fuel ratio is controlled by the air choke
actuator. The air choke controls the ow of air during
engine start-up. The air choke continues to control
the air ow during the increase in the engine speed
and in load. As the engine speed and load are
increased, the required inlet manifold air pressure
increases. The air choke opens in order to provide
more combustion air. When the air choke becomes
fully open, the air choke cannot further increase the
air ow. Then, the wastegate becomes active.
Conversely, the required inlet manifold air pressure is
reduced as the engine speed and load are reduced.
As the requirement for combustion air is reduced, the
wastegate opens. When the wastegate is fully open,
the wastegate cannot regulate a smaller quantity of
combustion air. Then, the air choke becomes active
again.
During start-up, the air choke is maintained at a xed
position until ten seconds after the engine achieves
the desired speed. This enables a correction of the
excessive error for inlet manifold air pressure. The
starting position for the air choke is set in the Cat ET
conguration screen. The starting position depends
on the number of cylinders. Typically, the starting
position is closed 60 to 80 percent. If the starting
position is set too high, the engine will not get enough
combustion air.
RENR5910-06 15
Troubleshooting Section
If the starting position is set too high and the engine
speed does not increase to the desired speed, the
programming in the software opens the air choke in
steps until the engine speed increases. This enables
a steady increase of the engine speed until the
desired speed is achieved.
The maximum position for the air choke can also be
set in the Cat ET conguration screen. The maximum
position is set in order to enable a sufcient ow of
air for combustion when the engine is running at no
load. Typically, the maximum position is closed 75
to 85 percent.
At ten seconds after the engine reaches the desired
speed, the air/fuel ratio is controlled directly by the
map for the air/fuel ratio. No correction factors are
related to any feedback: this is a correction factor
of 100 percent. This mode of operation uses no
feedback.
Normally, the map is calculated in order to provide
a low air/fuel ratio for loads up to approximately 40
percent. This provides a mixture that is sufciently
rich for operation at low temperatures. The air/fuel
ratio will continue to be controlled by the map until
the conditions allow operation in one of the feedback
modes or in the prechamber calibration mode.
A low air/fuel ratio is critical for operation after
start-up in order to keep the air choke partially closed.
Otherwise, the air choke may open fully and the
wastegate will control the inlet manifold air pressure.
This results in a period of misre and of excessive
fuel ow. Because of the excessive fuel ow, the
calculated engine load is excessive.
Programmable Desired Engine Exhaust Port
Temp parameter This parameter is set in the Cat
ET conguration screen. This is the desired exhaust
port temperature for a load of 25 percent. The control
uses this parameter during operation in the exhaust
port temperature feedback mode.
g00914203
Illustration 7
Graph of the calculated desired exhaust port temperature
The calculated desired exhaust port temperature
varies from the programmable Desired Engine
Exhaust Port Temp by 1 C (1.8 F) per 1 percent
of engine load. For each 1 percent of engine load
below 25 percent, the calculated desired exhaust
port temperature increases by 1 C (1.8 F). For
each 1 percent of engine load above 25 percent,
the calculated desired exhaust port temperature
decreases by 1 C (1.8 F).
Control's average exhaust port temperature
The ICSM continuously calculates the average
exhaust port temperature. If the actual temperature
of any cylinder exhaust port is less than 273 C
(523 F), the ICSM substitutes a temperature of
273 C (523 F) for that cylinder. This temperature
is substituted for any number of cylinders with an
exhaust port temperature that is less than 273 C
(523 F). The temperature is used in the calculation
of the average for all of the monitored cylinders.
Exhaust port temperature feedback In this mode
of operation, the air/fuel ratio is controlled in order
to achieve a desired exhaust port temperature.
Each cylinder exhaust port has a thermocouple that
is monitored by an ICSM. The ICSM monitors the
actual exhaust port temperatures for one bank of
cylinders. The ICSM calculates an average exhaust
port temperature for the bank of cylinders. The ECM
calculates the desired exhaust port temperature
for the load. The ECM sends the desired exhaust
port temperature to the ICSM. The ICSM calculates
the difference between the average exhaust
port temperature and the desired exhaust port
temperature. The ICSM sends a fuel correction factor
to the ECM. The ECM uses the fuel correction factor
to control the air choke actuator in order to maintain
the desired exhaust temperature.
16 RENR5910-06
Troubleshooting Section
After start-up, the exhaust port temperature feedback
mode is activated for the following conditions:
Viewing parameters
Parameter programming
Diagnostic code
Event code
Diagnostic Code A diagnostic code indicates
an electrical problem such as a short circuit or an
open circuit in the engine's wiring or in an electrical
component.
Event Code An event code is generated by the
detection of an abnormal engine operating condition.
For example, an event code will be generated if the
oil pressure is too low. In this case, the event code
indicates the symptom of a problem. Event codes
indicate abnormal operating conditions or mechanical
problems rather than electrical problems.
Codes can have two different states:
Active
Logged
Active Codes
An active code indicates that a problem is present.
Service the active code rst. For the appropriate
troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
Primary governor
Auxiliary governor
Air choke
Coolant level
Fuel supply
RENR5910-06 59
Troubleshooting Section
Exhaust system
Oil level
Oil supply
Wiring
Connectors
Be sure to check the connectors. This is very
important for problems that are intermittent. Refer to
Troubleshooting, Electrical Connectors - Inspect.
If these steps do not resolve the problem, refer to
Table 13 for the procedure to troubleshoot the event
code.
Parameter Settings of the Engine
Monitoring System
The default settings for the parameters are
programmed at the factory. If the delay time or the trip
point are programmable, the minimum and maximum
ranges will be listed in Table 15.
The parameter settings for the engine monitoring
system can also be viewed on Caterpillar Electronic
Technician (ET). In order to viewthe parameters of the
engine monitoring system, refer to Troubleshooting,
Engine Monitoring System.
