G3520C Trouble Shooting

RENR5979-03
March 2004
Troubleshooting
G3520C and G3520E Engines
GDB1-Up (Engine)
GHC1-Up (Engine)
GHE1-Up (Engine)
GHM1-Up (Engine)
GHR1-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 Inlet Air Temperature (High) .................................. 59

Intermittent Engine Shutdown ............................... 60
Jacket Water Inlet Pressure (High) ....................... 60
Jacket Water Pressure (Low) ................................ 61
Troubleshooting Section Jacket Water to Engine Oil Differential Temperature
(Low) ................................................................... 61
Electronic Troubleshooting
System Voltage ..................................................... 62
System Overview .................................................. 10
Turbocharger Turbine Temperature (High) ........... 62
Self-Diagnostics ..................................................... 11
Turbocharger Turbine Temperature (Low) ............ 63
Location of Components ....................................... 12
Electrical Connectors and Functions .................... 16
Troubleshooting with a Diagnostic Code
Electronic Service Tools ........................................ 18
Diagnostic Codes .................................................. 65
Engine Monitoring System .................................... 20
MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short
to +batt ................................................................ 66
Programming Parameters
MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short
Programming Parameters ..................................... 27
to ground ............................................................. 67
Customer Passwords ............................................ 27
MID 033 - CID 0168 - FMI 02 System Voltage
Factory Passwords ............................................... 27
intermittent/erratic ............................................... 67
Factory Passwords Worksheet ............................. 28
MID 033 - CID 0301 - FMI 05 Ignition Transformer
Flash Programming .............................................. 29
Primary #1 open circuit ....................................... 67
System Configuration Parameters ........................ 29
Replacing the ECM ............................................... 30
Primary #1 short .................................................. 68
Replacing the ITSM .............................................. 32
Troubleshooting Data Sheet ................................. 34
Troubleshooting without a Diagnostic Code
Primary #3 short .................................................. 68
Symptoms ............................................................. 36
Detonation ............................................................ 36
Driven Equipment ................................................. 38
ECM Will Not Accept Factory Passwords ............. 38
Primary #5 short .................................................. 69
Electronic Service Tool Will Not Communicate with
ECM (The Caterpillar Electronic Technician (ET)
Will Not Communicate With an Electronic Control
Module (ECM) and/or the Integrated Temperature
Primary #7 short .................................................. 70
Sensing Module (ITSM)) ..................................... 38
Engine Coolant Temperature (High) ..................... 39
Engine Coolant Temperature (Low) ...................... 41
Engine Cranks but Will Not Start .......................... 41
Primary #9 short .................................................. 71
Engine Misfires, Runs Rough or Is Unstable ........ 42
Engine Oil Filter Differential Pressure ................... 44
Primary #11 open circuit ..................................... 71
Engine Oil Pressure (Low) .................................... 44
Engine Oil Temperature (High) ............................. 45
Primary #11 short ................................................ 71
Engine Overcrank ................................................. 46
Engine Overload ................................................... 47
Engine Overspeed ................................................ 47
Engine Shutdown .................................................. 48
Primary #13 short ................................................ 72
Engine Shutdown (Unexpected) ........................... 48
Engine Shutdown without a Diagnostic Code ....... 50
Engine Starts but Stalls Immediately .................... 51
Engine Timing Does Not Match Programmed
Primary #15 short ................................................ 73
Timing ................................................................. 51
MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor
Engine Will Not Crank ........................................... 52
short to +batt ....................................................... 73
Exhaust Port Temperature (High) ......................... 53
MID 033 - CID 0320 - FMI 08 Engine Speed/Timing
Exhaust Port Temperature (Low) .......................... 54
signal abnormal ................................................... 74
Fuel Energy Content ............................................. 55
Fuel Metering Valve .............................................. 55
Secondary #1 open circuit .................................. 74
Fuel Pressure ....................................................... 55
Gas Fuel Differential Pressure (High) ................... 55
Secondary #1 short to ground ............................. 74
Gas Fuel Differential Pressure (Low) .................... 56
Gas Fuel Flow Rate (Low) .................................... 56
Secondary #3 open circuit .................................. 75
Gas Temperature (High) ....................................... 57
Generator Output Power Readings Do Not
Match .................................................................. 58
4
Table of Contents
MID 033 - CID 0405 - FMI 05 Ignition Transformer MID 033 - CID 1754 - FMI 06 Ignition Transformer
Secondary #5 open circuit .................................. 75 Primary #19 short to ground ............................... 87
MID 033 - CID 0405 - FMI 06 Ignition Transformer MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open
Secondary #5 short to ground ............................. 76 circuit ................................................................... 87
MID 033 - CID 0407 - FMI 05 Ignition Transformer MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short
Secondary #7 open circuit .................................. 76 to ground ............................................................. 87
MID 033 - CID 0407 - FMI 06 Ignition Transformer MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve
Secondary #7 short to ground ............................. 77 malfunction .......................................................... 88
MID 033 - CID 0409 - FMI 05 Ignition Transformer MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short
Secondary #9 open circuit .................................. 77 to +batt ................................................................ 88
MID 033 - CID 0409 - FMI 06 Ignition Transformer MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short
Secondary #9 short to ground ............................. 77 to ground ............................................................. 88
MID 033 - CID 0411 - FMI 05 Ignition Transformer MID 036 - CID 0100 - FMI 03 Engine Oil Pressure
Secondary #11 open circuit ................................. 78 open/short to +batt .............................................. 89
MID 033 - CID 0411 - FMI 06 Ignition Transformer MID 036 - CID 0100 - FMI 04 Engine Oil Pressure
Secondary #11 short to ground ........................... 78 short to ground .................................................... 89
MID 033 - CID 0413 - FMI 05 Ignition Transformer MID 036 - CID 0106 - FMI 03 Air Inlet Pressure
Secondary #13 open circuit ................................ 79 Sensor short to +batt .......................................... 90
MID 033 - CID 0413 - FMI 06 Ignition Transformer MID 036 - CID 0106 - FMI 08 Air Inlet Pressure
Secondary #13 short to ground ........................... 79 Sensor noisy signal ............................................. 90
MID 033 - CID 0415 - FMI 05 Ignition Transformer MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure
Secondary #15 open circuit ................................ 79 open/short to +batt .............................................. 90
MID 033 - CID 0415 - FMI 06 Ignition Transformer MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet
Secondary #15 short to ground ........................... 80 Pressure Sensor noisy signal ............................. 91
MID 033 - CID 0590 - FMI 09 Unable to communicate MID 036 - CID 0110 - FMI 03 Engine Coolant
with Engine ECM ................................................ 80 Temperature open/short to +batt ......................... 91
MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation MID 036 - CID 0110 - FMI 04 Engine Coolant
Sensor open/short to +batt ................................. 81 Temperature short to ground ............................... 91
MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation MID 036 - CID 0145 - FMI 03 12 Volt DC Power
Sensor short to ground ....................................... 81 Supply short to +batt ........................................... 92
MID 033 - CID 1505 - FMI 03 Cylinder #5 Detonation MID 036 - CID 0145 - FMI 04 12 Volt DC Power
Sensor open/short to +batt ................................. 81 Supply short to ground ........................................ 92
MID 033 - CID 1505 - FMI 04 Cylinder #5 Detonation MID 036 - CID 0168 - FMI 02 System Voltage
Sensor short to ground ....................................... 82 intermittent/erratic ............................................... 92
MID 033 - CID 1509 - FMI 03 Cylinder #9 Detonation MID 036 - CID 0172 - FMI 03 Intake Manifold Air
Sensor open/short to +batt ................................. 82 Temp open/short to +batt .................................... 93
MID 033 - CID 1509 - FMI 04 Cylinder #9 Detonation MID 036 - CID 0172 - FMI 04 Intake Manifold Air
Sensor short to ground ....................................... 82 Temp short to ground .......................................... 93
MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation MID 036 - CID 0175 - FMI 03 Engine Oil Temperature
Sensor open/short to +batt ................................. 83 open/short to +batt .............................................. 93
MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation MID 036 - CID 0175 - FMI 04 Engine Oil Temperature
Sensor short to ground ....................................... 83 short to ground .................................................... 94
MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation MID 036 - CID 0261 - FMI 13 Engine Timing
Sensor open/short to +batt ................................. 83 calibration required ............................................. 94
MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC
Sensor short to ground ....................................... 84 Power Supply short to +batt ................................ 95
MID 033 - CID 1748 - FMI 05 Ignition Transformer MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC
Secondary #17 open circuit ................................ 84 Power Supply short to ground ............................. 95
Secondary #17 short to ground ........................... 84 Primary #2 open circuit ....................................... 96
Secondary #19 open circuit ................................ 85 Primary #2 short .................................................. 96
Secondary #19 short to ground ........................... 85 Primary #4 open circuit ....................................... 96
Primary #17 open circuit ..................................... 85 Primary #4 short .................................................. 97
Primary #17 short to ground ............................... 86 Primary #6 open circuit ....................................... 97
Primary #19 open circuit ..................................... 86 Primary #6 short .................................................. 97
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Table of Contents
MID 036 - CID 0308 - FMI 05 Ignition Transformer MID 036 - CID 0443 - FMI 03 Crank Terminate Relay
Primary #8 open circuit ....................................... 98 short to +batt ..................................................... 109
MID 036 - CID 0308 - FMI 06 Ignition Transformer MID 036 - CID 0444 - FMI 05 Start Relay open
Primary #8 short .................................................. 98 circuit .................................................................. 110
MID 036 - CID 0310 - FMI 05 Ignition Transformer MID 036 - CID 0444 - FMI 06 Start Relay short to
Primary #10 open circuit ..................................... 98 ground ................................................................ 110
MID 036 - CID 0310 - FMI 06 Ignition Transformer MID 036 - CID 0445 - FMI 03 Run Relay short to
Primary #10 short ................................................ 99 +batt ................................................................... 110
MID 036 - CID 0312 - FMI 05 Ignition Transformer MID 036 - CID 0524 - FMI 03 Desired Engine Speed
Primary #12 open circuit ..................................... 99 Sensor short to +batt ......................................... 111
MID 036 - CID 0312 - FMI 06 Ignition Transformer MID 036 - CID 0524 - FMI 04 Desired Engine Speed
Primary #12 short .............................................. 100 Sensor short to ground ...................................... 111
MID 036 - CID 0314 - FMI 05 Ignition Transformer MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil
Primary #14 open circuit ................................... 100 Pressure open/short to +batt ............................. 111
MID 036 - CID 0314 - FMI 06 Ignition Transformer MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil
Primary #14 short .............................................. 100 Pressure short to ground ................................... 112
MID 036 - CID 0316 - FMI 05 Ignition Transformer MID 036 - CID 1042 - FMI 09 Unable to communicate
Primary #16 open circuit ................................... 101 with ITSM ........................................................... 112
MID 036 - CID 0316 - FMI 06 Ignition Transformer MID 036 - CID 1440 - FMI 09 Unable to communicate
Primary #16 short .............................................. 101 with Throttle Actuator Drv .................................. 113
MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor MID 036 - CID 1446 - FMI 05 Fuel Metering Module
short to +batt ..................................................... 101 open circuit ......................................................... 113
MID 036 - CID 0320 - FMI 08 Engine Speed/Timing MID 036 - CID 1446 - FMI 09 Unable to communicate
signal abnormal ................................................. 102 with Fuel Metering Module ................................. 113
MID 036 - CID 0323 - FMI 03 Shutdown Lamp short MID 036 - CID 1446 - FMI 12 Fuel Metering Module
to +batt .............................................................. 102 malfunction ......................................................... 114
MID 036 - CID 0324 - FMI 03 Warning Lamp short to MID 036 - CID 1446 - FMI 13 Fuel Metering Module
+batt .................................................................. 102 calibration required ............................................ 114
MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor
inputs ................................................................ 103 Module malfunction ............................................ 114
MID 036 - CID 0402 - FMI 05 Ignition Transformer MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation
Secondary #2 open circuit ................................ 103 Sensor open/short to +batt ................................ 114
Secondary #2 short to ground ........................... 103 Sensor short to ground ...................................... 115
Secondary #10 open circuit .............................. 106 Sensor open/short to +batt ................................ 117
Secondary #10 short to ground ......................... 107 Sensor short to ground ...................................... 117
MID 036 - CID 0412 - FMI 05 Ignition Transformer MID 036 - CID 1636 - FMI 09 Loss of Communication
Secondary #12 open circuit .............................. 107 with Engine #2 (Slave) ....................................... 118
MID 036 - CID 0412 - FMI 06 Ignition Transformer MID 036 - CID 1719 - FMI 03 Generator Output
Secondary #12 short to ground ......................... 107 Power Sensor open/short to +batt ..................... 118
Secondary #14 open circuit .............................. 108 Power Sensor short to ground ........................... 118
Secondary #14 short to ground ......................... 108 Power Sensor malfunction ................................. 119
MID 036 - CID 0416 - FMI 05 Ignition Transformer MID 036 - CID 1720 - FMI 09 Turbocharger
Secondary #16 open circuit .............................. 108 Compressor Bypass Valve Actuator not
MID 036 - CID 0416 - FMI 06 Ignition Transformer communicating on link ....................................... 119
Secondary #16 short to ground ......................... 109 MID 036 - CID 1749 - FMI 05 Ignition Transformer
Secondary #18 open circuit ............................... 119
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Table of Contents
MID 036 - CID 1749 - FMI 06 Ignition Transformer MID 111 - CID 1534 - FMI 04 Cyl #4 Exhaust Port
Secondary #18 short to ground ......................... 120 Temp Sensor short to ground ............................ 130
Secondary #20 open circuit .............................. 120 Temp Sensor open circuit ................................. 130
Secondary #20 short to ground ......................... 120 Temp Sensor short to +batt ............................... 131
Primary #18 open circuit ................................... 121 Temp Sensor short to ground ............................ 131
Primary #18 short to ground ............................. 121 Temp Sensor open circuit ................................. 132
Primary #20 open circuit ................................... 121 Temp Sensor short to +batt ............................... 132
Primary #20 short to ground ............................. 122 Temp Sensor short to ground ............................ 132
MID 111 - CID 0591 - FMI 12 EEPROM checksum MID 111 - CID 1536 - FMI 05 Cyl #6 Exhaust Port
fault or ECM not programmed ........................... 122 Temp Sensor open circuit ................................. 133
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 .................................. 122 Temp Sensor short to +batt ............................... 133
Temp Sens short to ground ............................... 123 Temp Sensor short to ground ............................ 133
Temp Sens open circuit ..................................... 123 Temp Sensor open circuit ................................. 134
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 ............................... 126 Temp Sensor short to +batt ............................... 138
Temp Sensor short to ground ............................ 127 Temp Sensor short to ground ............................ 138
Temp Sensor open circuit ................................. 127 Temp Sensor open circuit ................................. 138
7
Table of Contents
MID 111 - CID 1544 - FMI 04 Cyl #14 Exhaust Port E128 Engine Oil Filter Diff Pressure Low
Temp Sensor short to ground ............................ 141 Shutdown .......................................................... 156
MID 111 - CID 1544 - FMI 05 Cyl #14 Exhaust Port E129 Engine Oil Filter Diff Pressure High
Temp Sensor open circuit ................................. 142 Warning ............................................................. 157
MID 111 - CID 1545 - FMI 03 Cyl #15 Exhaust Port E130 Engine Oil Filter Diff Pressure High
Temp Sensor short to +batt ............................... 142 Shutdown .......................................................... 157
MID 111 - CID 1545 - FMI 04 Cyl #15 Exhaust Port E135 Low Jacket Water Pressure Shutdown ...... 157
Temp Sensor short to ground ............................ 142 E223 High Gas Temperature .............................. 158
MID 111 - CID 1545 - FMI 05 Cyl #15 Exhaust Port E224 High Jacket Water Inlet Pressure .............. 158
Temp Sensor open circuit ................................. 143 E225 Engine Overcrank ...................................... 158
MID 111 - CID 1546 - FMI 03 Cyl #16 Exhaust Port E226 Driven Equipment Not Ready .................... 158
Temp Sensor short to +batt ............................... 143 E229 Fuel Energy Content Setting Low .............. 159
MID 111 - CID 1546 - FMI 04 Cyl #16 Exhaust Port E230 Fuel Energy Content Setting High ............. 159
Temp Sensor short to ground ............................ 144 E231 Fuel Quality Out of Range ......................... 159
MID 111 - CID 1546 - FMI 05 Cyl #16 Exhaust Port E243 High Left Turbo Turbine Outlet
Temp Sensor open circuit ................................. 144 Temperature ...................................................... 159
MID 111 - CID 1547 - FMI 03 Cyl #17 Exhaust Port E244 High Right Turbo Turbine Outlet
Temp Sensor short to +batt ............................... 144 Temperature ...................................................... 160
MID 111 - CID 1547 - FMI 04 Cyl #17 Exhaust Port E245 High Right Turbo Turbine Inlet
Temp Sensor short to ground ............................ 145 Temperature ...................................................... 160
MID 111 - CID 1547 - FMI 05 Cyl #17 Exhaust Port E246 High Left Turbo Turbine Inlet
Temp Sensor open circuit ................................. 145 Temperature ...................................................... 161
MID 111 - CID 1548 - FMI 03 Cyl #18 Exhaust Port E264 Emergency Stop Activated ........................ 161
Temp Sensor short to +batt ............................... 145 E268 Unexpected Engine Shutdown .................. 161
MID 111 - CID 1548 - FMI 04 Cyl #18 Exhaust Port E269 Customer Shutdown Requested ............... 161
Temp Sensor short to ground ............................ 146 E270 Driven Equipment Shutdown Requested .. 162
MID 111 - CID 1548 - FMI 05 Cyl #18 Exhaust Port E337 High Engine Oil to Engine Coolant Diff
Temp Sensor open circuit ................................. 146 Temp ................................................................. 162
MID 111 - CID 1549 - FMI 03 Cyl #19 Exhaust Port E401 Cylinder #1 Detonation .............................. 163
Temp Sensor short to +batt ............................... 147 E402 Cylinder #2 Detonation .............................. 163
Temp Sensor short to ground ............................ 147 E404 Cylinder #4 Detonation .............................. 163
Temp Sensor open circuit ................................. 147 E406 Cylinder #6 Detonation .............................. 164
Temp Sensor short to +batt ............................... 148 E408 Cylinder #8 Detonation .............................. 164
Temp Sensor short to ground ............................ 148 E410 Cylinder #10 Detonation ............................ 165
MID 111 - CID 1550 - FMI 05 Cyl #20 Exhaust Port E411 Cylinder #11 Detonation ............................ 165
Temp Sensor open circuit ................................. 148 E412 Cylinder #12 Detonation ............................ 165
E413 Cylinder #13 Detonation ............................ 166
Troubleshooting with an Event Code E414 Cylinder #14 Detonation ............................ 166
Event Codes ...................................................... 150 E415 Cylinder #15 Detonation ............................ 166
E004 Engine Overspeed Shutdown .................... 152 E416 Cylinder #16 Detonation ............................ 166
E016 High Engine Coolant Temperature E417 Cylinder #17 Detonation ............................ 167
Shutdown .......................................................... 152 E418 Cylinder #18 Detonation ............................ 167
E017 High Engine Coolant Temperature E419 Cylinder #19 Detonation ............................ 167
Warning ............................................................. 153 E420 Cylinder #20 Detonation ............................ 167
E019 High Engine Oil Temperature Shutdown ... 153 E421 Cylinder #1 Detonation Shutdown ............. 168
E020 High Engine Oil Temperature Warning ...... 153 E422 Cylinder #2 Detonation Shutdown ............. 168
E026 High Inlet Air Temperature Shutdown ........ 153 E423 Cylinder #3 Detonation Shutdown ............. 168
E027 High Inlet Air Temperature Warning .......... 154 E424 Cylinder #4 Detonation Shutdown ............. 168
E038 Low Engine Coolant Temperature E425 Cylinder #5 Detonation Shutdown ............. 169
Warning ............................................................. 154 E426 Cylinder #6 Detonation Shutdown ............. 169
E040 Low Engine Oil Pressure Shutdown .......... 154 E427 Cylinder #7 Detonation Shutdown ............. 169
E042 Low System Voltage Shutdown ................. 155 E428 Cylinder #8 Detonation Shutdown ............. 169
E043 Low System Voltage Warning .................... 155 E429 Cylinder #9 Detonation Shutdown ............. 170
E050 High System Voltage Warning ................... 155 E430 Cylinder #10 Detonation Shutdown ........... 170
E053 Low Fuel Pressure Warning ...................... 155 E431 Cylinder #11 Detonation Shutdown ........... 170
E096 High Fuel Pressure .................................... 156 E432 Cylinder #12 Detonation Shutdown ........... 171
E100 Low Engine Oil Pressure Warning ............. 156 E433 Cylinder #13 Detonation Shutdown ........... 171
E127 Engine Oil Filter Diff Pressure Low E434 Cylinder #14 Detonation Shutdown ........... 171
Warning ............................................................. 156 E435 Cylinder #15 Detonation Shutdown ........... 171
8
Table of Contents
E436 Cylinder #16 Detonation Shutdown ........... 172 E846 Cyl #6 Exhaust Port Temp Deviating Low .. 191
E440 Cylinder #20 Detonation Shutdown ........... 173 E850 Cyl #10 Exhaust Port Temp Deviating
E801 Cylinder #1 High Exhaust Port Temp ........ 173 Low ................................................................... 193
E802 Cylinder #2 High Exhaust Port Temp ........ 173 E851 Cyl #11 Exhaust Port Temp Deviating
E810 Cylinder #10 High Exhaust Port Temp ...... 177 E855 Cyl #15 Exhaust Port Temp Deviating
E811 Cylinder #11 High Exhaust Port Temp ....... 177 Low ................................................................... 195
E813 Cylinder #13 High Exhaust Port Temp ...... 178 Low ................................................................... 195
E821 Cyl #1 Exhaust Port Temp Deviating High .. 181 Low ................................................................... 197
E822 Cyl #2 Exhaust Port Temp Deviating High .. 181 E864 Low Gas Fuel Differential Pressure ........... 197
E823 Cyl #3 Exhaust Port Temp Deviating High .. 182 E865 High Gas Fuel Differential Pressure .......... 197
E824 Cyl #4 Exhaust Port Temp Deviating High .. 182 E866 Low Gas Fuel Flow Rate ........................... 197
E825 Cyl #5 Exhaust Port Temp Deviating High .. 183 E867 Improper Gas Flow Control Valve
E826 Cyl #6 Exhaust Port Temp Deviating High .. 183 Response .......................................................... 198
E827 Cyl #7 Exhaust Port Temp Deviating High .. 183 E868 Gas Flow Control Valve Malfunction ......... 198
E828 Cyl #8 Exhaust Port Temp Deviating High .. 184
E829 Cyl #9 Exhaust Port Temp Deviating High .. 184 Diagnostic Functional Tests
E830 Cyl #10 Exhaust Port Temp Deviating +5V Sensor Voltage Supply ................................ 199
High ................................................................... 185 +8V Sensor Voltage Supply ................................ 206
E831 Cyl #11 Exhaust Port Temp Deviating Analog Sensor Signal ......................................... 214
High ................................................................... 185 CAT Data Link ..................................................... 223
E832 Cyl #12 Exhaust Port Temp Deviating Compressor Bypass ........................................... 229
High ................................................................... 185 Desired Speed Input (4 - 20 mA) ........................ 235
E833 Cyl #13 Exhaust Port Temp Deviating Detonation Sensors ............................................ 239
High ................................................................... 186 ECM Output Circuit (Fuel Control) ...................... 248
E834 Cyl #14 Exhaust Port Temp Deviating ECM Output Circuit (Starting Motor) ................... 257
High ................................................................... 186 ECM Status Indicator Output .............................. 269
E835 Cyl #15 Exhaust Port Temp Deviating Electrical Power Supply ...................................... 275
High ................................................................... 187 Engine Speed/Timing Sensor ............................. 282
E836 Cyl #16 Exhaust Port Temp Deviating Fuel Metering Valve ............................................ 289
High ................................................................... 187 Generator Output Power Sensor ........................ 298
E837 Cyl #17 Exhaust Port Temp Deviating Ignition Transformers Primary Circuit ................. 305
High ................................................................... 187 Ignition Transformers Secondary Circuit and Spark
E838 Cyl #18 Exhaust Port Temp Deviating Plugs ................................................................. 316
High ................................................................... 188 Inspecting Electrical Connectors ........................ 322
E839 Cyl #19 Exhaust Port Temp Deviating Integrated Temperature Sensing Module
High ................................................................... 188 (ITSM) ............................................................... 327
E840 Cyl #20 Exhaust Port Temp Deviating PWM Sensor ....................................................... 335
High ................................................................... 189 Throttle Actuator ................................................. 342
E841 Cyl #1 Exhaust Port Temp Deviating Low .. 189
E842 Cyl #2 Exhaust Port Temp Deviating Low .. 189 Calibration Procedures
E843 Cyl #3 Exhaust Port Temp Deviating Low .. 190 Engine Speed/Timing Sensor - Calibrate ............ 349
E844 Cyl #4 Exhaust Port Temp Deviating Low .. 190 Generator Output Power Sensor - Calibrate ....... 351
E845 Cyl #5 Exhaust Port Temp Deviating Low .. 191
9
Table of Contents
Index Section
Index ................................................................... 355
10
Troubleshooting Section
Troubleshooting Section Desired engine speed is determined by the status

of the idle/rated switch, the desired speed input
(analog voltage or 4 to 20 mA), and parameters
such as maximum engine high idle speed that
Electronic Troubleshooting are programmed into the software. Actual engine
speed is detected via a signal from the speed/timing
sensor. Parameters such as governor gain can be
i02072648 programmed with Cat ET.
System Overview
Air/Fuel Ratio Control
SMCS Code: 1900
The master ECM provides control of the air/fuel
mixture for performance and for efficiency at low
Introduction emission levels. The system consists of an electronic
fuel metering valve, output drivers in the master
Two Electronic Control Modules (ECM) are used to ECM, and maps in the master ECM. The control
control the engine. One module is the master ECM compensates for changes in the BTU of the fuel in
and the other module is the slave ECM. Each module order to maintain desired emission levels.
is an environmentally sealed unit that is mounted in a
terminal box on the engine. The following steps describe the basic operation:
The master ECM controls most of the functions of 1. The master ECM determines the desired flow
the engine. The master ECM monitors various inputs rates for the air and for the fuel. The flow rates are
from sensors in order to activate relays, solenoids, determined by these factors:
etc at the appropriate levels. The master ECM
supports the following five primary functions:
• Desired engine speed
• Engine speed governing • Actual engine speed
• Air/fuel ratio control • Calculated engine load
• Start/stop sequencing 2. The command for the flow of the fuel is sent to
the electronic fuel metering valve via the CAN
• Engine monitoring and protection data link.
• Control of the ignition and detonation of the left This process is repeated continuously during engine
cylinder bank operation.
The slave ECM primarily supports the control of
ignition and of detonation of the right cylinder bank. Start/Stop Sequencing
The master ECM contains the logic and the outputs
Engine Speed Governing for control of starting and of shutdown. The customer
programmable logic responds to signals from the
The master ECM maintains the desired engine following components: engine control, emergency
speed by controlling the actuator for the throttle. The stop switch, remote start switch, data link, and other
actuator is located at the inlet to the aftercooler. inputs.
The actuator is electrically controlled and electrically
actuated. When the programmable logic determines that it
is necessary to crank the engine, the master ECM
The master ECM issues a throttle command that supplies +Battery voltage to the relay for the starting
represents a percent of the level of electrical motor. The master ECM removes the voltage when
current. The output can be viewed on the Caterpillar the programmable crank terminate speed is reached
Electronic Technician (ET). or when a programmable cycle crank time has
expired.
11
The engine must be equipped with an energize-to-run The master ECM and the slave ECM provide
type of gas shutoff valve (GSOV). The source of extensive diagnostics for the ignition system. The
the voltage to the GSOV depends on the engine’s master ECM also provides a switch for ignition timing
configuration. The GSOV may be energized by the in order to allow operation with alternate fuels such
customer’s equipment or by the engine’s control as propane that require a timing offset.
system.
i01804722
If the engine’s control system controls the GSOV, the
master ECM supplies +Battery voltage to the GSOV
whenever the programmable logic determines that
Self-Diagnostics
fuel is required to operate the engine. SMCS Code: 1901
For more information on programmable parameters, Each Electronic Control Module (ECM) has the ability
see Troubleshooting, “Programming Parameters”. to detect problems with the electronic system and
with engine operation. When an ECM detects a
Engine Monitoring and Protection problem, the ECM generates a code. An alarm may
also be generated. There are two types of codes:
The master ECM monitors both the engine operation
and the electronic system. • Diagnostic
Problems with engine operation such as low oil • Event
pressure produce an event code. The master ECM
can issue a warning or a shutdown. This depends on Diagnostic Code – When a problem with the
the severity of the condition. For more information, electronic system or a component is detected, the
see Troubleshooting, “Troubleshooting With An Event master ECM or the slave ECM generates a diagnostic
Code”. code. The code indicates the specific problem with
the circuitry.
Problems with the electronic system such as an
open circuit produce a diagnostic code. For more Diagnostic codes can have two different states:
information, see Troubleshooting, “Troubleshooting
With A Diagnostic Code”. • Active
Ignition Control • Logged

Active Code – An active diagnostic code indicates
Each ECM provides variable ignition timing that is
that an active problem has been detected. Active
sensitive to detonation.
codes require immediate attention. Always service
active codes prior to servicing logged codes.
Each cylinder has an ignition transformer that is
located under the valve cover for the cylinder.
Logged Code – Every generated code is stored in
To initiate combustion, an ECM sends a pulse of
the memory of the ECM that detected the problem.
approximately 100 volts to the primary coil of an
The code is logged. Each ECM can store a maximum
ignition transformer at the appropriate time and for
of ten different codes at one time. Logged codes
the appropriate duration. The transformer steps up
remain in the memory of the ECM even if the power is
the voltage in order to create a spark across the
removed from the ECM. Logged codes may be useful
spark plug electrode.
to help troubleshoot intermittent problems. Logged
codes can also be used to review the performance of
Detonation sensors monitor the engine for
the engine and the electronic system.
excessive detonation. The G3520C Engine has
ten detonation sensors. Each sensor monitors two
Logged codes may not indicate that a repair is
adjacent cylinders. The sensors generate data on
needed. The problem may have been temporary. The
vibration that is processed by each ECM in order to
problem may have been resolved since the logging
determine detonation levels. If detonation reaches an
of the code. For example, if the system is powered
unacceptable level, the appropriate ECM retards the
and a sensor is disconnected, an ECM will detect the
ignition timing of the affected cylinder or cylinders. If
problem. The ECM will generate an active diagnostic
retarding the timing does not limit detonation to an
code for the problem. The ECM will also log the
acceptable level, the master ECM shuts down the
code. When the sensor is connected, the active code
engine.
will disappear. The logged code will remain in the
memory of the ECM until the code is cleared.
A code is cleared from memory when one of the

following conditions occur:
12
• The service technician manually clears the code. Actuators

• The code does not recur for 1000 hours.
• A new code is logged and there are already ten
codes in memory. In this case, the oldest code is
cleared.
Event Code – An event code is generated when

an ECM detects 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.
i02087842
Location of Components
SMCS Code: 1900
Fuel Metering Valve

g01012402
Illustration 2
Right side view
(1) Throttle actuator
(2) Actuator for the compressor bypass valve
Throttle actuator (1) and the actuator for the

compressor bypass valve (2) are electrically
controlled and electrically actuated. The master ECM
issues commands to the actuators via the CAN data
link.
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

and of shutoffs in response to abnormal operation.
Illustrations 3, 4, and 5 show the locations of the
sensors. Refer to Systems Operation/Testing and
Adjusting, “Engine Sensors” for the descriptions of
the sensors.
g01016786
Illustration 1
Top view of the engine. The 60 Hz configuration is shown. The
50 Hz configuration is similar.
The fuel metering valve is electrically controlled

and electrically actuated. The fuel metering valve
and the master Electronic Control Module (ECM)
communicate via the CAN data link.
13
g01064731
Illustration 3
Right side view
(1) Engine oil temperature sensor
(2) Pressure switch for the coolant pump
(inlet)
(3) Pressure sensor for unfiltered oil
(4) Pressure sensor for filtered oil
g01064733
Illustration 4
Top view
(5) Engine coolant temperature sensor (7) Inlet air temperature sensor
(6) Engine coolant pressure sensor (outlet) (8) Inlet air pressure sensor
14
g01064734
Illustration 5
Left side view
(9) Detonation sensor
(10) Speed/timing sensor
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.
Illustration 6 shows the locations of the

thermocouples. Refer to Systems Operation/Testing
and Adjusting, “Integrated Temperature Sensing
Module” for the descriptions of the thermocouples.
15
g01064747
Illustration 6
Locations of the thermocouples
(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
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.
Illustration 7 shows the location of the ITSM. Refer to

Systems Operation/Testing and Adjusting, “Integrated
Temperature Sensing Module” for the description of
the ITSM.
g01066046
Illustration 7
Integrated temperature sensing module on the left side of the
engine
16
i02088018 Terminal Box

Electrical Connectors and
Functions
SMCS Code: 7553-WW
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 8
g01064774
RD Red Rear view
WH White (1) Terminal box

(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 located
wire is stamped with a specific circuit number that is
between the terminal box and the engine.
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.
17
g01064776
Illustration 9
Components inside the terminal box
(3) Master ECM (9) Master ECM connector P1 (14) J10/P10 connector for the terminating
(4) Slave ECM (10) Ignition harness for the left bank resistor for the CAN data link
(5) Ground strap for the master ECM (11) Ground strap for the slave ECM (15) J6 connector for the customer
(6) P3 connector for the slave ECM (12) Ignition harness for the right bank (16) J9 connector
(7) Master ECM connector P2 (13) Service tool connector J5 for the (17) J7 connector
(8) P4 connector for the slave ECM Caterpillar Electronic Technician (ET) (18) J8 connector for the detonation sensors
18
Junction Box
g01059145
Illustration 10
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 The tools that are listed in Table 2 are required in
for the engine. The junction box also contains the order to enable a service technician to perform the
magnetic switches for the electric starting motors. procedures.
i02088034
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.
• Program parameters.
• Calibrate sensors.
19
Table 2
Service Tools
Pt. No. Description Functions
N/A Personal Computer (PC) The PC is required for the use of Cat ET.
“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
171-4400 (1) Communication Adapter Gp This group provides the communication between the PC and the
engine.
7X-1414 Data Link Cable As This cable connects the communication adapter to the service tool
connector on the engine.
237-7547 Adapter Cable As This cable connects to the USB port on computers that are not
equipped with a serial port.
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 of sockets from
Deutsch connectors and AMP connectors.
1U-5804 Crimp Tool This tool is used for work with CE electrical connectors.
146-4080 Digital Multimeter The multimeter is used for the testing and for 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.
(1) The 7X-1700 Communication Adapter Gp may also be used.
Note: For more information regarding the use of Cat Connecting Cat ET with the 171-4401
ET and of the PC requirements for Cat ET, refer to Communication Adapter II
the documentation that accompanies your Cat ET
software. The engine’s power supply supplies the
communication adapter with 24 VDC. Use the
Caterpillar Electronic Technician following procedure to connect Cat ET and the
communication adapter to the engine.
(ET)
1. Set the engine control to the OFF/RESET mode.
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
20
6. Connect cable (5) to the service tool connector

on terminal box (6).
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”.
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.
i02088048
Engine Monitoring System

SMCS Code: 7490
g01059043
Illustration 11 The master Electronic Control Module (ECM)
Right side view monitors the operating parameters of the engine.
(1) PC
The master ECM can initiate responses if a specific
(2) 196-0055 Serial Cable engine parameter exceeds an acceptable range.
(3) 171-4401 Communication Adapter II Two possible responses may be available for each
(4) 207-6845 Adapter Cable parameter: “WARNING” and “SHUTDOWN”. Some
(5) 7X-1414 Data Link Cable of the responses are not available for some of the
(6) Terminal box
parameters. Use the Caterpillar Electronic Technician
(ET) to perform the following activities:
Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
• Select the available responses.
2. Connect cable (2) to the RS232 serial port of PC
(1). • Program the level for monitoring.
Note: If your PC is not equipped with a serial port, • Program delay times for each response.
use the 237-7547 Adapter Cable As in order to
The default settings for the parameters are
connect to the USB port. Connect one end of the
programmed at the factory. To accommodate unique
adapter to the end of cable (2). Connect the other
applications and sites, the parameters may be
end of the adapter to a USB port on the PC.
reprogrammed with Cat ET. The screens of Cat ET
provide guidance for the changing of trip points.
3. Connect cable (2) to communication adapter (3).
Note: Some of the parameters are protected
4. Connect cable (4) to communication adapter (3).
by factory passwords. Other parameters can be
changed with customer passwords.
5. Connect cable (4) to cable (5).
21
Changing the Settings of the “Engine Overspeed”