Table 15
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E004(3) Engine
Overspeed
Shutdown
(900 rpm rating)
(3)
Shutdown
Always
On
Factory 1017 rpm 800 to 1300 rpm 0 0
E004(3) Engine
Overspeed
Shutdown
(1000 rpm
rating)
(3)
Shutdown
Always
On
Factory 1130 rpm 800 to 1300 rpm 0 0
E017(1) High
Engine Coolant
Temperature
Warning
88 C (190 F)
jacket water
(1)
Warning
On Customer
93 C
(199 F)
60
E016(3) High
Engine Coolant
Temperature
Shutdown
88 C (190 F)
jacket water
(3)
Shutdown
Always
On
Customer
98 C
(208 F)
80 to 129 C
(185 to 264 F)
20
1 to 60
(continued)
60 RENR5910-06
Troubleshooting Section
(Table 15, contd)
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E017(1) High
Engine Coolant
Temperature
Warning
99 C (210 F)
jacket water
(1)
Warning
On Customer
105 C
(221 F)
60
E016(3) High
Engine Coolant
Temperature
Shutdown
99 C (210 F)
jacket water
(3)
Shutdown
Always
On
Customer
110 C
(230 F)
80 to 129 C
(185 to 264 F)
20
1 to 60
E017(1) High
Engine Coolant
Temperature
Warning
110 C (230 F)
jacket water
(1)
Warning
On Customer
115 C
(239 F)
60
E016(3) High
Engine Coolant
Temperature
Shutdown
110 C (230 F)
jacket water
(3)
Shutdown
Always
On
Customer
120 C
(248 F)
80 to 129 C
(185 to 264 F)
20
1 to 60
E020(1) High
Engine Oil
Temperature
Warning
(1)
Warning
On Customer
88 C
(190 F)
85 to 102 C
(185 to 215 F)
5
E019(3) High
Engine Oil
Temperature
Shutdown
(3)
Shutdown
Always
On
Factory
90 C
(194 F)
85 to 104 C
(185 to 219 F)
1
1 to 60
E027(1) High
Inlet Air
Temperature
Warning (high
load)
32 C (90 F)
SCAC
(1)
Warning
On
57 C
(135 F)
E026(3) High
Inlet Air
Temperature
Shutdown (high
load)
32 C (90 F)
SCAC
(3)
Shutdown
Always
On
Customer
60 C
(140 F)
32 to 120 C
(90 to 248 F)
20 1 to 60
(continued)
RENR5910-06 61
Troubleshooting Section
(Table 15, contd)
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E027(1) High
Inlet Air
Temperature
Warning (high
load)
43 C (109 F)
SCAC
(1)
Warning
On
65 C
(149 F)
E026(3) High
Inlet Air
Temperature
Shutdown (high
load)
43 C (109 F)
SCAC
(3)
Shutdown
Always
On
Customer
68 C
(154 F)
32 to 120 C
(90 to 248 F)
20 1 to 60
E027(1) High
Inlet Air
Temperature
Warning (high
load)
54 C (129 F)
SCAC
(1)
Warning
On
72 C
(162 F)
E026(3) High
Inlet Air
Temperature
Shutdown (high
load)
54 C (129 F)
SCAC
(3)
Shutdown
Always
On
Customer
75 C
(167 F)
32 to 120 C
(90 to 248 F)
20 1 to 60
E027(1) High
Inlet Air
Temperature
Warning (low
load)
32 C (90 F)
SCAC
(1)
Warning
On
72 C
(162 F)
E026(3) High
Inlet Air
Temperature
Shutdown (low
load)
32 C (90 F)
SCAC
(3)
Shutdown
Always
On
Customer
75 C
(167 F)
32 to 100 C
(90 to 212 F)
20 1 to 60
E027(1) High
Inlet Air
Temperature
Warning (low
load)
43 C (109 F)
SCAC
(1)
Warning
On
77 C
(171 F)
E026(3) High
Inlet Air
Temperature
Shutdown (low
load)
43 C (109 F)
SCAC
(3)
Shutdown
Always
On
Customer
80 C
(176 F)
32 to 100 C
(90 to 212 F)
20 1 to 60
(continued)
62 RENR5910-06
Troubleshooting Section
(Table 15, contd)
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E027(1) High
Inlet Air
Temperature
Warning (low
load)
54 C (129 F)
SCAC
(1)
Warning
On
82 C
(180 F)
E026(3) High
Inlet Air
Temperature
Shutdown (low
load)
54 C (129 F)
SCAC
(3)
Shutdown
Always
On
Customer
85 C
(185 F)
32 to 100 C
(90 to 212 F)
20 1 to 60
E038(1) Low
Engine Coolant
Temperature
Warning
(1)
Warning
On Customer
25 C
(77 F)
5 to 80 C
(41 to 176 F)
20 1 to 60
E100(1) Low
Engine Oil
Pressure
Warning (under
600 rpm)
(1)
Warning
N/A
175 kPa
(25 psi)
N/A 5
E040(3) Low
Engine Oil
Pressure
Shutdown
(under 600 rpm)
(3)
Shutdown
Always
On
N/A
100 kPa
(14.5 psi)
N/A
0
This item is not
programmable.
E100(1) Low
Engine Oil
Pressure
Warning (over
600 rpm)
(1)
Warning
N/A
400 kPa
(58 psi)
N/A 5
E040(3) Low
Engine Oil
Pressure
Shutdown (over
600 rpm)
(3)
Shutdown
Always
On
N/A
350 kPa
(51 psi)
N/A
0
This item is not
programmable.
E042(3) Low
System Voltage
Shutdown
(3)
Shutdown
Always
On
N/A 18 volts N/A 10
E043(1) Low
System Voltage
Warning
(1)
Warning
On N/A 20 volts N/A
20
E050(1) High
System Voltage
Warning
(1)
Warning
On N/A 32 volts N/A 20
This item is not
programmable.