Monitoring System The trip point for this parameter is set at the factory.
This parameter is always ON. This parameter cannot
Use the following procedure to change settings of
be turned off. If the engine speed increases to the trip
the parameters:
point or if the engine speed exceeds the trip point,
the ECM will activate an engine shutdown. A typical
1. Use Cat ET and select the “Service/Monitoring
trip point is 118 percent of the engine’s rated speed
System” screen.
for generator set applications.
2. Highlight the desired parameter. Then click on the
“Change” button in the lower left corner of the “High Engine Oil Temperature”
screen.
The trip point for a warning for this parameter can
The “Change Monitor System” screen will appear. be programmed by the customer. The trip point for
a shutdown is set at the factory. This parameter is
3. Change the “State” to “On” or “Off”. always ON. This parameter cannot be turned off. If
the engine oil temperature increases to the trip point
4. Set the “Trip Point” and the “Delay Time” according or if the engine oil temperature exceeds the trip point,
to the “Allowed Values” in the lower half of the the ECM will generate a warning or a shutdown.
screen.
“High Oil Filter Differential Pressure”
5. Click the “OK” button.
The trip point for a warning for this parameter can
If a password is required, the “Enter Passwords” be programmed by the customer. The trip point for
screen will appear. Enter the correct passwords a shutdown is set at the factory. This parameter is
and then click the “OK” button. always ON. This parameter cannot be turned off. If
the engine oil filter differential pressure increases
The new settings will be effective immediately. to the trip point or if the engine oil filter differential
pressure exceeds the trip point, the ECM will
Monitoring Parameters generate a warning or a shutdown.
“Low System Voltage” “Low Oil Filter Differential Pressure”
The trip point for this parameter is set at the factory. The trip point for a warning for this parameter can
The trip point cannot be changed. This parameter be programmed by the customer. The trip point for a
is always ON. This parameter cannot be turned off. shutdown for this parameter is set at the factory. This
If the system voltage decreases to the trip point or parameter is always ON. This parameter cannot be
if the system voltage goes below the trip point, the turned off. If the engine oil filter differential pressure
ECM will generate a warning or a shutdown. decreases to the trip point or if the engine oil filter
differential pressure goes below the trip point, the
ECM will generate a warning or a shutdown.
“High Engine Coolant Temperature”
The trip points for this parameter can be programmed “High Fuel Temperature”
by the customer. The shutdown response is always
ON. The shutdown response cannot be turned off. If The trip point for this parameter can be programmed
the engine coolant temperature increases to the trip by the customer. If the fuel temperature increases to
point or if the engine coolant temperature exceeds the trip point or if the fuel temperature exceeds the
the trip point, the ECM will generate a warning or a trip point, the ECM will generate a warning.
shutdown.
“Low Fuel Pressure”
“Low Engine Coolant Temperature”
The trip point for this parameter can be programmed
The trip point for this parameter can be programmed by the customer. If the fuel pressure decreases to the
by the customer. If the engine coolant temperature trip point or if the fuel pressure goes below the trip
decreases to the trip point or if the engine coolant point, the ECM will generate a warning.
temperature goes below the trip point, the ECM will
generate a warning.
22
“High Engine Oil to Engine Coolant If the load is less than the trip point, the trip point
Differential Temperature” for the “High Inlet Air Temperature at Low Engine
Load” event is used for the logging of the high inlet
The trip point for a warning for this parameter can air temperature.
be programmed by the customer. The trip point for a
shutdown for this parameter is set at the factory. The “High Inlet Air Temperature at Low
shutdown response is always ON. The shutdown Engine Load”
response cannot be turned off. If the differential
temperature of the jacket water and the engine The “Service/Configuration” screen of Cat ET defines
oil increases to the trip point or if the differential the “High Inlet Air Temp Engine Load Set Point”. The
temperature of the jacket water and the engine oil ECM can activate a warning or a shutdown if the inlet
exceeds the trip point, the ECM will generate a air temperature increases to the trip point or if the
warning or a shutdown. inlet air temperature exceeds the trip point during the
low load operation that is defined.
“Low Gas Fuel Differential Pressure”
“High Inlet Air Temperature at High
by the customer. If the fuel differential pressure Engine Load”
decreases to the trip point or if the fuel differential
The “Service/Configuration” screen of Cat ET defines
pressure goes below the trip point, the ECM will
generate a warning. the “High Inlet Air Temp Engine Load Set Point”. The
ECM can activate a warning or a shutdown if the inlet
air temperature increases to the trip point or if the
“High Gas Fuel Differential Pressure” inlet air temperature exceeds the trip point during the
high load operation that is defined.
by the customer. If the fuel differential pressure
increases to the trip point or if the fuel differential “High Fuel Pressure”
pressure exceeds the trip point, the ECM will
generate a warning.
by the customer. The ECM will activate a warning if
the fuel pressure increases to the trip point or if the
“High System Voltage” fuel pressure exceeds the trip point.
The trip point for this parameter is set at the factory.
The trip point cannot be changed. This parameter is Default Settings of the Monitoring
always ON. This parameter cannot be turned off. If System
the system voltage increases to the trip point or if
the system voltage exceeds the trip point, the ECM Examples of the default settings for the parameters
will generate a warning. are listed in Table 3. The values may have changed.
Use the Cat ET to determine the programming for
Trip Points of the Engine Load for High your engine. Many of the items can be reprogrammed
Inlet Air Temperature in order to accommodate the requirements of
individual sites.
The trip points for these parameters can be
programmed by the customer. The 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 load. The
trip point is used for events that involve high inlet air
temperature. The trip point for the events is based
on the engine load. The possible responses of the
system include a warning or a shutdown.
If the load is greater than the trip point, the trip point
for the “High Inlet Air Temperature at High Engine
Load” event is used for the logging of the high inlet
air temperature.
23
Table 3
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 109 °C
“High Engine
Coolant 80 to 129 °C
Temperature” “E016 (3)” Shutdown On (1) 113 °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 This item cannot be programmed.
Voltage”
“High Inlet Air E027 (1) On 69 °C 32 to 85 °C
Temperature
at Low Engine E026 (3) Shutdown On (1) 73 °C
Load”
20
“High Inlet Air E027 (1) Warning On 53 °C 32 to 100 °C
Customer 1 to 60
Temperature
at High Engine E026 (3) Shutdown On (1) 57 °C
Load”
“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.
24
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
4.
Table 4
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.
25
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 5 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.
26
Table 5
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.
27
Programming Parameters After the customer passwords are entered, the

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

Changing the parameters during engine operation can memory of the Master Electronic Control Module
cause the engine to operate erratically. This can cause (ECM).
engine damage.
Make a copy of Table 6 and record your passwords.
Only change the settings of the parameters when the Store the passwords securely.
engine is STOPPED.
Table 6
Customer Passwords
i01902441 Customer Password #1
Customer Passwords Customer Password #2
SMCS Code: 0785

i01865997
Certain monitoring system parameters and system
configuration parameters may be protected with Factory Passwords
customer passwords. Use of the passwords helps
to prevent free access to the modification of the SMCS Code: 0785
parameters. If the customer passwords are not
programmed, all of the parameters are unprotected. Factory level security passwords are required for
clearing certain logged events and for changing
The customer passwords can be changed, if certain programmable parameters. Because of the
necessary. The customer passwords or a factory passwords, only authorized personnel can make
password is needed in order to change the customer changes to some of the programmable items in
passwords. If the customer passwords are forgotten, an Electronic Control Module (ECM). When the
factory passwords can be acquired from Caterpillar. correct passwords are entered, the changes are
programmed into the master ECM.
28
Factory passwords are required to program the i02089534

following shutdowns:
Factory Passwords Worksheet
• “Engine Overspeed”
SMCS Code: 0785
• “High Engine Oil Temperature”
• “High Oil Filter Differential Pressure”
The connection of any electrical equipment and
• “Low Oil Filter Differential” the disconnection of any electrical equipment may
cause an explosion hazard which may result in in-
• “High Engine Oil to Engine Coolant Differential jury or death. Do not connect any electrical equip-
Temperature” ment or disconnect any electrical equipment in an
explosive atmosphere.
The “Enter Factory Passwords” screen on Cat ET
will display the following parameters. To obtain the
proper passwords, the information must be given to Note: A mistake in recording this information will
an authorized Caterpillar dealer: result in incorrect passwords.
Table 7
• Current master ECM
Factory Passwords Worksheet
• Serial number of the service tool Dealer Code
• Serial number of the engine Customer’s Name

Address
• Serial number of the master ECM
• Diagnostic clock
Telephone Number
• Total Tattletale
Information from the “Enter Factory Passwords”
• Reason Screen on the Caterpillar Electronic
Technician (Cat ET)
The old interlock code is required to change the
Serial Number for Cat ET
interlock code on a used ECM. The passwords are
controlled by Caterpillar. The passwords may only be Engine Serial Number
obtained by an authorized Caterpillar dealer.
ECM Serial Number
The passwords may only be used for one Total Tattletale
programming session. After you exit the “Enter
Reason Code
Factory Passwords” screen on Cat ET, a different
set of passwords will be required before you can Factory Passwords
program the master ECM.
Factory Password (No. 1)
Factory passwords are not required for the first hour Factory Password (No. 2)
of operation for a new master ECM. After the hour
expires, factory passwords are required for some of
the programming.
29
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 order
SMCS Code: 1901-591 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 ECM, 7. Select the “Begin Flash” button in order to program
and the Integrated Temperature Sensing Module the personality module.
(ITSM). The Caterpillar Electronic Technician (ET)
can be used to flash new software into an ECM or When the flash is completed, this message will
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/Preferences” program any parameters that were not in the
option on the Cat ET. Select the “Communications” original software.
tab and click on “Advanced...”. Then select the baud
rate from the “Advanced Communication Settings” b. Access the “Configuration” screen under
menu and click the “OK” button. the “Service” menu in order to determine
the parameters that require programming.
If a communication error occurs, select a slower baud Look under the “Tattletale” column. All of the
rate in order to improve the reliability. parameters should have a tattletale of 1 or
more. If a parameter has a tattletale of 0,
1. Connect Cat ET to the service tool connector. program that parameter.
Refer to Troubleshooting, “Electronic Service
Tools”. “WinFlash” Error Messages
2. Set the engine control to the STOP mode. If you receive any error messages during flash
programming, click on the “Cancel” button in order
Cat ET will not flash if the engine control is in the to stop the process. Access the information about
OFF/RESET or START mode. the “ECM Summary” under the “Information” menu.
Make sure that you are flashing the correct file for
3. Select “WinFlash” from the “Utilities” menu on the your engine.
Cat ET.
“WinFlash” will try to detect an ECM. Allow a few i01945454
moments for “WinFlash” to detect the electronic

control modules and connect to the electronic
System Configuration
control modules. Parameters
4. When an ECM has been detected, the “ECM SMCS Code: 1901
Selector” window will appear. Select the
appropriate ECM and then select “OK”. Certain parameters are unique for each engine
application. Table 8 is a list of the parameters that can
The “Flash File Selection” window will appear. be configured for G3520C Engines. The parameters
are programmed into the Electronic Control Module
5. The flash files are located on a disk drive and in (ECM) via the Caterpillar Electronic Technician (Cat
a directory. Select the correct disk drive and the ET). The values of the parameters can be viewed on
directory from “Drives” and “Directories” on Cat the “Configuration” screen of Cat ET.
ET.
30
Refer to Systems Operation/Testing and Adjusting, (Table 8, contd)

“Electronic Control System Parameters” for the Configuration Parameters for G3520C Engines
descriptions of the parameters.
Power Monitoring
Table 8
“Generator Output Power Sensor Scale Factor”
Configuration Parameters for G3520C Engines
“Generator Output Power Sensor Offset”
Timing Control
“Engine Output Power Configuration”
“First Desired Timing”
“Engine Driven Accessory Load Configuration”
“Second Desired Timing”
Information for the ECM
Air/Fuel Ratio Control
“Engine Serial Number”
“Fuel Quality”
“Equipment ID”
“Gas Specific Gravity”
“Customer Password #1”
“Fuel Specific Heat Ratio”
“Customer Password #2”
“Desired Emission Gain Adjustment”
“Total Tattletale”
“Air/Fuel Proportional Gain”
“Air/Fuel Integral Gain”
i02088063
Speed Control
“Low Idle Speed”
Replacing the ECM
“Minimum High Idle Speed” SMCS Code: 1901-510
“Maximum High Idle Speed” Electronic control modules contain no moving parts.
“Engine Accel. Rate” Replacement of an Electronic Control Module (ECM)
can consume much time. Before you replace an
“Desired Speed Input Configuration” ECM, follow the troubleshooting procedures in this
“Governor Type Setting” manual in order to be sure that replacement of the
ECM will correct the problem.
“Engine Speed Droop”
“Governor Proportional Gain” Note: The master ECM and the slave ECM should
not be interchanged in order to determine if an
“Governor Integral Gain” ECM is faulty. If the master ECM and the slave ECM
“Governor Derivative Gain” are interchanged, all of the configuration data for
each ECM must be transferred into the Caterpillar
“Auxiliary Proportional Governor Gain 1” Electronic Technician (ET). The appropriate
“Auxiliary Integral Governor Gain 1” configuration data must then be re-entered into the
appropriate ECM. Failure to program each ECM
“Auxiliary Derivative Governor Gain 1” correctly may result in improper engine operation.
Start/Stop Control
Verify that the suspect ECM is the cause of the
“Driven Equipment Delay Time” problem. Install a test ECM in place of the suspect
“Crank Terminate Speed” ECM. Transfer the software from the suspect ECM
to the test ECM. Program all the parameters for the
“Engine Purge Cycle Time” test ECM in order to match the parameters of the
“Engine Cooldown Duration” suspect ECM. The parameters must match. Refer
to the following test steps for details on programming
“Cycle Crank Time” the parameters.
“Engine Overcrank Time”
If the test ECM resolves the problem, reconnect the
“Engine Speed Drop Time” suspect ECM. Verify that the problem recurs. If the
“Engine Pre-lube Time Out Period”
problem recurs, replace the suspect ECM with the
test ECM.
Monitoring and Protection
Note: If the parameters cannot be read from the
“High Inlet Air Temp Load Set Point”
suspect ECM, the parameters must be obtained from
(continued) records or from the factory.
31
Perform the following procedure to replace the ECM.
1. Use the “Service/Copy Configuration/ECM

Replacement” function of the Caterpillar Electronic
Technician (ET).
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 drop-down menu on Cat ET.
Cat ET will load the configuration parameters

and the monitoring system parameters of the
suspect ECM.
g01054206
Illustration 12
b. Select “Load from ECM” in the lower left corner Junction box
of the Cat ET screen. Select the suspect ECM
(1) 35 amp circuit breaker
and select “OK”.
After the loading is complete, the Cat ET will b. Switch 35 amp circuit breaker (1) to the OFF
display this message: “The data has been position.
successfully loaded from the ECM”. Select
“OK”.
c. Select “File/Disconnect F8” from the drop-down

menu.
Note: Do not terminate the Cat ET.
2. Replace the ECM.
Note: This procedure describes replacement of the

master ECM. Replacement of the slave ECM is
similar.
a. Set the engine control to the OFF/RESET

mode.
g01064809
Illustration 13
The master ECM is on the left side of the terminal box. The slave
ECM is on the right side of the terminal box.
(2) Mounting nut
(3) P2 connector
(4) P1 connector
c. Use a 4 mm allen wrench to disconnect

connectors (3) and (4).
d. Remove mounting nut (2) in order to disconnect

the ground strap. Remove the three remaining
mounting nuts.
32
Note: Rubber grommets behind the ECM are held in 5. Calibrate the speed/timing sensor.
place by the mounting studs. The grommets help to
reduce vibration. The grommets may fall when the See Troubleshooting, “Engine Speed/Timing
ECM is removed. Be sure not to lose the grommets. Sensor - Calibrate”.
e. Remove the ECM from the terminal box.

i02088110
3. Install the replacement ECM. Replacing the ITSM

a. Use the mounting hardware to install the new SMCS Code: 1901-510
ECM. Use a mounting nut to fasten the ground
strap for the ECM to the upper left mounting The Integrated Temperature Sensing Module (ITSM)
stud. Then install the other three mounting contains no moving parts. Replacement of the ITSM
nuts. can consume much time. Before you replace an
ITSM, follow the troubleshooting procedures in this
Check the mounting hardware and the ECM for manual in order to be sure that replacement of the
correct installation. A correctly installed ECM ITSM will correct the problem.
will move slightly on the rubber grommets.
If the ECM cannot move slightly on the Use the following guidelines to verify that the suspect
grommets, check that the washers, spacers, ITSM is the cause of the problem:
and grommets are positioned correctly.
Install a test ITSM in place of the suspect ITSM.
b. Use a 4 mm allen wrench to connect the P1 Transfer the software from the suspect ITSM to
and P2 connectors to the ECM. Tighten the the test ITSM. Program all the parameters for the
screws to a torque of 6 ± 1 N·m (55 ± 9 lb in). test ITSM in order to match the parameters of the
suspect ITSM. The parameters must match. Refer
4. Program the configuration parameters and to the following steps for details on programming the
the monitoring system parameters into the parameters.
replacement ECM.
If the test ITSM resolves the problem, reconnect the
a. Switch 35 amp circuit breaker (1) to the ON suspect ITSM. Verify that the problem recurs. If the
position. problem recurs, replace the suspect ITSM with the
test ITSM.
b. Set the engine control to the “STOP” mode.
Use the following procedure to replace the ITSM:
c. Select “File/Select ECM” from the drop-down
menu. Note: If the parameters cannot be read from the
suspect ITSM, the parameters must be obtained from
d. Select the replacement ECM and click “OK”. records or from the factory.
e. Select “Service/Copy Configuration/ECM 1. Use the “Service/Copy Configuration/ECM
Replacement” from the drop-down menu. Click Replacement” function of the Caterpillar Electronic
“OK” on the window. Technician (ET) in order to transfer the software
from the suspect ITSM.
f. Select “Program ECM” from the lower left
corner of the screen. Select the replacement You may also select the “Print” function in order to
ECM and click “OK”. If the correct ECM is obtain a paper copy of the parameter settings.
shown, select “Yes”.
Note: Before you replace an ITSM, record all of the
g. After the loading is complete, a window with logged events.
the message “Programming Conflict Warning”
will appear. Select “OK”. a. Connect Cat ET with the communications
adapter. Select “Service/Copy
h. A window with the message “Program ECM Configuration/ECM Replacement” from
Results” will appear. Select “OK”. the drop-down menu.
Note: When you program a new ECM, factory Cat ET will load the configuration parameters
passwords are not required for the first hour of and the monitoring parameters from the ECM.
operation. After one hour, factory passwords are
required for changing the parameters that are
normally protected with factory passwords.
33
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 drop-down

menu.
Note: Do not exit from Cat ET.
2. Replace the ITSM.
a. Set the engine control to the OFF/RESET

mode.
g01064840
Illustration 15
Rear view
(2) Connectors for the harness to the thermocouples
(3) Connectors for the harness to the terminal box for the master
ECM
c. Disconnect connectors (2) and (3) from the

ITSM.
g01054206
Illustration 14
Junction box
b. Switch 35 amp circuit breaker (1) to the OFF

position.
g01064841
Illustration 16
Mounting hardware for the ITSM
(4) Nut
(5) Ground strap
(6) Washer
(7) Mounting flange on the ITSM
d. Remove four 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.

34
3. Install the replacement ITSM. Orient the 54-pin i02089781

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 Illustration 17. Be sure to include the
Note: One of the washers is a lock washer. Be sure units 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 drop-down

menu of Cat ET.
d. Select the “Replacement ITSM” and click “OK”.
e. Select “Service/Copy Configuration/ECM

Replacement” from the drop-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.
35
g01013492
Illustration 17
Data sheet for troubleshooting
Report the Service Information Repair – Explain your repair of the problem. For
example, you may have installed a new wiring
After you have successfully repaired the engine, it harness. You may have replaced the ignition
is important to provide good information about the transformer per instructions from the factory.
repair. The following topics are recommended for
your report: The providing of complete, accurate information will
help Caterpillar to provide better service to you and
Complaint – Include a description of the customer’s to the customer.
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.
36
Troubleshooting without a Narrow the probable cause. Consider the operator

information, the conditions of operation, and the
Diagnostic Code history of the engine.
i01970297
Operator Information
Symptoms Obtain the following information from the operator:
SMCS Code: 1000-035 • The occurrence and the time of the occurrence
Some engine symptoms can be unrelated to • Determine the conditions for the occurrence. The
the electronic control system. This section is for conditions will include the engine rpm and the load.
troubleshooting problems that have symptoms
without active diagnostic codes. Conditions such as • Determine if there are any systems that were
poor fuel quality or improperly adjusted valves can installed by the dealer or by the customer that
cause some engine symptoms. could cause the symptom.
For basic troubleshooting of the engine, perform • Determine whether any other occurrences
the following steps first in order to diagnose a happened in addition to the symptom.
malfunction.
Diagnostic Codes and Event Codes
1. Gather information about the complaint from the
operator. Examine the following information regarding any
codes:
2. Verify that the complaint is not due to normal
engine operation. Verify that the complaint is not • The probable cause of the symptom is correlated
due to error of the operator. to the code.
3. Perform a visual inspection. Inspect the following • The code was generated when the symptom
items: occurred.
• Fuel supply • Codes that are repeatedly logged

• Oil level • The complaint is not due to normal engine
operation.
• Oil supply
• Coolant level Other Symptoms
• Wiring If other occurrences happened in addition to the
symptom, investigate the following conditions:
• Connectors
• The other occurrences are related to the symptom.
4. Check the diagnostic codes and event codes.
Repair any active codes. • The symptoms have a probable cause that is
common.
If these inspections do not reveal any problems,
identify the probable causes with the procedures in i02064369
this manual that best describe the symptoms. Refer to
Troubleshooting, “Troubleshooting With A Diagnostic Detonation
Code” or refer to Troubleshooting, “Troubleshooting
With an Event Code”. Check each probable cause SMCS Code: 1000-035
according to the tests that are recommended.
Be sure to check the connectors. This is specially Probable Causes

true for problems that are intermittent. Refer to
Troubleshooting, “Inspecting Electrical Connectors”. • Excessive load
• Excessive inlet manifold air pressure
• High inlet air temperature
37
• Incorrect air/fuel ratio Check the Base Timing

• Incorrect base timing Verify that the base timing is correct. Refer to
Systems Operation/Testing and Adjusting, “Ignition
• Changes in the fuel quality Timing - Adjust”.
• The engine speed/timing sensor is not calibrated. Check for Event Codes Regarding the
Fuel
• Faulty circuit for the detonation sensor(s)
Check for the following event codes:
• Excessive deposits in the combustion chamber
• “E229 (1) Fuel Energy Content Setting Low”
Recommended Repairs (warning)
Excessive Load • “E230 (1) Fuel Energy Content Setting High”

(warning)
Make sure that the load is not excessive. Reduce the
load. If necessary, disengage the driven equipment • “E231 (3) Fuel Quality Out Of Range” (shutdown)
and test the engine.
Refer to Troubleshooting, “Fuel Energy Content”.
Check the Inlet Manifold Air Pressure
Calibrate the Engine Speed/Timing
The calculated engine load increases when the inlet Sensor
manifold air pressure increases. Measure the inlet
manifold air pressure during engine operation with Note: Only perform this procedure if work on the
a load. For specific data on the engine, refer to the engine may have affected the engine timing. Also,
engine Technical Marketing Information. perform this procedure if the engine speed/timing
sensor has not been calibrated.
Check the Inlet Air Temperature
Calibrate the engine speed/timing sensor. Refer to
High inlet air temperature can cause detonation. Troubleshooting, “Engine Speed/Timing Sensor -
Check the inlet air temperature. Look for the following Calibrate”.
event codes:
Check the Detonation Sensors
• “E026 (3) High Inlet Air Temperature” (shutdown)
Troubleshoot the detonation sensors. Refer to
• “E027 (1) High Inlet Air Temperature” (warning) Troubleshooting, “Detonation Sensors”.
Refer to Troubleshooting, “Inlet Air Temperature Check for Deposits in the Cylinders
(High)”.
Overfilling of engine oil can lead to deposits. Make
Air/Fuel Ratio sure that the engine oil level is correct.
An air/fuel mixture that is too rich will cause Note: Excessive deposits contribute to guttering of
detonation. Verify that the exhaust emissions are the valves.
correct. Refer to Systems Operation/Testing and
Adjusting, “Air/Fuel Ratio Control - Adjust”. Use a borescope to inspect the cylinders. Look for
the following conditions:
A change in the fuel energy content will change the
air/fuel ratio. Obtain a fuel analysis. • Deposits on the valve seats
The fuel supply pressure must be adequate and • Deposits on the valve faces
stable.
• Deposits on the cylinder walls that are above the
Make sure that the fuel metering valve is operating upper limit of the piston stroke
correctly.
• Signs of internal leaks
Signs of internal leaks include excessive consumption
of engine oil, blue smoke, and excessive detonation.
38
If excessive deposits and/or signs of internal leaks • Total Tattletale

are found, investigate the cause of the condition.
Make repairs, as needed. • Reason Code
i02088119 Recommended Repairs

Driven Equipment 1. Verify that the correct passwords were entered.
Check every character in each password. Set the
SMCS Code: 1400-035 engine control to the OFF/RESET mode for 30
seconds and then retry.
Probable Causes
2. Verify that Cat ET is on the “Factory Password”
screen.
• The master Electronic Control Module (ECM) has
received a “Start Inhibit” or a “Shutdown” signal.
3. Verify that the following information from Cat ET
has been recorded correctly:
• The circuit for the signal is faulty.
• Serial Number of the engine
Recommended Repairs
• Serial Number of the Electronic Control Module
Check the Driven Equipment (ECM)
Determine whether the driven equipment has • Serial Number of the Cat ET
generated a “Start Inhibit” or “Shutdown” request.
Determine the cause for the request. Service the • Total Tattletale
driven equipment according to the recommendations
of the OEM of the equipment. • Reason Code
Check the Circuit for the Switch • Diagnostic Clock
The circuit for the switch must remain closed in order i01804831
to allow the engine to run. Check the wiring between
the driven equipment and the ECM connector for Electronic Service Tool Will
damage and/or corrosion. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. Repair the wiring, Not Communicate with ECM
as needed. (The Caterpillar Electronic
Check the resistance of the circuit between terminals Technician (ET) Will Not
P1-21 and P1-31 at the master ECM. The correct Communicate With an
resistance of the circuit is 5 Ohms or less. If the
resistance is greater than 5 Ohms, locate the source Electronic Control Module
of the excessive resistance. Make repairs, as needed. (ECM) and/or the Integrated
Temperature Sensing Module
(ITSM))
i01804809
ECM Will Not Accept Factory

SMCS Code: 0785-035
Passwords
SMCS Code: 1901-035 Probable Causes
Probable Causes • Electrical power supply
One of the following items may not be recorded • Electrical connectors

correctly on the Caterpillar Electronic Technician
(ET): • Communication adapter and/or cables
• Electronic service tool
• Passwords
• Serial Numbers • A problem with the harness code for the slave ECM
39
Recommended Repairs If the jumper wire is disconnected, the slave ECM

will assume the function of a master ECM. Cat ET
Electrical Power Supply will not communicate with any of the modules. Cat
ET will display “Duplicate Type on data link. Unable
Check power to the module. Refer to Troubleshooting, to Service”.
“Electrical Power Supply”.
Set the engine control to the OFF/RESET mode.
Note: If a module is not receiving power, the module Switch the 35 amp circuit breaker OFF. Check the
will not communicate. continuity between terminals J3-29 and J3-60. Verify
that the jumper wire is in good condition. Make
repairs, as needed.
Electrical Connectors
Check the following components: i01974132
• Power supply connections and ground to the Engine Coolant Temperature

module (High)
• Wiring harnesses and the connectors for the SMCS Code: 1395-035
module
Refer to Troubleshooting, “Inspecting Electrical Probable Causes

Connectors”.
• High ambient temperature and/or high inlet air
temperature
Communication Adapter and/or Cables
1. Check the condition of the fuse for the • Low coolant level and/or coolant leakage
communication adapter.
• Insufficient flow of air or coolant through the
radiator or heat exchanger
2. Disconnect the communication adapter and the
cables from the service tool connector. Then
reconnect the communication adapter. • Faulty water temperature regulators
If you are using the 171-4401 Communication • Faulty coolant temperature sensor and/or circuit
Adapter II, refer to Manual, “Communication
Adapter II User’s Manual”. • Insufficient flow of coolant through the engine
3. Verify that power supply voltage is present • Exhaust restriction

between terminals A and B of the J5 service tool
connector. If the communication adapter is not • Excessive load
receiving power, the display will be blank.
• Incorrect base timing
Electronic Service Tool • Incorrect air/fuel ratio
In order to eliminate Cat ET as the problem, connect
Cat ET to a different engine. If the same problem Recommended Repairs
occurs with a different engine, check Cat ET and the
related equipment in order to determine the cause Check for High Ambient Temperature
of the problem. and/or High Inlet Air Temperature
Check the Harness Code for the Slave Determine if the ambient air temperature is within the
ECM design specifications for the cooling system.
The harness inside the terminal box has a jumper Check for high inlet air temperature. Refer to
wire (harness code) that connects terminals J3-29 Troubleshooting, “Inlet Air Temperature (High)”.
and J3-60. The ECM that is connected to the harness
reads the harness code. This allows the ECM to Determine the cause of the high air temperature.
operate as the slave ECM. Make corrections, when possible.
40
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 Flow of Coolant Through the
Check the coolant level. Engine
Run the engine to operating temperature. Inspect the During normal operation, check the status of the
cooling system for leaks. following components:
Determine whether the leak occurs before the engine • Switch for the inlet pressure of the jacket water
overheats.
• Sensor for the outlet pressure of the jacket water
Add coolant, if necessary. If leaking is found, make
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. Check “Air Inlet and Exhaust System”.
the fan for proper operation.
If the back pressure exceeds the specifications for
If the radiator fins are obstructed, clean the fins. If the the engine, determine the cause of the excessive
fan does not operate properly, make the necessary back pressure. Make the necessary repairs.
repairs.
Excessive Load
Heat Exchanger
Check for sufficient flow and temperature of the load. If necessary, disengage the driven equipment
cooling water through the heat exchanger. If the and test the engine.
flow of cooling water through the heat exchanger is
insufficient, determine the location of the obstruction. Check the Base Timing
If the temperature of the cooling water is too high,
determine the cause. Make the necessary repairs. Verify that the base timing is correct. Refer to
Check the Water Temperature Regulators Timing - Adjust”.
Check the water temperature regulators for proper Air/Fuel Ratio

operation. Refer to Systems Operation/Testing and
Adjusting, “Testing the Cooling System”. An air/fuel mixture that is too rich will cause
overheating. Verify that the exhaust emissions are
Replace the water temperature regulators, if correct. Refer to Systems Operation/Testing and
necessary. Adjusting, “Air/Fuel Ratio Control - Adjust”.
Check the Coolant Temperature Sensor A change in the fuel energy content will change the
and/or the Circuit air/fuel ratio. Obtain a fuel analysis.
Check the reading of the coolant temperature on The fuel supply pressure must be adequate and
the Caterpillar Electronic Technician (ET). The stable.
temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable.
41
Strike the gas pressure regulator with a soft hammer. If the water temperature regulators are
If the engine speed changes, inspect the internal malfunctioning, check the water temperature
parts of the gas pressure regulator for wear. Inspect regulators according to Systems Operation/Testing
the gas pressure regulator’s diaphragm for leaks. and Adjusting, “Testing the Cooling System”. Replace
Make sure that the valve moves freely. The valve the water temperature regulators, if necessary.
must seat correctly.
i02088134
Ensure that the fuel metering valve is operating
correctly. Engine Cranks but Will Not
Start
i01727368
Engine Coolant Temperature SMCS Code: 1000-035; 1400-035
(Low) Probable Causes

SMCS Code: 1395-035
• Fuel supply
Probable Causes • Electrical connectors or power supply
• Faulty jacket water heater • No signal from the speed/timing sensor
• Faulty coolant temperature sensor and/or circuit • Ignition system
• Faulty water temperature regulators • Incorrect base timing
Recommended Repairs • Excessive load
Check the Jacket Water Heater Recommended Repairs

Determine if the jacket water heaters are functioning Fuel Supply
properly.
Make sure that fuel is supplied at a sufficient pressure
If the jacket water heaters are not functioning that is stable. Make sure that the size of the fuel line
properly, determine the cause of the malfunction of is sufficient. Inspect the fuel system for leaks.
the heaters. Make the necessary repairs.
The following conditions can cause the engine to
Check the Coolant Temperature Sensor malfunction:
and/or the Circuit
• Low fuel pressure
Check the reading of the coolant temperature with
the Caterpillar Electronic Technician (ET). The • High fuel pressure
temperature should rise steadily as the engine is
warmed. Ensure that the temperature is reasonable. • Poor fuel quality
Make sure that the fuel pressure is correct. When
If the reading on Cat ET for the coolant temperature
possible, interview the operator in order to determine
is not reasonable, troubleshoot the circuit if fuel quality is in question. Try to determine if the
and the coolant temperature sensor. Refer to
source of the fuel was changed.
Troubleshooting, “Analog Sensor Signal”.
Inspect the fuel system components: fuel filter,
Check the Water Temperature Regulators gas pressure regulator, gas shutoff valve, and fuel
metering valve. Verify that the system’s components
The water temperature regulators should not begin to are operating correctly.
open until jacket water reaches opening temperature
for the regulators. Allow the engine to cool and then Replace the fuel filter, if necessary.
start the engine. Check the hose at the outlet for
the jacket water. If the hose is warm and normal
operating temperature is not achieved yet, a regulator
may be stuck open.
42
Electrical Connectors or Power Supply • Electrical connectors or power supply

There may be an intermittent interruption of power. • Ignition system
Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal box. Inspect • Fuel supply
the power supply connections and the ground.
• Incorrect air/fuel ratio
Inspect the wiring from the power supply to the
master ECM and to the slave ECM. Check the power • Incorrect governor adjustment
and ground connections. Refer to Troubleshooting,
“Electrical Power Supply”. • Compressor bypass valve
No Signal from the Engine Speed/Timing • Air inlet restriction

Sensor
• Exhaust restriction
Make sure that the speed/timing sensor is installed
correctly. Refer to Troubleshooting, “Engine • Binding of the throttle actuator
Speed/Timing Sensor”.
• Incorrect valve lash
Make sure that the timing wheel is correctly installed.
• Cylinder head and related components
Ignition System • Throttle
Inspect the ignition transformers for loose
connections, moisture, short circuits, and open Recommended Repairs
circuits. Inspect the primary wiring and the secondary
electrical connections. Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine
Make sure that the correct transformers and spark operating temperature, etc), test the engine under
plugs are installed. Inspect the extenders for signs the conditions. Troubleshooting the symptom under
or pin holes and arcing. other conditions can give misleading results.
Maintain the spark plug according to Operation and The Caterpillar Electronic Technician (ET) and the
Maintenance Manual, “Ignition System Spark Plugs Integrated Temperature Sensing Module (ITSM)
- Replace”. can be used to detect a misfiring cylinder. Use the
following procedure:
Check the Base Timing 1. Use the “Data Link/Select ECM” option on the Cat
ET to select the ITSM.
Verify that the base timing is correct. Refer to
Systems Operation/Testing and Adjusting, “Ignition 2. Select “Diagnostics/Diagnostic Tests”.
Timing - Adjust”.
3. Select the suspect cylinder and click the “Start”
Excessive Load button in the lower left corner of the screen.
Make sure that the load is not excessive. Reduce the Cat ET will display a graph of the cylinder’s
load. If necessary, disengage the driven equipment exhaust gas temperature. The output voltage of
and test the engine. the transformer’s secondary circuit, the engine
speed, and the desired engine speed are also
displayed.
i02085470
Engine Misfires, Runs Rough Cold Cylinder

or Is Unstable Locate the misfiring cylinder. Check the following
components for failure: spark plug, extender, ignition
SMCS Code: 1000-035 transformer, and primary wiring. Inspect the extender
for signs of pin holes and/or arcing.
Probable Causes
Refer to Troubleshooting, “Ignition Transformers
• Cold cylinder Secondary Circuit and Spark Plugs”.
43
Electrical Connectors or Power Supply A change in the fuel energy content will change the
air/fuel ratio. Obtain a fuel analysis.
There may be an intermittent interruption of power.
Check the wiring harnesses and the connectors. The fuel supply pressure must be adequate and
Inspect the connectors in the terminal boxes. Inspect stable.
the power supply connections and the ground.
Governor Adjustment
Inspect the wiring from the power supply to the
control modules. Refer to Troubleshooting, “Electrical The governor’s parameters must be programmed
Power Supply”. with the values that provide stable operation. Refer
to Systems Operation/Testing and Adjusting, “Engine
Ignition System Governing - Adjust”.
Inspect the ignition transformers for the following Compressor Bypass Valve
items: loose connections, moisture, short circuits,
and open circuits. Inspect the primary wiring and the The actuator for the compressor bypass valve must
secondary electrical connections. be installed properly in order to provide stable
operation. Refer to Disassembly and Assembly,
Make sure that the correct transformers and spark “Actuator Bypass Valve (Variable) - Install”.
plugs are installed. Inspect the extenders for signs of
pin holes and of arcing.
Air Inlet Restriction
Maintain the spark plug according to the engine’s
Operation and Maintenance Manual. High inlet air restriction adversely affects engine
performance. Refer to the applicable Gas Engine
Technical Data Sheet for additional information.
Make sure that the ignition timing is correct.
The maximum allowable air inlet restriction is
Fuel Supply 3.75 kPa (15 inches of H2O). If the indication is higher
than the maximum permissible restriction, clean the
Make sure that fuel is supplied at a sufficient pressure filter element or install a new filter element. Check the
that is stable. Make sure that the size of the fuel line restriction again. If the restriction remains too high,
is sufficient. Inspect the fuel system for leaks. inspect the air inlet piping for obstructions.
The following conditions can cause the engine to For more information, refer to Systems
malfunction: Operation/Testing and Adjusting, “Restriction of Air
Inlet and Exhaust”.
• Low fuel pressure
Exhaust Restriction
• High fuel pressure
Check for restriction in the exhaust system. Refer
• Poor fuel quality to Systems Operation/Testing and Adjusting,
“Restriction of Air Inlet and Exhaust”.
Make sure that the fuel pressure is correct. When
if fuel quality is in question. Try to determine if the Check for Binding of the Throttle
source of the fuel was changed. Actuator
Inspect the fuel system components: fuel filter, Set the engine control to the OFF/RESET mode.
gas pressure regulator, gas shutoff valve, and fuel Switch the 35 amp circuit breaker OFF. Move the
metering valve. Verify that the system’s components throttle plate while you feel the motion. If the motion
are operating correctly. is sticky and/or rough, investigate the cause of the
binding. Make the necessary repairs.
Replace the fuel filter, if necessary.
Incorrect Valve Lash
Air/Fuel Ratio
Check the valve lash. Refer to Systems Operation,
An air/fuel mixture that is too rich or too lean will have Testing And Adjusting, “Valve Lash and Valve Bridge
an adverse effect on engine operation. Verify that Adjustment”.
the exhaust emissions are correct. Refer to Systems
Operation/Testing and Adjusting, “Air/Fuel Ratio
Control - Adjust”.
44
Cylinder Head and Related Components Check the Oil Filter Bypass Valve
Measure the cylinder compression. Refer to the An oil filter bypass valve that is stuck in the closed
engine’s Operation and Maintenance Manual, position can cause a high reading for differential
“Cylinder Pressure - Measure/Record”. pressure when the oil is cold. An oil filter bypass
valve that is stuck in the open position can cause a
Inspect the components of the valve train for good low reading for differential pressure when the oil is
condition. Check for signs of damage and/or wear hot. Check the operation of the oil filter bypass valve.
to the valves, cylinder head gasket, etc. Inspect the For more information, see Systems Operation/Testing
condition of the camshafts. If a camshaft is replaced, and Adjusting, “Measuring Engine Oil Pressure”.
new valve lifters must be installed.
If the oil filter bypass valve is faulty, repair the valve,
Throttle when possible. Replace the valve, if necessary.
Make sure that the throttle actuator is operating i01727510

properly. If the motion of the actuator is sticky and/or
rough, service the actuator. Engine Oil Pressure (Low)
SMCS Code: 1348-035-PX
i01727473
Engine Oil Filter Differential Probable Causes

Pressure
• Low engine oil level
SMCS Code: 1308-035
• Incorrect viscosity
Probable Causes • Contaminated engine oil
• Plugged oil filter or faulty oil filter • Faulty oil pressure sensors
• Faulty oil pressure sensor and/or circuit • Improper circulation of the engine oil
• Malfunctioning of the oil filter bypass valve • Worn components
Recommended Repairs Recommended Repairs

Check the Oil Filters Low Engine Oil Level
Check the oil filter differential pressure. Do not allow Check the oil level. Add oil, as needed.
the differential pressure to exceed 103 kPa (15 psi).
If the oil filter differential pressure is too high, change Contaminated Engine Oil
the oil filter elements.
Engine oil that is contaminated with another liquid
Inspect the oil filters for good condition. Replace any will cause low engine oil pressure. High engine oil
suspect oil filter.
level can be an indication of contamination. Obtain
an analysis of the engine oil. Determine the reason
Check the Oil Pressure Sensors and/or for contamination of the engine oil and make the
Circuits necessary repairs. Change the engine oil and the
engine oil filter. For the correct engine oil to use, refer
Use the Caterpillar Electronic Technician (ET) to to Operation and Maintenance Manual, “Engine Oil”.
compare the readings for the filtered oil pressure and
the unfiltered oil pressure while the engine is OFF. Incorrect Viscosity
Make sure that the sensors are correctly wired.
Make sure that the engine is supplied with the correct
If the readings are not approximately zero for both engine oil. For the correct engine oil to use, refer to
of the sensors, the sensors are wired improperly. Operation and Maintenance Manual, “Engine Oil”.
Troubleshoot the sensor circuit(s). Refer to
Troubleshooting, “Analog Sensor Signal”.
45
Faulty Engine Oil Pressure Sensors i01727521
Use the Caterpiller Electronic Technician (ET) to Engine Oil Temperature (High)
compare the readings of the filtered engine oil
pressure and the unfiltered engine oil pressure while SMCS Code: 1348-035
the engine is OFF. Both readings should be close to
zero pressure. Probable Causes
If a reading is significantly different from zero, replace • Faulty oil temperature sensor and/or circuit
the suspect engine oil pressure sensor.
• Insufficient flow of coolant through the oil cooler
Improper Circulation of the Engine Oil
• Insufficient flow of oil through the oil cooler
Several factors could cause improper circulation of
the engine oil: Recommended Repairs
• The engine oil filter is clogged. Replace the engine Check the Oil Temperature Sensor and/or
oil filter.
the Circuit
• An engine oil line or a passage for engine oil is
disconnected or broken. Check the reading of the oil temperature on
the Caterpillar Electronic Technician (ET). The
• The engine oil cooler is clogged. Thoroughly clean temperature should rise steadily as the engine is
the engine oil cooler. warmed. Ensure that the temperature is reasonable.
• There is a problem with a piston cooling jet. If the reading on Cat ET for the oil temperature
Breakage, a restriction, or incorrect installation of a is not reasonable, troubleshoot the circuit for the
piston cooling jet will cause seizure of 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 Check the Flow of Coolant Through the
cause cavitation and a loss of engine oil pressure. Oil Cooler
Check the inlet screen on the suction tube and
remove any material that may be restricting engine
Oil Coolers that are Cooled with Jacket Water
oil flow.
Check for “High Engine Coolant Temperature”
• The suction tube is drawing in air. Check the joints events. Refer to Troubleshooting, “Engine coolant
of the tube for cracks or a damaged O-ring seal. Temperature (High)”.
• There is a problem with the engine oil pump. Check Oil Coolers that are Cooled by the Separate
the gears of the engine oil pump for excessive Circuit
wear. Engine oil pressure is reduced by gears that
have too much wear.
Compare the temperature of the coolant at the inlet
of the oil cooler to the regulated temperature. If the
• The engine oil pump’s pressure regulating valve or inlet temperature is OK, check the temperature of the
a bypass valve is stuck in the open position. Clean
coolant at the outlet of the oil cooler.
the valve. Replace parts, if necessary.
A high temperature difference indicates an insufficient
Worn Components flow rate. Investigate the cause of the obstruction.
Make the necessary repairs.
Excessive clearance at the crankshaft or camshaft
bearings will cause low engine oil pressure. Also,
Check the Flow of Oil Through the Oil
inspect the clearance between the rocker arm shafts
and the rocker arms. Check the engine components Cooler
for excessive clearance.
Run the engine at normal operating temperature.
Obtain an analysis of the engine oil. Check the Determine the pressure differential between the inlet
analysis for the level of wear metals in the engine oil. and the outlet of the oil cooler. For comparative data,
refer to the Technical Marketing Information for the
engine.
46
If the pressure differential between the inlet and Check the Status of the Relay for the
the outlet of the oil cooler exceeds the data that is Starting Motor
published for the engine, there is an insufficient flow
of oil through the oil cooler. Determine the cause of Attempt to start the engine while you observe the
the obstruction. Make the necessary repairs. status of the relay for the starting motor on Cat ET.
i01974116
If the status of the relay for the starting motor
indicates that the engine should crank but no
Engine Overcrank cranking occurs, troubleshoot the starting circuit.
SMCS Code: 1400-035 “Air/Electric Starting System”.
If the engine should crank and cranking occurs,

Probable Causes check the engine rpm.
• The gas supply to the engine is insufficient.
Check the Engine Speed
• A feature for engine protection prevents the engine
from starting. The master ECM must detect a minimum of 50 rpm
before the gas and the ignition are supplied to the
• The starting motor circuit is faulty. engine. Use Cat ET to monitor the engine speed
while you crank the engine.
• There is no engine speed signal to the master
Electronic Control Module (ECM). If no engine speed is displayed on Cat ET or if
the engine speed is not stable, troubleshoot the
• The ignition system is not functioning. speed/timing sensor. Refer to Troubleshooting,
“Engine Speed/Timing Sensor”.
• The base timing is incorrect.
Check for Diagnostic Codes
• The quality of the gas does not match the
parameter for “Fuel Quality”. 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,
Recommended Repairs troubleshoot the diagnostic code.
Check the Gas Supply to the Engine Check the Base Timing
Check for low gas pressure. If the gas pressure is
low, refer to Troubleshooting, “Fuel Pressure”.
Timing - Adjust”.
If the throttle does not open, check for binding of
the throttle actuator. Move the throttle plate while
you feel the motion. If the motion is sticky and/or Check the Fuel Quality
rough, investigate the cause of the binding. Make the
necessary repairs. Compare the Low Heat Value (LHV) of the gas supply
to the “Fuel Quality” parameter that is programmed
by the customer into the master ECM. The master
Check for Active Shutdowns ECM uses the setting for start-up and for air/fuel ratio
control at low loads.
Use the Caterpillar Electronic Technician (ET) to
check for active diagnostic codes or event codes
If the LHV of the fuel does not match the “Fuel
which may prevent the engine from starting.
Quality” parameter that is programmed into the
master ECM, program the master ECM with the
Correct the cause of the active code. Before the
correct setting for the “Fuel Quality” parameter.
engine can be started, you must recycle the power to
the engine. Set the engine control to the OFF/RESET
mode. Then set the control to the STOP mode.
47
i01804844 • Binding of the throttle actuator

Engine Overload
Recommended Repairs
SMCS Code: 1000-035
Check the Trip Point
Probable Causes Note: Do not program the trip point for engine
overspeed higher than the maximum ratings of the
• Excessive inlet manifold air pressure driven equipment.
• The Low Heat Value (LHV) of the gas or the The trip point or engine overspeed may be too low.
specific gravity of the gas is significantly different
Verify that the trip point for the engine overspeed is
from the value that is programmed.
properly programmed. Typically, this parameter is set
at 118 percent of rated speed.
Recommended Repairs
This parameter requires a factory password in order
Check the Inlet Manifold Air Pressure to change the trip point. Change the trip point to an
acceptable speed.
The calculated engine load increases when the inlet
manifold air pressure increases. Measure the inlet Check for Diagnostic Codes that Relate
manifold air pressure during engine operation with to the Signal from the Signal Driver in the
a load. For specific data on the engine, refer to the
engine Technical Marketing Information. Master ECM
Check for diagnostic codes that relate to the actuator
Obtain a Fuel Analysis and Program the of the throttle.
Fuel Energy Content
Investigate the diagnostic code(s). Make the
Obtain an analysis of the gas in order to determine necessary repairs.
the LHV. Program the correct LHV for the “Fuel
Quality” configuration parameter. Check the Driven Equipment
If the LHV of the gas does not match the “Fuel Determine if the driven equipment has additional
Quality” parameter value that is programmed into inputs of energy that could drive the engine beyond
the ECM, program the master ECM with the correct the rated rpm. Make corrections to the installation in
value for the “Fuel Quality” parameter by selecting order to prevent the overspeed from recurring.
the “Change” button in the lower left corner of the
screen. Type the correct value and then select “OK”.
Check for Slow Governor Response
If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program the Observe the “Speed Governor Adjustment” screen
“Fuel Quality” configuration parameter to the average on the Caterpillar Electronic Technician (ET). Look
value of the LHV. for the engine response to the worst cases for
step-loading and unloading.
i01804850 Check for Binding of the Throttle

Engine Overspeed Actuator
SMCS Code: 1000-035 Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. Move the
throttle plate while you feel the motion. If the motion
Probable Causes is sticky and/or rough, investigate the cause of the
binding. Make the necessary repairs.
• Low trip point for engine overspeed
• Signal from the signal driver in the master
Electronic Control Module (ECM) for the actuator
of the throttle
• Energy of the driven equipment

• Slow governor response
48
i02052150 Inspect the Stop Switches

Engine Shutdown Inspect the stop switches for evidence of damage
that has been caused by vibration. Disassemble the
SMCS Code: 1400-035 switches. Inspect the components for looseness,
cracks, and abrasion. Use an ohmmeter and toggle
Probable Causes the switches in order to check for proper electrical
operation.
• The “Emergency Stop” button is pressed.
Replace any faulty components.
• The circuit for the emergency stop is faulty.
i01804861
• The normal stop switch that is installed by the
customer is activated. Engine Shutdown
• The circuit for the normal stop switch is faulty. (Unexpected)
• Either switch is activated by excessive vibration. SMCS Code: 1400-035
Recommended Repairs Probable Causes
Talk to the operator • There is a problem with the Gas Shutoff Valve
(GSOV).
Ask the operator if the stop was intentional. Make
sure that the reason for the stop has been corrected. • Incorrect input(s) for the mode of operation to the
master Electronic Control Module (ECM)
Reset the control system. Resume normal operation.
If the stop was accidental, reset the control system. • There is a problem with the “Crank Terminate”
relay.
Resume normal operation.
• There is a problem with the relay for the starting
Check the Circuit for the Stop Switches motor.
Note: The circuit for the normal stop switch and the • A shutdown has been requested by the driven
circuit for the emergency stop switch must remain equipment.
closed in order for the engine to run.
• There is a problem with the “Run” relay.
Inspect the wiring between the switches and the
connector of the electronic control module. Look for • The “Crank Terminate Speed” is incorrectly
damage and/or corrosion. Refer to Troubleshooting, programmed.
“Inspecting Electrical Connectors”.
• The “Cycle Crank Time” is incorrectly programmed.
For the emergency stop switch, close the switch and
check the resistance between terminals 22 and 31 • The “Engine Overcrank Time” is incorrectly
of the P1 connector. programmed.
For the normal stop switch, close the switch and • The delay time for the driven equipment is
check the resistance between terminals 23 and 31 excessive.
of the P1 connector.
• There is a problem with the harness code for the
The correct resistance between the terminals is less slave ECM.
than 5 Ohms. If the resistance is greater than 5
Ohms, locate the source of the excessive resistance.
Make repairs, as needed. Recommended Repair
Check the Circuit for the GSOV
Troubleshoot for the following diagnostic codes:
• 17-05 Fuel Shutoff Valve open circuit

49
• 17-06 Fuel Shutoff Valve short to ground If the “Crank Terminate Speed” is too slow, the
engine will shut down. Use the Caterpillar Electronic
• 17-12 Fuel Shutoff Valve malfunction Technician (ET) to check the programmed “Crank
Terminate” speed. Use Cat ET to adjust the “Crank
Refer to Troubleshooting, “ECM Output Circuit (Fuel Terminate Speed”, if necessary.
Control)”. Make repairs, as needed.
Check the “Cycle Crank Time”
Check the Inputs for the Mode of
Operation to the Master ECM The “Cycle Crank Time” is a parameter that can be
configured. This parameter determines the time for
Troubleshoot for the “336-02 Incorrect ECS Switch engagement of the starting motor and the gas shutoff
inputs” diagnostic code. valve during the crank cycle. If the engine does not
start within the programmed “Cycle Crank Time”,
Refer to Troubleshooting, “Electrical Power Supply”. the attempt to start is suspended for an equal “Rest”
Make repairs, as needed. cycle.
If the “Cycle Crank Time” is insufficient, the “Engine

Check the “Crank Terminate” Relay Overcrank Time” can elapse before the engine is
able to start.
Troubleshoot for the “443-03 Crank Terminate Relay
short to +batt” diagnostic code. Use Cat ET to check the “Cycle Crank Time”. Use
Cat ET to increase the time, if necessary.
Refer to Troubleshooting, “ECM Status Indicator
Output”. Make repairs, as needed.
Check the “Engine Overcrank Time”
Check the “Start” Relay The “Engine Overcrank Time” is a parameter that
can be configured. This parameter determines the
Troubleshoot for the following diagnostic codes:
length of time for the crank cycle. If the engine does
not start within the programmed “Engine Overcrank
• 444-05 Start Relay open circuit time”, the attempt to start is terminated. An “E225 (3)
Engine Overcrank” event is generated.
• 444-06 Start Relay short to ground
If the “Cycle Crank Time” is insufficient, the “Engine
Refer to Troubleshooting, “ECM Output Circuit
Overcrank Time” can elapse before the engine is
(Starting Motor)”. Make repairs, as needed.
able to start.
Check for a Request for a Shutdown by Use Cat ET to check the “Engine Overcrank Time”.
the Driven Equipment Use Cat ET to increase the “Engine Overcrank Time”,
if necessary.
Determine whether a shutdown for the driven
equipment has been requested. Refer to Check the “Driven Equipment Delay
Troubleshooting, “Driven Equipment”. Make Time”
corrections, as needed.
The “Driven Equipment Delay Time” is a parameter
Check the “Run” Relay that can be configured. The master ECM provides
a switch input for the driven equipment in order to
Troubleshoot for the “445-03 Run Relay short to delay engine start-up until the driven equipment is
+batt” diagnostic code. ready. The master ECM will not attempt to start the
engine until the switch input for the driven equipment
Refer to Troubleshooting, “ECM Status Indicator closes to ground and the prelubrication (if equipped)
Output”. Make repairs, as needed. is complete.
Check the “Crank Terminate Speed” An event code is generated if the “Driven Equipment
Delay Time” elapses without closure of the switch
The “Crank Terminate Speed” is a parameter that can input. To disable this feature, program the delay time
be configured. The master Electronic Control Module to zero.
(ECM) disengages the starting motor when the
engine exceeds the programmed “Crank Terminate If the programmed delay time is too long, the engine
Speed”. The default value of 250 rpm should be may not start. Use Cat ET to check the “Driven
sufficient for all applications. Equipment Delay Time”. Use Cat ET to program the
delay time to a reasonable amount of time.
50
Check the Harness Code for the Slave 3. Inspect the electronic control modules and
ECM the terminal box for proper installation of the
connectors.
The harness inside the terminal box has a jumper
wire (harness code) that connects terminals J3-29 4. Check the 35 amp circuit breaker on the power
and J3-60. The ECM that is connected to the harness distribution box. Check the wiring connections to
reads the harness code. This allows the ECM to the 35 amp circuit breaker for proper installation.
operate as the slave ECM. The jumper wire must
remain connected in order for the engine to run. Speed/Timing Sensor
The engine will shut down if the jumper wire becomes A loss of supply voltage to the speed/timing sensor
disconnected during engine operation. will cause a shutdown. Refer to Troubleshooting,
“Engine Speed/Timing Sensor”.
Check the continuity between terminals J3-29 and
J3-60. Verify that the jumper wire is in good condition. Fuel Supply
Make repairs, as needed.
• Check the fuel supply pressure.
i01804877
• Inspect the fuel lines for foreign objects and for
Engine Shutdown without a obstructions that can block the fuel supply.
Diagnostic Code Misfiring Cylinders
SMCS Code: 1400-035
For a shutdown that is due to misfiring cylinders, the
shutdown is likely to occur only when the engine is
Probable Causes operating under a load.
• An external shutdown or a customer shutdown The Caterpillar Electronic Technician (ET) and the
was requested. ITSM can be used to detect a misfiring cylinder. Use
the following procedure:
• The power supply becomes disconnected from the
engine control system. 1. Use the “Data Link/Select ECM” screen on Cat
ET to select the ITSM.
lost the supply voltage for the speed/timing sensor. 2. Select “Diagnostics/Diagnostic Tests”.
• There is a problem with the fuel supply. 3. Select the suspect cylinder and click the “Start”
button in the lower left corner of the screen.
• A cylinder or cylinders are misfiring.
Cat ET will display a graph of the cylinder’s
Recommended Repairs exhaust gas temperature. The transformer’s
secondary circuit, the engine speed, and the
desired engine speed are also displayed.
External Shutdown or Customer
Shutdown Locate the misfiring cylinder. Check the following
components for failure: spark plug, extender, ignition
Check the master ECM and the Integrated transformer, and primary wiring. Inspect the extender
Temperature Sensing Module (ITSM) for logged for signs of pin holes and/or arcing.
codes of events that are shutdowns.
Power Supply to the Engine Control Secondary Circuit and Spark Plugs”.
System
1. Refer to Troubleshooting, “Electrical Power
Supply”.
2. Inspect the ground strap and the power supply for

connections that are loose and/or corroded.
51
i01804883 2. Use the Caterpillar Electronic Technician (ET) to

check for the 168-02 diagnostic code for “System
Engine Starts but Stalls Voltage intermittent/erratic”. If this diagnostic code
Immediately is logged, proceed to Troubleshooting, “Electrical
Power Supply”.
SMCS Code: 1250-035; 1400-035
Engine Speed/Timing Sensor
Probable Causes Make sure that the speed/timing sensor is
installed correctly. See Troubleshooting, “Engine
• Fuel supply Speed/Timing Sensor”.
• Electrical connectors or power supply Make sure that the timing wheel is correctly installed.
• Engine speed/timing sensor
Ignition System
• Ignition system
Inspect the ignition transformers for the following
• Excessive load items: loose connections, moisture, short circuits,
and open circuits. Inspect the primary wiring and the
secondary electrical connections.
Recommended Repairs
Make sure that the correct transformers and spark
Fuel Supply plugs are installed. Inspect the extenders for signs of
pin holes and of arcing.
Make sure that fuel is supplied at a sufficient pressure
that is stable. Make sure that the size of the fuel line Maintain the spark plug according to the engine’s
is sufficient. Inspect the fuel system for leaks. Operation and Maintenance Manual.
The following conditions can cause the engine to Excessive Load

malfunction:
• Low fuel pressure load. If necessary, disengage the driven equipment
• High fuel pressure
• Poor fuel quality i01804902
Make sure that the fuel pressure is correct. When Engine Timing Does Not Match
if fuel quality is in question. Try to determine if the
Programmed Timing
source of the fuel was changed. SMCS Code: 1000-035; 1400-035
Inspect the fuel system components: fuel filter, gas
pressure regulator, gas shutoff valve, fuel metering Probable Causes
valve, and actuator for the throttle. Verify that the
system’s components are operating correctly. • The timing may be retarded due to detonation.
Replace the fuel filter, if necessary. • The timing may be retarded due to the selection of
the map for speed or the map for load.
Electrical Connectors or Power Supply
• The input for the selection of the base timing may
be incorrect.
1. Inspect the power supply connections and the
ground. Check the wiring harnesses and the
connectors from the power supply to the power Recommended Repairs
distribution box. Check the wiring harnesses
and the connectors from the power distribution Note: If the symptom only occurs under certain
box to the terminal box. Inspect the connectors operating conditions (high idle, full load, engine
in the terminal box. Refer to Troubleshooting, operating temperature, etc), test the engine under
“Inspecting Electrical Connectors”. the conditions. Troubleshooting the symptom under
other conditions can give misleading results.
52
Detonation a. Charge the batteries. Refer to Special

Instruction, SEHS7633, “Battery Test
Use the Caterpillar Electronic Technician (ET) Procedure”.
to review the logged codes. Look for codes
“E401-1” through “E416-1”. Refer to the topic in b. Load test the batteries. Refer to Special
Troubleshooting for the particular event code. Instruction, SEHS9249, “Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Map Acid Batteries”.
Use the “Service/Configuration” screen of Cat ET Starting Circuit

in order to verify the value that is programmed for
the timing. Check the “First Desired Timing”, the Check the starting circuit. Refer to the schematic
“Second Desired Timing”, and the “Desired Timing” diagram in Troubleshooting, “ECM Output Circuit
parameters. Refer to Troubleshooting, “Programming (Starting Motor)”.
Parameters”.
Starting Motor or Flywheel Ring Gear
Timing Selection
If the pinion engages the flywheel but the flywheel
Verify that the input for the selection of the base does not turn, there may be a problem with the
timing is correct. An open circuit between terminals starting motor. If the starting motor turns but the
J1-20 and J1-31 selects the “First Desired Timing”. flywheel does not turn, inspect the gear teeth, the
A short circuit between terminals J1-20 and J1-31 clutch jaws, or other parts.
selects the “Second Desired Timing”.
Inspect the pinion and the flywheel ring gear for
damage. If the teeth of the pinion and/or of the
i01822829
flywheel ring gear are worn or broken, replace the
Engine Will Not Crank parts.
SMCS Code: 1000-035; 1400-035 If the pinion does not engage correctly with the
flywheel, the pinion shaft may be stuck. Remove the
pinion. Grease the splines of the drive shaft and the
Probable Causes pinion.
• Batteries and/or battery cables If the pinion does not engage the flywheel, the clutch
jaws may be broken.
• Starting circuit
Before you remove the starting motor, turn the
• Starter motor pinion or flywheel ring gear crankshaft by hand. Ensure that a mechanical failure
inside the engine is not preventing the crankshaft
• Low air pressure from turning. If the crankshaft will turn by hand, try
the starting motor again. If the starting motor does not
• Static load turn the crankshaft, remove the starting motor. Repair
the starting motor or replace the starting motor.
• Internal mechanical problem
Low Air Pressure
• There is a problem with the harness code for the
slave Electronic Control Module (ECM). Determine the cause of the low air pressure. Inspect
the air lines for leaks. Repair any leaks in the air lines.
Recommended Repairs
Static Load
Batteries and/or Battery Cables
Make sure that the driven equipment is not
1. Inspect the main power switch, battery posts, preventing the crankshaft from turning. Try to turn
and battery cables for loose connections and the crankshaft by hand. If necessary, disengage the
corrosion. If the battery cables are corroded, driven equipment and test the engine.
remove the battery cables and clean the battery
cables. Tighten any loose connections.
2. Inspect the batteries.

53
Internal Mechanical Problem Recommended Repairs

If the crankshaft will not turn and the driven Check the Inlet Air Temperature
equipment is disengaged, remove the spark plugs.
Check for fluid in the cylinders. If this is not the High inlet air temperature can cause detonation.
problem, the engine must be disassembled in order Check the inlet air temperature.
to investigate internal mechanical problems. Possible
internal problems include the following conditions: Refer to Troubleshooting, “Inlet Air Temperature
(High)”.
• Bearing seizure
Inlet Air Restriction
• Piston seizure
High inlet air restriction adversely affects engine
• Valve and piston contact performance. Refer to the applicable Gas Engine
Technical Data Sheet for additional information.
Check the Harness Code for the Slave
ECM The maximum allowable inlet air restriction is
3.75 kPa (15 inches of H2O). If the indication is higher
The harness inside the terminal box for the slave than the maximum permissible restriction, clean the
ECM has a jumper wire (harness code) that filter element or install a new filter element. Check
connects terminals J3-29 and J3-60. The ECM that the restriction again. If the restriction remains too
is connected to the harness reads the harness code. high, inspect the air inlet piping before the air cleaner
This allows the ECM to operate as the slave ECM. for obstructions.
the engine to crank. The jumper wire must remain Air/Fuel Ratio
connected in order for the engine to run.
An air/fuel mixture that is too rich will increase
Check the continuity between terminals J3-29 and the exhaust temperature. Verify that the exhaust
J3-60. Verify that the jumper wire is in good condition. emissions are correct. Refer to Systems
Make repairs, as needed. Operation/Testing and Adjusting, “Air/Fuel Ratio
Control - Adjust”.
i02085826
A change in the fuel energy content will change the
Exhaust Port Temperature air/fuel ratio. Obtain a fuel analysis.
(High) The fuel supply pressure must be adequate and
stable.
SMCS Code: 1059-035
Excessive Load
Probable Causes
• High inlet air temperature load. If necessary, disengage the driven equipment
• Inlet air restriction
Check the Base Timing
• Air/fuel ratio
• Excessive load Systems Operation/Testing and Adjusting, “Ignition
Timing - Adjust”.
• Incorrect base timing
• Exhaust restriction Measure the Exhaust Restriction
• A buildup of deposits in the cylinder or internal oil Measure the exhaust restriction during engine
leaks operation with a load. For data that is specific to the
engine, refer to the Technical Marketing Information.
Investigate the cause of the exhaust restriction.

Perform adjustments and/or make repairs, as
needed.
54
Check for Deposits in the Cylinder and Check for Diagnostic Codes from the
Check for Internal Oil Leaks Integrated Temperature Sensing Module
(ITSM)
Use a borescope to inspect the cylinders. Look for
the following conditions: Use the Caterpillar Electronic Technician (ET)
to check for diagnostic codes that relate to
• Deposits on the valve seats the thermocouples for exhaust temperatures.
Troubleshoot the code.
• Deposits on the valve faces
Check for Suspect Thermocouples
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke
Observe the temperatures from the thermocouples
after the engine is shut off.
• Signs of internal oil leaks
When the engine is operating properly, the
Other signs of internal oil leaks include high oil
temperatures from similar locations are reduced at
consumption and blue smoke.
a similar rate. Also, the temperatures from similar
locations are comparable.
Note: Excessive deposits contribute to guttering of
the valves.
If any discrepancies are found, switch the suspect
thermocouple for another thermocouple. If the
If excessive deposits and/or signs of internal oil leaks
temperature problem follows the thermocouple,
are found, investigate the cause of the condition.
Make repairs, as needed. replace the thermocouple.
If the temperature problem stays at the original

i01727687 location of the suspect thermocouple, investigate the
cause for the low temperature.
Exhaust Port Temperature
(Low) Check for Insufficient Ignition
SMCS Code: 1059-035 Use Cat ET to check for logged diagnostic codes that
relate to the ignition system. Troubleshoot the code.
Probable Causes Primary Circuit”.
• Operation with a light load If no logged diagnostic codes are present for
the suspect cylinder, inspect the components
• Active diagnostic code from the Integrated of the ignition system for the cylinder. Refer to
Temperature Sensing Module (ITSM) Troubleshooting, “Ignition Transformers Secondary
Circuit and Spark Plugs”.
• A faulty thermocouple
• Insufficient ignition Check the Cylinder Compression
• Low cylinder compression Measure the cylinder pressures of the suspect bank
in order to check for problems that are related to
compression.
Recommended Repairs
If low compression is found, investigate the cause of
Check for Misfire the low compression. Make repairs, as needed.
Operation with a low load can result in low exhaust

temperatures. Operate the engine at low idle or near
low idle in order to identify a misfire problem.
Troubleshoot the cause of the misfire. Refer to

Troubleshooting, “Engine Misfires,Runs Rough or Is
Unstable”.
55
i01804917 Check the Fuel Metering Valve

Fuel Energy Content Shut OFF the fuel supply. Disconnect the fuel lines
from the fuel metering valve. Visually inspect the
SMCS Code: 1250-035 internal mechanism of the valve. Check for binding
due to dirt and/or contamination. Check for binding
Probable Causes due to wear of internal components.
• The Low Heat Value (LHV) of the gas or the specific Clean the valve, if necessary. If the valve is binding
gravity of the gas is significantly different from the due to wear of internal components, refer to the
value that is programmed into the electronic control literature that is provided by the OEM of the valve.
module.
i01727704
• Condensation is forming in the gas.
Fuel Pressure
Recommended Repairs
SMCS Code: 1250-035
Obtain a Fuel Analysis and Program the
“Fuel Quality” Parameter Probable Causes
Obtain an analysis of the gas in order to determine • Incorrect setting of the gas pressure regulator
the LHV. Program the “Fuel Quality” parameter to the
actual value of the LHV. • Faulty gas pressure regulator
If the quality of the gas is not consistent, obtain Recommended Repairs

several analyses over a period of time. Program the
“Fuel Quality” parameter to the average value of the Check the Gas Pressure Regulator
LHV.
Check the Dryer for the Gas observe the absolute fuel pressure and the fuel
differential pressure. The fuel metering valve requires
Check the dryer for the gas for proper operation. a gas supply that is regulated to a pressure between
Repair the dryer, if necessary. 10 to 35 kPa (1.5 to 5 psi).
If the fuel pressure is not within the acceptable range,

i01804920
adjust the gas pressure regulator in order to achieve
Fuel Metering Valve the correct pressure. Verify that the emissions are
within specifications.
SMCS Code: 1274-035
If the gas pressure regulator cannot be adjusted to
the correct setting, repair the regulator or replace the
Probable Causes regulator.
• Low operating voltage for the fuel metering valve

i01369481
• Internal binding of the fuel metering valve Gas Fuel Differential Pressure
Recommended Repairs (High)
SMCS Code: 1250-035
Check the Operating Voltage for the Fuel
Metering Valve
Probable Causes
Check the operating voltage for the fuel metering
valve. Refer to Troubleshooting, “Electrical Power • Excessive fuel supply pressure
Supply”.
• Leaks in the piping after the fuel metering valve
56
Recommended Repairs Adjust the gas pressure regulator in order to achieve

the correct pressure.
Check the Fuel Supply Pressure
If the gas pressure regulator cannot be adjusted to
Check the pressure of the fuel supply to the fuel the correct setting, repair the regulator or replace the
metering valve for high pressure. The maximum 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 achieve Check the fuel filter for restriction. Replace the fuel
the correct pressure. filter, if necessary.
If the gas pressure regulator cannot be adjusted to Inspect the screen inside the inlet of the fuel metering
the correct setting, repair the regulator or replace the valve for cleanliness. Clean the screen, if necessary.
regulator.
Inspect the fuel supply lines to the fuel metering valve
Check for Leaks for obstructions. Clean the lines and make repairs,
as needed.
Use a gas detector to check for leaks in the piping
between the outlet of the fuel metering valve and the Check the Gas Shutoff Valve (GSOV) for proper
turbocharger compressor. operation. Verify that the valve is fully open when the
valve is energized. Verify that the GSOV does not
Repair the piping, if necessary. stick in a partially open position. Repair the GSOV.
Replace the GSOV, if necessary.
i01804929
Check the Fuel Outlet for Obstructions
Gas Fuel Differential Pressure Inspect the piping for obstructions between the fuel
(Low) metering valve and the inlet to the turbocharger
compressor.
SMCS Code: 1250-035
Clean the piping and make repairs, as needed.
Probable Causes
i01727721
• Improper installation of the fuel metering valve
Gas Fuel Flow Rate (Low)
• Low fuel supply pressure
SMCS Code: 1250-035
• Obstructed fuel supply
Probable Causes
• Obstructed fuel outlet
• High fuel temperature
Recommended repairs
• Faulty gas pressure regulator or low fuel supply
Check the Installation of the Fuel pressure
Metering Valve
• Obstructions in the fuel supply
An “E864 Low Gas Fuel Differential Pressure” event
will be generated if the fuel metering valve is installed • Inadequate fuel energy content or moisture in the
gas
backward. Ensure that the fuel metering 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.
57
Recommended Repairs Check Cat ET for a “E230 (1) Fuel Energy Content
Setting High” event code. If the code is present, refer
Check the Fuel Temperature to Troubleshooting, “Fuel Energy Content”.
Measure the temperature of the gas that is entering Obtain an analysis of the gas in order to determine
the fuel metering valve. Compare the measurement the LHV. Program the Fuel Energy Content to the
to the reading for the fuel temperature on the actual value of the LHV.
Caterpillar Electronic Technician (ET). Check Cat ET
for a “E223 High Gas Temperature” event code. If the quality of the gas is not consistent, obtain
several analyses over a period of time. Program the
If the temperature on Cat ET is different, determine Fuel Energy Content to the average value of the LHV.
the reason for the faulty signal from the fuel metering
valve. Check the Dryer for the Gas
If the fuel temperature is high, determine the cause of Check the dryer for the gas for proper operation.
the high fuel temperature. Check for proper operation Repair the dryer, if necessary.
of the equipment that treats the gas prior to the
engine.
i01758553
If there is an active “E223 High Gas Temperature”

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

If the fuel energy content is too low, the fuel metering
valve could demand an excessive supply of fuel.
58
i02089727 • The offset voltage at the input to the master ECM

from the power sensor is too high.
Generator Output Power
Readings Do Not Match • There is an incorrect value for one or more of the
“Power Monitoring” parameters.
SMCS Code: 5574-035-PWR
Read the rest of this procedure before you adjust the
The master Electronic Control Module (ECM) “Power Monitoring” parameters.
monitors the generator’s output power in order to
accurately control the air/fuel ratio. The master ECM Recommended Repairs
uses an output from one of the following sources in
order to monitor the generator’s output power:
Generators that are Equipped with EMCP
• Electronic Modular Control Panel II+ (EMCP II+) II+
• Programmable Logic Controller (PLC) Verify that the transformers and the ATB+ are
operating correctly. Refer to the appropriate service
• Wattmeter literature for the EMCP II+.
The PLC and the wattmeter are also called power Verify that the values for the “Air/Fuel Ratio Control”
sensors. configuration parameters are correct. Refer to
Troubleshooting, “Electronic Control System
Parameters”.
Probable Causes
Verify that the values for the “Power Monitoring”
The following probable causes apply if the generator configuration parameters are correct. Refer to
is equipped with the EMCP II+: Troubleshooting, “Electronic Control System
Parameters”.
• There is an incorrect calibration value for the AC
Transformer Box + (ATB+).
Generators that are Equipped with a
• A potential transformer in the ATB+ is faulty. Power Sensor
• A current transformer in the ATB+ is faulty. Verify that the transformers for the power sensor are
operating correctly. Refer to the service literature for
• The ATB+ is faulty. the power sensor.
• There is an incorrect value for one or more of the Verify that the power sensor is operating correctly.
parameters for the fuel. Refer to the service literature for the power sensor.
• There is an incorrect value for one or more of the Verify that the values for the “Air/Fuel Ratio Control”
“Power Monitoring” parameters. configuration parameters are correct. Refer to
Troubleshooting, “Electronic Control System
The following probable causes apply if the generator Parameters”.
is equipped with a power sensor:
Check the wiring between the power sensor and
• There is a faulty potential transformer for the power the master ECM for corrosion and for pinch points.
sensor. Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
• There is a faulty current transformer for the power
sensor. The master ECM must receive an accurate voltage
from the power sensor. If the voltage is not accurate,
• The power sensor is faulty. the master ECM may not accurately control the
air/fuel ratio. When the generator’s output is zero,
• There is a problem with the wiring between the the voltage from the power sensor must be less than
power sensor and the master ECM. 0.01 VDC. This voltage is called the offset voltage.
• There is an incorrect value for one or more of the Use the following procedure in order to determine if
parameters for the fuel. the offset voltage is too high. Perform this procedure
before you adjust the “Power Monitoring” parameters.
59
Note: This measurement must be taken at the master Coolant Temperature

ECM P1 connector. The engine must be stopped.
Refer to Troubleshooting, “Engine Coolant
1. If the engine is running, stop the engine. Temperature (High)”.
2. Insert 7X-1710 Multimeter Probes into terminals Check for High Inlet Air Restriction
P1-19 and P1-25. Connect a digital voltmeter to
the probes. The polarity of the connections is not
and/or High Altitude
important.
When inlet air pressure is low, the turbocharger works
harder in order to achieve the desired inlet manifold
3. Verify that the probes are making good contact
with the terminals inside the connector. Measure pressure. This increases inlet air temperature.
the DC voltage at the terminals.
Measure the inlet air pressure while the engine is
The voltage is acceptable if the voltage is less operating under load. For specific data, refer to the
Technical Marketing Information for the engine.
than ±0.01 VDC.
If the voltage is less than ±0.01 VDC, the values Inlet Air Restriction
for the “Power Monitoring” parameters may be
Check for plugged air filters. Check for obstructions
incorrect. Refer to Systems Operation/Testing
and Adjusting, “Electronic Control System to the air inlet.
Parameters”.
Replace the air filters and/or remove the obstruction
If the voltage is greater than ±0.01 VDC, the circuit from the air inlet.
between the power sensor and the master ECM
High Altitude
must be calibrated. Refer to Troubleshooting,
“Generator Output Power Sensor - Calibration”.
Make sure that the settings for the engine are correct
for the altitude.
i01623042
Check the Temperature Sensor and/or
Inlet Air Temperature (High) the Circuit
SMCS Code: 1087-035
Allow the sensor to cool and remove the sensor.
Check the reading for the inlet air temperature.
Probable Causes If the sensor is OK, the reading and the ambient
temperature are approximately equal.
• High ambient air temperature
If the reading is not correct, switch the sensor with
• High coolant temperature a sensor that is known to be good. Verify that the
problem is solved.
• High inlet air restriction and/or high altitude
Check for Sufficient Flow of Cooling
• Faulty inlet air temperature sensor and/or circuit
Water Through the Aftercooler
• Insufficient flow of cooling water through the
aftercooler Check the inlet temperature of the coolant for the
aftercooler. Compare the reading to the regulated
• Insufficient flow of air through the aftercooler temperature. If the temperature is OK, check the
outlet temperature of the coolant. A high temperature
differential indicates an insufficient flow rate.
Recommended Repairs
If there is a high differential between the inlet
High Ambient Air Temperature temperature and the outlet temperature of the coolant
for the aftercooler, perform the following procedures:
Determine if the ambient air temperature is within the
design specifications for the cooling system. • Check the water circuit of the aftercooler for
obstructions.
Determine the cause of the high air temperature.
Make corrections, when possible. • Check the pump for proper operation.
• Make repairs, if necessary.
60
Check for Sufficient Flow of Air Through 3. Inspect the wiring from the power supply to
the Aftercooler the power distribution box. Inspect the wiring
from the power distribution box to the electronic
Determine the pressure differential of the inlet air control modules. Check the power and ground
across the aftercooler. For specific data, refer to the connections at each electronic control module.
Technical Marketing Information for the engine. Refer to Troubleshooting, “Electrical Power
Supply” for more information.
If the pressure differential of the air across the
aftercooler does not match the specifications, clean Circuit Breakers
the aftercooler.
Check the 35 amp circuit breaker on the power
distribution box. The circuit breaker may exceed
i01804935
the trip point due to overheating. Reset the circuit
Intermittent Engine Shutdown breaker if the circuit breaker is tripped.
SMCS Code: 1400-035 Engine Speed/Timing Signal

Note: Use this procedure only if the engine shuts Loss of the signal from the speed/timing sensor will
down completely and the engine must be restarted. cause a shutdown. Use Cat ET to check for logged
diagnostic codes. For more information, refer to
Troubleshooting, “Engine Speed/Timing Sensor”.
Probable Causes
• Active engine shutdown Fuel Supply
• Electrical connectors 1. Check the fuel lines for the following problems:
restrictions, obstructions, collapsed lines, and
• Circuit breaker pinched lines. If problems are found with the fuel
lines, repair the lines and/or replace the lines.
• Engine speed/timing signal
2. Check the restriction of the fuel filter. If the fuel
• Fuel supply pressure is low, replace the fuel filter.
• Spark plug 3. Check the fuel quality.
4. Check the fuel pressure. Refer to Systems