(continued)
RENR5910-06 63
Troubleshooting Section
(Table 15, contd)
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E123(1) Jacket
Water to Engine
Oil Temp Low
Warning
(1)
Warning
On Customer
10 C
(50 F)
E124(3) Jacket
Water to Engine
Oil Temp Low
Shutdown
(3)
Shutdown
Always
On
Factory
15 C
(59 F)
0 to 80 C
(32 to 176 F)
60 1 to 60
E125(1) Engine
Oil Pressure
High Warning
(1)
Warning
On Customer
650 kPa
(94 psi)
E126(3) Engine
Oil Pressure
High Shutdown
(3)
Shutdown
Always
On
Customer
1000 kPa
(145 psi)
600 to 1200 kPa
(87 to 174 psi)
25 1 to 60
E129(1) Engine
Oil Filter Diff
Pressure High
Warning
(1)
Warning
On Customer
100 kPa
(15 psi)
15
E130(3) Engine
Oil Filter Diff
Pressure High
Shutdown
(3)
Shutdown
Always
On
Factory
300 kPa
(44 psi)
0 to 350 kPa
(0 to 51 psi)
25
1 to 60
E223(1)
High Gas
Temperature
(1)
Warning
On Customer
60 C
(140 F)
0 to 60 C
(140 F)
20 1 to 60
E224(3) High
Jacket Water
Inlet Pressure
(3)
Shutdown
Always
On
N/A
462 kPa
(67 psi)
N/A 10
This item is not
programmable.
E228(1) Low
Jacket Water
Outlet Pressure
(1)
Warning
On
124 kPa
(18 psi)
E228(3) Low
Jacket Water
Outlet Pressure
(3)
Shutdown
Always
On
N/A
103 kPa
(15 psi)
N/A 10
This item is not
programmable.
E242(2) Engine
Overload
(2)
Derate
Always
On
N/A
110 percent
of rated
load
N/A 0
This item is not
programmable.
E337(1) High
Engine Oil to
Engine Coolant
Diff Temp
(1)
Warning
On Customer
10 C
(50 F)
60
E337(3) High
Engine Oil to
Engine Coolant
Diff Temp
(3)
Shutdown
Always
On
Factory
13 C
(55 F)
0 to 80 C
(176 F)
60
1 to 60
E384(1) Left Air
Inlet Restriction
(1)
Warning
Always
On
N/A N/A 0
This item is not
programmable.
E384(3) Left Air
Inlet Restriction
(3)
Shutdown
Off Customer
5.23 kPa
(0.76 psi)
N/A 20 1 to 60
(continued)
64 RENR5910-06
Troubleshooting Section
(Table 15, contd)
Default Settings of the Programmable Monitoring System
Parameter Action
Default
State
Security
Level
Password
Trip Point Range
Delay in
Seconds
Range of
the Delay in
Seconds
E385(1) Right
Air Inlet
Restriction
(1)
Warning
Always
On
N/A N/A 0
This item is not
programmable.
E385(3) Right
Air Inlet
Restriction
(3)
Shutdown
Off Customer
5.23 kPa
(0.76 psi)
N/A 20 1 to 65
E864 Low Gas
Fuel Differential
Pressure
(1)
Warning
On Customer
5 kPa
(0.7 psi)
0 to 100 kPa
(14.5 psi)
60 1 to 60
E865 High Gas
Fuel Differential
Pressure
(1)
Warning
On Customer
160 kPa
(23 psi)
0 to 195 kPa
(28 psi)
30 1 to 60
Conditions for Parameters
Some of the programmable parameters are
dependent on the status of an 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
16.
Table 16
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
High Oil Filter Differential Pressure
High Fuel Temperature
The crank terminate relay is energized for more than 30 seconds.
Low Fuel Pressure The fuel control relay is energized.
High Jacket Water to Engine Oil Temp Differential The crank terminate relay is energized for more than 30 seconds.
High System Voltage None
High Inlet Air Temperature at Low Engine Load
High Inlet Air Temperature at High Engine Load
The crank terminate relay is energized for more than 30 seconds.
RENR5910-06 65
Troubleshooting Section
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.
Integrated Combustion Sensing
Module (ICSM)
The ICSM monitors the temperatures of the cylinder
exhaust ports, the inlets of the turbocharger turbine,
and the outlets of the turbocharger turbines. The
ICSM also monitors the combustion sensors.
If a temperature exceeds an acceptable range, the
ICSM can initiate a warning or a shutdown. Both of
the responses are available for all of the parameters.
Note: To initiate the responses, the ICSM sends
commands to the ECM via the Cat Data Link.
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. Use Cat
ET to perform the following activities:
Electrical problem
Insufcient ow of coolant
Insufcient ow of coolant
Recommended Actions
Check the Coolant Level and Inspect the
Cooling System for Leaks
Check coolant level. If the coolant level is low, inspect
the cooling system for leaks.
If the coolant level is low, ll the cooling system. If
leaks are found, make the necessary repairs.
Check the Flow of Coolant
Use Cat ET to observe the pressure at the jacket
water outlet when the engine is not running. Then
observe the reading during engine operation.
If the reading is not reasonable or if the reading is
not within specications, install a pressure gauge
near the pressure sensor at the jacket water outlet.
Compare the gauge reading with the reading from
Cat ET.
If the readings from the comparative gauge do not
agree approximately with Cat ET, troubleshoot the
circuit for the pressure sensor at the jacket water
outlet. Refer to Troubleshooting, Sensor Signal
(PWM) - Test.
If the readings from the comparative gauge agree
approximately with Cat ET, check the following
components:
Exhaust restriction
Excessive load
A cylinder is misring.
Faulty sensor
Insufcient lubrication
Excessive load
Misre
Coolant in a cylinder
Mechanical problem
Recommended Repairs
Excessive Load
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment
and test the engine.
Misre
If a cylinder is misring, the other cylinders can
be overloaded. Overloading will cause the other
cylinders to detonate. To eliminate the detonation,
rst eliminate the misre. Refer to Troubleshooting,
Engine Misres, Runs Rough or Is Unstable.
Needle Valves
Misre can occur in the precombustion chamber if the
air/fuel mixture is too lean. If a cylinder is misring,
the other cylinders can be overloaded. Overloading
will cause the other cylinders to detonate.
Determine whether the adjustment of the needle
valves is correct. If the needle valves require
adjustment, fully close all of the needle valves. Then
open all of the needle valves for four full turns.
Operate the engine and use an emissions analyzer
to obtain the correct level of exhaust emissions.
Note: The recommended minimum position of the
needle valve should not be less than two turns open.
Check the Inlet Air Temperature
High inlet air temperature can cause detonation.
Check the inlet air temperature. Check for an event
code for the inlet air temperature.
If an event code for the inlet air temperature is active,
refer to Troubleshooting, Inlet Air Temperature Is
High.