Recommended Repairs Operation/Testing and Adjusting, “Fuel System”
for the correct pressure values. If the fuel pressure
Active Engine Shutdown is still low, check the gas regulator and the fuel
metering valve.
check for any active engine shutdowns and/or logged Spark Plug
engine shutdowns. Determine the reason for the
shutdown. After correcting the problem, set the An engine shutdown that is due to a faulty spark
engine control to the OFF/RESET mode for at least plug is likely to occur when the engine is operating
15 seconds before you try to restart the engine. under a load. Refer to Troubleshooting, “Ignition
Transformers Secondary Circuit and Spark Plugs”.
Electrical Connectors
i01368495
1. Check the wiring harnesses and the connectors.
Inspect the connectors in the terminal boxes.
Inspect the power supply connections and the
Jacket Water Inlet Pressure
ground. Refer to Troubleshooting, “Inspecting (High)
Electrical Connectors”.
SMCS Code: 1350-035
2. Use Cat ET to check for the 168-02 diagnostic
code for “System Voltage Intermittent”. If Probable Causes
this diagnostic code is logged, proceed to
Troubleshooting, “Electrical Power Supply”.
• The circuit for the engine coolant pump pressure
switch (inlet) is OPEN.
61
• The pressure at the inlet for the jacket water is Recommended Repairs
excessive.
Check the Coolant Level and Inspect the
Recommended Repairs Cooling System for Leaks
Check the Circuit for the Engine Coolant Check coolant level. If the coolant level is low, inspect
Pump Pressure Switch (Inlet) the cooling system for leaks.
The circuit for the switch must remain closed in order If the coolant level is low, fill the cooling system. If
to avoid an “E224 High Jacket Water Inlet Pressure” leaks are found, make the necessary repairs.
event. Check wiring for damage or corrosion. Refer to
Troubleshooting, “Inspecting Electrical Connectors”. Check the Flow of Coolant
If a problem with the wiring for the circuit is found, Use the Caterpillar Electronic Technician (ET) to
repair the wiring, as needed. observe the pressure at the jacket water outlet with
the engine OFF. Then observe the reading during
Check the Inlet Pressure of the Jacket engine operation.
Water If the reading is not reasonable or if the reading is
not within specifications, install a pressure gauge
The engine coolant pump pressure switch (inlet) near the pressure sensor at the jacket water outlet.
is designed to open across pin B and pin C at a Compare the gauge reading with the reading from
pressure of 462 ± 41 kPa (67 ± 6 psi). Use a gauge Cat ET.
to check the pressure at the inlet for the jacket water.
If the readings from the comparative gauge do not
If the pressure is less than 462 ± 41 kPa (67 ± 6 psi) agree approximately with Cat ET, troubleshoot the
but the event code “E224 High Jacket Water Inlet circuit for the pressure sensor at the jacket water
Pressure” is occurring, replace the pressure switch at outlet. Refer to Troubleshooting, “PWM Sensor”.
the inlet for the jacket water.
If the readings from the comparative gauge agree
If a pressure of at least 462 ± 41 kPa (67 ± 6 psi) is approximately with Cat ET, check the following
measured at the inlet for the jacket water, the high components:
pressure may be caused by a restriction in the jacket
water system. Inspect the system for restrictions. • Check the water temperature regulators for proper
Make repairs, as needed. operation.
Note: If the outlet pressure of the coolant is greater • Check for plugging of the radiator or the heat
than approximately 444 kPa (64 psi), a 109-08 exchanger.
diagnostic code will be generated. The “Engine
Coolant Outlet Pressure Sensor noisy signal” • Inspect the jacket water pump for damage to the
diagnostic will be generated although there is no impeller.
malfunction in the electrical circuit. If this code is
generated, verify the actual outlet pressure of the Make the necessary repairs.
coolant with a pressure gauge. If the actual pressure
is greater than approximately 444 kPa (64 psi),
reduce the pressure. This will prevent a false 109-08 i01866678
from being logged.
Jacket Water to Engine Oil
i01727750
Differential Temperature (Low)
Jacket Water Pressure (Low) SMCS Code: 1350-035
SMCS Code: 1350-035 Probable Causes

Probable Causes • High engine oil temperature or low engine coolant
temperature
• Low coolant level
• Faulty temperature sensor and/or circuit
• Insufficient flow of coolant
• Faulty water temperature regulators
62
Recommended Repairs Check the water temperature regulators according to

Systems Operation/Testing and Adjusting, “Testing
Check for Event Codes for the Engine Oil the Cooling System”. Replace the water temperature
regulators, if necessary.
and for the Engine Coolant
Use the Caterpillar Electronic Technician (ET) to i01368006
check for the following event codes:
System Voltage
• E019 (3) High Engine Oil Temperature (shutdown)
SMCS Code: 1400-035
• E020 (1) High Engine Oil Temperature (warning)
Probable Causes
• E038 (1) Low Engine Coolant Temperature
(warning) There is a problem with the electrical system.
• E337 (1) Hign Engine Oil to Engine Coolant Diff

Temp (warning) Recommended Repairs
• E337 (3) High Engine Oil to Engine Coolant Diff Troubleshoot the electrical system. Refer to
Temp (shutdown) Troubleshooting, “Electrical Power Supply”.
If one or more of the codes is active, troubleshoot i02064382

the code. Refer to Troubleshooting, “Troubleshooting
with an Event Code”. Turbocharger Turbine
Check the Engine Oil Temperature and
Temperature (High)
the Engine Coolant Temperature SMCS Code: 1052-035

check the temperature of the engine oil and the Probable Causes
engine coolant.
• High inlet manifold temperature
If the engine oil temperature is high, refer to
Troubleshooting, “Engine Oil Temperature (High)”. • Incorrect base timing
If the temperature of the engine coolant is low, refer • Exhaust restriction

to Troubleshooting, “Engine Coolant Temperature
(Low)”. • A buildup of deposits in the cylinder or internal oil
leaks
Check the Temperature Sensors and/or
Circuits Recommended Repairs
Use a separate device to measure the temperatures Check for Event Codes for High Inlet
of the engine oil and the engine coolant. Compare the Manifold Air Temperature
measured temperatures to the readings on Cat ET.
If one or both of the readings are incorrect, check for the following event codes:
troubleshoot the circuit(s). Refer to Troubleshooting,
“Analog Sensor Signal”. • E026 (3) High Inlet Air Temperature (shutdown)
Check the Water Temperature Regulators • E027 (1) High Inlet Air Temperature (warning)
The water temperature regulators should not begin to If one or more of the codes is active, refer to
open until jacket water reaches opening temperature Troubleshooting, “Inlet Air Temperature (High)”.
for the regulators. Allow the engine to cool and then
start the engine. Check the tube at the outlet for the
jacket water. If the tube is warm and normal operating
temperature is not achieved yet, a regulator may be
stuck open.
63
Check the Base Timing • Low cylinder compression

Recommended Repairs
Timing - Adjust”.
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 near
Measure the exhaust restriction during engine
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
Investigate the cause of the exhaust restriction.
Is Unstable”.
Perform adjustments and/or make repairs, as
needed.
Check for Diagnostic Codes from the
Check for Deposits in the Cylinder and Integrated Temperature Sensing Module
Check for Internal Oil Leaks (ITSM)
Use a borescope to inspect the cylinders. Look for Use the Caterpillar Electronic Technician (ET)
the following conditions: to check for diagnostic codes that relate to the
thermocouples. Troubleshoot the code.
• Deposits on the valve seats
Check the Temperatures of the Cylinder
• Deposits on the valve faces Exhaust Ports
• Deposits on the cylinder walls that are above the Observe the temperatures for the exhaust ports of
upper limit of the piston stroke the cylinders in the suspect bank.
• Signs of internal oil leaks If any of the temperatures for the exhaust ports are
significantly different, determine the reason for the
Other signs of internal oil leaks include high oil difference in the exhaust port temperatures. Make
consumption and blue smoke. repairs, as needed.
Note: Excessive deposits contribute to guttering of
the valves. Check for Suspect Thermocouples
Observe the temperatures from the thermocouples
If excessive deposits and/or signs of internal oil leaks
are found, investigate the cause of the condition. for the turbocharger(s) after the engine is shut off.
When the engine is operating properly, the
temperatures from similar locations are reduced at
i01804955 a similar rate. Also, the temperatures from similar
locations are comparable.
Turbocharger Turbine
Temperature (Low) If any discrepancies are found, switch the suspect
thermocouple for another thermocouple. If the
SMCS Code: 1052-035 temperature problem follows the thermocouple,
replace the thermocouple.
Probable Causes If the temperature problem stays at the original

location of the thermocouple, investigate the cause
• Operation with a light load for the low temperature.
• Diagnostic code from the Integrated Temperature Check for Diagnostic Codes that Relate
Sensing Module (ITSM)
to Ignition
• Low temperature from the cylinder exhaust ports
Use Cat ET to check for diagnostic codes that relate
• A faulty temperature sensor to the ignition system. Troubleshoot the code.
• Faulty ignition
64
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.
65
Troubleshooting with a Table 9
Diagnostic Code Failure Mode Identifiers

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 in 03 “Voltage above normal or shorted high”
the electronic system has been detected. Diagnostic
codes also indicate the nature of the problem to 04 “Voltage below normal or shorted low”
the service technician. The Caterpillar Electronic 05 “Current below normal or open circuit”
Technician (ET) is a software program that is
designed to run on a personal computer. Diagnostic 06 “Current above normal or grounded
codes may be viewed on a personal computer that circuit”
has Cat ET software. Diagnostic codes consist of 07 “Mechanical system not responding
the module identifier (MID), the component identifier properly”
(CID), and the failure mode identifier (FMI).
08 “Abnormal frequency, pulse, or period”
Module Identifier (MID) – The MID is a code with 09 “Abnormal update”
two or three digits that indicates the electronic
module which generated the diagnostic code. The 10 “Abnormal rate of change”
MID for the master Electronic Control Module (ECM) 11 “Failure mode not identifiable”
is 36. The MID for the slave ECM is 33. The MID for
the Integrated Temperature Sensing Module (ITSM) 12 “Bad device or component”
is 111. Some electronic displays do not display the 13 “Out of calibration”
MID because the module which generates the code
is obvious. 14 “Not used”
15 “Not used”
Component Identifier (CID) – The CID is a number
with three or four digits. The CID indicates the 16 “Parameter not available”
component that generated the code. For example, 17 “Module not responding”
the CID number 0017 identifies the fuel shutoff valve.
18 “Sensor supply fault”
Failure Mode Identifier (FMI) – The FMI is a two 19 “Condition not met”
digit code that indicates the type of failure. Table 9 is
a list of the failure mode identifiers that are adapted 20 “Not used”
from the “SAE J1587” standard.
The master ECM will generate all of the diagnostic
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 18 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.
66
This information is a valuable indicator for

troubleshooting intermittent problems.

• The service technician manually clears the code.

• The code does not recur for 1000 hours.
• A new code is logged and there are already ten
cleared.
Some diagnostic codes may be easily triggered.

Some diagnostic codes may log occurrences that
did not result in complaints. The most likely cause
of an intermittent problem is a faulty connection
or damaged wiring. The next likely cause is a
component failure. The least likely cause is the failure
of an electronic module. Diagnostic codes that are
Illustration 18
g00791619 logged repeatedly may indicate a problem that needs
Typical operating range of an oil temperature sensor
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 with Conditions Which Generate This Code:
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 Default values are assumed for the inputs to the
list 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 activated.
When an ECM generates a diagnostic code, the ECM The code is logged.
logs the code in permanent memory. Each ECM has
an internal diagnostic clock. Each ECM will record Possible Performance Effect:
the following information when a code is generated:
Since the engine protection is disabled, the engine is
• The hour of the first occurrence of the code shut down.
• The hour of the last occurrence of the code

• The number of occurrences of the code
67
Troubleshooting: • The power supply voltage is less than 6 VDC for

a minimum of 0.060 seconds. The power supply
Perform the following diagnostic procedure: “+8V voltage returns to the normal range within 0.015
Sensor Voltage Supply” seconds.
Results: • There are three voltage readings of less than 6

VDC within 7 seconds.
• OK – STOP.
System Response:
i01775014
The alarm output is activated. The code is logged.
MID 033 - CID 0041 - FMI 04 8 Note: If power supply voltage is lost and the voltage
Volt DC Supply short to ground does not return, the slave ECM will not log this
diagnostic code. The engine will shut down.
SMCS Code: 5574-038
Possible Performance Effect:
Conditions Which Generate This Code:
The intermittent problem may not affect engine
The voltage supply from the slave Electronic Control operation. However, the engine may experience
Module (ECM) to the detonation sensors on the right speed burps, intermittent shutdowns, and/or
side of the engine is below the normal range. complete shutdowns.
System Response: Perform the following diagnostic procedure:

“Electrical Power Supply”
Default values are assumed for the inputs to the
slave ECM from all of the detonation sensors on the Results:
right side of the engine. All of the diagnostic codes
for the detonation sensors on the right side of the • OK – STOP.
engine are disabled while this code is active.
The fuel is shut off. The shutdown output is activated. i01769134
The code is logged.

MID 033 - CID 0301 - FMI 05
Possible Performance Effect: Ignition Transformer Primary
#1 open circuit
shut down.
SMCS Code: 1561-038
Troubleshooting:
Perform the following diagnostic procedure: “+8V
The primary circuit of the transformer is diagnosed
Sensor Voltage Supply”
with an open circuit.
Results:
System Response:
• OK – STOP. The alarm output is activated. The code is logged.
i01935325 Possible Performance Effect:

MID 033 - CID 0168 - The cylinder will misfire.
FMI 02 System Voltage Troubleshooting:
intermittent/erratic
One of the following conditions is the source of the
SMCS Code: 1408-038 diagnostic code:
Conditions Which Generate This Code: • A broken circuit driver’s wire for the transformer
The slave Electronic Control Module (ECM) has been • A broken return wire for the transformer
powered for at least 5 seconds. The engine has been
running. Either of the following conditions occur:
68
• 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:
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

• 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 Electronic • OK – STOP.
Control Module (ECM) to the transformer
• A short circuit within the primary winding of the i01758841

transformer
MID 033 - CID 0303 - FMI 06
• An internal failure of the slave ECM Ignition Transformer Primary
Perform the following diagnostic procedure: “Ignition #3 short
SMCS Code: 1561-038
Results:
• OK – STOP.
The path for the circuit driver of the transformer is
System Response:

69
Possible Performance Effect: Results:
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01758849

diagnostic code:
MID 033 - CID 0305 - FMI 06
• A short circuit in the wiring from the slave Electronic #5 short
SMCS Code: 1561-038
• A short circuit within the primary winding of the
transformer Conditions Which Generate This Code:
• An internal failure of the slave ECM The path for the circuit driver of the transformer is
System Response:
Results:
• OK – STOP. Possible Performance Effect:
i01758846 The cylinder will misfire.
MID 033 - CID 0305 - FMI 05 Troubleshooting:

Ignition Transformer Primary One of the following conditions is the source of the
#5 open circuit diagnostic code:
SMCS Code: 1561-038 • A short circuit in the wiring from the slave Electronic
The primary circuit of the transformer is diagnosed transformer
System Response:
The alarm output is activated. The code is logged. Transformers Primary Circuit”
The cylinder will misfire. • OK – STOP.

Troubleshooting:
i01758852

diagnostic code:
MID 033 - CID 0307 - FMI 05
• An open circuit in the wiring from the slave #7 open circuit
transformer
SMCS Code: 1561-038
• An open circuit within the primary winding of the Conditions Which Generate This Code:
transformer
• An internal failure of the slave ECM with an open circuit.
70
System Response: • A short circuit within the primary winding of the

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

diagnostic code:
i01758859
transformer
MID 033 - CID 0309 - FMI 05
• An open circuit within the primary winding of the #9 open circuit
transformer
SMCS Code: 1561-038
Results:
System Response:
• OK – STOP.
i01758853
MID 033 - CID 0307 - FMI 06
Ignition Transformer Primary The cylinder will misfire.
#7 short Troubleshooting:
SMCS Code: 1561-038 One of the following conditions is the source of the
diagnostic code:
The path for the circuit driver of the transformer is Electronic Control Module (ECM) to the
diagnosed with a short circuit. transformer
System Response: • An open circuit within the primary winding of the

transformer

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

Electronic Control Module (ECM) and the
transformer
71

MID 033 - CID 0309 - FMI 06 The cylinder will misfire.
Troubleshooting:
#9 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
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:
i01758875
• A short circuit in the wiring between the slave MID 033 - CID 0311 - FMI 06
transformer Ignition Transformer Primary
• A short circuit within the primary winding of the #11 short
transformer
SMCS Code: 1561-038
• An internal failure of the slave ECM Conditions Which Generate This Code:
Transformers Primary Circuit” The path for the circuit driver of the transformer is
Results:
System Response:

Troubleshooting:
#11 open circuit
Conditions Which Generate This Code: • A short circuit in the wiring between the slave

72
• An internal failure of the slave ECM i01758889
Perform the following diagnostic procedure: “Ignition MID 033 - CID 0313 - FMI 06
Transformers Primary Circuit” Ignition Transformer Primary
Results: #13 short
• OK – STOP. SMCS Code: 1561-038

i01758886
MID 033 - CID 0313 - FMI 05 diagnosed with a short circuit.
System Response:
#13 open circuit
SMCS Code: 1561-038
with an open circuit. Troubleshooting:
System Response: One of the following conditions is the source of the
diagnostic code:

transformer
Troubleshooting:
transformer
diagnostic code:
• An open circuit in the wiring from the slave Transformers Primary Circuit”
transformer Results:
• An open circuit within the primary winding of the • OK – STOP.
transformer
• An internal failure of the slave ECM i01758898
Results: #15 open circuit

System Response:

73
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.
• An open circuit in the wiring from the slave i01775725
transformer MID 033 - CID 0320 - FMI 03
• An open circuit within the primary winding of the Speed/Timing Sensor short to
transformer
+batt
• An internal failure of the slave ECM SMCS Code: 1912-038
To activate this code, all of the following conditions
Results:
must occur:
• OK – STOP. The slave Electronic Control Module (ECM) has
been powered for at least one second. The pattern
i01758902 of the timing reference gear is lost for more than one
second. The engine speed is greater than 150 rpm.
MID 033 - CID 0315 - FMI 06 Neither of the following diagnostic codes are active:
Ignition Transformer Primary • 145 - 03 12 Volt DC Power Supply short to +batt
#15 short
• 145 - 04 12 Volt DC Power Supply short to ground
SMCS Code: 1561-038
Note: The 0320 - 03 code is set after the pattern of
Conditions Which Generate This Code: the timing reference gear is lost for more than one
second. However, the logic hesitates for 1.5 seconds
The path for the circuit driver of the transformer is before the code is activated. If a 145 - 03 or 145 - 04
diagnosed with a short circuit. is activated during the 1.5 seconds, then the 0320 -
03 code is deactivated.
System Response:
System Response:
If the engine is running, the ignition signals stop. The
Possible Performance Effect: shutdown output is activated. The code is logged.
The cylinder will misfire. Possible Performance Effect:
Troubleshooting: If the engine is running, the engine will be shut down.

If the engine is not running, the engine will not start.
diagnostic code: Troubleshooting:
• A short circuit in the wiring between the slave Perform the following diagnostic procedure: “Engine
Electronic Control Module (ECM) and the Speed/Timing Sensor”
transformer
Results:
transformer • OK – STOP.
74

Engine Speed/Timing signal
Troubleshooting:
abnormal
Conditions Which Generate This Code: • A problem with the transformer’s ground
The slave Electronic Control Module (ECM) must be • An open circuit within the secondary winding of
powered for at least one second. The engine speed the transformer
is greater than 150 rpm. One of the following two
conditions occurs: • A problem with the connection to the spark plug’s
terminal post
• An invalid pattern for the timing reference gear
is detected. For example, reverse rotation is • The spark plug has internal damage or an open
detected. circuit.
• The pattern for the timing reference gear is lost for • The spark plug gap is too wide.
less than one second.
System Response: Transformers Secondary Circuit and Spark Plugs”
If the engine is running, the ignition signals stop. The Results:

shutdown output is activated. The code is logged.
• OK – STOP.
If the engine is running, the engine will be shut down. i01864793

MID 033 - CID 0401 - FMI
Troubleshooting: 06 Ignition Transformer
Perform the following diagnostic procedure: “Engine Secondary #1 short to ground
Speed/Timing Sensor”
SMCS Code: 1561-038
Results:
• OK – STOP. The transformer’s secondary circuit is diagnosed with
a short circuit.
i01864730
System Response:
MID 033 - CID 0401 - FMI
05 Ignition Transformer The status of the transformer’s secondary output is
set to zero percent. The alarm output is activated and
Secondary #1 open circuit the code is logged.
SMCS Code: 1561-038 Possible Performance Effect:
Conditions Which Generate This Code: The cylinder will misfire.
The transformer’s secondary circuit is diagnosed with Troubleshooting:

an open circuit.
System Response: diagnostic code:
The status of the transformer’s secondary output is • A short circuit within the secondary winding of the
set to 120 percent. The alarm output is activated and transformer
the code is logged.
75
• The spark plug is fouled. i01864797
• The spark plug gap is closed. MID 033 - CID 0403 - FMI
06 Ignition Transformer
Transformers Secondary Circuit and Spark Plugs” Secondary #3 short to ground
Results: SMCS Code: 1561-038
• OK – STOP. Conditions Which Generate This Code:
The transformer’s secondary circuit is diagnosed with

i01864795 a short circuit.
MID 033 - CID 0403 - FMI System Response:
The status of the transformer’s secondary output is
Secondary #3 open circuit set to zero percent. The alarm output is activated and
the code is logged.
SMCS Code: 1561-038
an open circuit. Troubleshooting:
diagnostic code:
set to 120 percent. The alarm output is activated and
the code is logged.
• A short circuit within the secondary winding of the
transformer
• The spark plug is fouled.
• The spark plug gap is closed.
Transformers Secondary Circuit and Spark Plugs”
• A problem with the transformer’s ground • OK – STOP.
• An open circuit within the secondary winding of
the transformer i01864798
• A problem with the connection to the spark plug’s MID 033 - CID 0405 - FMI
terminal post 05 Ignition Transformer
• The spark plug has internal damage or an open Secondary #5 open circuit
circuit.
SMCS Code: 1561-038
• The spark plug gap is too wide.
Transformers Secondary Circuit and Spark Plugs” The transformer’s secondary circuit is diagnosed with
an open circuit.
Results:
System Response:
• OK – STOP.
the code is logged.
76
Possible Performance Effect: • A short circuit within the secondary winding of the
transformer
Generation of the diagnostic code does not affect
engine performance. However, the engine will • The spark plug is fouled.
probably misfire. This will cause the engine to run
rough. The engine may shut down. • The spark plug gap is closed.

• An open circuit within the secondary winding of i01864802
the transformer
MID 033 - CID 0407 - FMI
• A problem with the connection to the spark plug’s
terminal post 05 Ignition Transformer
• The spark plug has internal damage or an open
Secondary #7 open circuit
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 with
an open circuit.
Results: System Response:
• OK – STOP. The status of the transformer’s secondary output is
i01864800 the code is logged.
MID 033 - CID 0405 - FMI Possible Performance Effect:

06 Ignition Transformer The cylinder will misfire.
Secondary #5 short to ground
Troubleshooting:
SMCS Code: 1561-038
Conditions Which Generate This Code: diagnostic code:
The transformer’s secondary circuit is diagnosed with • A problem with the transformer’s ground
a short circuit.
System Response: the transformer
The status of the transformer’s secondary output is • A problem with the connection to the spark plug’s
set to zero percent. The alarm output is activated and terminal post
the code is logged.
Possible Performance Effect: circuit.
The cylinder will misfire. • The spark plug gap is too wide.
diagnostic code:
77

the code is logged.
i01864806

Secondary #7 short to ground Troubleshooting:
SMCS Code: 1561-038
a short circuit.
the transformer
System Response:
terminal post
the code is logged.
circuit.

• A short circuit within the secondary winding of the • OK – STOP.

transformer
i01864812
MID 033 - CID 0409 - FMI
• The spark plug gap is closed. 06 Ignition Transformer
Perform the following diagnostic procedure: “Ignition Secondary #9 short to ground
SMCS Code: 1561-038
Results:
• OK – STOP.
a short circuit.
i01864809

the code is logged.
SMCS Code: 1561-038
an open circuit.
78
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 the Results:

transformer
• OK – STOP.
i01864821
MID 033 - CID 0411 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Ignition Transformer
Results:
SMCS Code: 1561-038
• OK – STOP.
i01864818
MID 033 - CID 0411 - FMI a short circuit.
05 Ignition Transformer System Response:
SMCS Code: 1561-038 set to zero percent. The alarm output is activated and
the code is logged.
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 and diagnostic code:
the code is logged.
Possible Performance Effect: transformer
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

terminal post

circuit.
79

MID 033 - CID 0413 - FMI The status of the transformer’s secondary output is
05 Ignition Transformer set to zero percent. The alarm output is activated and
the code is logged.
SMCS Code: 1561-038
Troubleshooting:
an open circuit. One of the following conditions is the source of the
diagnostic code:
System Response:
The status of the transformer’s secondary output is transformer
the code is logged. • The spark plug is fouled.
Possible Performance Effect: • The spark plug gap is closed.
Troubleshooting:
Results:
• A problem with the transformer’s ground
i01864826
• An open circuit within the secondary winding of MID 033 - CID 0415 - FMI
the transformer
• A problem with the connection to the spark plug’s Secondary #15 open circuit
terminal post
SMCS Code: 1561-038
circuit.
• The spark plug gap is too wide. The transformer’s secondary circuit is diagnosed with
Perform the following diagnostic procedure: “Ignition an open circuit.
System Response:
Results:
• OK – STOP. the code is logged.

MID 033 - CID 0413 - FMI The cylinder will misfire.
Troubleshooting:
The transformer’s secondary circuit is diagnosed with • An open circuit within the secondary winding of
a short circuit. the transformer
80
• A problem with the connection to the spark plug’s i01796190

terminal post
MID 033 - CID 0590 - FMI 09
• The spark plug has internal damage or an open Unable to communicate with
circuit.
Engine ECM
SMCS Code: 1901-038
Transformers Secondary Circuit and Spark Plugs” Conditions Which Generate This Code:
Results: The master Electronic Control Module (ECM) has

sent ten consecutive messages to the slave ECM via
• OK – STOP. the Cat data link. None of the messages have been
received by the slave ECM. Alternatively, the master
ECM has sent messages to the slave ECM over a
i01864829 period of time, and two-thirds of the messages have
not been received by the slave ECM. Neither ECM is
MID 033 - CID 0415 - FMI being flashed.
Note: Although there is a failure to communicate
Secondary #15 short to ground with the slave ECM, the master ECM may still be
able to communicate with the Caterpillar Electronic
SMCS Code: 1561-038 Technician (ET).
Conditions Which Generate This Code: System Response:
The transformer’s secondary circuit is diagnosed with The alarm output is activated.
a short circuit.
The code is logged by the slave ECM.
System Response:
Engine ignition is terminated.
set to zero percent. The alarm output is activated and Note: If Cat ET cannot communicate with the master
the code is logged. ECM, the values will display “Unavailable”.
Possible Performance Effect: Possible Performance Effect:
The cylinder will misfire. The engine is shut down.
Troubleshooting: Perform the following diagnostic procedure: “Cat
Data Link”
transformer

Results:
• OK – STOP.
81

MID 033 - CID 1501 - FMI 03 The shutdown output is activated. The code is logged.
Cylinder #1 Detonation Sensor
open/short to +batt
The engine is shut down.
SMCS Code: 1559-038
Troubleshooting:
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 1 and 3 to the slave Electronic Control Results:
Module (ECM) is greater than 4.8 VDC for ten
seconds. • OK – STOP.
Neither of the following diagnostic codes are active:
i01761195
• 0041 - 03 8 Volt DC Supply short to +batt MID 033 - CID 1505 - FMI 03
• 0041 - 04 8 Volt DC Supply short to ground Cylinder #5 Detonation Sensor
System Response: open/short to +batt
The shutdown output is activated. The code is logged. SMCS Code: 1559-038
Possible Performance Effect: Conditions Which Generate This Code:
The engine is shut down. The run relay and the crank terminate relay are
Troubleshooting: for cylinders 5 and 7 to the slave Electronic Control
Perform the following diagnostic procedure: seconds.
“Detonation Sensors”
Results:
• 0041 - 03 8 Volt DC Supply short to +batt
• OK – STOP.
• 0041 - 04 8 Volt DC Supply short to ground
short to ground
SMCS Code: 1559-038
Troubleshooting:
Module (ECM) is less than 1.0 VDC for ten seconds.
• OK – STOP.

82

short to ground
SMCS Code: 1559-038
Troubleshooting:
• OK – STOP.
• 0041 - 03 8 Volt DC Supply short to +batt i01761215

MID 033 - CID 1509 - FMI 04
System Response:
short to ground
The shutdown output is activated. The code is logged.
SMCS Code: 1559-038
The run relay and the crank terminate relay are
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 less than 1.0 VDC for ten seconds.
Results:
• OK – STOP.
open/short to +batt
SMCS Code: 1559-038
Troubleshooting:
energized. The signal from the detonation sensor for
cylinders 9 and 11 to the slave Electronic Control Results:

83

MID 033 - CID 1513 - FMI The shutdown output is activated. The code is logged.
03 Cylinder #13 Detonation
Sensor open/short to +batt
SMCS Code: 1559-038
Troubleshooting:
i01761242
• 0041 - 03 8 Volt DC Supply short to +batt MID 033 - CID 1517 - FMI
• 0041 - 04 8 Volt DC Supply short to ground 03 Cylinder #17 Detonation
System Response: Sensor open/short to +batt
The shutdown output is activated. The code is logged. SMCS Code: 1559-038
The engine is shut down. The run relay and the crank terminate relay are
Troubleshooting: cylinders 17 and 19 to the slave Electronic Control
Perform the following diagnostic procedure: seconds.
Results:
• OK – STOP.
MID 033 - CID 1513 - FMI The shutdown output is activated. The code is logged.
Sensor short to ground
SMCS Code: 1559-038
Troubleshooting:
• OK – STOP.

84

Troubleshooting:
The run relay and the crank terminate relay are • An open circuit within the secondary winding of
energized. The signal from the detonation sensor for the transformer
cylinders 17 and 19 to the slave Electronic Control
Module (ECM) is less than 1.0 VDC for ten seconds. • A problem with the connection to the spark plug’s
terminal post
• 0041 - 03 8 Volt DC Supply short to +batt circuit.
• 0041 - 04 8 Volt DC Supply short to ground • The spark plug gap is too wide.
System Response: Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting: i01760914

MID 033 - CID 1748 - FMI
“Detonation Sensors” 06 Ignition Transformer
Results: Secondary #17 short to ground
SMCS Code: 1561-038
• OK – STOP.
i01760803
the code is logged.
the code is logged.
transformer
85
Transformers Secondary Circuit and Spark Plugs” Secondary #19 short to ground

i01760805 a short circuit.
the code is logged.
SMCS Code: 1561-038
an open circuit. Troubleshooting:
diagnostic code:
the code is logged.
transformer
the transformer i01760301
• A problem with the connection to the spark plug’s MID 033 - CID 1752 - FMI 05
terminal post Ignition Transformer Primary
• The spark plug has internal damage or an open #17 open circuit
circuit.
SMCS Code: 1561-038
Transformers Secondary Circuit and Spark Plugs” The primary circuit of the transformer is diagnosed
Results:
System Response:
• OK – STOP.
86

Troubleshooting:
Results:
• An open circuit in the wiring from the slave i01760309
transformer MID 033 - CID 1754 - FMI 05
• An open circuit within the primary winding of the Ignition Transformer Primary
transformer
#19 open circuit
• An internal failure of the slave ECM SMCS Code: 1561-038
Results:
• OK – STOP. System Response:
i01760305 The alarm output is activated. The code is logged.
MID 033 - CID 1752 - FMI 06 Possible Performance Effect:

#17 short to ground
Troubleshooting:
SMCS Code: 1561-038
The path for the circuit driver of the transformer is • An open circuit in the wiring from the slave
diagnosed with a short circuit. Electronic Control Module (ECM) to the
transformer
System Response:
The alarm output is activated. The code is logged. transformer

Troubleshooting:
Results:
transformer

transformer
87
i01760311 • There is a short circuit to the +Battery in the wiring

for the fuel control relay.
MID 033 - CID 1754 - FMI 06
Ignition Transformer Primary Note: This code cannot be detected by the master
ECM when the output for the fuel control relay is ON.
#19 short to ground The output is normally ON when the engine control is
in the START mode and the engine RPM is greater
SMCS Code: 1561-038 than zero.
The path for the circuit driver of the transformer is No fuel is provided to the engine. The alarm output is
diagnosed with a short circuit. activated. The code is logged.
System Response: Possible Performance Effect:
The alarm output is activated. The code is logged. The engine will not start due to the lack of fuel.
Possible Performance Effect: Troubleshooting:
The cylinder will misfire. The most likely cause is one of the following
conditions:
Troubleshooting:
• An open circuit in the harness or in the fuel control
One of the following conditions is the source of the relay
diagnostic code:
• A short circuit to the +Battery in the harness or in
• A short circuit in the wiring between the slave the fuel control relay
transformer Perform the following diagnostic procedure: “ECM
Output Circuit (Fuel Control)”
transformer Results:
• An internal failure of the slave ECM • OK – STOP.

Transformers Primary Circuit” i01805813
Results: MID 036 - CID 0017 - FMI 06

Fuel Shutoff Valve short to
• OK – STOP. ground
i02088213 SMCS Code: 1259-038
MID 036 - CID 0017 - FMI 05 Conditions Which Generate This Code:
Fuel Shutoff Valve open circuit
• The output for the fuel control relay is ON.
SMCS Code: 1259-038
• The master Electronic Control Module (ECM)
Conditions Which Generate This Code: detects excessive current on the output for the
fuel control relay.
The master Electronic Control Module (ECM) has
detected a positive voltage source on the output for Note: This condition cannot be detected by the
the fuel shutoff valve. The most likely cause is one of master ECM when the output for the fuel control relay
the following conditions: is OFF. The output is normally OFF when the engine
control is in the STOP mode.
• The wiring harness has an open circuit.
• The fuel control relay has an open coil.
88
System Response: i01914066
The master ECM will continue attempting to energize MID 036 - CID 0041 - FMI 03 8
the relay. The engine may shut down due to a lack Volt DC Supply short to +batt
of fuel. The alarm output is activated. The code is
logged. SMCS Code: 5574-038
The engine will not start due to the lack of fuel. The voltage supply from the master Electronic
Control Module (ECM) for the 8 volt sensors has
Troubleshooting: exceeded the normal range.
The condition is probably caused by a short circuit in System Response:
the harness or by an internal short circuit in the fuel
control relay. Default values are assumed for the inputs to the
master ECM from all of the 8 volt sensors. All of the
Perform the following diagnostic procedure: “ECM diagnostic codes for the 8 volt sensors to the ECM
Output Circuit (Fuel Control)” are disabled while this code is active.
Results: The fuel is shut off. The shutdown output is activated.
The code is logged.
• OK – STOP.
i01758598
MID 036 - CID 0017 - FMI 12 shut down.
Fuel Shutoff Valve malfunction Troubleshooting:
SMCS Code: 1259-038 Perform the following diagnostic procedure: “+8V
Results:
The driver in the master Electronic Control Module
(ECM) for the gas shutoff valve is OFF but the engine
still runs.
• OK – STOP.
The master ECM will disable the ignition system MID 036 - CID 0041 - FMI 04 8
and the gas shutoff valve in order to shut down the Volt DC Supply short to ground
engine. The shutdown output is activated. The code
is logged. SMCS Code: 5574-038
The engine is shut down. The voltage supply from the master Electronic
Control Module (ECM) for the 8 volt sensors is below
Troubleshooting: the normal range.
Perform the following diagnostic procedure: “ECM System Response:
Output Circuit (Fuel Control)”
Default values are assumed for the inputs to the
Results: master ECM from all of the 8 volt sensors. All of the
diagnostic codes for the 8 volt sensors to the ECM
• OK – STOP. are disabled while this code is active.

The code is logged.
89
Since the engine protection is disabled, the engine is • OK – STOP.

shut down.
i01758623
Troubleshooting:
Perform the following diagnostic procedure: “+8V

MID 036 - CID 0100 - FMI 04
Sensor Voltage Supply” Engine Oil Pressure short to
Results:
ground
SMCS Code: 1924-038
• OK – STOP.
i01758614
The signal from the filtered oil pressure sensor to the
MID 036 - CID 0100 - FMI master Electronic Control Module (ECM) is less than
03 Engine Oil Pressure 0.2 VDC for at least five seconds.
open/short to +batt Additionally, neither of the following diagnostic codes

are active:
SMCS Code: 1924-038
• 262 - 03 5 Volt Sensor DC Power Supply short to
Conditions Which Generate This Code: +batt
The signal from the filtered oil pressure sensor to the • 262 - 04 5 Volt Sensor DC Power Supply short to
master Electronic Control Module (ECM) is greater ground
than 4.8 VDC for at least five seconds.
System Response:
Additionally, neither of the following diagnostic codes
are active: The master ECM assumes the last valid value for the
engine oil pressure. The monitoring of the oil pressure
• 262 - 03 5 Volt Sensor DC Power Supply short to is disabled. This disables the engine protection for
+batt low oil pressure and for excessive oil pressure.
• 262 - 04 5 Volt Sensor DC Power Supply short to The fuel is shut off. The shutdown output is activated.
ground The code is logged.
The master ECM assumes the last valid value for the Since the engine protection is disabled, the engine is
engine oil pressure. The monitoring of the oil pressure shut down.
is disabled. This disables the engine protection for
low oil pressure and for excessive oil pressure. Troubleshooting:
The fuel is shut off. The shutdown output is activated. Perform the following diagnostic procedure: “Analog
The code is logged. Sensor Signal”
Since the engine protection is disabled, the engine is • OK – STOP.

shut down.
Troubleshooting:
This condition indicates an open circuit or a short

circuit to a positive voltage source.
Perform the following diagnostic procedure: “Analog

Sensor Signal”
90
i01780399 • 41 - 04 8 Volt DC Supply short to ground

MID 036 - CID 0106 - FMI 03 Air System Response:
Inlet Pressure Sensor short to
+batt The code is logged.
SMCS Code: 5574-038-PX Possible Performance Effect:

Conditions Which Generate This Code: The engine is shut down.
The duty cycle for the inlet manifold pressure sensor Troubleshooting:
is greater than the maximum value.
Perform the following diagnostic procedure: “PWM
Additionally, neither of the following diagnostic codes Sensor”
are active:
Results:
• OK – STOP.

MID 036 - CID 0109 - FMI
The code is logged. 03 Coolant Outlet Pressure
Possible Performance Effect: open/short to +batt
The engine is shut down. SMCS Code: 5574-038-PX
Troubleshooting: Conditions Which Generate This Code:
This condition indicates a possible open circuit or a The duty cycle of the pressure sensor for the outlet of
possible short circuit. the engine coolant is greater than the maximum limit.
Perform the following diagnostic procedure: “PWM Additionally, neither of the following diagnostic codes
Sensor” are active:
Results: • 41 - 03 8 Volt DC Supply short to +batt
• OK – STOP. • 41 - 04 8 Volt DC Supply short to ground

System Response:
i01636377
MID 036 - CID 0106 - FMI 08 Air
Inlet Pressure Sensor noisy Possible Performance Effect:
signal The engine performance is not affected.
SMCS Code: 5574-038-PX Troubleshooting:
Conditions Which Generate This Code: The condition indicates a possible open circuit or a
short circuit.
The duty cycle or the frequency for the inlet manifold
pressure sensor is out of range. Perform the following diagnostic procedure: “PWM
Sensor”
are active: Results:
• 41 - 03 8 Volt DC Supply short to +batt • OK – STOP.