78 RENR5910-06
Troubleshooting Section
Air/Fuel Ratio
An air/fuel mixture that is too rich will cause
detonation. A change in the fuel energy content
will change the air/fuel ratio. Obtain a fuel analysis.
Enter the data into Caterpillar Software Program,
LEKQ6378, Methane Number Program. Use Cat
ET to program the correct LHV and specic gravity
of the fuel into the ECM.
The fuel supply pressure must be adequate and
stable.
Make sure that the electrohydraulic actuator for the
fuel is operating correctly.
Verify that the exhaust emissions are correct.
Coolant in a Cylinder
Under some circumstances, detonation can occur
if a solution of water and glycol leaks into a
precombustion chamber and the coolant is burned. If
a water/glycol solution is used, monitor the cylinder
exhaust port temperature. If the temperature is higher
than the average, inspect the cylinder for evidence of
coolant leaks in the precombustion chamber.
Note: Signicant leaking of any type of coolant will
cause the cylinder to misre.
Check for Deposits in the Cylinders
Overlling of engine oil can lead to deposits. Make
sure that the engine oil level is correct.
Note: Excessive deposits contribute to guttering of
the valves.
Use a borescope to inspect the cylinders. Look for
the following conditions:
Slow cranking
Cold engine
Excessive load
Ignition system
Recommended Actions
Air/Fuel Pressure Module
Perform a calibration procedure on the Air/Fuel
pressure module. Refer to Troubleshooting, Air/Fuel
Pressure Module - Calibrate.
Fuel Pressure is Present During Initial
Cranking
If fuel pressure is present before the fuel command,
the engine will not start.
If an unexpected shutdown or a fast shutdown
occurred, the fuel actuator may have remained open.
If service was performed on the actuator, the actuator
may have remained open. Before you crank the
engine again, make sure that the actuator is closed.
Inspect the fuel actuator and the actuator's linkage.
Inspect the rod ends for damage and/or for wear.
Make sure that the components are fastened
securely. Make corrections, if necessary.
Make sure that the linkage is adjusted according to
the engine's Specications, Fuel Control.
The fuel actuator may be stuck. Make sure that the
actuator can move smoothly. Inspect the actuator
according to Operation and Maintenance Manual,
Electrohydraulic Actuator - Inspect. Recondition the
actuator, if necessary.
Slow Cranking
The cranking speed must be sufcient for engine
start-up. Inspect the starting system. Make sure that
the air supply has sufcient pressure. If the starting
motor is suspect, refer to Troubleshooting, Air
Starting Motor Problem.
Note: The target minimum cranking speed is 80 rpm.
RENR5910-06 81
Troubleshooting Section
Cold Engine
If the engine is too cold, the engine may not start.
Refer to Application and Installation, LEKQ7249,
Ambient Considerations.
Excessive Load
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment
and test the engine.
Air Choke
The air choke is maintained at a xed position during
start-up. If the air choke is closed too far, there may
be insufcient air for combustion. If the air choke is
opened too far, the air/fuel mixture may be too lean
for combustion.
Make sure that the programmable Engine Start
Choke Position is correct. Refer to Systems
Operation/Testing and Adjusting, Electronic Control
System Parameters.
Inlet Air Restriction
The air lter elements may be plugged. For
optimum operation, replace the air lter elements
when the inlet air restriction reaches 2.5 kPa
(10 inches of H2O). The maximum allowable inlet air
restriction is 3.75 kPa (15 inches of H
2
O).
If the inlet air restriction is excessive, determine the
cause of the restriction and correct the condition.
Air/Fuel Mixture
The following conditions can cause the engine to
malfunction:
Driven equipment
Gear train
Piston
Detonation
Recommended Actions
Driven Equipment
Inspect the alignment and the balance of the driven
equipment. Inspect the coupling. If necessary,
disconnect the driven equipment and test the engine.
Cylinder Head and Related Components
Inspect the components of the valve train. Check for
signs of damage and/or wear to the valves, valve
bridges, valve lifters, cylinder head gasket, etc.
Inspect the condition of the camshafts. If a camshaft
is replaced, new valve lifters must be installed.
Connecting Rod Bearing
Inspect the connecting rod bearings and the
crankshaft's bearing surfaces. Inspect the engine oil
lters for debris from the bearings. Install new parts,
if necessary.
Gear Train
Inspect the condition of the gear train.
Inspect the engine oil lters for nonferrous material.
Flaking of nonferrous material could indicate worn
gear train bearings.
Crankshaft
Inspect the crankshaft and the related components.
Inspect the main bearings and the bearing surfaces
on the crankshaft. Make sure that the bearings are in
the correct position.
Look for worn thrust plates and wear on the
crankshaft.
Check the bolts of the counterweights. Refer to
Specications, Crankshaft.
Piston
Make sure that the piston pin is correctly installed.
The retaining rings must be secure.
Inspect the condition of the pistons according
to Guidelines for Reusable Parts and Salvage
Operations.
Detonation
Check the control panel's display for the occurrence
of detonation. Refer to Troubleshooting, Detonation
Occurrence.
RENR5910-06 83
Troubleshooting Section
i02905374
Engine Misres, Runs Rough
or Is Unstable
SMCS Code: 1000-035
Use this procedure if one of the following event
codes is active. Refer to Troubleshooting, Event
Codes for information about event codes and the
default trip points for these codes. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip points
for these codes.
Table 28
Diagnostic Codes Table
Description Conditions
which Activate
the Code
System
Response
E200(1)
Continuous
Cylinder Misre
The engine is
operating in
the mode for
combustion
feedback. At
least 50 percent
of the cylinders
have continuous
misre. The
cylinder has
an active
Exhaust Port
Temp Deviating
Low event.
The Integrated
Combustion
Sensing Module
(ICSM) has
not received
a signal from
the cylinder's
combustion
sensor for 40
minutes.
The shutdown
output is
activated. The
code is logged.
E201(1) Cylinder
#1 Intermittent
Misre
E202(1) Cylinder
#2 Intermittent
Misre
E203(1) Cylinder
#3 Intermittent
Misre
E204(1) Cylinder
#4 Intermittent
Misre
The engine is
operating in
the mode for
combustion
feedback or in
the prechamber
calibration mode.