91
i01691110 The fuel is shut off. The shutdown output is activated.

The code is logged.
MID 036 - CID 0109 - FMI
08 Engine Coolant Outlet Possible Performance Effect:
Pressure Sensor noisy signal Since the engine protection is disabled, the engine is
shut down.
SMCS Code: 5574-038-PX
Troubleshooting:
This condition indicates a possible open circuit or a
The duty cycle or the frequency of the signal from the possible short circuit.
pressure sensor for the outlet of the engine coolant
is out of range. Perform the following diagnostic procedure: “Analog
Sensor Signal”
are active: Results:

i01758638
System Response:
MID 036 - CID 0110 - FMI 04
The alarm output is activated. The code is logged. Engine Coolant Temperature
Possible Performance Effect: short to ground
The engine performance is not affected. SMCS Code: 1906-038
Perform the following diagnostic procedure: “PWM The signal from the engine coolant temperature
Sensor” sensor to the master Electronic Control Module
(ECM) is less than 0.2 VDC for at least five seconds.
Results:
System Response:
• OK – STOP. The master ECM assumes the last valid value for the
engine coolant temperature. The monitoring of the
i01758632 coolant temperature is disabled. This disables the
engine protection for low coolant temperature and for
MID 036 - CID 0110 - FMI 03 high coolant temperature.
Engine Coolant Temperature The fuel is shut off. The shutdown output is activated.
open/short to +batt The code is logged.
SMCS Code: 1906-038 Possible Performance Effect:
Conditions Which Generate This Code: Since the engine protection is disabled, the engine is
shut down.
The signal from the engine coolant temperature
sensor to the master Electronic Control Module Troubleshooting:
(ECM) is greater than 4.8 VDC for at least five
seconds. Perform the following diagnostic procedure: “Analog
Sensor Signal”
System Response:
Results:
The master ECM assumes the last valid value for
engine coolant temperature. The monitoring of the • OK – STOP.
coolant temperature is disabled. This disables the
engine protection for low coolant temperature and for
high coolant temperature.
92
i01866770 Troubleshooting:
MID 036 - CID 0145 - FMI 03 12 Perform the following diagnostic procedure: “Engine
Volt DC Power Supply short to Speed/Timing Sensor”
+batt Results:
SMCS Code: 5574-038 • OK – STOP.

i01921808
been powered for at least five seconds. The 12 volt MID 036 - CID 0168 -
sensor supply voltage becomes greater than 14.2 V FMI 02 System Voltage
for at least one second.
intermittent/erratic
System Response:
SMCS Code: 1408-038
If the engine is running, the fuel is shut off. The
shutdown output is activated. The code is logged. Conditions Which Generate This Code:
Possible Performance Effect: The master Electronic Control Module (ECM) has
been powered for at least 5 seconds. The engine is
The engine is shut down or the engine will not start. running. Either of the two following conditions occur:
Troubleshooting: • The power supply voltage is less than 6 VDC for a

minimum of 0.060 seconds. The voltage returns to
Perform the following diagnostic procedure: “Engine the normal range within 0.015 seconds.
Speed/Timing Sensor”
• There are three voltage readings of less than 6
Results: VDC within 7 seconds.
System Response:
• OK – STOP.
i01866808
Note: If power supply voltage is lost and the voltage
MID 036 - CID 0145 - FMI 04 12 does not return, the master ECM will not log this
Volt DC Power Supply short to diagnostic code. The engine will shut down.
ground Possible Performance Effect:
SMCS Code: 5574-038 The intermittent problem may not affect engine
operation. However, the engine may experience
Conditions Which Generate This Code: speed burps, intermittent shutdowns, and/or
complete shutdowns.
been powered for at least five seconds. The 12 volt Troubleshooting:
sensor supply voltage becomes less than 11 VDC
for at least one second. Perform the following diagnostic procedure:
“Electrical Power Supply”
System Response:
Results:
If the engine is running, the fuel is shut off. The
shutdown output is activated. The code is logged. • OK – STOP.
The engine is shut down or the engine will not start.

93
i01875963 i01758674
MID 036 - CID 0172 - FMI 03 MID 036 - CID 0172 - FMI 04
Intake Manifold Air Temp Intake Manifold Air Temp short
open/short to +batt to ground
SMCS Code: 5574-038-TA SMCS Code: 5574-038-TA
Conditions Which Generate This Code: Conditions Which Generate This Code:
The master Electronic Control Module (ECM) has The signal from the inlet manifold temperature sensor
been powered for at least five seconds. The signal to the master Electronic Control Module (ECM) is
from the inlet manifold temperature sensor to the less than 0.2 VDC for at least five seconds.
master ECM is greater than 4.8 VDC for at least
five seconds. Additionally, neither of the following Additionally, neither of the following diagnostic codes
diagnostic codes are active: are active:
• 262 - 03 5 Volt Sensor DC Power Supply short to • 262 - 03 5 Volt Sensor DC Power Supply short to
+batt +batt
• 262 - 04 5 Volt Sensor DC Power Supply short to • 262 - 04 5 Volt Sensor DC Power Supply short to
ground ground
System Response: System Response:
The master ECM assumes the last valid value for The master ECM assumes the last valid value for
the inlet manifold air temperature. The monitoring of the inlet manifold air temperature. The monitoring of
the inlet manifold air temperature is disabled. This the inlet manifold air temperature is disabled. This
disables the engine protection for high inlet manifold disables the engine protection for high inlet manifold
air temperature. The air/fuel ratio control cannot air temperature. The air/fuel ratio control cannot
compensate for the inlet air temperature. compensate for the inlet air temperature.
The fuel is shut off. The shutdown output is activated. The fuel is shut off. The shutdown output is activated.
The code is logged. The code is logged.
The engine is shut down. The engine is shut down.
Troubleshooting: Troubleshooting:
The condition indicates a possible open circuit or a Perform the following diagnostic procedure: “Analog
short circuit to a positive voltage source. Sensor Signal”
Perform the following diagnostic procedure: “Analog Results:

Sensor Signal”
• OK – STOP.
Results:
i01758680
• OK – STOP.
MID 036 - CID 0175 - FMI
03 Engine Oil Temperature
open/short to +batt
SMCS Code: 5574-038-TA
The signal from the engine oil temperature sensor

to the master Electronic Control Module (ECM) is
greater than 4.8 VDC for at least five seconds.
94
Additionally, neither of the following diagnostic codes System Response:

are active:
The master ECM assumes the last valid value for the
• 262 - 03 5 Volt Sensor DC Power Supply short to engine oil temperature. The monitoring of the engine
+batt oil temperature is disabled. Also, monitoring for a
high difference in temperature between the engine oil
• 262 - 04 5 Volt Sensor DC Power Supply short to and the engine coolant is disabled. This disables the
ground engine protection for both parameters.
System Response: The shutdown output is activated. The code is logged.
The master ECM assumes the last valid value for the Possible Performance Effect:
engine oil temperature. The monitoring of the engine
oil temperature is disabled. Also, the monitoring for a Since engine protection is disabled, the engine is
high difference in temperature between the engine oil shut down.
and the engine coolant is disabled. This disables the
engine protection for both parameters. Troubleshooting:
The shutdown output is activated. The code is logged. Perform the following diagnostic procedure: “Analog
Sensor Signal”
Results:
Since engine protection is disabled, the engine is
shut down. • OK – STOP.
Troubleshooting:
i01636386
The condition indicates a possible open circuit or a

short circuit to a positive voltage source.
MID 036 - CID 0261 - FMI 13
Engine Timing calibration
Sensor Signal”
required
SMCS Code: 1905-038
Results:
• OK – STOP.
The timing calibration has not been performed.
i01758708
System Response:
MID 036 - CID 0175 - FMI 04
Engine Oil Temperature short The alarm output is activated. The code is logged.
to ground Possible Performance Effect:
SMCS Code: 5574-038-TA The timing will be advanced or the timing will be
retarded. Either condition will result in reduced
Conditions Which Generate This Code: engine performance. If the condition is not corrected,
engine damage will result.
The signal from the engine oil temperature sensor to
the master Electronic Control Module (ECM) is less Troubleshooting:
than 0.2 VDC for at least five seconds.
Calibrate the engine speed/timing sensor.
are active: Perform the following diagnostic procedure: “Engine
Speed/Timing Sensor - Calibrate”
+batt Results:
• 262 - 04 5 Volt Sensor DC Power Supply short to • OK – STOP.

ground
95
i01805835 i01805855
MID 036 - CID 0262 - FMI 03 5 MID 036 - CID 0262 - FMI 04 5
Volt Sensor DC Power Supply Volt Sensor DC Power Supply
short to +batt short to ground
SMCS Code: 5574-038 SMCS Code: 5574-038
The supply voltage from the master Electronic The supply voltage from the master Electronic
Control Module (ECM) to the sensors for the following Control Module (ECM) to the sensors for the following
parameters is exceeding the normal level: parameters is less than the normal level:
• Inlet air temperature • Inlet air temperature

• Engine oil temperature • Engine oil temperature
• Unfiltered engine oil pressure • Unfiltered engine oil pressure
• Filtered engine oil pressure • Filtered engine oil pressure
If the engine is equipped with a desired speed If the engine is equipped with a desired speed
potentiometer, a short circuit in the signal wire for the potentiometer, a short circuit in the signal wire for the
desired speed potentiometer can generate this code. desired speed potentiometer can generate this code.
All of the inputs to the master ECM for the 5 volt All of the inputs to the master ECM for the 5 volt
sensors assume default values. All other diagnostic sensors assume default values. All other diagnostic
codes for the 5 volt sensors are disabled while this codes for the 5 volt sensors are disabled while this
diagnostic code is active. The “Status” screen of diagnostic code is active. The “Status” screen of the
Caterpillar Electronic Technician (ET) indicates a Caterpillar Electronic Technician (ET) indicates a
“Sensor Supply Fault” for each sensor. This indicates “Sensor Supply Fault” for each sensor. This indicates
that the sensors are not operating due to an active that the sensors are not operating due to an active
diagnostic code. diagnostic code.
The shutdown indicator is activated. The code is The shutdown output is activated. The code is logged.
logged.
Since engine protection is disabled, the engine is
Since engine protection is disabled, the engine is shut down.
shut down.
Troubleshooting:
Troubleshooting:
The condition indicates a possible short circuit to
Perform the following diagnostic procedure: “+5V ground or a short circuit between the sensor supply
Sensor Voltage Supply” and the return.
Results: Perform the following diagnostic procedure: “+5V

• OK – STOP.
Results:
• OK – STOP.
96

Troubleshooting:
#2 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
Possible Performance Effect: Perform the following diagnostic procedure: “Ignition
Results:
Troubleshooting:
• OK – STOP.
diagnostic code:
i01758842
• An open circuit in the wiring from the master MID 036 - CID 0304 - FMI 05
Electronic Control Module (ECM) to the transformer
• An open circuit within the primary winding of the #4 open circuit
transformer
SMCS Code: 1561-038
• An internal failure of the master ECM
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
Results: with an open circuit.
System Response:
• OK – STOP.
i01758836
MID 036 - CID 0302 - FMI 06
#2 short Troubleshooting:
diagnostic code:
• An open circuit in the wiring from the master
The path for the circuit driver of the transformer is Electronic Control Module (ECM) to the transformer

97
• An internal failure of the master ECM i01758850
Results: #6 open circuit

i01758843
MID 036 - CID 0304 - FMI 06 with an open circuit.
System Response:
#4 short
SMCS Code: 1561-038
diagnosed with a short circuit. Troubleshooting:
diagnostic code:

transformer
Troubleshooting:

diagnostic code: Perform the following diagnostic procedure: “Ignition
• A short circuit in the wiring between the master
Electronic Control Module (ECM) and the Results:
transformer
• OK – STOP.
transformer
i01758851
MID 036 - CID 0306 - FMI 06
#6 short
Results:
SMCS Code: 1561-038
• OK – STOP.

System Response:

98

diagnostic code:
i01758856
transformer
MID 036 - CID 0308 - FMI 06
• A short circuit within the primary winding of the #8 short
transformer
SMCS Code: 1561-038
Results:
System Response:
• OK – STOP.
i01758855
MID 036 - CID 0308 - FMI 05
#8 open circuit Troubleshooting:
diagnostic code:
The primary circuit of the transformer is diagnosed Electronic Control Module (ECM) and the
with an open circuit. transformer
System Response: • A short circuit within the primary winding of the

transformer

diagnostic code:
i01758862
Electronic Control Module (ECM) to the transformer MID 036 - CID 0310 - FMI 05
• An open circuit within the primary winding of the Ignition Transformer Primary
transformer
#10 open circuit
• An internal failure of the master ECM SMCS Code: 1561-038
99
System Response: • An internal failure of the master ECM

The alarm output is activated. The code is logged. Perform the following diagnostic procedure: “Ignition
Results:
• OK – STOP.
Troubleshooting:
i01758879
diagnostic code: MID 036 - CID 0312 - FMI 05
• An open circuit in the wiring from the master Ignition Transformer Primary
#12 open circuit
• An open circuit within the primary winding of the SMCS Code: 1561-038
transformer
System Response:
Results:
• OK – STOP.
i01758867
MID 036 - CID 0310 - FMI 06
Ignition Transformer Primary Troubleshooting:
#10 short One of the following conditions is the source of the

diagnostic code:
SMCS Code: 1561-038
Conditions Which Generate This Code: Electronic Control Module (ECM) to the transformer
The path for the circuit driver of the transformer is • An open circuit within the primary winding of the
diagnosed with a short circuit. transformer
System Response: • An internal failure of the master ECM

Results:
• OK – STOP.
Troubleshooting:

diagnostic code:

transformer

transformer
100

Troubleshooting:
#12 short
Conditions Which Generate This Code: • An open circuit in the wiring from the master
diagnosed with a short circuit. • An open circuit within the primary winding of the
transformer
System Response:
Possible Performance Effect: Transformers Primary Circuit”
The cylinder will misfire. Results:
Troubleshooting: • OK – STOP.
diagnostic code: i01758894

MID 036 - CID 0314 - FMI 06
Electronic Control Module (ECM) and the Ignition Transformer Primary
transformer
#14 short
• A short circuit within the primary winding of the SMCS Code: 1561-038
transformer
Perform the following diagnostic procedure: “Ignition The path for the circuit driver of the transformer is
Transformers Primary Circuit” diagnosed with a short circuit.

• OK – STOP.
i01758891
MID 036 - CID 0314 - FMI 05
Ignition Transformer Primary Troubleshooting:
#14 open circuit One of the following conditions is the source of the
diagnostic code:
SMCS Code: 1561-038
Conditions Which Generate This Code: Electronic Control Module (ECM) and the
transformer
with an open circuit. • A short circuit within the primary winding of the
transformer
System Response:

101
• An internal failure of the master ECM i01758913
Results: #16 short

i01758906
MID 036 - CID 0316 - FMI 05 diagnosed with a short circuit.
System Response:
#16 open circuit
SMCS Code: 1561-038
with an open circuit. Troubleshooting:
diagnostic code:

transformer
Troubleshooting:
transformer
diagnostic code:
• An open circuit in the wiring from the master Transformers Primary Circuit”
Results:
transformer
• OK – STOP.
i01760423
Transformers Primary Circuit” MID 036 - CID 0320 - FMI 03
Speed/Timing Sensor short to
Results:
+batt
• OK – STOP.
SMCS Code: 1912-038
To activate this code, all of the following conditions

must occur:

been powered for at least one second. The pattern
of the timing reference gear is lost for more than one
second. The engine speed is greater than 150 rpm.
102
• 145 - 03 12 Volt DC Power Supply short to +batt Possible Performance Effect:
• 145 - 04 12 Volt DC Power Supply short to ground If the engine is running, the engine will be shut down.
Note: The 0320 - 03 code is set after the pattern of
the timing reference gear is lost for more than one Troubleshooting:
second. However, the logic hesitates for 1.5 seconds
before the code is activated. If a 145 - 03 or 145 - 04 Perform the following diagnostic procedure: “Engine
is activated during the 1.5 seconds, then the 0320 - Speed/Timing Sensor”
03 code is deactivated.
Results:
System Response:
• OK – STOP.
If the engine is running, the ignition signals stop. The
i01760427
Possible Performance Effect: MID 036 - CID 0323 - FMI 03

If the engine is running, the engine will be shut down. Shutdown Lamp short to +batt
SMCS Code: 7400-038-IND
Troubleshooting:
Perform the following diagnostic procedure: “Engine
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.
System Response:
i01760426
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
The engine operation is not affected.
SMCS Code: 1912-038
Troubleshooting:
Perform the following diagnostic procedure: “ECM
The master Electronic Control Module (ECM) must
Status Indicator Output”
be powered for at least one second. The engine
speed is greater than 150 rpm. One of the following
Results:
two conditions occurs:
• OK – STOP.
• An invalid pattern for the timing reference gear
is detected. For example, reverse rotation is
detected. i01760430
• The pattern for the timing reference gear is lost for MID 036 - CID 0324 - FMI 03
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 Conditions Which Generate This Code:
The master Electronic Control Module (ECM) detects
excessive current for the alarm output.
103
Note: This diagnostic condition cannot be detected i01864831

when the alarm output is OFF.
MID 036 - CID 0402 - FMI
System Response: 05 Ignition Transformer
The master ECM limits the current for the alarm Secondary #2 open circuit
output to 0.3 amperes. The code is logged.
SMCS Code: 1561-038
The engine operation is not affected.
Troubleshooting: an open circuit.
Perform the following diagnostic procedure: “ECM System Response:

Status Indicator Output”
Results: set to 120 percent. The alarm output is activated and
the code is logged.
• OK – STOP.
Incorrect ECS Switch inputs
The master Electronic Control Module (ECM) detects • An open circuit within the secondary winding of
an invalid combination on these inputs from the the transformer
Engine Control Switch (ECS): “Switched +Battery”,
“Start”, “Stop”, and “Auto”. • A problem with the connection to the spark plug’s
terminal post
System Response:
The shutdown output is activated. The code is logged. circuit.
Possible Performance Effect: • The spark plug gap is too wide.

If the engine is running, the engine will be shut down. Perform the following diagnostic procedure: “Ignition
Troubleshooting:
Results:
“Electrical Power Supply” • OK – STOP.
Results:
i01864834
• OK – STOP. MID 036 - CID 0402 - FMI

SMCS Code: 1561-038

a short circuit.
104
System Response: • An open circuit within the secondary winding of

the transformer
set to zero percent. The alarm output is activated and • A problem with the connection to the spark plug’s
the code is logged. terminal post
Possible Performance Effect: • The spark plug has internal damage or an open
circuit.
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
diagnostic code:
Results:
transformer • OK – STOP.
Perform the following diagnostic procedure: “Ignition 06 Ignition Transformer
i01864835 The transformer’s secondary circuit is diagnosed with

a short circuit.
MID 036 - CID 0404 - FMI
Secondary #4 open circuit The status of the transformer’s secondary output is

SMCS Code: 1561-038 the code is logged.
Conditions Which Generate This Code: Possible Performance Effect:
The transformer’s secondary circuit is diagnosed with The cylinder will misfire.
an open circuit.
Troubleshooting:
System Response:
The status of the transformer’s secondary output is diagnostic code:
the code is logged. • A short circuit within the secondary winding of the
transformer
Troubleshooting:
One of the following conditions is the source of the Transformers Secondary Circuit and Spark Plugs”
diagnostic code:
Results:
• OK – STOP.
105

the code is logged.
SMCS Code: 1561-038
Troubleshooting:
diagnostic code:
System Response:
Possible Performance Effect: • The spark plug gap is closed.
Troubleshooting:
Results:
i01864848
• An open circuit within the secondary winding of MID 036 - CID 0408 - FMI
the transformer
• A problem with the connection to the spark plug’s Secondary #8 open circuit
terminal post
SMCS Code: 1561-038
circuit.
• The spark plug gap is too wide. The transformer’s secondary circuit is diagnosed with
Perform the following diagnostic procedure: “Ignition an open circuit.
System Response:
Results:
• OK – STOP. the code is logged.

Troubleshooting:
106

terminal post
MID 036 - CID 0410 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
SMCS Code: 1561-038
Results: The transformer’s secondary circuit is diagnosed with

an open circuit.
• OK – STOP.
System Response:
i01864849 The status of the transformer’s secondary output is

MID 036 - CID 0408 - FMI the code is logged.
SMCS Code: 1561-038
Troubleshooting:
The transformer’s secondary circuit is diagnosed with diagnostic code:
a short circuit.
System Response:

the transformer
the code is logged.
terminal post

circuit.
Troubleshooting:
• A short circuit within the secondary winding of the Results:
transformer
• OK – STOP.
Results:
• OK – STOP.
107

Troubleshooting:
System Response: • A problem with the connection to the spark plug’s

terminal post
set to zero percent. The alarm output is activated and • The spark plug has internal damage or an open
the code is logged. circuit.
Possible Performance Effect: • The spark plug gap is too wide.

Troubleshooting:
Results:
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

• OK – STOP. a short circuit.

the code is logged.
SMCS Code: 1561-038
Troubleshooting:
diagnostic code:
System Response:
108
• The spark plug gap is closed. i01864863
Perform the following diagnostic procedure: “Ignition MID 036 - CID 0414 - FMI
Transformers Secondary Circuit and Spark Plugs” 06 Ignition Transformer
Results: Secondary #14 short to ground

i01864862
System Response:
the code is logged.
the code is logged.

transformer
Troubleshooting:
the transformer

terminal post
MID 036 - CID 0416 - FMI
• The spark plug has internal damage or an open 05 Ignition Transformer
circuit.
SMCS Code: 1561-038
Results: The transformer’s secondary circuit is diagnosed with

an open circuit.
• OK – STOP.
109
the code is logged.
Possible Performance Effect: transformer
The cylinder will misfire. • The spark plug is fouled.

Troubleshooting: • The spark plug gap is closed.

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 spark plug gap is too wide. SMCS Code: 4493-038
Perform the following diagnostic procedure: “Ignition Conditions Which Generate This Code:
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 OFF.
i01864865 The output is normally OFF when the engine control
is in the STOP mode.
MID 036 - CID 0416 - FMI
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.
Conditions Which Generate This Code: Troubleshooting:
The transformer’s secondary circuit is diagnosed with Perform the following diagnostic procedure: “ECM
a short circuit. Status Indicator Output”
System Response: Results:
The status of the transformer’s secondary output is • OK – STOP.

the code is logged.

110

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

by the master ECM when the output for the starting
motor relay is ON. The output is normally ON when
the engine control is changed from the STOP mode
to the START mode. The output is ON until the crank
terminate relay is energized.
111

MID 036 - CID 0524 - FMI 03 When the “Idle/Rated” switch is in the “Rated”
Desired Engine Speed Sensor position, the master ECM assumes a default value
for the desired engine speed.
short to +batt
SMCS Code: 5574-038
The default value for the desired engine speed is
The master Electronic Control Module (ECM) has equal to the “Minimum Engine High Idle Speed” that
been powered up for at least five seconds. The is programmed on the “Service/Configuration” screen
current to the master ECM for the desired speed input of the Caterpillar Electronic Technician (ET).
is greater than 22 mA for more than five seconds.
Troubleshooting:
System Response:
The diagnostic code is generated by one of the
When the “Idle/Rated” switch is in the “Rated” following conditions:
position, the master ECM assumes a default value
for the desired engine speed. • An open circuit or a short circuit to ground
The alarm output is activated. The code is logged. • An open circuit or a short circuit to the +Battery
Possible Performance Effect: Perform the following diagnostic procedure: “Desired
Speed Input (4 - 20 mA)”
The default value for the desired engine speed is
equal to the “Minimum Engine High Idle Speed” that Results:
is programmed on the “Service/Configuration” screen
of the Caterpillar Electronic Technician (ET). • OK – STOP.
Troubleshooting:
i01761094
The diagnostic code is generated by one of the
following conditions:
MID 036 - CID 0542 - FMI 03
Unfiltered Engine Oil Pressure
• A short circuit to the +Battery side open/short to +batt
• A short circuit to ground SMCS Code: 1924-038
Perform the following diagnostic procedure: “Desired
Speed Input (4 - 20 mA)” Conditions Which Generate This Code:
Results: 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
• OK – STOP. seconds. Also, neither of the following diagnostic
codes are active:
i01761093
MID 036 - CID 0524 - FMI 04 +batt
Desired Engine Speed Sensor
short to ground ground
SMCS Code: 5574-038 System Response:

Conditions Which Generate This Code: The master ECM assumes the last valid value
for unfiltered engine oil pressure. Monitoring for
The master Electronic Control Module (ECM) has restriction of the oil filters is disabled.
been powered up for at least five seconds. The
current to the master ECM for the desired speed The alarm output is activated. The code is logged.
input is less than 2 mA for more than five seconds.
112
Possible Performance Effect: i01946568
Engine operation is not affected. MID 036 - CID 1042 - FMI 09

Unable to communicate with
Troubleshooting:
ITSM
Sensor Signal” SMCS Code: 1901-038
• OK – STOP. The master Electronic Control Module (ECM) has

been powered up for at least five seconds. The
Integrated Temperature Sensing Module (ITSM) has
i01761095 sent ten consecutive messages to the master ECM
via the CAT Data Link. None of the messages have
MID 036 - CID 0542 - FMI 04 been received by the master ECM.
Unfiltered Engine Oil Pressure
Note: This diagnostic code is logged by the master
short to ground ECM only. This code is not activated or logged by
the ITSM. Although there is a failure to communicate
SMCS Code: 1924-038 with the master ECM, the ITSM may still be able
to communicate with the Caterpillar Electronic
Conditions Which Generate This Code: Technician (ET).
The signal to the master Electronic Control Module System Response:
(ECM) from the sensor for unfiltered engine oil
pressure is less than 0.2 VDC for at least five The alarm output is activated. The code is logged.
seconds. Also, neither of the following diagnostic
codes are active: Note: If Cat ET cannot communicate with the ITSM,
the values for the ITSM “Status Parameter” will
• 262 - 03 5 Volt Sensor DC Power Supply short to display “Unavailable”.
+batt
ground If the engine is not running, the engine will not start.
If the engine is running, the engine is shut down.
System Response:
Troubleshooting:
The master ECM assumes the last valid value
for unfiltered engine oil pressure. Monitoring for Perform the following diagnostic procedure: “CAT
restriction of the oil filters is disabled. Data Link”
The alarm output is activated. The code is logged. Results:
Troubleshooting:
• OK – STOP.
Sensor Signal”
Results:
• OK – STOP.
113
i01830219 Table 10
MID 036 - CID 1440 - FMI 09 X = 3.0 V − [ ( G · 1.75 V ) ÷ 300 CFM ]
Unable to communicate with G is the flow of the fuel in CFM.
Throttle Actuator Drv System Response:

SMCS Code: 1716-038
The “Status Parameter” for “Fuel Valve Position” will
Conditions Which Generate This Code: display “0 %” on the Caterpillar Electronic Technician
(ET). The alarm output is activated. The code is
The master Electronic Control Module (ECM) has logged.
been powered for at least five seconds. Messages
on the CAN data link between the master ECM and Possible Performance Effect:
the throttle actuator have been lost for 0.48 seconds,
indicating a short circuit or an open circuit on one of Engine performance is affected.
the wires or both of the wires for the CAN data link.
Troubleshooting:
System Response:
Perform the following diagnostic procedure: “Fuel
The fuel is shut off. The shutdown output is activated. Metering Valve”
The code is logged.
Results:
• OK – STOP.
If the engine is running, the engine is shut down. i01761115
Troubleshooting: MID 036 - CID 1446 - FMI 09

Perform the following diagnostic procedure: “Throttle
Unable to communicate with
Actuator” Fuel Metering Module

i01884041
been powered up for more than 5 seconds. Ten
MID 036 - CID 1446 - FMI 05 consecutive messages have been sent from the fuel
metering valve to the master ECM via the CAN Data
Fuel Metering Module open Link. None of the messages have been received by
circuit the master ECM.
SMCS Code: 1741-038 System Response:
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
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 Troubleshooting:
(300 CFM).
• The voltage of the signal is less than “X” for 5 Metering Valve”
seconds. The calculation for “X” is given in Table
10.
114
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 with
SMCS Code: 1741-038
the fuel metering valve.
System Response: Conditions Which Generate This Code:
The fuel metering valve sends a signal to the master

The code is logged. The shutdown output is activated.
Electronic Control Module (ECM) via the CAN data
link. The signal indicates that there is a problem with
the fuel metering valve’s sensor module.
System Response:
Troubleshooting:
The code is logged. The shutdown output is activated.
Metering Valve”
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
SMCS Code: 1559-038
System Response:
The code is logged. The alarm output is activated.
Possible Performance Effect: The run relay and the crank terminate relay are
cylinders 2 and 4 to the master Electronic Control
The fuel metering valve is shutdown. This prevents
the engine from running. Module (ECM) is greater than 4.8 VDC for ten
seconds.

115
• 0041 - 03 8 Volt DC Supply short to +batt i01761203
• 0041 - 04 8 Volt DC Supply short to ground MID 036 - CID 1506 - FMI 03
System Response:
open/short to +batt
SMCS Code: 1559-038
Troubleshooting: energized. The signal from the detonation sensor for
Perform the following diagnostic procedure: Module (ECM) is greater than 4.8 VDC for ten
“Detonation Sensors” seconds.
Results: Neither of the following diagnostic codes are active:
• OK – STOP. • 0041 - 03 8 Volt DC Supply short to +batt

i01761191
System Response:
MID 036 - CID 1502 - FMI 04
Cylinder #2 Detonation Sensor The shutdown output is activated. The code is logged.
short to ground Possible Performance Effect:
SMCS Code: 1559-038 The engine is shut down.
The run relay and the crank terminate relay are Perform the following diagnostic procedure:
energized. The signal from the detonation sensor for “Detonation Sensors”
Module (ECM) is less than 1.0 VDC for ten seconds. Results:
• OK – STOP.
i01761210
MID 036 - CID 1506 - FMI 04
System Response: Cylinder #6 Detonation Sensor
The shutdown output is activated. The code is 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: cylinders 6 and 8 to the master 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

116
The shutdown output is activated. The code is logged. MID 036 - CID 1510 - FMI
SMCS Code: 1559-038
Troubleshooting:
“Detonation Sensors” The run relay and the crank terminate relay are
Results: cylinders 10 and 12 to the master Electronic Control
• OK – STOP.
i01761217 • 0041 - 03 8 Volt DC Supply short to +batt

MID 036 - CID 1510 - FMI • 0041 - 04 8 Volt DC Supply short to ground
System Response:
SMCS Code: 1559-038
energized. The signal from the detonation sensor Troubleshooting:
for cylinders 10 and 12 to the master Electronic
Control Module (ECM) is greater than 4.8 VDC for Perform the following diagnostic procedure:
ten seconds. “Detonation Sensors”
Neither of the following diagnostic codes are active: Results:
i01761236
System Response:
MID 036 - CID 1514 - FMI
The shutdown output is activated. The code is logged. 03 Cylinder #14 Detonation
Possible Performance Effect: Sensor open/short to +batt
The engine is shut down. SMCS Code: 1559-038
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 14 and 16 to the master Electronic
Results: Control Module (ECM) is greater than 4.8 VDC for
ten seconds.
• OK – STOP.

117
SMCS Code: 1559-038
Troubleshooting:
“Detonation Sensors” The run relay and the crank terminate relay are
Results: for cylinders 18 and 20 to the master Electronic
Control Module (ECM) is greater than 4.8 VDC for
• OK – STOP. ten seconds.

i01761239
MID 036 - CID 1514 - FMI • 0041 - 03 8 Volt DC Supply short to +batt
04 Cylinder #14 Detonation • 0041 - 04 8 Volt DC Supply short to ground
Sensor short to ground System Response:
SMCS Code: 1559-038 The shutdown output is activated. The code is logged.
The run relay and the crank terminate relay are The engine is shut down.
cylinders 14 and 16 to the master 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:
i01761252
MID 036 - CID 1518 - FMI
Possible Performance Effect: 04 Cylinder #18 Detonation
The engine is shut down. Sensor short to ground
Troubleshooting: SMCS Code: 1559-038
Perform the following diagnostic procedure: Conditions Which Generate This Code:
Results: energized. The signal from the detonation sensor for
• OK – STOP. Module (ECM) is less than 1.0 VDC for ten seconds.

118
03 Generator Output Power
Troubleshooting:
“Detonation Sensors” One of the following conditions has occurred:
Results: • The load signal from the Electronic Modular Control

Panel II+ (EMCP II+) is missing.
• OK – STOP.
• The load signal from the power sensor to the
master Electronic Control Module (ECM) is
i01796209 missing.
MID 036 - CID 1636 - FMI 09 • The load signal from the power sensor to the
Loss of Communication with master ECM is greater than 4.8 VDC.
Engine #2 (Slave) System Response:
SMCS Code: 1901-038 The diagnostic code is logged and the engine is shut
down.
Troubleshooting:
The slave Electronic Control Module (ECM) has sent
ten consecutive messages to the master ECM via Perform the following diagnostic procedure:
the Cat data link. None of the messages have been “Generator Output Power Sensor”
received by the master ECM.
Results:
Note: Although there is a failure to communicate
with the master ECM, the slave ECM may still be
able to communicate with the Caterpillar Electronic
• OK – STOP.
Technician (ET).
i02088252
System Response:
MID 036 - CID 1719 - FMI
The alarm output is activated. 04 Generator Output Power
The code is logged by the master ECM. Sensor short to ground
Engine ignition is terminated. SMCS Code: 5574-038-PWR
Note: If Cat ET cannot communicate with the slave Conditions Which Generate This Code:
ECM, the values will display “Unavailable”.
This diagnostic code is not applicable to generators
Possible Performance Effect: that are equipped with the Electronic Modular Control
Panel II+ (EMCP II+).
Both of the following conditions occur:
Perform the following diagnostic procedure: “Cat
Data Link” • The engine load is greater than 20 percent.
Results: • The signal from the power sensor to the master
Electronic Control Module (ECM) is less than 0.2
• OK – STOP. VDC.
119
The diagnostic code is logged and the engine is shut The fuel is shut off. The shutdown output is activated.
down. The code is logged.
Troubleshooting: Possible Performance Effect:
Perform the following diagnostic procedure: If the engine is not running, the engine will not start.
“Generator Output Power Sensor” If the engine is running, the engine is shut down.
Results: Perform the following diagnostic procedure: “Bypass

Valve”
• OK – STOP.
Results:
i02088262
• OK – STOP.
MID 036 - CID 1719 - FMI
12 Generator Output Power i01760808
Sensor malfunction MID 036 - CID 1749 - FMI

SMCS Code: 1561-038
This diagnostic code is applicable to generators that
are equipped with the Electronic Modular Control Conditions Which Generate This Code:
Panel II+ (EMCP II+) only.
The master Electronic Control Module (ECM) has an open circuit.
determined that the load signal from the EMCP II+
may be invalid. System Response:
System Response: The status of the transformer’s secondary output is

The diagnostic code is logged and the engine is shut the code is logged.
down.
Troubleshooting:
“Generator Output Power Sensor” Troubleshooting:
Results: One of the following conditions is the source of the

diagnostic code:
• OK – STOP.
i01904169
MID 036 - CID 1720 - FMI 09 the transformer
Turbocharger Compressor • A problem with the connection to the spark plug’s

Bypass Valve Actuator not terminal post
communicating on link • The spark plug has internal damage or an open

circuit.
SMCS Code: 1052-038-BV
The master Electronic Control Module (ECM) cannot Transformers Secondary Circuit and Spark Plugs”
communicate with the actuator for the bypass valve.
120

the code is logged.
i01760946

Secondary #18 short to ground Troubleshooting:
SMCS Code: 1561-038
a short circuit.
the transformer
System Response:
terminal post
the code is logged.
circuit.


transformer
i01760951
MID 036 - CID 1751 - FMI
• The spark plug gap is closed. 06 Ignition Transformer
Perform the following diagnostic procedure: “Ignition Secondary #20 short to ground
SMCS Code: 1561-038
Results:
• OK – STOP.
a short circuit.
i01760821

the code is logged.
SMCS Code: 1561-038
an open circuit.
121
One of the following conditions is the source of the MID 036 - CID 1753 - FMI 06
diagnostic code: Ignition Transformer Primary
• A short circuit within the secondary winding of the #18 short to ground
transformer
SMCS Code: 1561-038
Perform the following diagnostic procedure: “Ignition diagnosed with a short circuit.
System Response:
Results:
• OK – STOP.

#18 open circuit diagnostic code:
SMCS Code: 1561-038
Conditions Which Generate This Code: transformer
transformer
System Response:
Results:
Troubleshooting:
• OK – STOP.
One of the following conditions is the source of the i01760312

diagnostic code:
MID 036 - CID 1755 - FMI 05
• An open circuit in the wiring from the master Ignition Transformer Primary
#20 open circuit
transformer SMCS Code: 1561-038
• An internal failure of the master ECM Conditions Which Generate This Code:
Perform the following diagnostic procedure: “Ignition The primary circuit of the transformer is diagnosed
Transformers Primary Circuit” with an open circuit.