The ICSM has
not received
20 percent of
the signals from
the cylinder's
combustion
sensor during
a four minute
period.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
(continued)
(Table 28, contd)
Diagnostic Codes Table
Description Conditions
which Activate
the Code
System
Response
E205(1) Cylinder
#5 Intermittent
Misre
E206(1) Cylinder
#6 Intermittent
Misre
E207(1) Cylinder
#7 Intermittent
Misre
E208(1) Cylinder
#8 Intermittent
Misre
The engine is
operating in
the mode for
combustion
feedback or in
the prechamber
calibration mode.
The ICSM has
not received
20 percent of
the signals from
the cylinder's
combustion
sensor during
a four minute
period.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
E209(1) Cylinder
#9 Intermittent
Misre
E210(1) Cylinder
#10 Intermittent
Misre
E211(1) Cylinder
#11 Intermittent
Misre
E212(1) Cylinder
#12 Intermittent
Misre
The engine is
operating in
the mode for
combustion
feedback or in
the prechamber
calibration mode.
The ICSM has
not received
20 percent of
the signals from
the cylinder's
combustion
sensor during
a four minute
period.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
E213(1) Cylinder
#13 Intermittent
Misre
E214(1) Cylinder
#14 Intermittent
Misre
E215(1) Cylinder
#15 Intermittent
Misre
E216(1) Cylinder
#16 Intermittent
Misre
The engine is
operating in
the mode for
combustion
feedback or in
the prechamber
calibration mode.
The ICSM has
not received
20 percent of
the signals from
the cylinder's
combustion
sensor during
a four minute
period.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
Table 29
Diagnostic Codes Table
Description Conditions
which Generate
this Code
System
Response
(continued)
84 RENR5910-06
Troubleshooting Section
(Table 29, contd)
Diagnostic Codes Table
Description Conditions
which Generate
this Code
System
Response
E601(1) Cylinder
#1 Continuous
Misre
E602(1) Cylinder
#2 Continuous
Misre
E603(1) Cylinder
#3 Continuous
Misre
E604(1) Cylinder
#4 Continuous
Misre
The engine is
operating in
the mode for
combustion
feedback. There
is an active
event for the
low temperature
deviation of
the cylinder's
exhaust port.
The ICSM has
not received
a signal from
the cylinder's
combustion
sensor for 40
consecutive
potential ring
cycles.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
E605(1) Cylinder
#5 Continuous
Misre
E606(1) Cylinder
#6 Continuous
Misre
E607(1) Cylinder
#7 Continuous
Misre
E608(1) Cylinder
#8 Continuous
Misre
The engine is
operating in
the mode for
combustion
feedback. There
is an active
event for the
low temperature
deviation of
the cylinder's
exhaust port.
The ICSM has
not received
a signal from
the cylinder's
combustion
sensor for 40
consecutive
potential ring
cycles.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
E609(1) Cylinder
#9 Continuous
Misre
E610(1) Cylinder
#10 Continuous
Misre
E611(1) Cylinder
#11 Continuous
Misre
E612(1) Cylinder
#12 Continuous
Misre
The engine is
operating in
the mode for
combustion
feedback. There
is an active
event for the
low temperature
deviation of
the cylinder's
exhaust port.
The ICSM has
not received
a signal from
the cylinder's
combustion
sensor for 40
consecutive
potential ring
cycles.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
(continued)
(Table 29, contd)
Diagnostic Codes Table
Description Conditions
which Generate
this Code
System
Response
E613(1) Cylinder
#13 Continuous
Misre
E614(1) Cylinder
#14 Continuous
Misre
E615(1) Cylinder
#5 Continuous
Misre
E616(1) Cylinder
#16 Continuous
Misre
The engine is
operating in
the mode for
combustion
feedback. There
is an active
event for the
low temperature
deviation of
the cylinder's
exhaust port.
The ICSM has
not received
a signal from
the cylinder's
combustion
sensor for 40
consecutive
potential ring
cycles.
The alarm
output is
activated. The
code is logged.
The engine will
run rough.
Probable Causes
Cold cylinder
Spark plug
Check valve
Needle valve
Ignition transformer
Precombustion chamber
Valve lash
Driven equipment
Excessive load
Cold engine
Recommended Actions
Excessive Load
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment
and test the engine.
Crank Cycle
Note: A maximum of one crank cycle per overcrank
is recommended.
Make sure that the engine can be cranked for a
sufcient amount of time. Use Cat ET to check
the Cycle Crank Time and the Overcrank Time
parameters. Remember that the purge cycle is part
of the total crank cycle. Reprogram the parameters,
if necessary. For instructions, refer to Systems
Operation/Testing and Adjusting, Electronic Control
System Parameters.
Check the Gas Supply to the Engine
Check for low gas pressure. If the gas pressure is low,
refer to Troubleshooting, Fuel Pressure Problem.
If the gas shutoff valve is closed, refer to Operation
and Maintenance Manual, Gas Shutoff Valve -
Inspect.
Check the customer's gas shutoff valves for proper
operation.
Check the Status of the Relay for the
Starting Motor's Solenoid
Attempt to start the engine while you observe the
status of the relay for the starting motor's solenoid on
the control panel's display.
88 RENR5910-06
Troubleshooting Section
If the status of the relay for the starting motor's
solenoid indicates that the engine should crank but
no cranking occurs, troubleshoot the starting circuit.
Refer to Troubleshooting, Starting - Test.
If the engine should crank and cranking occurs,
check the engine rpm.
Check the Engine RPM
The Electronic Control Module (ECM) must detect a
minimum of 50 rpm before the gas and the ignition
are supplied to the engine. Monitor the engine speed
while you crank the engine.
The minimum recommended cranking speed is 80
rpm.
The maximum recommended cranking speed is 150
rpm.
Ignition System
Check for active diagnostic codes that relate to
the ignition system. If there is at least one active
diagnostic code that relates to the ignition system,
troubleshoot the diagnostic code.
Check the Fuel Quality
Compare the Low Heat Value (LHV) of the gas supply
to the Fuel Quality parameter that is programmed
by the customer into the ECM. The ECM uses the
setting for start-up and for air/fuel ratio control at low
loads.