122
Possible Performance Effect: • An internal failure of the master ECM

Troubleshooting:
Results:
• An open circuit in the wiring from the master i01636449
MID 111 - CID 0591 - FMI 12
transformer EEPROM checksum fault or
ECM not programmed
SMCS Code: 1901-038
Results:
detects a problem within the EPROM circuit.
• OK – STOP.
System Response:
i01760313
Monitoring of the exhaust temperature is lost. Also,
MID 036 - CID 1755 - FMI 06 protection against high exhaust temperatures is lost.
Ignition Transformer Primary The alarm output is activated. The code is logged.
#20 short to ground
Troubleshooting:
SMCS Code: 1561-038
There is a problem with the ITSM.
Replace the ITSM. Follow the instructions in
The path for the circuit driver of the transformer is Troubleshooting, “Replacing the ITSM”.
Results:
System Response:
• OK – STOP.
i01728761

MID 111 - CID 1489 - FMI 03 Left
Turbo Turbine Out Temp Sens
Troubleshooting:
short to +batt
One of the following conditions is the source of the SMCS Code: 5574-038
diagnostic code:
transformer
detects a short circuit to the +Battery side for the
input from the thermocouple of the turbocharger.
transformer
123
System Response: Results:
Monitoring of the temperature for the port of the • OK – STOP.

turbine is lost. Also, protection for the port is lost. The
code is logged. The “Status” screen of the Caterpillar
i01728782
Electronic Technician (ET) displays “Open/Shorted
High” for the port of the turbine. MID 111 - CID 1489 - FMI 05 Left
This diagnostic code remains active until the Turbo Turbine Out Temp Sens
condition that caused the problem is not present for
30 seconds.
open circuit
SMCS Code: 5574-038
Engine operation is not affected.
Troubleshooting: (ITSM) detects an open circuit for the input from the
thermocouple of the turbocharger.
“Integrated Temperature Sensing Module (ITSM)” System Response:
Results:
Monitoring of the exhaust temperature for the port
of the turbine is lost. Also, protection for the port
• OK – STOP. is lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays
i01728777 “Open/Shorted High” for the port of the turbine.
MID 111 - CID 1489 - FMI 04 Left Possible Performance Effect:

Turbo Turbine Out Temp Sens Engine operation is not affected.
short to ground
Troubleshooting:
SMCS Code: 5574-038
Conditions Which Generate This Code: “Integrated Temperature Sensing Module (ITSM)”
The Integrated Temperature Sensing Module (ITSM) Results:

detects one of the following conditions for the input
from the thermocouple of the turbocharger: • OK – STOP.
• A short circuit to the −Battery side i01728785
• A short circuit to the ground MID 111 - CID 1490 - FMI 03 Rt

System Response: Turbo Turbine Out Temp Sens
Monitoring of the temperature for the port of the
short to +batt
SMCS Code: 5574-038
Electronic Technician (ET) displays “Shorted to
Ground” for the port of the turbine.
System Response:
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)”
High” for the port of the turbine.
124
This diagnostic code remains active until the i01728794

30 seconds. MID 111 - CID 1490 - FMI 05 Rt
Turbo Turbine Out Temp Sens
open circuit
SMCS Code: 5574-038
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module
(ITSM) detects an open circuit for the input from the
Results: thermocouple of the turbocharger.

i01728791 of the turbine is lost. Also, protection for the port
is lost. The code is logged. The “Status” screen of
MID 111 - CID 1490 - FMI 04 Rt the Caterpillar Electronic Technician (ET) displays
Turbo Turbine Out Temp Sens “Open/Shorted High” for the port of the turbine.
SMCS Code: 5574-038 Engine operation is not affected.
The Integrated Temperature Sensing Module (ITSM) Perform the following diagnostic procedure:
detects one of the following conditions for the input “Integrated Temperature Sensing Module (ITSM)”
from the thermocouple of the turbocharger:
Results:
• A short circuit to the −Battery side
• OK – STOP.
• A short circuit to the ground
Monitoring of the temperature for the port of the MID 111 - CID 1491 - FMI 03 Rt
turbine is lost. Also, protection for the port is lost. The Turbo Turbine In Temp Sens
Electronic Technician (ET) displays “Shorted to short to +batt
SMCS Code: 5574-038
Troubleshooting: detects a short circuit to the +Battery side for the
Results: Monitoring of the temperature for the port of the

• OK – STOP. code is logged. The “Status” screen of the Caterpillar
125
This diagnostic code remains active until the i01728800

30 seconds. MID 111 - CID 1491 - FMI 05 Rt
Turbo Turbine In Temp Sens
open circuit
SMCS Code: 5574-038
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module
Results: thermocouple of the turbocharger.

i01728797 of the turbine is lost. Also, protection for the port
is lost. The code is logged. The “Status” screen of
MID 111 - CID 1491 - FMI 04 Rt the Caterpillar Electronic Technician (ET) displays
Turbo Turbine In Temp Sens “Open/Shorted High” for the port of the turbine.
SMCS Code: 5574-038 Engine operation is not affected.
The Integrated Temperature Sensing Module (ITSM) Perform the following diagnostic procedure:
detects one of the following conditions for the input “Integrated Temperature Sensing Module (ITSM)”
from the thermocouple of the turbocharger:
Results:
• OK – STOP.
Monitoring of the temperature for the port of the MID 111 - CID 1492 - FMI 03 Left
turbine is lost. Also, protection for the port is lost. The Turbo Turbine In Temp Sens
Electronic Technician (ET) displays “Shorted to short to +batt
SMCS Code: 5574-038
Troubleshooting: detects a short circuit to the +Battery side for the
Results: Monitoring of the temperature for the port of the

• OK – STOP. code is logged. The “Status” screen of the Caterpillar
This diagnostic code remains active until the

30 seconds.
126
Engine operation is not affected. MID 111 - CID 1492 - FMI 05 Left
Turbo Turbine In Temp Sens
Troubleshooting:
open circuit
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 5574-038
• OK – STOP. The Integrated Temperature Sensing Module

thermocouple of the turbocharger.
i01728806
System Response:
MID 111 - CID 1492 - FMI 04 Left
Turbo Turbine In Temp Sens Monitoring of the exhaust temperature for the port
of the turbine is lost. Also, protection for the port
short to ground is lost. The code is logged. The “Status” screen of
the Caterpillar Electronic Technician (ET) displays
SMCS Code: 5574-038 “Open/Shorted High” for the port of the turbine.
The Integrated Temperature Sensing Module (ITSM) Engine operation is not affected.
from the thermocouple of the turbocharger: Troubleshooting:
• A short circuit to the −Battery side Perform the following diagnostic procedure:
Results:
System Response:

• OK – STOP.
code is logged. The “Status” screen of the Caterpillar i01728819
Electronic Technician (ET) displays “Shorted to
Ground” for the port of the turbine. MID 111 - CID 1531 - FMI 03 Cyl
#1 Exhaust Port Temp Sensor
short to +batt
SMCS Code: 1919
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module (ITSM)
Results: input from the thermocouple of the cylinder.
Monitoring of the exhaust temperature for the cylinder

is lost. Also, protection for the cylinder is lost.
The thermocouple is removed from the calculation for

the average temperature of the engine.
127
The code is logged. The “Status” screen of the Results:

Caterpillar Electronic Technician (ET) displays
“Open/Shorted High” for the cylinder. • OK – STOP.
The diagnostic code remains active until the condition
i01728828
that caused the code is not present for 30 seconds.

MID 111 - CID 1531 - FMI 05 Cyl
open circuit
Troubleshooting:
SMCS Code: 1919
Results: (ITSM) detects an open circuit for the input from the
thermocouple of the cylinder.
• OK – STOP.
System Response:
i01728826
MID 111 - CID 1531 - FMI 04 Cyl is lost. Also, protection for the cylinder is lost.
#1 Exhaust Port Temp Sensor The thermocouple is removed from the calculation for
short to ground 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 condition
detects one of the following conditions for the input that caused the code is not present for 30 seconds.
from the thermocouple of the cylinder.
Troubleshooting:
System Response:
Monitoring of the exhaust temperature for the cylinder “Integrated Temperature Sensing Module (ITSM)”
Results:
the average temperature of the engine. • OK – STOP.
The code is logged. The “Status” screen of the
i01728833
“Shorted to ground” for the cylinder. MID 111 - CID 1532 - FMI 03 Cyl
The diagnostic code remains active until the condition #2 Exhaust Port Temp Sensor
short to +batt
Possible Performance Effect: SMCS Code: 1919
Troubleshooting:
Perform the following diagnostic procedure: input from the thermocouple of the cylinder.
128
System Response: The diagnostic code remains active until the condition
is lost. Also, protection for the cylinder is lost. Possible Performance Effect:
The thermocouple is removed from the calculation for Engine operation is not affected.
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 condition Results:

• OK – STOP.
i01728837
Troubleshooting:
MID 111 - CID 1532 - FMI 05 Cyl
open circuit
SMCS Code: 1919
Results:
• OK – STOP.
i01728835 (ITSM) detects an open circuit for the input from the
MID 111 - CID 1532 - FMI 04 Cyl
#2 Exhaust Port Temp Sensor System Response:
short to ground Monitoring of the exhaust temperature for the cylinder

SMCS Code: 1919
Conditions Which Generate This Code: the average temperature of the engine.
The Integrated Temperature Sensing Module (ITSM) The code is logged. The “Status” screen of the
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 condition
System Response:
is lost. Also, protection for the cylinder is lost. Troubleshooting:
The thermocouple is removed from the calculation for Perform the following diagnostic procedure:
the average temperature of the engine. “Integrated Temperature Sensing Module (ITSM)”
The code is logged. The “Status” screen of the Results:

“Shorted to ground” for the cylinder. • OK – STOP.
129

MID 111 - CID 1533 - FMI 03 Cyl Monitoring of the exhaust temperature for the cylinder
#3 Exhaust Port Temp Sensor is lost. Also, protection for the cylinder is lost.
short to +batt The thermocouple is removed from the calculation for

SMCS Code: 1919
Conditions Which Generate This Code: Caterpillar Electronic Technician (ET) displays
“Shorted to ground” for the cylinder.
detects a short circuit to the +Battery side for the The diagnostic code remains active until the condition
input from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.
Monitoring of the exhaust temperature for the cylinder Engine operation is not affected.
Troubleshooting:
the average temperature of the engine. Perform the following diagnostic procedure:
Caterpillar Electronic Technician (ET) displays Results:
“Open/Shorted High” for the cylinder.
• OK – STOP.
i01728915
MID 111 - CID 1533 - FMI 05 Cyl
Engine operation is not affected. #3 Exhaust Port Temp Sensor
Troubleshooting: open circuit
Perform the following diagnostic procedure: SMCS Code: 1919
Results:
• OK – STOP. thermocouple of the cylinder.

short to ground The thermocouple is removed from the calculation for

SMCS Code: 1919
detects one of the following conditions for the input The diagnostic code remains active until the condition
from the thermocouple of the cylinder. that caused the code is not present for 30 seconds.
• A short circuit to the −Battery side Possible Performance Effect:
• A short circuit to the ground Engine operation is not affected.

130
Perform the following diagnostic procedure: MID 111 - CID 1534 - FMI 04 Cyl
“Integrated Temperature Sensing Module (ITSM)” #4 Exhaust Port Temp Sensor
Results: short to ground
• OK – STOP. SMCS Code: 1919

i01728917
MID 111 - CID 1534 - FMI 03 Cyl detects one of the following conditions for the input
#4 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 cylinder
detects a short circuit to the +Battery side for the is lost. Also, protection for the cylinder is lost.
input from the thermocouple of the cylinder.
System Response: the average temperature of the engine.
Monitoring of the exhaust temperature for the cylinder The code is logged. The “Status” screen of the
is lost. Also, protection for the cylinder is lost. Caterpillar Electronic Technician (ET) displays
the average temperature of the engine. The diagnostic code remains active until the condition
Caterpillar Electronic Technician (ET) displays Possible Performance Effect:
that caused the code is not present for 30 seconds. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
Results:
Troubleshooting:

• OK – STOP.
i01728928
Results:
MID 111 - CID 1534 - FMI 05 Cyl
• OK – STOP. #4 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919

131
Monitoring of the exhaust temperature for the cylinder Perform the following diagnostic procedure:
is lost. Also, protection for the cylinder is lost. “Integrated Temperature Sensing Module (ITSM)”
The thermocouple is removed from the calculation for Results:

• OK – STOP.
i01728940

MID 111 - CID 1535 - FMI 04 Cyl
that caused the code is not present for 30 seconds. #5 Exhaust Port Temp Sensor
short to ground
SMCS Code: 1919
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” from the thermocouple of the cylinder.
Results:
• OK – STOP. • A short circuit to the ground

SMCS Code: 1919
Troubleshooting:
• OK – STOP.

132

open circuit The thermocouple is removed from the calculation for

SMCS Code: 1919
(ITSM) detects an open circuit for the input from the The diagnostic code remains active until the condition
thermocouple of the cylinder. that caused the code is not present for 30 seconds.
Troubleshooting:
• OK – STOP.
i01728968
MID 111 - CID 1536 - FMI 04 Cyl
Troubleshooting: short to ground
Results:
• OK – STOP. from the thermocouple of the cylinder.
i01728959 • A short circuit to the −Battery side

MID 111 - CID 1536 - FMI 03 Cyl • A short circuit to the ground
System Response:
short to +batt
SMCS Code: 1919 is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code: The thermocouple is removed from the calculation for
detects a short circuit to the +Battery side for the The code is logged. The “Status” screen of the
input from the thermocouple of the cylinder. Caterpillar Electronic Technician (ET) displays
133
The diagnostic code remains active until the condition i01728993

MID 111 - CID 1537 - FMI 03 Cyl
Possible Performance Effect: #7 Exhaust Port Temp Sensor
Engine operation is not affected. short to +batt
Troubleshooting: SMCS Code: 1919
Results: detects a short circuit to the +Battery side for the
• OK – STOP.
System Response:
i01728976 Monitoring of the exhaust temperature for the cylinder

MID 111 - CID 1536 - FMI 05 Cyl
#6 Exhaust Port Temp Sensor The thermocouple is removed from the calculation for
open circuit
SMCS Code: 1919 Caterpillar Electronic Technician (ET) displays
The Integrated Temperature Sensing Module that caused the code is not present for 30 seconds.
thermocouple of the cylinder. Possible Performance Effect:
System Response: Engine operation is not affected.
Monitoring of the exhaust temperature for the cylinder Troubleshooting:
The thermocouple is removed from the calculation for “Integrated Temperature Sensing Module (ITSM)”
Results:
• OK – STOP.
The diagnostic code remains active until the condition i01728999

MID 111 - CID 1537 - FMI 04 Cyl
Possible Performance Effect: #7 Exhaust Port Temp Sensor
Engine operation is not affected. short to ground
Troubleshooting: SMCS Code: 1919
Results: detects one of the following conditions for the input
• OK – STOP.
134
Troubleshooting:
• OK – STOP.
i01729015
Possible Performance Effect: MID 111 - CID 1538 - FMI 03 Cyl

Troubleshooting:
short to +batt
SMCS Code: 1919
“Integrated Temperature Sensing Module (ITSM)” Conditions Which Generate This Code:
Results:
• OK – STOP. input from the thermocouple of the cylinder.
open circuit The thermocouple is removed from the calculation for

SMCS Code: 1919
(ITSM) detects an open circuit for the input from the The diagnostic code remains active until the condition
thermocouple of the cylinder. that caused the code is not present for 30 seconds.
Troubleshooting:
• OK – STOP.
135


SMCS Code: 1919

• OK – STOP.
“Shorted to ground” for the cylinder. i01729257

MID 111 - CID 1539 - FMI 03 Cyl
Possible Performance Effect: short to +batt
Engine operation is not affected. SMCS Code: 1919
Perform the following diagnostic procedure: The Integrated Temperature Sensing Module (ITSM)
“Integrated Temperature Sensing Module (ITSM)” detects a short circuit to the +Battery side for the
Results:
System Response:
• OK – STOP. Monitoring of the exhaust temperature for the cylinder
i01729025
MID 111 - CID 1538 - FMI 05 Cyl the average temperature of the engine.
open circuit Caterpillar Electronic Technician (ET) displays
SMCS Code: 1919
Conditions Which Generate This Code: that caused the code is not present for 30 seconds.
The Integrated Temperature Sensing Module Possible Performance Effect:

thermocouple of the cylinder. Engine operation is not affected.
136
Results: open circuit

i01761374
MID 111 - CID 1539 - FMI 04 Cyl (ITSM) detects an open circuit for the input from the
#9 Exhaust Port Temp Sensor thermocouple of the cylinder.
short to ground System Response:
SMCS Code: 1919 Monitoring of the exhaust temperature for the cylinder
The Integrated Temperature Sensing Module (ITSM) the average temperature of the engine.
from the thermocouple of the cylinder. The code is logged. The “Status” screen of the
• A short circuit to the −Battery side “Open/Shorted High” for the cylinder.
• A short circuit to the ground The diagnostic code remains active until the condition
System Response:
is lost. Also, protection for the cylinder is lost. Engine operation is not affected.
The thermocouple is removed from the calculation for Troubleshooting:
The code is logged. The “Status” screen of the “Integrated Temperature Sensing Module (ITSM)”
“Shorted to ground” for the cylinder. Results:
• OK – STOP.
Engine operation is not affected. MID 111 - CID 1540 - FMI 03 Cyl
Troubleshooting:
short to +batt
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919
• OK – STOP. The Integrated Temperature Sensing Module (ITSM)

137
Troubleshooting:
• OK – STOP.
i01729271

Troubleshooting:
open circuit
SMCS Code: 1919
Results:

SMCS Code: 1919

• OK – STOP.

138


SMCS Code: 1919
Troubleshooting:
• OK – STOP.
i01729277
MID 111 - CID 1541 - FMI 05 Cyl
Results:


SMCS Code: 1919

139
Troubleshooting:
short to ground
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919
• OK – STOP. The Integrated Temperature Sensing Module (ITSM)

i01729278
MID 111 - CID 1542 - FMI 03 Cyl • A short circuit to the −Battery side
#12 Exhaust Port Temp Sensor • A short circuit to the ground
short to +batt System Response:
The Integrated Temperature Sensing Module (ITSM) the average temperature of the engine.
input from the thermocouple of the cylinder. The code is logged. The “Status” screen of the
System Response: “Shorted to ground” for the cylinder.
Monitoring of the exhaust temperature for the cylinder The diagnostic code remains active until the condition
is lost. Also, protection for the cylinder is lost. that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for Possible Performance Effect:
Caterpillar Electronic Technician (ET) displays Troubleshooting:
The diagnostic code remains active until the condition “Integrated Temperature Sensing Module (ITSM)”
Results:

• OK – STOP.
Results: open circuit

140
Troubleshooting:
• OK – STOP.
i01729291

Troubleshooting:
short to ground
SMCS Code: 1919
Results:
• OK – STOP. from the thermocouple of the cylinder.
i01729287 • A short circuit to the −Battery side

MID 111 - CID 1543 - FMI 03 Cyl • A short circuit to the ground
#13 Exhaust Port Temp Sensor System Response:
short to +batt
SMCS Code: 1919 is lost. Also, protection for the cylinder is lost.
Conditions Which Generate This Code: The thermocouple is removed from the calculation for
detects a short circuit to the +Battery side for the The code is logged. The “Status” screen of the
input from the thermocouple of the cylinder. Caterpillar Electronic Technician (ET) displays
System Response:
Monitoring of the exhaust temperature for the cylinder that caused the code is not present for 30 seconds.
the average temperature of the engine. Engine operation is not affected.
The code is logged. The “Status” screen of the Troubleshooting:

“Open/Shorted High” for the cylinder. Perform the following diagnostic procedure:
that caused the code is not present for 30 seconds. Results:
• OK – STOP.
141
i01729294 The thermocouple is removed from the calculation for

MID 111 - CID 1543 - FMI 05 Cyl
#13 Exhaust Port Temp Sensor The code is logged. The “Status” screen of the
open circuit “Open/Shorted High” for the cylinder.
SMCS Code: 1919 The diagnostic code remains active until the condition
(ITSM) detects an open circuit for the input from the Engine operation is not affected.
Troubleshooting:
System Response:
Monitoring of the exhaust temperature for the cylinder “Integrated Temperature Sensing Module (ITSM)”
Results:
the average temperature of the engine. • OK – STOP.
Caterpillar Electronic Technician (ET) displays i01729303
MID 111 - CID 1544 - FMI 04 Cyl
The diagnostic code remains active until the condition #14 Exhaust Port Temp Sensor
short to ground
SMCS Code: 1919
Troubleshooting:
Perform the following diagnostic procedure: detects one of the following conditions for the input
“Integrated Temperature Sensing Module (ITSM)” from the thermocouple of the cylinder.
Results: • A short circuit to the −Battery side
• OK – STOP. • A short circuit to the ground

System Response:
i01729297
MID 111 - CID 1544 - FMI 03 Cyl is lost. Also, protection for the cylinder is lost.
short to +batt the average temperature of the engine.
SMCS Code: 1919 The code is logged. The “Status” screen of the
Conditions Which Generate This Code: “Shorted to ground” for the cylinder.
The Integrated Temperature Sensing Module (ITSM) The diagnostic code remains active until the condition
detects a short circuit to the +Battery side for the that caused the code is not present for 30 seconds.
System Response:
142
Results: short to +batt

i01729306
MID 111 - CID 1544 - FMI 05 Cyl detects a short circuit to the +Battery side for the
#14 Exhaust Port Temp Sensor input from the thermocouple of the cylinder.
open circuit System Response:
The Integrated Temperature Sensing Module the average temperature of the engine.
thermocouple of the cylinder. The code is logged. The “Status” screen of the
System Response: “Open/Shorted High” for the cylinder.
Monitoring of the exhaust temperature for the cylinder The diagnostic code remains active until the condition
is lost. Also, protection for the cylinder is lost. that caused the code is not present for 30 seconds.
The thermocouple is removed from the calculation for Possible Performance Effect:
Caterpillar Electronic Technician (ET) displays Troubleshooting:
The diagnostic code remains active until the condition “Integrated Temperature Sensing Module (ITSM)”
Results:

• OK – STOP.


143

• OK – STOP.
i01729314

MID 111 - CID 1546 - FMI 03 Cyl
short to +batt
SMCS Code: 1919
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” input from the thermocouple of the cylinder.
Results:
System Response:
i01729312
#15 Exhaust Port Temp Sensor The code is logged. The “Status” screen of the
SMCS Code: 1919
The Integrated Temperature Sensing Module Possible Performance Effect:

thermocouple of the cylinder. Engine operation is not affected.

• OK – STOP.


144


SMCS Code: 1919

• OK – STOP.
“Shorted to ground” for the cylinder. i01761434

MID 111 - CID 1547 - FMI 03 Cyl
Possible Performance Effect: short to +batt
Engine operation is not affected. SMCS Code: 1919-038
Perform the following diagnostic procedure: The Integrated Temperature Sensing Module (ITSM)
“Integrated Temperature Sensing Module (ITSM)” detects a short circuit to the +Battery side for the
Results:
System Response:
i01729319
SMCS Code: 1919

145
Troubleshooting:
open circuit
“Integrated Temperature Sensing Module (ITSM)” SMCS Code: 1919-038
• OK – STOP. The Integrated Temperature Sensing Module

i01761445
System Response:
MID 111 - CID 1547 - FMI 04 Cyl
#17 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the cylinder
short to ground
SMCS Code: 1919-038 the average temperature of the engine.
Conditions Which Generate This Code: The code is logged. The “Status” screen of the
The Integrated Temperature Sensing Module (ITSM) “Open/Shorted High” for the cylinder.
from the thermocouple of the cylinder. The diagnostic code remains active until the condition
System Response:
Troubleshooting:
is lost. Also, protection for the cylinder is lost. Perform the following diagnostic procedure:
the average temperature of the engine. Results:
• OK – STOP.
i01761436
that caused the code is not present for 30 seconds. MID 111 - CID 1548 - FMI 03 Cyl
short to +batt
SMCS Code: 1919-038
Troubleshooting:
“Integrated Temperature Sensing Module (ITSM)” The Integrated Temperature Sensing Module (ITSM)
Results: input from the thermocouple of the cylinder.

146
The thermocouple is removed from the calculation for 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 condition • OK – STOP.

i01761457

MID 111 - CID 1548 - FMI 05 Cyl
Troubleshooting:
open circuit
Perform the following diagnostic procedure: SMCS Code: 1919-038
Results:
• OK – STOP. (ITSM) detects an open circuit for the input from the
i01761446
System Response:
MID 111 - CID 1548 - FMI 04 Cyl
#18 Exhaust Port Temp Sensor Monitoring of the exhaust temperature for the cylinder
short to ground
SMCS Code: 1919-038 the average temperature of the engine.
Conditions Which Generate This Code: The code is logged. The “Status” screen of the
The Integrated Temperature Sensing Module (ITSM) “Open/Shorted High” for the cylinder.
from the thermocouple of the cylinder. The diagnostic code remains active until the condition
System Response:
Troubleshooting:
is lost. Also, protection for the cylinder is lost. Perform the following diagnostic procedure:
the average temperature of the engine. Results:
The code is logged. The “Status” screen of the • OK – STOP.



147


SMCS Code: 1919-038
Troubleshooting:
• OK – STOP.
i01761460
MID 111 - CID 1549 - FMI 05 Cyl
Perform the following diagnostic procedure: SMCS Code: 1919-038
Results:


SMCS Code: 1919-038

148

i01761438
MID 111 - CID 1550 - FMI 03 Cyl detects one of the following conditions for the input
#20 Exhaust Port Temp Sensor from the thermocouple of the cylinder.
short to +batt • A short circuit to the −Battery side
SMCS Code: 1919-038
The Integrated Temperature Sensing Module (ITSM) Monitoring of the exhaust temperature for the cylinder
detects a short circuit to the +Battery side for the is lost. Also, protection for the cylinder is lost.
System Response: the average temperature of the engine.
Monitoring of the exhaust temperature for the cylinder The code is logged. The “Status” screen of the
is lost. Also, protection for the cylinder is lost. Caterpillar Electronic Technician (ET) displays
the average temperature of the engine. The diagnostic code remains active until the condition
Caterpillar Electronic Technician (ET) displays Possible Performance Effect:
that caused the code is not present for 30 seconds. Troubleshooting:
Possible Performance Effect: Perform the following diagnostic procedure:
Results:
Troubleshooting:

• OK – STOP.
i01761461
Results:
MID 111 - CID 1550 - FMI 05 Cyl
• OK – STOP. #20 Exhaust Port Temp Sensor
open circuit
SMCS Code: 1919-038

149
System Response:




Troubleshooting:

Results:
• OK – STOP.
150
Troubleshooting with an
Event Code
i02088275
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 G3500 engines that g00791619
have a single ECM. The events that are diagnosed Illustration 19
by the slave ECM are a subset of the events that are Typical operating range of an oil temperature sensor
diagnosed by the master ECM. All of the events that (1) In these areas, the output voltage of the sensor is too high
are pertinent to the slave ECM have the same setting or too low. The output is outside of the normal range. The
conditions and the same conditions for clearing as electronic problem will generate a diagnostic code.
(2) In this area, the oil temperature above 102 °C (216 °F) is
the master ECM. higher than normal. The output voltage of the sensor will
generate an event code for a warning or a shutdown for high oil
Event codes alert the operator that an abnormal temperature. The sensor does not have an electronic problem.
engine operating condition such as low oil pressure (3) This area represents the normal operating temperature for the
or high coolant temperature has been detected. engine oil. The normal output voltage of the sensor is between
0.2 and 4.1 volts.
Events do not indicate problems with the electronic
system. Event codes also indicate the nature of the
The following format is used for event codes:
problem. The Caterpillar Electronic Technician (ET)
is designed to run on a personal computer. Event
codes may be viewed on a personal computer that • “EXXX (X) Description of the code”
has the Cat ET software.
The “E” means that the code is an event code.
The “XXX” represents a numeric identifier for the
Illustration 19 represents the operating range of an
event code. The fourth “(X)” represents a numeric
oil temperature sensor. The diagram is a reference.
identifier for the severity of the code. This is followed
Do not use the diagram to troubleshoot the oil
by a description of the code. Refer to the following
temperature sensor.
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 shutdown.
Shutdown (3) – For this condition, the engine is

shut down in order to help prevent possible engine
damage.
151
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 load.
• Gather enough information about the complaint in
order to describe the symptom(s) adequately.
• Determine if there are any systems that were
installed by the dealer or the customer that could
• Verify that the complaint is not due to normal cause the symptom.
engine operation.
• Determine whether any other occurrences
• Repair all active diagnostic codes. See happened in addition to the symptom.
Troubleshooting, “Troubleshooting With A
Diagnostic Code”.
Diagnostic Codes and Event Codes
Troubleshooting Examine the following information regarding any
codes:
For basic troubleshooting of the engine, perform
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 • Codes that are repeatedly logged
due to error of the operator.
• The complaint is not due to normal engine
operation.
3. Perform a visual inspection. Inspect the following
items:
Other Symptoms
• Fuel supply
If other occurrences happened in addition to the
• Oil level symptom, investigate the following conditions:
• Oil supply • The other occurrences are related to the symptom.

• Wiring • The symptoms have a probable cause that is
common.
• Connectors
4. Check the diagnostic codes and event codes.
Active Event Codes
Repair any active codes. An active event code represents a problem with
engine operation. Correct the problem as soon as
If these inspections do not reveal any problems, possible.
identify the probable causes with the procedures in
this manual that best describe the symptoms. Check
each probable cause according to the tests that are
recommended.
152
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 Alarm E004 Engine Overspeed
Status” on Cat ET) is activated in order to alert the Shutdown
operator. If the condition that generated the code
is momentary, the message disappears. The event SMCS Code: 1348-038
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 numerical The engine rpm has exceeded the trip point that
order on Cat ET. The code with the lowest number is programmed into the master Electronic Control
is listed first. Module (ECM) and the delay time has expired. The
master ECM has determined that the detected speed
Logged Event Codes 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 off.
an internal diagnostic clock. Each ECM will record The shutdown output is activated. The code is logged.
the following information when a code is generated:
• The hour of the first occurrence of the code
• The hour of the last occurrence of the code
Troubleshooting:
• The number of occurrences of the code
Refer to Troubleshooting, “Engine Overspeed”.
This information can be helpful for troubleshooting
intermittent problems. Logged codes can also be Results:
used to review the performance of the engine.
• OK – STOP.
i01633543
• The service technician manually clears the code. E016 High Engine Coolant
• The code does not recur for 1000 hours. Temperature Shutdown
• A new code is logged and there are already ten SMCS Code: 1395-038
cleared. Conditions Which Generate This Code:
Logged events are listed in chronological order. The The crank terminate relay is set and the engine has
most recent event code is listed first. been running for at least 30 seconds. The engine
coolant temperature has exceeded the trip point and
Note: Always clear logged event codes after the delay time has expired. No other codes for the
investigating and correcting the problem which engine coolant are active.
generated the code.
System Response:

The code is logged.
Troubleshooting:

Temperature (High)”.
153
• OK – STOP. Refer to Troubleshooting, “Engine Oil Temperature

(High)”.
i01633545
Results:
E017 High Engine Coolant
• OK – STOP.
Temperature Warning
SMCS Code: 1395-038 i01633605

E020 High Engine Oil
Temperature Warning
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 the Conditions Which Generate This Code:
engine coolant are active.
System Response: been running for at least 30 seconds. The engine
oil temperature has exceeded the trip point and the
The alarm output is activated. The code is logged. 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 rise, The alarm output is activated. The code is logged.
the engine will be shut down.
Troubleshooting:
Refer to Troubleshooting, “Engine Coolant However, if the engine oil temperature continues to
Temperature (High)”. rise, the engine can be shut down.
• OK – STOP. Refer to Troubleshooting, “Engine Oil Temperature

(High)”.
i01633603
Results:
E019 High Engine Oil
• OK – STOP.
Temperature Shutdown
SMCS Code: 1348-038 i01633755

E026 High Inlet Air
Temperature Shutdown
been running for at least 30 seconds. The engine SMCS Code: 1050-038
oil temperature has exceeded the trip point and the
delay time has expired. No other codes for the engine Conditions Which Generate This Code:
oil temperature are active.
System Response: been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the
The fuel is shut off. The shutdown output is activated. delay time has expired. No other codes for the inlet
The code is logged. air temperature are active.
The engine is shut off.

154
The fuel is shut off. The shutdown output is activated. E038 Low Engine Coolant
The code is logged. Temperature Warning
Troubleshooting: The crank terminate relay is set and the engine
has been running for at least 30 seconds. The
Refer to Troubleshooting, “Inlet Air Temperature temperature of the engine coolant is less than the trip
(High)”. point and the delay time has expired. No other codes
for the coolant temperature are active.
Results:
System Response:
• OK – STOP.
i01633756
E027 High Inlet Air
Temperature Warning
Troubleshooting:
SMCS Code: 1050-038
Conditions Which Generate This Code: Temperature (Low)”.
The crank terminate relay is set and the engine has Results:
been running for at least 30 seconds. The inlet air
temperature has exceeded the trip point and the
delay time has expired. No other codes for the inlet
• OK – STOP.
air temperature are active.
i01633762
System Response:
E040 Low Engine Oil Pressure
The alarm output is activated. The code is logged. Shutdown
Possible Performance Effect: SMCS Code: 1348-038-PX
The engine operation is not immediately affected. Conditions Which Generate This Code:
However, if the inlet air temperature continues to rise,
the engine may be shut down. The crank terminate relay is set and the engine has
been running for at least 10 seconds. The engine oil
Troubleshooting: pressure is less than the trip point and the delay time
has expired. No codes for the engine oil pressure
Refer to Troubleshooting, “Inlet Air Temperature sensor are active.
(High)”.
System Response:
Results:
• OK – STOP. The code is logged.
Troubleshooting:
Refer to Troubleshooting, “Engine Oil Pressure

(Low)”.
155
Results: Results:
• OK – STOP. • OK – STOP.
i01633763 i01877738
E042 Low System Voltage E050 High System Voltage

Shutdown Warning
The voltage is less than the trip point and the delay The voltage is greater than the trip point and the
time has expired. No other codes for the system delay time has expired. No other codes for the
voltage are present. system voltage are present.
The shutdown output is activated. The code is logged. The alarm output is activated. The code is logged.
The engine is shut down. The engine operation is not immediately affected.
However, engine components could be damaged if
Troubleshooting: the system voltage continues to increase.
Refer to Troubleshooting, “System Voltage”. Troubleshooting:
Results: Refer to Troubleshooting, “System Voltage”.
• OK – STOP. Results:
i01633765
• OK – STOP.
E043 Low System Voltage i01637578
Warning E053 Low Fuel Pressure

SMCS Code: 1400-038 Warning
Conditions Which Generate This Code: SMCS Code: 1250-038
The voltage is less than the trip point and the delay Conditions Which Generate This Code:
time has expired. No other codes for the system
voltage are present. The fuel pressure is less than the trip point and the
delay time has expired.
System Response:
System Response:
However, if the system voltage continues to be The engine operation is not immediately affected.
reduced, the engine will be shut down. However, if the fuel pressure continues to be
reduced, the supply may become inadequate for the
Troubleshooting: fuel metering valve.
Refer to Troubleshooting, “System Voltage”. Troubleshooting:
Refer to Troubleshooting, “Fuel Pressure”.

156
• OK – STOP. Refer to Troubleshooting, “Engine Oil Pressure

(Low)”.
i01637590
Results:
E096 High Fuel Pressure
• OK – STOP.
SMCS Code: 1250-038
i01633790
E127 Engine Oil Filter Diff
The fuel pressure is higher than the trip point and the
Pressure Low Warning
System Response: SMCS Code: 1308-038

The engine operation is not immediately affected. filter differential pressure is less than the trip point
and the delay time has expired. There are no active
However, if the fuel pressure continues to increase,
codes for the oil pressure sensors.
the supply may exceed the maximum limit for the fuel
metering valve.
System Response:
Troubleshooting:
Refer to Troubleshooting, “Fuel Pressure”.
Results:
However, if the engine oil filter differential pressure
• OK – STOP. continues to be reduced, the engine may be shut
down.
i01633787
Troubleshooting:
E100 Low Engine Oil Pressure
Warning Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”.
SMCS Code: 1348-038
Results:
• OK – STOP.
been running for at least ten seconds. The engine i01633814
oil pressure is less than the trip point and the delay
time has expired. There are no active codes for the E128 Engine Oil Filter Diff
engine oil pressure sensor.
Pressure Low Shutdown
System Response:
SMCS Code: 1308-038
The engine operation is not immediately affected. been running for at least 30 seconds. The oil filter
differential pressure is less than the trip point and the
However, if the oil pressure continues to be reduced,
delay time has expired. There are no active codes for
the engine may be shut down.
the oil pressure sensors.
157
The fuel is shut off. The shutdown output is activated. E130 Engine Oil Filter Diff
The code is logged. Pressure High Shutdown
Troubleshooting: The crank terminate relay is set and the engine has
Refer to Troubleshooting, “Engine Oil Filter filter differential pressure is greater than the trip point
Differential Pressure”. and the delay time has expired. There are no active
Results:
System Response:
• OK – STOP.
i01633828
The code is logged.
E129 Engine Oil Filter Diff Possible Performance Effect:

Pressure High Warning The engine is shut down.
SMCS Code: 1308-038 Troubleshooting:
Conditions Which Generate This Code: Refer to Troubleshooting, “Engine Oil Filter
Differential Pressure”.
been running for at least 30 seconds. The oil filter Results:
differential pressure is greater than the trip point
and the delay time has expired. There are no active
• OK – STOP.
The alarm output is activated. The code is logged. E135 Low Jacket Water
Pressure Shutdown
SMCS Code: 1350-038
However, if the oil filter differential pressure continues Conditions Which Generate This Code:
to increase, the engine may be shut down.
Troubleshooting: been running for at least ten seconds. The pressure
of the jacket water is less than the trip point and the
Refer to Troubleshooting, “Engine Oil Filter delay time has expired. There are no active codes for
Differential Pressure”. the pressure sensor at the outlet for the jacket water.
• OK – STOP. The fuel is shut off. The shutdown output is activated.

The code is logged.
Troubleshooting:
Refer to Troubleshooting, “Jacket Water Pressure

(Low)”.
158
• OK – STOP. Refer to Troubleshooting, “Jacket Water Inlet

Pressure (High)”.
i01633954
Results:
E223 High Gas Temperature
• OK – STOP.
SMCS Code: 1250-038
i01633959
E225 Engine Overcrank
The crank terminate relay is set and the engine
has been running for at least 30 seconds. The SMCS Code: 1400-038
temperature of the gas has exceeded the trip point
and the delay timer has expired. There are no active Conditions Which Generate This Code:
codes for the fuel temperature sensor.
The engine did not start within the programmed
System Response: parameters for starting.
The alarm output is activated. The code is logged. System Response:
Possible Performance Effect: The fuel is shut off. Engine cranking is prevented.
The code is logged.
However, if the fuel temperature continues to Possible Performance Effect:
increase, the air/fuel ratio and the inlet manifold air
temperature can be affected. The engine will not start.
Refer to Troubleshooting, “Gas Temperature (High)”. Refer to Troubleshooting, “Engine Overcrank”.
Results: Results:
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 activated. The shutdown output is activated. Engine cranking
The code is logged. is prevented. The code is logged.
The engine is shut down. The engine will not start.