If the LHV of the fuel does not match the Fuel
Quality parameter that is programmed into the ECM,
program the ECM with the correct setting for the
Fuel Quality parameter. If the LHV of the fuel does
not match, use an emissions analyzer and tune
the engine according to Systems Operation/Testing
and Adjusting, BTU and Precombustion Chamber
Adjustments.
Cold Engine
Jacket water heaters are recommended for
temperatures below 21 C (70 F) or in extremely
humid conditions. Lube oil heaters are recommended
for temperatures below 10 C (50 F).
i02905656
Engine Overloads
SMCS Code: 1000-035; 1900-035
Use this procedure in order to troubleshoot an engine
overload. Use this procedure if the following event
code is active. Refer to Troubleshooting, Event
Codes for information about event codes and the
default trip points for this code. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip points
for this code.
Table 31
Event Code
Description Conditions
which Activate
the Code
System
Response
E242(2) Engine
Overload
The calculation
by the Electronic
Control Module
(ECM) for the
engine load is
greater than 110
percent of the
rated load.
The alarm output
is activated.
The code is
logged. The
engine power
is reduced.
Probable Causes
Driven equipment
Misre
GSOV
ECS
Run relay
Check the Crank Terminate Speed
The Crank Terminate Speed is a parameter that
can be congured. The ECM disengages the starting
motor when the engine exceeds the programmed
Crank Terminate Speed. The default value of 250
rpm should be sufcient for all applications.
If the Crank Terminate Speed is too slow, the
engine will shut down. Use the Cat ET to check the
programmed Crank Terminate speed. Use Cat ET
to adjust the Crank Terminate Speed, if necessary.
RENR5910-06 91
Troubleshooting Section
Check the Cycle Crank Time
The Cycle Crank Time is a parameter that can be
congured. This parameter determines the time for
engagement of the starting motor and the gas shutoff
valve during the crank cycle. If the engine does not
start within the programmed Cycle Crank Time,
the attempt to start is suspended for an equal Rest
cycle.
If the Cycle Crank Time is insufcient, the Engine
Overcrank Time can elapse before the engine is
able to start.
Use Cat ET to check the Cycle Crank Time. Use
Cat ET to increase the time, if necessary.
Check the Engine Overcrank Time
The Engine Overcrank Time is a parameter that
can be congured. This parameter determines the
length of time for the crank cycle. If the engine does
not start within the programmed Engine Overcrank
time, the attempt to start is terminated.
If the Cycle Crank Time is insufcient, the Engine
Overcrank Time can elapse before the engine is
able to start.
Use Cat ET to check the Engine Overcrank Time.
Use Cat ET to increase the Engine Overcrank Time,
if necessary.
Check the Driven Equipment Delay
Time
The Driven Equipment Delay Time is a parameter
that can be congured. The ECM provides a switch
input for the driven equipment in order to delay engine
start-up until the driven equipment is ready. The ECM
will not attempt to start the engine until the switch
input for the driven equipment closes to ground and
the prelubrication (if equipped) is complete.
An event code is generated if the Driven Equipment
Delay Time elapses without closure of the switch
input. To disable this feature, program the delay time
to zero.
If the programmed delay time is too long, the engine
may not start. Use Cat ET to check the Driven
Equipment Delay Time. Use Cat ET to program the
delay time to a reasonable amount of time.
Battery Power to the ECM
1. Refer to Troubleshooting, Electrical Power Supply
- Test.
2. Inspect the ground strap and the battery for
connections that are loose and/or corroded.
3. Inspect the ECM and the terminal box for proper
installation of the connectors.
4. Check the circuit breaker for the ECM in the
terminal box.
High Starting Load
If the engine has a high load at start-up, this fault may
occur. This is especially true if the engine is not warm.
i02905688
Engine Shutdown Occurrence
SMCS Code: 1900-035
Use this procedure if one of the following event
codes is active. Refer to Troubleshooting, Event
Codes for information about event codes and the
default trip points for these codes. You must access
the monitoring system on Caterpillar Electronic
Technician (ET) in order to view the current trip points
for these codes.
Table 34
Event Code
Description Conditions
which Activate
the Code
System
Response
E264(3)
Emergency Stop
Activated
The Emergency
Stop button is
pressed.
The Electronic
Control
Module (ECM)
commands the
gas shutoff valve
to close and the
ECM terminates
the ignition. The
shutdown output
is activated. The
code is logged.
E269(3)
Customer
Shutdown
Requested
The engine is
either cranking
or running. The
input for the stop
is set for 200 ms.
The fuel is
shut off. The
shutdown output
is activated. The
code is logged.
Probable Causes
Fuel supply
Ignition system
Excessive load
Recommended Actions
Fuel Supply
Make sure that fuel is supplied at a sufcient pressure
that is stable. Make sure that the size of the fuel line
is sufcient. Inspect the fuel system for leaks.
The following conditions can cause the engine to
malfunction:
Engine supports
Driven equipment
Engine Misring or Running Rough
Engine misring
Running rough
94 RENR5910-06
Troubleshooting Section
Recommended Actions
Inspect the Vibration Damper
Check the vibration damper for damage. Install a
new vibration damper, if necessary. Inspect the
mounting bolts for damage and/or for wear. Replace
any damaged bolts. Refer to the Disassembly and
Assembly manual.
Engine Supports
Inspect the mounts and the brackets while you run
the engine through the speed range. Look for mounts
and brackets that are loose and/or broken. Tighten
all of the mounting bolts. If necessary, replace any
damaged components. Check the alignment of the
following before operating the engine under load for
any length of time:
Mounts
Coupling
Crankshaft deection
Driven Equipment
Inspect the mounting bolts for the driven equipment.
Inspect the alignment and the balance of the driven
equipment. Inspect the coupling. If necessary,
disconnect the driven equipment and test the engine.
Engine Misring or Running Rough
Refer to Troubleshooting, Engine Misres, Runs
Rough or Is Unstable.
i02906262
Exhaust Emission and Fuel
Consumption Are High
SMCS Code: 1088-035; 1250-035
Probable Causes
Misre
Air/Fuel ratio
Excessive load
Exhaust restriction
Misre
Lean operation
External leak
Internal leak
Worn components
Incorrect viscosity
Worn components
Recommended Actions
Low Engine Oil Level
Check the oil level. Add oil, as needed.
Contaminated Engine Oil
Engine oil that is contaminated with another liquid
will cause low engine oil pressure. High engine oil
level can be an indication of contamination. Obtain
an analysis of the engine oil. Determine the reason
for contamination of the engine oil and make the
necessary repairs. Change the engine oil and the
engine oil lter. For the correct engine oil to use, refer
to the Operation and Maintenance Manual.
Incorrect Viscosity
Make sure that the engine is supplied with the correct
engine oil. For the correct engine oil to use, refer to
the Operation and Maintenance Manual.
Faulty Engine Oil Pressure Sensors
Use Cat ET to compare the readings of the ltered
engine oil pressure and the unltered engine oil
pressure while the engine is OFF. Both readings
should be close to zero pressure.
If a reading is signicantly different from zero, refer
to Troubleshooting, Sensor Signal (Analog, Active) -
Test.
Improper Circulation of the Engine Oil
Several factors could cause improper circulation of
the engine oil:
Mechanical friction
Recommended Actions
Contaminated Engine Oil
Engine oil that is contaminated with another liquid
can cause low engine oil temperature. High engine
oil level can be an indication of contamination. Obtain
an analysis of the engine oil. Determine the reason
for contamination of the engine oil and make the
necessary repairs. Change the engine oil and the
engine oil lter. For the correct engine oil to use, refer
to Operation and Maintenance Manual, Engine Oil.
Check the Engine Oil Temperature
Regulators
Make sure that the engine oil temperature regulators
open according to the correct values. Refer to
Specications, Engine Oil Temperature Regulators.
Check the Engine Oil Temperature
Sensor
Check the reading of the engine oil temperature
on Cat ET. Compare the reading to a reading from
a separate device. The temperature should rise
steadily as the engine is warmed.
If the reading on Cat ET for the engine oil temperature
is not reasonable, replace the engine oil temperature
sensor.
Check the Cooling System
Make sure that the heat exchanger for the engine
oil cooler and the aftercooler is operating properly.
The heat exchanger must be properly sized for
the ambient conditions. Check the plumbing for
obstructions.
Check the Flow through the Engine Oil
Cooler
Run the engine at normal operating temperature.
Determine the pressure differential for the coolant
and for the engine oil between the inlet and the outlet
of the engine oil cooler. For comparative data, refer
to the Technical Marketing Information for the engine.
RENR5910-06 115
Troubleshooting Section
If the pressure differential between the inlet and the
outlet of the engine oil cooler exceeds the data that
is published for the engine, there is an insufcient
ow of coolant or of engine oil through the engine oil
cooler. Clean the engine oil cooler.
Mechanical Friction
Friction of gears and/or of bearings will raise the
engine oil temperature. Measure the engine oil
temperature at various locations in order to locate the
hot spot. Obtain an analysis of the engine oil. Make
the necessary repairs.
i02908799
Prelubrication Pressure Is Low
SMCS Code: 1319-035-PX
Use this procedure if the following event code is
active. Refer to Troubleshooting, Event Codes for
information about event codes and the default trip
point for this code. You must access the monitoring
system on Caterpillar Electronic Technician (ET) in
order to view the current trip point for this code.
Table 48
Event Code
Description Conditions
which Activate
the Code
System
Response
E233(3) Low
Engine Pre-Lube
Pressure
The prelube oil
pressure is less
than the trip point
and the delay
time has expired.
The shutdown
output is
activated.
Starting of
the engine is
prevented. The
signal driver
for the prelube
pump remains
activated. The
code is logged.
The engine will
not start.
Probable Causes
Electrical problem
Excessive load
Low load
Excessive load
Exhaust restriction
118 RENR5910-06
Troubleshooting Section
ECM J1/P1
Crankcase pressure
Fuel temperature
Sensor
ECM
The most likely cause of a code is a problem with an
electrical connector or wiring. The least likely cause
of a code is the ECM.
The ECM can be congured for one of these types of
speed control:
0 to 5 V potentiometer
4 to 20 mA
The DESIRED SPEED potentiometer (if equipped)
must be supplied with +5 VDC from the ECM. If the
DESIRED SPEED potentiometer has a short circuit
or the potentiometer's wiring has a short circuit, a
262-03 or 262-04 diagnostic code may be activated.
There are no diagnostic codes for the circuit of the
DESIRED SPEED potentiometer.
RENR5910-06 277
Troubleshooting Section
g01665733
Illustration 191
Schematic for the in-line engines and the vee engines
278 RENR5910-06
Troubleshooting Section
g01431172
Illustration 192
P1 ECM connector
(2) 5 V supply
(3) Analog return
(14) Inlet manifold air temperature
(15) Fuel temperature
(16) Desired engine speed
(17) Engine oil temperature
(18) 5 V supply
(24) Filtered engine oil pressure
(25) Crankcase pressure
(35) Analog return
g01431198
Illustration 193
Terminal Box
(1) ECM connector J2/P2
(2) ECM connector J1/P1
(3) 16 amp circuit breaker
(4) Connectors J3/P3 for the customer's connector
(5) Connectors J4/P4 for the optional control panel (if equipped)