159
Refer to Troubleshooting, “Driven Equipment”. Refer to Troubleshooting, “Fuel Energy Content”.
Results: Results:
i01633972 i01746483
E229 Fuel Energy Content E231 Fuel Quality Out of Range

Setting Low SMCS Code: 1250-038
SMCS Code: 1250-038
been running for at least 30 seconds. The Low Heat
The crank terminate relay is set and the engine Value (LHV) of the fuel is less than the trip point OR
has been running for at least 30 seconds. The fuel
the LHV of the fuel is greater than the trip point for
correction factor is less than the trip point for 20
20 seconds.
seconds.
System Response:
System Response:
The code is logged.
The engine performance may be erratic.
Troubleshooting:
Troubleshooting:
Refer to Troubleshooting, “Fuel Energy Content”. Refer to Troubleshooting, “Fuel Energy Content”.
Results:
Results:
i01633976
i01634015
E230 Fuel Energy Content E243 High Left Turbo Turbine

Setting High Outlet Temperature
SMCS Code: 1250-038
SMCS Code: 1052-038
The crank terminate relay is set and the engine
The temperature at the outlet for the left turbocharger
has been running for at least 30 seconds. The fuel turbine has exceeded the trip point and the delay
correction factor is greater than the trip point for 20
time has expired.
seconds.
System Response:
System Response:
The following event codes are logged according to
The alarm output is activated. The code is logged. the trip points for the temperature:
• E243 (1) High Left Turbo Turbine Outlet
Temperature (warning)
The engine performance may be erratic.
• E243 (3) High Left Turbo Turbine Outlet
Temperature (shutdown)
160
If a warning is generated, the alarm output is Troubleshooting:

activated.
Refer to Troubleshooting, “Turbocharger Turbine
If a shutdown is generated, the shutdown output is Temperature (High)”.
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 and the delay
• OK – STOP. time has expired.
System Response:
i01634039
E244 High Right Turbo Turbine The following event codes are logged according to
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 and If a warning is generated, the alarm output is
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 is
Temperature (warning) not immediately affected.
• E244 (3) High Right Turbo Turbine Outlet The engine will be shut down if the trip point for the
Temperature (shutdown) shutdown is exceeded.

activated.
If a shutdown is generated, the shutdown output is Temperature (High)”.
activated.
Results:
• OK – STOP.
161

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 programmed
Possible Performance Effect: speed of the postlube cycle for 200 ms.
If a warning is generated, the engine performance is System Response:

The engine will be shut down if the trip point for the The code is logged.
Troubleshooting:
Temperature (High)”. Troubleshooting:
Results: Refer to Troubleshooting, “Engine Shutdown

(Unexpected)”.
• OK – STOP. Results:
i01634059 • OK – STOP.
E264 Emergency Stop
Activated i01634093
E269 Customer Shutdown

SMCS Code: 1400-038
Requested
SMCS Code: 1400-038
The input for the emergency stop is activated.
The engine is either cranking or running. The input

for the stop is set for 200 ms.
162
The fuel is shut off. The shutdown output is activated. E337 High Engine Oil to Engine
The code is logged. Coolant Diff Temp
The engine is shut off. Conditions Which Generate This Code:
Troubleshooting: The crank terminate relay is set and the engine has
been running for at least 30 seconds. The differential
Refer to Troubleshooting, “Engine Shutdown”. between the temperature of the engine oil and the
temperature of the engine coolant has exceeded the
Results: trip point. Also, the delay time has expired. There are
no active codes for the sensors for the engine oil
• OK – STOP. temperature and the engine coolant.
i01634097
System Response:
E270 Driven Equipment The following event codes are logged according to
the trip points for the temperature differential:
Shutdown Requested
SMCS Code: 1400-038
• E337 (1) High Engine Oil to Engine Coolant Diff
Temp (warning)
• E337 (3) High Engine Oil to Engine Coolant Diff
Temp (shutdown)
The crank terminate relay is set and the engine is
running. The input requests a shutdown for 200 ms. If a warning is activated, the alarm output is activated.
System Response: If a shutdown is activated, the shutdown output is
activated.
The code is logged. Possible Performance Effect:
Possible Performance Effect: If a warning is generated, the engine operation is not
immediately affected.
Troubleshooting: shutdown is exceeded.
Refer to Troubleshooting, “Driven Equipment”. Troubleshooting:
Results: Refer to Troubleshooting, “Jacket Water to Engine
Oil Differential Temperature (Low)”.
• OK – STOP.
Results:
• OK – STOP.
163
i01637607 i01637627
E401 Cylinder #1 Detonation E403 Cylinder #3 Detonation

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

Results: Results:
164
i01637642 i01637648

Results: Results:
i01637646 i01637651

Results: Results:
165
i01637653 i01637663

Results: Results:
i01637657 i01637665

Results: Results:
166
i01637696 i01637702

Results: Results:
i01637699 i01637706

Results: Results:
167
i01762523 i01762525

Results: Results:
i01762524 i01762527

Results: Results:
168
i01634664 Results:
E421 Cylinder #1 Detonation • OK – STOP.
Shutdown
i01634838
SMCS Code: 1000-038
E423 Cylinder #3 Detonation
Shutdown
The level of detonation has exceeded the trip point.
Maximum retardation of the timing was unable to SMCS Code: 1000-038
control the detonation adequately during the number
of ignition sparks that are allowed. There is no active Conditions Which Generate This Code:
diagnostic code for the cylinder’s detonation sensor.
System Response: Maximum retardation of the timing was unable to
The fuel is shut off. The shutdown output is activated. of ignition sparks that are allowed. There is no active
The code is logged. diagnostic code for the cylinder’s detonation sensor.
Possible Performance Effect: System Response:
The engine is shut down. The fuel is shut off. The shutdown output is activated.
The code is logged.
Troubleshooting:
Refer to Troubleshooting, “Detonation”.
Results:
Troubleshooting:
• OK – STOP. Refer to Troubleshooting, “Detonation”.
i01634746 Results:
Shutdown
i01635415
SMCS Code: 1000-038
Shutdown
The code is logged.
Troubleshooting:
169
Refer to Troubleshooting, “Detonation”. The engine is shut down.
Results:
i01635416

Shutdown i01635420
SMCS Code: 1000-038

Conditions Which Generate This Code: Shutdown
The level of detonation has exceeded the trip point. SMCS Code: 1000-038
Maximum retardation of the timing was unable to
control the detonation adequately during the number Conditions Which Generate This Code:
of ignition sparks that are allowed. There is no active
diagnostic code for the cylinder’s detonation sensor. The level of detonation has exceeded the trip point.
System Response: control the detonation adequately during the number
The fuel is shut off. The shutdown output is activated. diagnostic code for the cylinder’s detonation sensor.
The code is logged.
System Response:
The engine is shut down. The code is logged.
Results:
i01635417

Shutdown
i01635421
SMCS Code: 1000-038 E428 Cylinder #8 Detonation

The code is logged.
170
The fuel is shut off. The shutdown output is activated. E430 Cylinder #10 Detonation
The code is logged. Shutdown
Troubleshooting: The level of detonation has exceeded the trip point.
Refer to Troubleshooting, “Detonation”. control the detonation adequately during the number
Results: diagnostic code for the cylinder’s detonation sensor.
i01635423
The code is logged.
Shutdown
SMCS Code: 1000-038
Troubleshooting:
Maximum retardation of the timing was unable to Results:
• OK – STOP.
The fuel is shut off. The shutdown output is activated. E431 Cylinder #11 Detonation
The code is logged. Shutdown
Troubleshooting: The level of detonation has exceeded the trip point.
Refer to Troubleshooting, “Detonation”. control the detonation adequately during the number
Results: diagnostic code for the cylinder’s detonation sensor.

The code is logged.
Troubleshooting:

171
Results:
i01635429

Shutdown
i01635433
SMCS Code: 1000-038

The code is logged.
System Response:
Results:
i01635431

Shutdown i01635435
SMCS Code: 1000-038

The code is logged.
System Response:
172
The code is logged.
Troubleshooting:
Results:
Troubleshooting:
• OK – STOP.
i01635436
Results:
• OK – STOP.
Shutdown
SMCS Code: 1000-038 i01762529

Shutdown
The code is logged.
Troubleshooting:
Results:
Troubleshooting:
• OK – STOP.
i01762528
Results:
• OK – STOP.
Shutdown
SMCS Code: 1000-038

173
i01762530 Results:
Shutdown
i01635494
SMCS Code: 1000-038
E801 Cylinder #1 High Exhaust
Port Temp
The cylinder exhaust temperature has exceeded the
System Response: trip point and the delay time has expired.
The fuel is shut off. The shutdown output is activated. System Response:
The code is logged.
Possible Performance Effect: the trip points for the temperature:
The engine is shut down. • E801 (1) Cylinder #1 High Exhaust Port Temp
(warning)
Troubleshooting:
• E801 (3) Cylinder #1 High Exhaust Port Temp
Refer to Troubleshooting, “Detonation”. (shutdown)
Results: If a warning is generated, the alarm output is

activated.
• OK – STOP. If a shutdown is generated, the shutdown output is
activated and the fuel is shut off.
i01762532
Shutdown If a warning is generated, the engine performance is
SMCS Code: 1000-038
Conditions Which Generate This Code: shutdown is exceeded.
The level of detonation has exceeded the trip point. Troubleshooting:

control the detonation adequately during the number Refer to Troubleshooting, “Exhaust Port Temperature
of ignition sparks that are allowed. There is no active (High)”.
Results:
System Response:
• OK – STOP.
The code is logged. i01635500
Possible Performance Effect: E802 Cylinder #2 High Exhaust

The engine is shut down. Port Temp
Troubleshooting: SMCS Code: 1059-038
Refer to Troubleshooting, “Detonation”. Conditions Which Generate This Code:

trip point and the delay time has expired.
174

• E802 (1) Cylinder #2 High Exhaust Port Temp If a warning is generated, the engine performance is
(warning) not immediately affected.
• E802 (3) Cylinder #2 High Exhaust Port Temp The engine will be shut down if the trip point for the
(shutdown) shutdown is exceeded.

activated.
Refer to Troubleshooting, “Exhaust Port Temperature
If a shutdown is generated, the shutdown output is (High)”.
Results:
• OK – STOP.
i01635505
Port Temp
Troubleshooting:
SMCS Code: 1059-038
(High)”. Conditions Which Generate This Code:
Results: The cylinder exhaust temperature has exceeded the

• OK – STOP.
System Response:
i01635503 The following event codes are logged according to
E803 Cylinder #3 High Exhaust the trip points for the temperature:
Port Temp • E804 (1) Cylinder #4 High Exhaust Port Temp

(warning)
SMCS Code: 1059-038
Conditions Which Generate This Code: (shutdown)
The cylinder exhaust temperature has exceeded the If a warning is generated, the alarm output is
trip point and the delay time has expired. activated.

If a warning is generated, the alarm output is

activated.
175
Refer to Troubleshooting, “Exhaust Port Temperature E806 Cylinder #6 High Exhaust

(High)”. Port Temp
i01635508
System Response:
Port Temp
SMCS Code: 1059-038 the trip points for the temperature:
(warning)
(shutdown)
System Response:
The following event codes are logged according to activated.
• E805 (1) Cylinder #5 High Exhaust Port Temp activated and the fuel is shut off.
(warning)
(shutdown) If a warning is generated, the engine performance is
activated. The engine will be shut down if the trip point for the
activated and the fuel is shut off. Troubleshooting:
Possible Performance Effect: Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
not immediately affected. Results:
• OK – STOP.
Refer to Troubleshooting, “Exhaust Port Temperature E807 Cylinder #7 High Exhaust

(High)”. Port Temp

System Response:

176
• E807 (1) Cylinder #7 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E807 (3) Cylinder #7 High Exhaust Port Temp 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:
not immediately affected. • OK – STOP.
i01635546
Troubleshooting:
Port Temp
(High)”. SMCS Code: 1059-038
• OK – STOP. The cylinder exhaust temperature has exceeded the

E808 Cylinder #8 High Exhaust The following event codes are logged according to
Port Temp the trip points for the temperature:
SMCS Code: 1059-038 • E809 (1) Cylinder #9 High Exhaust Port Temp
(warning)
The cylinder exhaust temperature has exceeded the (shutdown)
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.
• E808 (1) Cylinder #8 High Exhaust Port Temp Possible Performance Effect:
(warning)
• E808 (3) Cylinder #8 High Exhaust Port Temp 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)”.
177
• OK – STOP. The following event codes are logged according to

i01635549
E810 Cylinder #10 High (warning)
Exhaust Port Temp • E811 (3) Cylinder #11 High Exhaust Port Temp
(shutdown)
SMCS Code: 1059-038
Conditions Which Generate This Code: activated.
The cylinder exhaust temperature has exceeded the If a shutdown is generated, the shutdown output is
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 is
the trip points for the temperature: not immediately affected.
(warning) shutdown is exceeded.
• E810 (3) Cylinder #10 High Exhaust Port Temp Troubleshooting:

(shutdown)
If a warning is generated, the alarm output is (High)”.
activated.
Results:
activated and the fuel is shut off. • OK – STOP.
i01635568

E812 Cylinder #12 High
Exhaust Port Temp
shutdown is exceeded. SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded the
(High)”. trip point and the delay time has expired.
• OK – STOP. The following event codes are logged according to

i01635556
E811 Cylinder #11 High (warning)
(shutdown)
SMCS Code: 1059-038
178
If a warning is generated, the engine performance is • OK – STOP.

i01635577
shutdown is exceeded. E814 Cylinder #14 High
Troubleshooting: Exhaust Port Temp
Refer to Troubleshooting, “Exhaust Port Temperature SMCS Code: 1059-038
(High)”.
Results:
• OK – STOP. trip point and the delay time has expired.
System Response:
i01635570
E813 Cylinder #13 High The following event codes are logged according to
Exhaust Port Temp
SMCS Code: 1059-038 (warning)
Conditions Which Generate This Code: • E814 (3) Cylinder #14 High Exhaust Port Temp
(shutdown)
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 is
(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 is • OK – STOP.

Troubleshooting:

(High)”.
179
i01635578 • E816 (1) Cylinder #16 High Exhaust Port Temp

(warning)
(shutdown)
SMCS Code: 1059-038
(warning) shutdown is exceeded.
• E815 (3) Cylinder #15 High Exhaust Port Temp Troubleshooting:

(shutdown)
If a warning is generated, the alarm output is (High)”.
activated.
Results:
activated and the fuel is shut off. • OK – STOP.
If a warning is generated, the engine performance is E817 Cylinder #17 High

Exhaust Port Temp
shutdown is exceeded. SMCS Code: 1059-038
Refer to Troubleshooting, “Exhaust Port Temperature The cylinder exhaust temperature has exceeded the
(High)”. trip point and the delay time has expired.

• OK – STOP. the trip points for the temperature:
i01635584 • E817 (1) Cylinder #17 High Exhaust Port Temp

(warning)
(shutdown)
SMCS Code: 1059-038
180
The engine will be shut down if the trip point for the i01762535
(High)”.
Results:
i01762534
System Response:
E818 Cylinder #18 High The following event codes are logged according to
Exhaust Port Temp
SMCS Code: 1059-038
(warning)
(shutdown)
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 is
(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)”.
• OK – STOP.
The engine will be shut down if the trip point for the i01762536
(High)”.
Results:
181


activated.
Results:
• OK – STOP.
i01635593
E822 Cyl #2 Exhaust Port Temp
Deviating High
Troubleshooting:
SMCS Code: 1059-038
Results: The cylinder exhaust temperature is higher than the

average temperature for all of the cylinders. The
• OK – STOP. amount of deviation has exceeded the trip point and
the delay time has expired.
E821 Cyl #1 Exhaust Port Temp The following event codes are logged according to
Deviating High the trip points for the temperature:
SMCS Code: 1059-038 • E822 (1) Cyl #2 Exhaust Port Temp Deviating High
(warning)
• E822 (3) Cyl #2 Exhaust Port Temp Deviating High
The cylinder exhaust temperature is higher than the (shutdown)
amount of deviation has exceeded the trip point and If a warning is generated, the alarm output is

• E821 (1) Cyl #1 Exhaust Port Temp Deviating High If a warning is generated, the engine performance is
• E821 (3) Cyl #1 Exhaust Port Temp Deviating High The engine will be shut down if the trip point for the

activated.
182
Refer to Troubleshooting, “Exhaust Port Temperature E824 Cyl #4 Exhaust Port Temp
(High)”. Deviating High
i01635600
The cylinder exhaust temperature is higher than the
E823 Cyl #3 Exhaust Port Temp amount of deviation has exceeded the trip point and
Deviating High
System Response:
SMCS Code: 1059-038
Conditions Which Generate This Code: the trip points for the temperature:
(warning)
amount of deviation has exceeded the trip point and
(shutdown)
System Response:
The following event codes are logged according to activated.
• E823 (1) Cyl #3 Exhaust Port Temp Deviating High activated and the fuel is shut off.
(warning)
(shutdown) If a warning is generated, the engine performance is
activated. The engine will be shut down if the trip point for the
activated and the fuel is shut off. Troubleshooting:
Possible Performance Effect: Refer to Troubleshooting, “Exhaust Port Temperature
(High)”.
not immediately affected. Results:
• OK – STOP.
Troubleshooting:

(High)”.
Results:
• OK – STOP.
183

(warning)

• E825 (3) Cyl #5 Exhaust Port Temp Deviating High The engine will be shut down if the trip point for the

activated.
Results:
• OK – STOP.
not immediately affected. i01635614
The engine will be shut down if the trip point for the E827 Cyl #7 Exhaust Port Temp
Deviating High
Troubleshooting:
SMCS Code: 1059-038

• OK – STOP. the delay time has expired.

(warning)
184
If a shutdown is generated, the shutdown output is Troubleshooting:

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

• OK – STOP.
i01635618
Troubleshooting: E829 Cyl #9 Exhaust Port Temp

Refer to Troubleshooting, “Exhaust Port Temperature Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
i01635616 amount of deviation has exceeded the trip point and
E828 Cyl #8 Exhaust Port Temp the delay time has expired.
Deviating High System Response:
SMCS Code: 1059-038 The following event codes are logged according to
The cylinder exhaust temperature is higher than the (warning)
amount of deviation has exceeded the trip point and • E829 (3) Cyl #9 Exhaust Port Temp Deviating High
the delay time has expired. (shutdown)
System Response: If a warning is generated, the alarm output is

activated.
the trip points for the temperature: If a shutdown is generated, the shutdown output is
(warning) Possible Performance Effect:
(shutdown) not immediately affected.
If a warning is generated, the alarm output is The engine will be shut down if the trip point for the
activated. shutdown is exceeded.


• OK – STOP.
185

E830 Cyl #10 Exhaust Port The following event codes are logged according to
Temp Deviating High the trip points for the temperature:
SMCS Code: 1059-038 • E831 (1) Cyl #11 Exhaust Port Temp Deviating
High (warning)
• E831 (3) Cyl #11 Exhaust Port Temp Deviating
The cylinder exhaust temperature is higher than the High (shutdown)

• E830 (1) Cyl #10 Exhaust Port Temp Deviating If a warning is generated, the engine performance is
High (warning) not immediately affected.
• E830 (3) Cyl #10 Exhaust Port Temp Deviating The engine will be shut down if the trip point for the
High (shutdown) shutdown is exceeded.

activated.
Results:
• OK – STOP.
The engine will be shut down if the trip point for the E832 Cyl #12 Exhaust Port
Temp Deviating High
Troubleshooting:
SMCS Code: 1059-038


High (warning)
186


• OK – STOP.
i01635656
Troubleshooting: E834 Cyl #14 Exhaust Port

Refer to Troubleshooting, “Exhaust Port Temperature Temp Deviating High
(High)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
E833 Cyl #13 Exhaust Port the delay time has expired.
Temp Deviating High System Response:
The cylinder exhaust temperature is higher than the High (warning)
amount of deviation has exceeded the trip point and • E834 (3) Cyl #14 Exhaust Port Temp Deviating
the delay time has expired. High (shutdown)

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


• OK – STOP.
187

High (warning)


activated.
Results:
• OK – STOP.
Temp Deviating High
Troubleshooting:
SMCS Code: 1059-038


High (warning)
188


• OK – STOP.
i01762539

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

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


• OK – STOP.
189

SMCS Code: 1059-038 • E841 (1) Cyl #1 Exhaust Port Temp Deviating Low
(warning)
• E841 (3) Cyl #1 Exhaust Port Temp Deviating Low


activated.
If a shutdown is generated, the shutdown output is (Low)”.
Results:
• OK – STOP.
Deviating Low
Troubleshooting:
SMCS Code: 1059-038
Results: The cylinder exhaust temperature is less than the


Deviating Low the trip points for the temperature:
(warning)
The cylinder exhaust temperature is less than the (shutdown)
190

Possible Performance Effect: (Low)”.

• OK – STOP.
i01635670

Refer to Troubleshooting, “Exhaust Port Temperature Deviating Low
(Low)”.
SMCS Code: 1059-038
Results:
• OK – STOP.
The cylinder exhaust temperature is less than the
Deviating Low System Response:
The cylinder exhaust temperature is less than the (warning)
amount of deviation has exceeded the trip point and • E844 (3) Cyl #4 Exhaust Port Temp Deviating Low

activated.
• E843 (3) Cyl #3 Exhaust Port Temp Deviating Low If a warning is generated, the engine performance is


• OK – STOP.
191

(warning)

• E845 (3) Cyl #5 Exhaust Port Temp Deviating Low The engine will be shut down if the trip point for the

activated.
Results:
• OK – STOP.
Deviating Low
Troubleshooting:
SMCS Code: 1059-038
(Low)”. Conditions Which Generate This Code:


(warning)
192


• OK – STOP.
i01635683

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 and • E849 (3) Cyl #9 Exhaust Port Temp Deviating Low

activated.


• OK – STOP.
193

Temp Deviating Low the trip points for the temperature:
Low (warning)
The cylinder exhaust temperature is less than the Low (shutdown)

Low (warning) not immediately affected.
Low (shutdown) shutdown is exceeded.

activated.
Results:
• OK – STOP.
Temp Deviating Low
Troubleshooting:
SMCS Code: 1059-038


Low (warning)
194


• OK – STOP.
i01635692

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)
the delay time has expired. Low (shutdown)

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


• OK – STOP.
195

Low (warning)

Low (warning) not immediately affected.
Low (shutdown) shutdown is exceeded.

activated.
Results:
• OK – STOP.
Temp Deviating Low
Troubleshooting:
SMCS Code: 1059-038


Low (warning)
196


• OK – STOP.
i01762545

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)
the delay time has expired. Low (shutdown)

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


• OK – STOP.
197

E860 Cyl #20 Exhaust Port The alarm output is activated. The code is logged.
Temp Deviating Low
SMCS Code: 1059-038
The engine performance is not immediately affected.
Troubleshooting:
average temperature for all of the cylinders. The Refer to Troubleshooting, “Gas Fuel Differential
amount of deviation has exceeded the trip point and Pressure (Low)”.
Results:
System Response:
• OK – STOP.
the trip points for the temperature: i01637716
• E860 (1) Cyl #20 Exhaust Port Temp Deviating E865 High Gas Fuel Differential
Low (warning)
Pressure
• E860 (3) Cyl #20 Exhaust Port Temp Deviating SMCS Code: 1250-038
Low (shutdown)
If a warning is generated, the alarm output is Conditions Which Generate This Code:
activated.
The Gas Shutoff Valve (GSOV) is energized. The
If a shutdown is generated, the shutdown output is difference in fuel pressure between the inlet and the
activated and the fuel is shut off. outlet of the fuel metering valve is greater than the
trip point. The delay time has expired.
System Response:
not immediately affected. The alarm output is activated. The code is logged.
The engine will be shut down if the trip point for the Possible Performance Effect:
Troubleshooting:
Troubleshooting:
(Low)”. Refer to Troubleshooting, “Gas Fuel Differential
Pressure (High)”.
Results:
Results:
• OK – STOP.
• OK – STOP.
i01637712
i01637720
E864 Low Gas Fuel Differential E866 Low Gas Fuel Flow Rate
Pressure
SMCS Code: 1250-038
SMCS Code: 1250-038
The fuel metering valve is fully open. However, the
The gas shutoff valve (GSOV) is energized. The flow rate that is computed by the valve does not
difference in fuel pressure between the outlet and the match the fuel demand for a delay time of 5 seconds.
inlet of the fuel metering valve is less than the trip
point. The delay time has expired.
198
The engine performance is not immediately affected. The engine performance is not immediately 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
System Response:
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
and the delay time has expired.
199
Diagnostic Functional A “5 Volt Sensor DC Power Supply short to ground”

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

i02088364
+5V Sensor Voltage Supply • The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
desired speed.
SMCS Code: 5574-038
System Operation Description:
The master Electronic Control Module (ECM)

supplies 5.0 ± 0.5 VDC to the sensors for these
parameters:
• Inlet air temperature

• Engine oil temperature
• Unfiltered engine oil pressure
• Filtered engine oil pressure
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.
• The “DESIRED SPEED” potentiometer is near

the maximum desired speed or at the maximum
desired speed.
200
g01065037
Illustration 20
Schematic for the 5 V supply
201
Test Step 1. Inspect the Electrical • J1/P1 connectors

Connectors and Wiring
• J6/P6, and J7/P7 connectors
a. Check the torque of the allen head screws for
the 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).
g01054206
Illustration 21
Junction box
g01053671
(1) 35 amp circuit breaker Illustration 23
Harness side of the P1 connector
A. Set the engine control to the OFF/RESET mode. (P1-2) 5 volt supply
Switch 35 amp circuit breaker (1) to the OFF (P1-3) Return
position. (P1-14) Signal for the inlet manifold air temperature
(P1-16) Signal for the desired speed
Note: For the following steps, refer to (P1-17) Signal for the engine oil temperature
(P1-18) 5 volt supply
Troubleshooting, “Inspecting Electrical Connectors”. (P1-24) Signal for the filtered engine oil pressure
(P1-26) Signal for the unfiltered engine oil pressure
(P1-35) Return
g01065031
Illustration 22
Terminal box g00929111
Illustration 24
(2) J1/P1 connectors for the master ECM
(3) J6/P6 connectors for the customer Harness side of the J6 connector
(4) J7/P7 connectors for the harness from the 5 volt sensors (J6-5) 5 volt supply
(J6-15) Return
B. Thoroughly inspect each of the following (J6-25) Signal for desired speed
connectors: (J6-35) Shield
202
g01065032
Illustration 26
Right side view
(6) Unfiltered oil pressure sensor
(7) Filtered oil pressure sensor
g00929117
Illustration 25
Harness side of the J7 connector
(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.
g01065033
Illustration 27
Top view
(8) Inlet air temperature sensor
d. Check the harness and wiring for corrosion,

abrasion and pinch points from the 5 volt
sensors to the master ECM.
Expected Result:
All connectors, pins, and sockets are connected

properly. The connectors and the wiring do not have
corrosion, abrasion, or pinch points.
203
Results: Repair: There may be a problem with the wiring

and/or a connector. Refer to Troubleshooting,
• OK – All connectors, pins, and sockets are “Inspecting Electrical Connectors”.
connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points. Verify that the wiring and/or connectors are OK.
The components are in good condition with proper Check for diagnostic codes again. Proceed to Test
connections. Proceed to Test Step 2. Step 3, if necessary.
• Not OK – At least one of the connectors, pins, or Test Step 3. Check the Analog Speed
sockets are not connected properly. At least one Circuit
of the connectors and the wiring has corrosion,
abrasion, and/or pinch points. Note: If the engine is not equipped with a “DESIRED
SPEED” potentiometer, proceed to Test Step 9.
Repair: Perform the necessary repairs and/or
replace parts, if necessary. A. Rotate the “DESIRED SPEED” potentiometer
(if equipped) clockwise to the maximum speed
STOP. position.
Test Step 2. Check for Diagnostic Codes Expected Result:
A. Connect Cat ET to the service tool connector. The 262-03 code or the 262-04 code is not active.
Tools”. Results:
B. Rotate the “DESIRED SPEED” potentiometer • No codes – Rotating the “DESIRED SPEED”
(if equipped) counterclockwise to the minimum potentiometer clockwise to the maximum speed
speed position. position did not cause an active code. The +5 V
sensor voltage supply is operating correctly at this
C. Switch the 35 amp circuit breaker ON. Set the time. Resume normal operation. STOP.
engine control to the STOP mode.
• Active code – Rotating the “DESIRED SPEED”
D. Observe the “Active Diagnostic” screen on Cat ET. potentiometer clockwise to the maximum speed
Wait at least 30 seconds so that any codes may position caused an active code. There is a problem
become activated. Look for these codes: with the analog speed circuit. Proceed to Test Step
4.
• 262-03 5 Volt Sensor DC Power Supply short
to +batt Test Step 4. Check the Wiring for the
“DESIRED SPEED” Potentiometer
to ground A. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF.
E. Observe the “Logged Diagnostic” screen on Cat
ET. Look for the same codes. B. Label the wiring that is connected to the
“DESIRED SPEED” potentiometer. Disconnect the
Expected Result: wiring from the “DESIRED SPEED” potentiometer.
The 262-03 code or the 262-04 code is not active C. Disconnect the P1 connector from the master
or logged. ECM.
Results: D. Measure the resistance between terminals P1-16

and P1-69.
• No codes – There are no active codes or logged
codes. Proceed to Test Step 3. Expected Result:
• Active code – The 262-03 code or the 262-04 The resistance is greater than 20,000 Ohms.
code is active. Proceed to Test Step 5.
Results:
• Logged code – The 262-03 code or the 262-04
code is not active. However, there is at least one • OK – The resistance is greater than 20,000
logged code for the 5 volt sensor supply. Ohms. The wiring for the “DESIRED SPEED”
potentiometer appears to be OK.
204
Repair: The “DESIRED SPEED” potentiometer Results:

may have a problem. Perform the following
procedure: • No codes – The 262-03 code or the 262-04 code
is not active. Disconnecting all of the +5 V wiring
1. Check the “DESIRED SPEED” potentiometer from the master ECM eliminated the active “5
in order to ensure that the potentiometer does Volt Sensor Supply” diagnostic code. There is a
not have an internal short circuit. Replace the problem with a connector and/or the wiring in a
“DESIRED SPEED” potentiometer, if necessary. harness. Proceed to Test Step 6.
Continue with this procedure when the
“DESIRED SPEED” potentiometer is operating • Active code – The 262-03 code or the 262-04
correctly. code is active. Disconnecting all of the 5 volt wiring
from the master ECM did not eliminate the active
2. Reconnect the wiring to the “DESIRED SPEED” “5 Volt Sensor Supply” diagnostic code. There may
potentiometer. Be sure to connect the wires to be a problem with the master ECM.
the appropriate terminals.
Repair: It is unlikely that the master ECM has
3. Reconnect the P1 connector to the master ECM. failed. Exit this procedure and perform this
procedure again. If the problem is not resolved,
4. Perform this entire procedure again. Verify that perform the following steps:
the original problem is resolved.
Temporarily install a new master ECM. Refer to
STOP. Troubleshooting, “Replacing the ECM”.
• Not OK – The resistance is less than 20,000 If the problem is resolved with the new ECM,
Ohms. There is a problem with the wiring for the install the original ECM and verify that the problem
“DESIRED SPEED” potentiometer. The problem returns. If the new ECM operates correctly and the
could be between the P1 connector and the J6 original ECM does not operate correctly, replace
connector. Alternatively, the problem could be in the original ECM. Refer to Troubleshooting,
the P6 connector or the wiring that is connected to “Replacing the ECM”.
the P6 connector.
STOP.
Repair: Perform any necessary repairs or replace
parts, if necessary. Test Step 6. Connect the 5 Volt Wiring for
the Analog Speed Circuit to the Master
STOP. ECM
Test Step 5. Isolate the Wiring Harnesses A. Set the engine control to the OFF/RESET mode.
from the Master ECM Switch the 35 amp circuit breaker OFF.
A. Set the engine control to the OFF/RESET mode. B. Insert terminal P1-18 into the P1 connector. Pull
Switch the 35 amp circuit breaker OFF. on the wire in order to verify that the terminal is
fully inserted into the connector.
B. Reconnect the P1 connector to the master ECM.
C. Rotate the “DESIRED SPEED” potentiometer
C. Use a 151-6320 Wire Removal Tool to remove clockwise to the maximum speed position.
terminals P1-2 and P1-18. This will disconnect all
of the +5 V wiring from the master ECM. D. Switch the 35 amp circuit breaker ON. Set the
D. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. E. Use Cat ET to look for diagnostic codes.
E. Use Cat ET to look for diagnostic codes. Expected Result:
Expected Result: No active codes
No active codes
205
Results: • Unfiltered engine oil pressure

• No codes – The 262-03 code or the 262-04 code • Filtered engine oil pressure
is not active. Connecting the wiring for the analog
speed circuit to the master ECM did not cause a C. Switch the 35 amp circuit breaker ON. Set the
diagnostic code. The wiring for the analog speed engine control to the STOP mode.
circuit appears to be OK. Proceed to Test Step 7.
Note: An “Open Circuit” code will be generated for
• Active codes – The 262-03 code or the 262-04 each sensor that is disconnected. This is normal.
code is active. Connecting the wiring for the Clear the codes after you complete this procedure.
analog speed circuit to the master ECM caused a
diagnostic code. Proceed to Test Step 4. D. Observe the “Active Diagnostic” screen on Cat ET.
Verify that the 262-03 code or the 262-04 code
Test Step 7. Connect the 5 Volt Wiring for is not active.
the Sensors to the Master ECM
E. Reconnect the sensors for the following
A. Set the engine control to the OFF/RESET mode. parameters one at a time. After you reconnect
Switch the 35 amp circuit breaker OFF. each sensor, wait for at least 30 seconds and then
observe the “Active Diagnostic” screen on Cat ET.
B. Insert terminal P1-2 into the P1 connector. Pull on
the wire in order to verify that the terminal is fully • Inlet air temperature
inserted into the connector.
C. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. • Unfiltered engine oil pressure
D. Use Cat ET to look for diagnostic codes. • Filtered engine oil pressure
Expected Result: Expected Result:
No active codes The original “5 Volt Sensor” diagnostic code is

activated when a particular sensor is disconnected.
Results:
Results:
• No codes – The 262-03 code or the 262-04 code
is not active. Connecting the 5 VDC for the sensors • Yes – The original “5 Volt Sensor” diagnostic
did not cause a diagnostic code. The problem code is activated when a particular sensor is
appears to be resolved. reconnected. The sensor and/or the wiring for the
sensor has a short circuit.
Repair: The initial diagnostic code was probably
caused by a poor electrical connection. Resume Repair: Perform the following procedure:
normal operation.
1. Set the engine control to the OFF/RESET mode.
STOP.
2. Disconnect the suspect sensor.
• Active code – The 262-03 code or the 262-04 code
is active. Connecting the 5 VDC for the sensors 3. Set the engine control to the STOP mode. Use
caused a diagnostic code. Proceed to 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 the
B. Disconnect the sensors for the following problem is eliminated.
parameters:
STOP.
206
• No – The original “5 Volt Sensor” diagnostic code Results:

was still active while all of the 5 volt sensors were
disconnected. Do not reconnect the sensors. • OK – Each check of the resistance is greater
Proceed to Test Step 9. than 20,000 Ohms. The 5 volt wires in the engine
harnesses do not have a problem. The problem
Test Step 9. Check the Harnesses appears to be resolved. The initial diagnostic
code was probably caused by a poor electrical
A. Set the engine control to the OFF/RESET mode. connection.
Repair: Reconnect all of the connectors. Resume
B. Disconnect the P1 connector. Verify that all of normal operation.
the sensors for the following parameters are
disconnected from the engine harness: STOP.
• Inlet air temperature • Not OK – At least one check of the resistance is

less than 20,000 Ohms. There is a problem with a
• Engine oil temperature connector and/or at least one of the 5 volt wires
in a harness.
• Unfiltered engine oil pressure
Repair: The problem may be between the P1
• Filtered engine oil pressure connector and the P7 connector. Alternatively,
the problem may be in the engine harness that is
C. Measure the resistance between terminal P1-2 connected to the J7 connector.
and the points that are listed in Table 11. During
each measurement, wiggle the harnesses in Repair the connection and/or the wire, when
order to check for an intermittent problem with possible. Replace parts, if necessary. Verify that
the harness. Be sure to wiggle the harnesses the problem is resolved.
near each of the connectors for the disconnected
sensors. Also, wiggle the harness at the P7 STOP.
connector.
Table 11 i02088517
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.
A “+8 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 an ECM.
207

to a file.

resolved.
208
g01065067
Illustration 28
209
Schematic for the 8 V supply
Test Step 1. Inspect the Electrical B. Thoroughly inspect each of the following
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
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 29
Junction box
A. Set the engine control to the OFF/RESET mode.

g01065914
Note: For the following steps, refer to Illustration 31
Troubleshooting, “Inspecting Electrical Connectors”. Harness side of the P1 connector
(P1-4) 8 volt supply for the pressure sensors
(P1-5) Return for the pressure sensors
(P1-10) Signal for the inlet air pressure
g01065068
Illustration 30
Terminal box
(4) J7/P7 connectors for the harness from the 8 volt sensors
(5) J8/P8 connectors for the detonation sensors
(6) J4/P4 connectors for the slave ECM
210
g01065070
Illustration 32
(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 34
(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
g01065071
Illustration 33
211
g01065072
Illustration 36
Top view
(7) Engine coolant pressure sensor
(8) Inlet air pressure sensor
g00929380
Illustration 35
(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
(J8-20) Return for the detonation sensor for cylinders 17 and 19 Illustration 37
g01065074
(J8-21) Signal from the detonation sensor for cylinders 2 and 4
(J8-22) Signal from the detonation sensor for cylinders 6 and 8 Detonation sensors
(J8-24) Signal from the detonation sensor for cylinders 14 and 16 d. Check the harness and wiring for abrasion
and pinch points from the 8 volt sensors to the
(J8-27) Signal from the detonation sensor for cylinders 5 and 7 electronic control modules.
(J8-29) Signal from the detonation sensor for cylinders 13 and 15 Expected Result:
(J8-31) Shield for the detonation sensor for cylinders 2 and 4
(J8-32) Shield for the detonation sensor for cylinders 6 and 8 All connectors, pins, and sockets are connected
(J8-33) Shield for the detonation sensor for cylinders 10 and 12 properly. The connectors and the wiring do not have
(J8-34) Shield for the detonation sensor for cylinders 14 and 16 corrosion, abrasion, or pinch points.
Results:
(J8-39) Shield for the detonation sensor for cylinders 13 and 15 • OK – All connectors, pins, and sockets are
(J8-40) Shield for the detonation sensor for cylinders 17 and 19 connected properly. The connectors and the wiring
do not have corrosion, abrasion, or pinch points.
c. Perform a 45 N (10 lb) pull test on each of the The components are in good condition with proper
wires that are associated with the circuit for the connections. Proceed to Test Step 2.
8 volt sensors.
212
• Not OK – At least one of the connectors, pins, and B. Disconnect each 8 volt sensor one at a time. After
sockets are not connected properly. At least one you disconnect each sensor, wait for at least 30
of the connectors and/or the wiring has corrosion, seconds and then observe the “Active Diagnostic”
abrasion, and/or pinch points. screen on Cat ET.
Repair: Perform the necessary repairs and/or Note: An “Open Circuit” code will be generated for
replace parts, if necessary. each sensor that is disconnected. This is normal.
Clear the codes after you complete this procedure.
STOP.
Expected Result:
Test Step 2. Check for Diagnostic Codes
The original “8 Volt DC Supply” diagnostic code is
A. Connect Cat ET to the service tool connector. deactivated when a particular sensor is disconnected.
Tools”. Results:
B. Switch the 35 amp circuit breaker ON. Set the • Yes – The original “8 Volt DC Supply” diagnostic
engine control to the STOP mode. code is deactivated when a particular sensor is
disconnected. The sensor and/or the wiring for the
C. Observe the “Active Diagnostic” screen on Cat ET. sensor has a short circuit.
Wait at least 30 seconds so that any codes may
become activated. Look for these codes: Repair: Perform the following procedure:
• 41-03 8 Volt DC Supply short to +batt 1. Reconnect the suspect sensor. Verify that the
diagnostic code recurs.
• 41-04 8 Volt DC Supply short to ground
2. Disconnect the suspect sensor. Verify that the
D. Observe the “Logged Diagnostic” screen on Cat diagnostic code is deactivated.
ET. Look for the same codes.
If these conditions are true, repair the sensor
Expected Result: or the sensor’s harness. Replace parts, if
necessary.
The 41-03 code or the 41-04 code is not active.
3. Clear all of the diagnostic codes. Verify that the
Results: problem is eliminated.
• No codes – The 41-03 code or the 41-04 code is STOP.