or for a customer's connector
(6) J5/P5 connectors for the harness from the sensors
(7) J6/P6 connectors for the harness from the sensors
g01431200
Illustration 194
Terminal strip in the control panel
RENR5910-06 279
Troubleshooting Section
g01431233
Illustration 195
P5 terminals on bottom of terminal box for an in-line engine
(P5-15) Return for the ltered oil pressure sensor
(P5-16) Filtered engine oil pressure
(P5-17) +5 VDC for the ltered oil pressure sensor
(P5-25) Return for the unltered oil pressure sensor
(P5-26) Unltered engine oil pressure
(P5-27) +5 VDC for the unltered oil pressure sensor
(P5-33) Return for the engine oil temperature sensor
(P5-34) Engine oil temperature
(P5-35) +5 VDC for the engine oil temperature sensor
(P6-37) Return for the fuel temperature sensor
(P5-38) Fuel temperature
(P6-39) +5 VDC for the fuel temperature sensor
(P5-54) Return for the crankcase pressure sensor
(P5-59) Return for the inlet air temperature sensor
(P5-60) Inlet air temperature
(P5-61) +5 VDC for the inlet air temperature sensor
(P5-66) Crankcase pressure
(P5-67) +5 VDC for the crankcase pressure sensor
g01431234
Illustration 196
P5 terminals on bottom of terminal box for a vee engine
(P5-15) Return for the engine oil temperature sensor
(P5-16) Engine oil temperature
(P5-17) +5 VDC for the engine oil temperature sensor
(P5-25) Return for the unltered oil pressure sensor
(P5-26) Unltered engine oil pressure
(P5-27) +5 VDC for the unltered oil pressure sensor
(P5-33) Return for the ltered oil pressure sensor
(P5-34) Filtered engine oil pressure
(P5-35) +5 VDC for the ltered oil pressure sensor
(P5-49) Return for the crankcase pressure sensor
(P5-50) Crankcase pressure
(P5-51) +5 VDC for the crankcase pressure sensor
(P5-59) Return for the inlet air temperature sensor
(P5-60) Inlet air temperature
(P5-61) +5 VDC for the inlet air temperature sensor
280 RENR5910-06
Troubleshooting Section
g01436909
Illustration 197
P6 terminals on bottom of terminal box for a vee engine
(P6-56) Fuel temperature
(P6-68) Return for the fuel temperature sensor
(P6-69) +5 VDC for the fuel temperature sensor
g01431259
Illustration 198
Harness connectors for the various sensors
(A) 5 V supply
(B) Return
(C) Signal
Test Step 1. Determine if the Code is
Logged or Active
A. Connect Cat ET to the service tool connector.
B. Switch the 16 amp circuit breaker for the ECM
ON. Turn the engine control switch to the STOP
position.
C. Clear any logged diagnostic codes.
D. Monitor the active diagnostic code and the logged
diagnostic codes on Cat ET.
Note: Wait at least 30 seconds in order for diagnostic
codes to become active.
Identify the diagnostic code.
Results:
Logged code
Repair: Do not troubleshoot a logged code unless
the code relates to an operator complaint. If the
code is logged and the code does not relate to an
operator complaint, clear the code.
If the code is logged and the code relates to an
operator complaint, proceed to Test Step 2.
Sensor
ECM
The most likely cause of a code is a problem with an
electrical connector or wiring. The least likely cause
of a code is the ECM.
286 RENR5910-06
Troubleshooting Section
g01431487
Illustration 199
Schematic for the passive analog sensor
g01420865
Illustration 200
Terminal locations at the P1 ECM connector for the passive analog
sensors
(P1-3) Analog return
(P1-27) Engine coolant temperature
g01155187
Illustration 201
Terminal locations at the connector for the passive analog sensor
(Terminal 1) Sensor signal
(Terminal 2) Analog sensor return
g01431495
Illustration 202
P5 terminals on bottom of terminal box for an in-line engine
(P5-50) Engine coolant temperature
(P5-49) Analog return
RENR5910-06 287
Troubleshooting Section
g01431502
Illustration 203
P5 terminals on bottom of terminal box for a vee engine
(P5-41) Analog return
(P5-42) Engine coolant temperature
g01431198
Illustration 204
Terminal Box
(1) ECM connector J2/P2
(2) ECM connector J1/P1
(3) 16 amp circuit breaker
(4) Connectors J3/P3 for the customer's connector
(5) Connectors J4/P4 for the optional control panel (if equipped)
or for a customer's connector
(6) J5/P5 connectors for the harness from the sensors
(7) J6/P6 connectors for the harness from the sensors
Test Step 1. Check for Active or
Logged Diagnostic Codes
A. Connect Cat ET to the service tool connector.
B. Switch the 16 amp circuit breaker for the ECM
ON. Turn the engine control switch to the STOP
position.
C. Monitor the diagnostic codes on Cat ET. Check
and record any diagnostic codes.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active.
D. Determine if a diagnostic code has occurred
several times.
Note: A diagnostic code that is logged several
times is an indication of an intermittent problem.
Most intermittent problems are the result of a
poor connection between a socket and a pin in a
connector or of a poor connection between a wire
and a terminal.
E. Determine if the problem is active and related to
one of the following failure modes for the analog
passive sensor:
-3
-4
Expected Result:
A diagnostic code is not active.
Results:
Crankcase pressure
Fuel temperature
0 to 5 V potentiometer
4 to 20 mA
The desired speed potentiometer (if equipped)
must be supplied with +5 VDC from the ECM. If the
desired speed potentiometer has a short circuit or the
potentiometer's wiring has a short circuit, a 262-03
or 262-04 diagnostic code may be activated. There
are no diagnostic codes for the circuit of the desired
speed potentiometer.
g01442989
Illustration 218
Control Panel (if equipped)
(1) Desired speed potentiometer
The internal circuits for J2-2 (sensor supply) and
J2-18 (speed control supply) are wired to the same
voltage source inside the ECM. A short circuit on one
of these terminals will cause a short circuit on the
other terminal.
A 262-4 5 Volt Sensor DC Power Supply voltage
below normal will be activated if the following
conditions occur:
Crankcase pressure
Fuel temperature
Passwords
Serial numbers
Total tattletale
Reason code
Recommended Actions
1. Verify that the correct passwords were entered.
Check every character in each password. Remove
the electrical power from the engine for 30
seconds and then retry.
2. Verify that Cat ET is displaying the Enter Factory
Passwords dialog box.
3. Use Cat ET to verify that the following information
has been entered correctly:
Total tattletale
Reason code
For additional information, refer to Troubleshooting,
Factory Passwords.
i02916572
Electronic Service Tool Does
Not Communicate
SMCS Code: 0785; 1900
System Operation Description:
Use this procedure to solve communication problems
between Caterpillar Electronic Technician (ET) and
the Electronic Control Module (ECM). Cat ET must
communicate with the ECM in order to fully service
the engine.
There is a Power indicator on the communication
adapter that indicates that the communication
adapter is receiving power. An indicator on the
communication adapter indicates that communication
is occurring on the data link. Cat ET displays a
message if Cat ET can not communicate with the
data link.
The following conditions can cause a communication
problem:
Cat ET
Missing seals
Exposed insulation
Emergency stop
Engine overspeed