not active. The 8 volt sensor supply is operating
correctly at this time. STOP. • No – The original “8 Volt DC Supply” diagnostic
code is still active when a particular sensor is
• Active code – The 41-03 code or the 41-04 code disconnected. Do not reconnect the sensors.
is active. Proceed to Test Step 3. Proceed to Test Step 4.
• Logged code – The 41-03 code or the 41-04 code Test Step 4. Isolate the Wiring Harnesses
is not active. However, there is at least one logged from the Electronic Control Modules
code for the 8 volt sensor supply.
Repair: There may be a problem with the wiring Switch the 35 amp circuit breaker OFF.
and/or a connector. Refer to Troubleshooting,
“Inspecting Electrical Connectors”. B. If you are troubleshooting an 8 volt problem with
the master ECM, use a 151-6320 Wire Removal
Verify that the wiring and/or connectors are OK. Tool to remove the wires from the following
Check for diagnostic codes again. Proceed to Test terminals:
Step 3, if necessary.
• P1-4
Test Step 3. Disconnect the 8 Volt
Sensors and Look for Active Diagnostic • P2-56
Codes.
• P2-57
A. Turn on the “Active Diagnostic” screen on Cat ET.
Verify that the “41-03” or “41-04” code is active.
213
C. If you are troubleshooting an 8 volt problem with Test Step 5. Check the Wiring Harnesses
the slave ECM, use a 151-6320 Wire Removal on the Left Side of the Engine
Tool to remove the wires from the following
terminals: A. Set the engine control to the OFF/RESET mode.
• P4-56
B. Insert all of the terminals that were removed. Pull
• P4-57 on the wires in order to verify that the terminals
are fully inserted into the connector.
engine control to the STOP mode. C. Disconnect all of the 8 volt sensors.
E. Wait for at least 30 seconds and then observe the D. Disconnect the P1 connector and the P2
“Active Diagnostics” screen on Cat ET. Determine connector for the master ECM.
if a 41-03 code or a 41-04 code is active.
E. Measure the resistance between the terminals
Expected Result: that are listed in Table 12.
No active codes During each measurement, wiggle the harnesses

in order to check for an intermittent problem.
Results: Be sure to wiggle the wires near each of the
connectors.
• No codes – The 41-03 code or the 41-04 code is
not active. Disconnecting all of the 8 volt wiring Table 12
from the ECM eliminated the active “8 Volt DC Points for the Measurement of Resistance for
Supply” diagnostic code. There is a problem in a the Left Side of the Engine
connector and/or the wiring in a harness. Proceed
to Test Step 5. Connector and Terminal Connector and Terminal
P1-4 (8 volt supply) All of the remaining
• Active code – There is an active 41-03 or 41-04 terminals on the P1
code. Disconnecting all of the 8 volt wiring from connector
the ECM did not eliminate the active “8 Volt DC
All of the terminals on the
Supply” diagnostic code. There may be a problem P2 connector
with an ECM.
Repair: Set the engine control to the OFF/RESET terminals on the P2
mode. Switch the 35 amp circuit breaker OFF. connector
All of the terminals on the
Insert all of the terminals that were removed. Pull P1 connector
on the wires in order to verify that the terminals are
fully inserted into the connector. P2-57 (8 volt supply) All of the remaining
terminals on the P2
connector
It is unlikely that the ECM has failed. Exit this
procedure and perform this procedure again. If All of the terminals on the
the problem is not resolved, perform the following P1 connector
steps:
Expected Result:
Temporarily install a new ECM. Refer to
Troubleshooting, “Replacing the ECM”. Each check of the resistance is greater than 20,000
Ohms.
If the problem is resolved with the new ECM,
install the original ECM and verify that the problem Results:
returns. If the new ECM operates correctly and the
original ECM does not operate correctly, replace
the original ECM. Refer to Troubleshooting,
• OK – Each check of the resistance is greater than
20,000 Ohms. The 8 volt wires and connectors
“Replacing the ECM”. on the left side of the engine do not have a short
circuit. Proceed to Test Step 6.
STOP.
• Not OK – At least one check of the resistance is
connector and/or at least one of the 8 volt wires
in a harness.
214
Repair: The problem may be inside the terminal Repair: The problem could be inside the terminal
box. Alternatively, the problem may be in an engine box. Alternatively, the problem may be in an engine
harness. harness.
Repair the connection and/or the wire, when Repair the connection and/or the wire, when
possible. Replace parts, if necessary. possible. Replace parts, if necessary.
STOP. STOP.
Test Step 6. Check the Wiring Harnesses

on the Right Side of the Engine i02088679
A. Disconnect the P3 connector and the P4

Analog Sensor Signal
connector for the slave ECM. SMCS Code: 5574-038
B. Measure the resistance between the terminals System Operation Description:
that are listed in Table 13.
Use this procedure to troubleshoot diagnostic codes
During each measurement, wiggle the harnesses for open circuits or short circuits for the sensors of
in order to check for an intermittent problem. these parameters:
Be sure to wiggle the wires near each of the
connectors. • Engine coolant temperature
Table 13
Points for the Measurement of Resistance for
the Right Side of the Engine • Engine oil temperature
Connector and Terminal Connector and Terminal
• Filtered engine oil pressure
terminals on the P4 • Unfiltered engine oil pressure
connector
P4-57 (8 volt supply) All of the remaining Note: The engine coolant temperature sensor does
terminals on the P4 not require +5 VDC from the master Electronic
connector Control Module (ECM). The engine coolant
temperature sensor is a passive sensor of the analog
Expected Result: type. The sensor operates without a voltage supply
from the master ECM.
Each check of the resistance is greater than 20,000
Ohms. The master ECM can be configured for one of these
types of speed control:
Results:
• Potentiometer
• OK – Each check of the resistance is greater than
20,000 Ohms. The 8 volt wires and connectors on • 4-20 ma
the right side of the engine do not have a short
circuit. The problem seems to be resolved. The The “DESIRED SPEED” potentiometer (if equipped)
initial diagnostic code was probably caused by a must be supplied with +5 VDC from the master
poor electrical connection. ECM. If the “DESIRED SPEED” potentiometer has
a short circuit or the potentiometer’s wiring has a
Repair: Reconnect all of the connectors and short circuit, a 262-03 or 262-04 diagnostic code may
resume normal operation. be activated. There are no diagnostic codes for the
circuit of the “DESIRED SPEED” potentiometer.
STOP.
The -03 code is probably caused by a problem in
an engine harness. There may be an open circuit
• Not OK – At least one check of the resistance is in a harness, or a short circuit to a positive voltage
harness on the right side of the engine. source in a harness. The next likely cause is a sensor
problem. The least likely cause is a problem with the
master ECM.
215
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.

to a file.

Clear the diagnostic code after the problem is
resolved.
216
g01065103
Illustration 38
Schematic for the analog sensors
217
Test Step 1. Inspect the Electrical • J1/P1 connectors

6 ± 1 N·m (55 ± 9 lb in).
b. Check the torque of the allen head screws

for the terminal box’s connectors. The proper
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 39
Junction box
g01065104
(1) 35 amp circuit breaker Illustration 41
A. Set the engine control to the OFF/RESET mode. (P1-2) 5 volt supply
Switch 35 amp circuit breaker (1) to the OFF (P1-3) Return
position. (P1-14) Signal for the inlet manifold air temperature
(P1-16) Signal for the desired speed
Note: For the following steps, refer to (P1-17) Signal for the engine oil temperature
Troubleshooting, “Inspecting Electrical Connectors”. (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
g01065031
Illustration 40
Terminal box
(3) J6/P6 connectors for the customer
(4) J7/P7 connectors for the harness from the 5 volt sensors
B. Thoroughly inspect each of the following

connectors:
218
g00929111
Illustration 42
(J6-5) 5 volt supply
(J6-15) Return
(J6-25) Signal for desired speed
(J6-35) Shield
g00929594
Illustration 43
(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

analog sensors.
219
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,

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

replace parts, if necessary.
STOP.

for the Power Supply
Illustration 44
g01065032 A. Connect Cat ET to the service tool connector.
Right side view
Tools”.
(6) Unfiltered oil pressure sensor
(7) Filtered oil pressure sensor B. Switch the 35 amp circuit breaker ON. Set the
C. Observe the “Active Diagnostic” screen on ET.

Allow a minimum of 30 seconds for any codes to
activate. Look for these codes:

to +batt

to ground
Expected Result:
There are no active “5 Volt Sensor DC Power Supply”

diagnostic codes.
Results:
• No codes – There are no active “5 Volt Sensor DC

Power Supply” diagnostic codes. Proceed to Test
g01065110
Step 3.
Illustration 45
Top view • Active code – There is an active “5 Volt Sensor DC
(8) Engine coolant temperature sensor Power Supply” diagnostic code. This procedure will
(9) Engine coolant pressure sensor (outlet) not work when this type of code is active.
d. Check the harness and wiring for abrasion and Repair: Refer to Troubleshooting, “+5V Sensor
for pinch points from the analog sensors to the Supply”.
master ECM.
If necessary, return to this functional test in order
Expected Result: to troubleshoot the analog sensor after the “+5 V
Sensor Supply” diagnostic code has been resolved.
properly. The connectors and the wiring do not have STOP.
220
Test Step 3. Check for Active Analog • Active “short to ground” (FMI 04) – There is an
Sensor Diagnostic Codes active “short to ground” diagnostic code. Proceed
to Test Step 4.
A. Observe the “Active Diagnostic” screen on Cat
ET. Wait at least 30 seconds so that any codes Test Step 4. Create an Open Circuit for
may become activated. Look for the codes that the Sensor
are listed in Table 14:
Table 14
Analog Sensor Diagnostic Codes B. Disconnect the sensor that has the “short to
ground” diagnostic code.
100-03 Engine Oil Pressure open/short to +batt
100-04 Engine Oil Pressure short to ground C. Set the engine control to the STOP mode.
110-03 Engine Coolant Temperature open/short to D. Observe the “Active Diagnostic” screen on Cat ET.
+batt Allow a minimum of 30 seconds for any codes to
110-04 Engine Coolant Temperature short to ground activate. Look for an active “open/short to +batt”
diagnostic code.
172-03 Intake Manifold Air Temp open/short to +batt
172-04 Intake Manifold Air Temp short to ground Expected Result:
175-03 Engine Oil Temperature open/short to +batt There is an active “open/short to +batt” diagnostic
175-04 Engine Oil Temperature short to ground code for the disconnected sensor.
542-03 Unfiltered Engine Oil Pressure open/short to Results:
+batt
542-04 Unfiltered Engine Oil Pressure short to ground • Yes – Before the suspect sensor was
disconnected, there was an active “short to
ground” diagnostic code for the sensor. After the
B. If one of the above codes is active, identify the suspect sensor was disconnected, there was an
type of diagnostic according to the condition: the active “open/short to +batt” diagnostic code for the
diagnostic code is either “open/short to +batt” (FMI sensor.
03) or “short to ground” (FMI 04).
Repair: Reconnect the sensor. If the active “short
Expected Result: to ground” diagnostic code recurs, replace the
original sensor.
None of the above codes are active.
Verify that the code does not activate when the
Results: new sensor is installed. Clear the logged diagnostic
code from the master ECM.
• No active codes – None of the above codes are
active. STOP.
Repair: If any of the above codes are logged • No – Before the suspect sensor was disconnected,
and the engine is not running properly, refer to there was an active “short to ground” diagnostic
Troubleshooting, “Troubleshooting Without a code for the sensor. After the suspect sensor
Diagnostic Code”. was disconnected, the active “open/short to
+batt” diagnostic code remained. If you are
If the engine is running properly at this time, troubleshooting the sensor for engine coolant
there may be an intermittent problem in the temperature, proceed to Test Step 6. Otherwise,
harness that is causing the codes to be logged. proceed to Test Step 5.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”. Test Step 5. Check the Supply Voltage at
the Sensor Connector
STOP.
A. Verify that the suspect sensor is disconnected
• Active “open/short to +batt” (FMI 03) – There is an from the engine harness.
active “open/short to +batt” diagnostic code. If you
are troubleshooting the sensor for engine coolant
temperature, proceed to Test Step 6. Otherwise,
proceed to Test Step 5.
221
g00889729 g00889801
Illustration 46 Illustration 47
Harness connectors for the various sensors Harness connectors for the various sensors
(A) 5 volt supply (A) 5 volt supply
(B) Return (B) Return
(C) Signal (C) Signal
(1) Signal
(2) Return
B. At the harness connector for the suspect sensor,
measure the voltage between terminals A and B.
B. At the harness connector for the suspect sensor,
Expected Result: measure the voltage between terminals B and C,
or between terminals 1 and 2.
The voltage is between 4.5 VDC and 5.5 VDC.
Expected Result:
Results:
• OK – The voltage between terminals A and B is Results:
between 4.5 VDC and 5.5 VDC. The 5 volt supply
is present at the sensor connector. Proceed to Test
Step 6. • OK – The voltage between the signal terminal and
the return terminal is between 6.0 VDC and 7.0
VDC. The pull-up voltage that is created by the
• Not OK – The voltage between terminals A and master ECM is present at the sensor connector.
terminal B is not between 4.5 VDC and 5.5 VDC.
The 5 volt supply is not present at the sensor The signal wire and the return wire for the suspect
connector. The 5 volts must be present at the sensor appear to be OK. Proceed to Test Step 8.
sensor in order to continue this procedure. The 5
volt wiring problem may be inside the terminal box, • Not OK – The voltage between the signal terminal
or in the engine harness. and the return terminal is not between 6.0 VDC
and 7.0 VDC. The pull-up voltage that is created
Repair: Verify that the wiring and/or connectors by the master ECM is not present at the sensor
are OK. Repair any faulty wiring and/or connectors, connector. Proceed to Test Step 7.
when possible. Replace parts, if necessary.
Refer to Troubleshooting, “Inspecting Electrical Test Step 7. Check the Pull-Up Voltage
Connectors”. Check for diagnostic codes again. at the Master ECM
STOP. A. Set the engine control to the OFF/RESET mode.

Test Step 6. Check the Pull-Up Voltage at
the Sensor B. Use a 151-6320 Wire Removal Tool to remove
the signal wire for the suspect sensor from the
A. Verify that the suspect sensor’s connector is P1 connector.
disconnected from the engine harness.
C. Use a jumper wire with Deutsch terminals on the
ends. Insert one end of the jumper wire into the
open terminal of the P1 connector.
D. Connect a multimeter lead to the end of the jumper

wire that is not inserted into the connector.
E. At the harness side of the P1 connector, insert a

7X-1710 Multimeter Probe along terminal 3.
F. Connect the other multimeter lead to the probe.
G. Switch the 35 amp circuit breaker ON. Set the

222
H. Measure the pull-up voltage at the master ECM. Results:
Expected Result: • OK – No diagnostic codes are activated when a

good sensor is temporarily installed. Connecting a
The voltage is between 6.0 VDC and 7.0 VDC. new sensor resolved the problem.
Results: Repair: Perform the following procedure:
• OK – The pull-up voltage for the suspect sensor at 1. Reconnect the suspect sensor. Verify that the
the master ECM is between 6.0 VDC and 7.0 VDC. “open/short to +batt” diagnostic code recurs.
The master ECM is producing a pull-up voltage
that is valid. There is a problem with the signal wire 2. Disconnect the suspect sensor. Verify that
between P1 and the harness connector for the the “open/short to +batt” diagnostic code is
sensor. There may be a problem with a connector. deactivated.
Repair: Perform the following procedure: 3. Connect the new connector. Verify that no
diagnostic codes are activated.
Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. If these conditions are true, replace the faulty
sensor with the new sensor. For the proper
Disconnect the multimeter leads. torque value for the new sensor, refer to the
Specifications manual.
Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P1 connector. 4. Clear all of the diagnostic codes. Verify that the
problem has been resolved.
Reinstall the terminal that was removed from the
P1 connector. Pull on the wire in order to verify STOP.
proper installation of the terminal.
• Not OK – The active “open/short to +batt” code
Verify that the wiring and/or connectors are OK. remains. Connecting a new sensor did not resolve
Repair any faulty wiring and/or connectors, when the problem. Proceed to Test Step 9.
possible. Replace any wiring and/or connectors, if
necessary. Refer to Troubleshooting, “Inspecting Test Step 9. Check the Operation of the
Electrical Connectors”. Master ECM
STOP. A. Verify that the signal wire for the suspect sensor
has been removed from the P1 connector.
• Not OK – The pull-up voltage for the suspect
sensor at the master ECM is not between 6.0 VDC B. Clear any existing diagnostic codes.
and 7.0 VDC. Proceed to Test Step 9.
Test Step 8. Check the Sensor Allow a minimum of 30 seconds for any codes to
activate.
A. Temporarily connect a sensor that is known to be
good to the engine harness. An active “open/short to +batt” diagnostic code is
generated for the sensor.
B. Switch the 35 amp circuit breaker ON. Set the
engine control to the STOP mode. D. Set the engine control to the OFF/RESET mode.
C. Observe the “Active Diagnostic” screen on Cat
ET. Allow a minimum of 30 seconds for any codes E. Use a jumper wire that is the appropriate length
to activate. with Deutsch terminals on the ends. Install one
end of the jumper wire into the terminal for
Expected Result: the signal wire that was removed from the P1
connector. Install the other end of the jumper wire
No diagnostic codes are activated. into terminal 19 of the P1 connector. This will
replace the sensor circuit with a short circuit.
F. Switch the 35 amp circuit breaker ON. Set the

223
G. Observe the “Active Diagnostic” screen on Cat i02088853

ET. Allow a minimum of 30 seconds for any codes
to activate. CAT Data Link
An active “short to ground” diagnostic code is SMCS Code: 1901-038
generated.
Expected Result:
The CAT data link is used to share information
Active “open/short to +batt” and “short to ground” between the following components:
diagnostic codes are generated according to the
above steps. • Master Electronic Control Module (ECM)
Results: • Slave ECM
• OK – Active “open/short to +batt” and “short to • Integrated Temperature Sensing Module (ITSM)
ground” diagnostic codes are generated according
to the above steps. The master ECM is operating • Service tool
correctly. The initial diagnostic code was probably
caused by a poor electrical connection. • Customer installed components
Repair: Perform the following procedure: Illustration 48 shows the information that is shared
between the master ECM and the slave ECM via the
Set the engine control to the OFF/RESET mode. CAT data link.
Use a 151-6320 Wire Removal Tool to remove

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

P1 connector. Pull on the wire in order to verify
proper installation of the terminal.
STOP.
• Not OK – No active “open/short to +batt” and

“short to ground” diagnostic codes were generated.
The master ECM is not operating correctly.

failed. Exit this procedure and perform this entire
perform the following steps:

Troubleshooting, “Replacing the ECM”.

install the original ECM and verify that the problem
the ECM. Refer to Troubleshooting, “Replacing
the ECM”.
STOP.
224
g00951847
Illustration 48
Information that is shared between the master ECM and the slave ECM
Each ECM and the ITSM communicate with the Perform this procedure for all problems that are
Caterpillar Electronic Technician Cat ET via the CAT associated with the CAT data link. If this procedure
data link. does not solve the problem, there may be a faulty
ignition transformer. A faulty ignition transformer can
The CAT data link consists of two wires that are cause the ECM to reset. When the reset occurs, the
twisted together. One wire is designated as +. The ECM also generates a diagnostic code for the CAT
other wire is designated as -. data link. If the engine is not running, the engine will
not start. If the engine is running, the engine will
The signals on the data link wires are a square shut down. Temporarily install a transformer that is
wave type signal. The signals operate at a very high known to be good into a cylinder. Then check for the
frequency. The signals cannot be measured with diagnostic code. If the code is still active, install the
common service tools. Therefore, only continuity good transformer into a different cylinder. When the
measurements can be made on the wires for the suspect transformer is removed, the ECM will not
CAT data link. reset.
The most likely cause of a diagnostic code for the Harness Code for the Slave ECM
CAT data link are an open circuit or a short circuit.
Connector terminals that are not fully seated in the The harness inside the terminal box has a jumper
connector body can create an open circuit condition. wire (harness code) that connects terminals J3-29
Be careful not to interchange the + wire and the - wire and J3-60. The ECM that is connected to the harness
in a connector. The CAT data link will not operate reads the harness code. This allows the ECM to
if the + wire and the - wire are interchanged in a operate as the slave ECM.
connector.
If the jumper wire is disconnected, the slave ECM
The CAT data link can fail if a module is not receiving will assume the function of a master ECM. Cat ET
power. This can happen if there is a problem with the will not communicate with any of the modules. Cat
wiring that provides power to the module. ET will display “Duplicate Type on data link. Unable
to Service”.
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.
225
g01065141
Illustration 49
Schematic of the CAT data link
Test Step 1. Inspect the Electrical Note: For the following steps, refer to
Connectors and Wiring Troubleshooting, “Inspecting Electrical Connectors”.
g01054206 g01065143
Junction Box Terminal box
(1) 35 amp circuit breaker (2) Ground strap
(3) J5 connector for Cat ET
A. Set the engine control to the OFF/RESET mode. (5) J6 connector for the customer
Switch 35 amp circuit breaker (1) to the OFF (6) J9/P9 connectors for the CAT data link
position. (7) J3/P3 connectors for the slave ECM
226
g01065145
Illustration 53
(P1-8) CAT data link +
(P1-9) CAT data link −
g01065149
Illustration 52
(8) ITSM
(9) 14-pin connectors for the harness to the terminal box for the
master ECM

connectors:
• J1/P1 connectors
• J5, J6, and J9/P9 connectors g01065147
Illustration 54
• 14-pin connectors for the ITSM Harness side of the P3 connector

(P3-8) CAT data link +
a. Check the torque of the allen head screw for (P3-9) CAT data link −
the ECM connectors. The proper torque is (P3-29) Harness code
(P3-60) harness code
6 ± 1 N·m (53 ± 9 lb in).
CAT data link.
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
d. Check the harness and wiring for abrasion and
for pinch points from the slave ECM to the
master ECM.
e. Check the harnesses and wiring for abrasion

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

227
Results: Repair: If any of the above codes are logged

and the engine is not running properly, refer to
• OK – The components are in good condition with Troubleshooting, “Troubleshooting Without a
proper connections. Proceed to Test Step 2. Diagnostic Code”.
• Not OK – The components are not in good If any of the above codes are logged and the
condition and/or at least one connection is engine is running properly, there may be an
improper. intermittent problem in a connector or a wiring
harness. Refer to Troubleshooting, “Inspecting
Repair: Perform the necessary repairs and/or Electrical Connectors”.
STOP.
STOP.
• Not OK – At least one of the modules is not
Test Step 2. Check the CAT Data Link displayed on the “ECM Selector” screen. There
may be an active diagnostic code for the CAT data
A. Verify that the engine control is in the OFF/RESET link. Proceed to Test Step 3.
mode. Verify that the 35 amp circuit breaker is
OFF. Test Step 3. Check the Wiring for the CAT
Data Link
B. Connect Cat ET to the service tool connector.
Refer to Troubleshooting, “Electronic Service A. Set the engine control to the OFF/RESET mode.
Tools”. Switch the 35 amp circuit breaker OFF.
C. Set the engine control to the STOP mode. Switch B. Disconnect Cat ET from the service tool connector.
the 35 amp circuit breaker ON.
C. Disconnect the following connectors:
D. Select the “File/Select ECM” menu on the Cat ET.
Verify that all of the modules are displayed on the • P1 connector from the master ECM
“ECM Selector” screen.
• P3 connector from the slave ECM
Verify that the following diagnostic codes are not
activated. • P6 connector (if equipped)
• 0590-09 Unable to communicate with Engine • 14-pin connector from the ITSM
ECM
D. Measure the resistance between the points that
• 1636-09 Loss of communication with Engine are listed in Table 15. During each measurement,
#2 (Slave) wiggle the wires in the harness in order to check
for an intermittent problem. Be sure to wiggle the
• 1042-09 Unable to communicate with ITSM wires near each of the connectors.
Note: If Cat ET displays “Duplicate Type on data

link. Unable to Service”, there may be a problem with
the harness inside the terminal box. Set the engine
control to the OFF/RESET mode. Switch the 35 amp
circuit breaker OFF. Check the continuity between
terminals J3-29 and J3-60. Verify that the jumper wire
is in good condition. Make repairs, as needed.
Expected Result:
All of the modules are displayed on the “ECM

Selector” screen. There are no active diagnostic
codes for the CAT data link.
Results:
• OK – All of the modules are displayed on the “ECM

Selector” screen. There are no active diagnostic
codes for the CAT data link. The problem seems
to be resolved.
228
Table 15 4. Verify that Cat ET is able to communicate with

Resistance Measurements for the CAT Data Link
each of the modules.
Connector and Terminal Connector and Terminal 5. If Cat ET is unable to communicate with a
P1-8 P3-8
module, there may be a problem with the supply
voltage to the module. Refer to Troubleshooting,
J5-D “Electrical Power Supply”.
J6-7
6. If the problem is not resolved, there may be a
Terminal J of the 14-pin problem with the wiring for the CAT data link
connector on the ITSM between the J6 connector and the customer’s
P3-8 J5-D equipment. Verify that the wiring for the CAT
data link between the J6 connector and the
P1-9 P3-9 customer’s equipment is working properly.
J5-E
7. If the problem is not resolved, there may
J6-17 be a problem with the module that is not
Terminal N of the 14-pin
communicating with Cat ET.
connector on the ITSM
It is unlikely that a module has failed. Exit this
P3-9 J5-E procedure and perform this procedure again. If
P1-34 Ground strap for the the problem is not resolved, temporarily replace
master ECM the module that is not communicating. Refer
to Troubleshooting, “Replacing the ECM” or
P1-50 Ground strap for the Troubleshooting, “Replacing the ITSM”. Verify
master ECM that the problem is resolved.
Expected Result: If the problem is resolved with the new module,

reinstall the original module and verify that
Each check of the resistance between the connectors the problem returns. If the new module works
is less than 5 Ohms. correctly and the original module does not work
correctly, replace the original module. Refer
Each check of the resistance between the connector to Troubleshooting, “Replacing the ECM” or
and the ground strap is greater than 20,000 Ohms. Troubleshooting, “Replacing the ITSM”.
Results: STOP.
• OK – Each check of the resistance for the CAT • Not OK – At least one check of the resistance for
data link is within the specification. The wiring for the CAT data link is incorrect. There is a problem
the CAT data link appears to be OK. with the wiring for the CAT data link.
Repair: Perform the following procedure: Repair: Repair the connection and/or the wire,
when possible. Replace parts, if necessary. Verify
1. Connect the following connectors: that the problem is resolved.
• P1 connector to the master ECM STOP.
• P3 connector to the slave ECM

• 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

229
i02088898 If the master ECM cannot communicate with the

actuator, the master ECM activates a 1720-09
Compressor Bypass diagnostic code and the engine is shut down. A
1720-09 diagnostic code is probably caused by a
SMCS Code: 1052-038-BV problem with an electrical connector or a harness.
The next likely cause is a problem with the actuator.
System Operation Description: The least likely cause is a problem with the master
ECM.
A bypass valve is connected between the outlets
for the turbocharger compressors and the inlets for Terminating resistors must be connected to each
the turbocharger compressors. The bypass valve end of the CAN data link. The terminating resistors
is activated by an actuator. The master Electronic improve the communication between the devices. If
Control Module (ECM) activates the actuator for the there is an intermittent diagnostic code for any of the
bypass valve during these conditions: devices that are connected to the CAN data link, be
sure to check the terminating resistor that is inside
• Turbocharger surge the terminal box. Also check the jumper wire that is
connected between terminals J and K on the actuator
• Engine shutdown for the bypass valve. Make repairs, when possible.
Replace parts, if necessary.
Turbocharger Surge
Identification on the CAN Data Link
A rapid drop in the output power of the generator
can cause the engine’s speed to quickly increase. When the actuator for the bypass valve is powered
The increased speed of the engine causes the up, the actuator looks for a ground on terminal N. If
turbochargers to overspeed temporarily. This is there is a ground on terminal N, the actuator will have
called a turbocharger surge. Surging can damage a unique identification on the CAN data link.
the turbochargers.
If there is no ground on terminal N and the actuator
The master ECM continuously monitors the speed is powered up, the actuator for the bypass valve and
of the engine. The master ECM responds to a rapid the throttle actuator will have the same identification.
increase in the speed of the engine by activating the The master ECM will not communicate with the
actuator for the bypass valve. The actuator opens actuator for the bypass valve. Instead, the master
the valve. ECM will activate a 1720-09 diagnostic code. The
engine will not start.
The valve allows the compressed air/fuel mixture in
the aftercooler’s inlet to flow into the intake of the The electrical connector for the actuator is designed
turbocharger’s compressor. This reduces the boost so that the terminals for electrical power are
pressure in the air inlet manifold. connected before terminal N. For this reason,
electrical power must be removed before the
Engine Shutdown connector for the actuator is connected.
Engine shutdown occurs when the output for the
fuel control relay is OFF and the engine RPM is
above 100. The master ECM activates the actuator
for the bypass valve until the engine RPM drops to
zero. This scavenges any unburned gases in the
components of the system during engine shutdown.
CAN Data Link
The master ECM and the actuator communicate

via the CAN data link. The master ECM sends a
command signal to the actuator. The actuator sends
the following information to the master ECM: actuator
position, CCM heartbeat, software version, and
internal fault diagnosis.
230
g01065173
Illustration 55
Schematic for the circuit of the actuator for the bypass valve
231
• Connectors on the actuator for the bypass valve
a. Check the torque of the allen head screw for
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 56
Junction box

Switch 35 amp circuit breaker (1) to the OFF
position.
g01065176
Illustration 58
Note: For the following steps, refer to Harness side of the P1 connector
Troubleshooting, “Inspecting Electrical Connectors”. (P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
g01065175
Illustration 57
Terminal box
g00934039
Illustration 59
(2) Ground strap
(3) J1/P1 connectors for the master ECM Harness side of the J9 connector
(4) J9/P9 connectors for the CAN data link (J9-6) CAN data link +
(5) J10/P10 connectors for the terminating resistor for the CAN (J9-12) CAN data link −
data link (J9-18) CAN shield
232

wires that are associated with the actuator for
the bypass valve.
g00935459
Illustration 60
Right side views
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 to engine control to the STOP mode.
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 connected Expected Result:
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.
233
Terminating resistors must be connected to each Repair: The open circuit could be caused by a poor
end of the CAN data link. The terminating resistors electrical connection in a connector. Alternatively,
improve the communication between the devices. the open circuit could be caused by one of the
If there is an intermittent diagnostic code for any of following components:
the devices that are connected to the CAN data
link, be sure to check the terminating resistor that • The harness inside the terminal box
is inside the terminal box. Also check the jumper
wire that is connected between terminals J and K • The harness between the terminal box and the
on the actuator for the bypass valve. Make repairs, fuel metering valve
• The harness between the fuel metering valve
STOP. and the throttle actuator
• Not OK (Active 1720-09) – The master ECM • The harness between the throttle actuator and
has detected a problem with the communication the actuator for the bypass valve
between the master ECM and the actuator for the
bypass valve. Proceed to Test Step 3. • The fuel metering valve
Test Step 3. Check the CAN Data Link for • The throttle actuator
Continuity Between the Actuator for the
Bypass Valve and the Master ECM Make repairs, when possible. Replace parts, if
necessary.
Switch the 35 amp circuit breaker OFF. STOP.
B. Disconnect the P1 connector. Disconnect the Test Step 4. Check the CAN Data Link for
connector for the actuator for the bypass valve. a Short Circuit
C. Use a multimeter to check for continuity between A. Verify that the engine control is in the OFF/RESET
the points that are listed in Table 16. During each mode and that the 35 amp circuit breaker is OFF.
measurement, wiggle the harnesses in order to
check for an intermittent problem with the harness. B. Use a multimeter to check for continuity between
Be sure to wiggle the harness near each of the the points that are listed in Table 17. During each
connectors. Be sure to wiggle the harness near measurement, wiggle the harnesses in order to
the fuel metering valve and the throttle actuator. check for an intermittent problem with the harness.
Be sure to wiggle the harness near each of the
Table 16 connectors. Be sure to wiggle the harness near
Points to Check for Continuity the fuel metering valve and the throttle actuator.
Connector and Harness Connector for the Table 17
Terminal Actuator for the Bypass Valve
Points to Check for Continuity
P1-34 Terminal “B” (CAN data link −)
P1-50 Terminal “A” (CAN data link +)
P1-34 (CAN data link −) P1-50 (CAN data link +)
P1-42 Terminal “M” (CAN shield) P1-42 (CAN shield)
P1-52 (+ Battery)
Ground strap for the ECM
Expected Result:
P1-50 (CAN data link +) P1-42 (CAN shield)
The continuity of the circuits between the terminals P1-52 (+ Battery)
is good. Ground strap for the ECM
P1-42 (CAN shield) P1-52 (+ Battery)
Results: Ground strap for the ECM
• OK – The continuity of the circuits between the Expected Result:

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
Results:
for the CAN data link between the actuator for the
bypass valve and the master ECM.
• OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short
circuit.
234
Repair: Reconnect the P1 connector. Reconnect Repair: The active 1720-09 code could be caused
the connector for the actuator for the bypass valve. by one of the following components:
Proceed to Test Step 5. • The master ECM

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

that is causing the code to be logged, refer
to Troubleshooting, “Inspecting Electrical
Connectors”.
STOP.
• Not OK – The 1720-09 code is active.

235
i02088933 The troubleshooting procedure may generate

Desired Speed Input (4 - 20 correcting the cause of the original diagnostic code.
mA) Clear the diagnostic codes after the problem is
resolved.
SMCS Code: 1901-038
Note: For this troubleshooting procedure,

the “Desired Speed Input” configuration
parameter must be set to “4-20 mA Input” in the
“Service/Configuration” screen of the Caterpillar
Electronic Technician (ET). Do not select “PWM”. The
master Electronic Control Module (ECM) cannot be
configured to accept a PWM input signal for control
of the engine speed.
The selection of the “4-20 mA Input” setting requires

a 4 to 20 mA signal for regulation of the desired g01065191
Illustration 61
engine speed. If the “Desired Speed Input” is set
to “0-5 VDC Input”, do not use this procedure to Schematic of the 4 to 20 mA desired speed input
troubleshoot the circuit.
Test Step 1. Inspect the Electrical
When the desired speed input is correspondingly Connectors and Wiring
configured, the master ECM controls the engine
speed according to the 4 to 20 mA current.
The value of the current corresponds to a range

of desired engine speeds between minimum high
idle and maximum high idle. The “Minimum Engine
High Idle Speed” and the “Maximum Engine High
Idle Speed” are set with the “Service/Configuration”
screen of ET. For more information, refer to Systems
Operation/Testing and Adjusting, “Electronic Control
System Parameters”.
When the “Idle/Rated” switch is in the Rated position,

a current value of 4.0 mA corresponds to the
programmed “Minimum Engine High Idle Speed”. A
current value of 20.0 mA corresponds to “Maximum
Engine High Idle Speed”. Current values within this
range will vary the desired engine speed in a linear
fashion between “Minimum Engine High Idle Speed”
and “Maximum Engine High Idle Speed”.
Current values that are greater than 22.0 mA will Illustration 62

g01054206
activate the “524-03 Desired Engine Speed Sensor Junction box
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. A. Set the engine control to the OFF/RESET mode.
The most likely causes of the diagnostic code are a position.
poor connection or a problem in a wiring harness. The
next likely cause is a problem with a component. The Note: For the following steps, refer to
least likely cause is a problem with the master ECM. Troubleshooting, “Inspecting Electrical Connectors”.

Before you begin this procedure, use ET to print the
logged codes to a file.
236
g00905060
Illustration 64
(P1-36) + Signal
(P1-37) - Signal
g01065192
Illustration 63
Terminal box
(2) Ground strap
B. Thoroughly inspect the following components:
• 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).
g00929720
Illustration 65
b. Check the torque of the allen head screws Harness side of the J6 connector
for the terminal box’s connectors. The proper (J6-37) + Signal
torque is 2.25 ± 0.25 N·m (20 ± 2 lb in). (J6-27) - Signal

wires that are associated with the 4 to 20 mA
circuit.
d. Check the harness and wiring for abrasion

and for pinch points between the device that
supplies the 4 to 20 mA signal and the master
ECM.
Expected Result:

237
Results: Repair the connection and/or the wire, when

possible. Replace parts, if necessary. Verify that
• OK – The components are in good condition with the problem is resolved.
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.
A. Verify that the engine control is in the OFF/RESET
• Not OK – The components are not in good mode and that the 35 amp circuit breaker is OFF.
condition and/or at least one connection is
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.
Test Step 2. Check for an Open Circuit Expected Result:
A. Remove the two wires (“+” and “-”) for the 4 to 20 The resistance is greater than 20,000 Ohms.
mA signal from the device that supplies the 4 to
20 mA signal. Results:
B. Install a jumper wire between the two wires (“+” • Yes – The resistance is greater than 20,000 Ohms.
and “-”) that were removed from the device that The wiring from terminal P1-36 is not shorted to the
supplies the 4 to 20 mA signal. +Battery side. Do not reconnect any connectors.
Proceed to Test Step 4.
C. Disconnect the P1 connector from the master
ECM. • No – The resistance is less than 20,000 Ohms.
There is a problem with a connection and/or the
D. Use an ohmmeter to measure the resistance wiring from terminal P1-36.
between terminals P1-36 and P1-37 on the ECM
side of the P1 connector. Repair: The problem may be between the P1
connector and the J6 connector. Alternatively, the
Expected Result: problem may be between the P6 connector and
the device that provides the 4 to 20 mA signal.
The resistance is less than 5 Ohms.
Repair the connection and/or the wire, when
Results: possible. Replace parts, if necessary. Verify that
the problem is resolved.
• OK – The resistance is less than 5 Ohms. The
circuit is not open. STOP.
Repair: Remove the jumper wire. Insulate the wire Test Step 4. Check for a Short to Ground
leads with electrical tape in order to ensure that the at Terminal P1-37
leads do not create a short circuit.
Proceed to Test Step 3. mode and that the 35 amp circuit breaker is OFF.
• Not OK – The resistance is greater than 5 Ohms. B. Make sure that the leads of the wires for the 4 to
There is a problem with a connector and/or the 20 mA signal do not create a short circuit.
wiring from the P1 connector.
C. Use an ohmmeter to measure the resistance
Repair: The problem may be between the P1 between the ground strap for the master ECM and
connector and the J6 connector. Alternatively, the terminal P1-37.
problem may be between the J6 connector and the
device that provides the 4 to 20 mA signal. Expected Result:
The resistance is greater than 20,000 Ohms.

238
Results: Repair: The problem may be between the P1

• Yes – The resistance is greater than 20,000 Ohms. problem may be between the J6 connector and the
The wiring from terminal P1-37 appears to be OK. device that provides the 4 to 20 mA signal.
Repair: Reconnect the P1 connector. Reconnect Repair the connection and/or the wire, when
the two wires (“+” and “-”) for the 4 to 20 mA signal possible. Replace parts, if necessary. Verify that
to the device that supplies the 4 to 20 mA signal. the problem is resolved.
Proceed to Test Step 7. STOP.
• No – The resistance is less than 20,000 Ohms. Test Step 6. Check for a Short Circuit to
There is a problem with a connection and/or the Ground at Terminal P1-36
wiring that is connected to P1-37.
Repair: The problem may be between the P1 mode and that the 35 amp circuit breaker is OFF.
problem may be between the P6 connector and B. Make sure that the ends of the wires for the 4 to
the device that provides the 4 to 20 mA signal. 20 mA signal do not create a short circuit.
Locate the wire with the short circuit and replace C. Use an ohmmeter to measure the resistance
the wire. Verify that the problem is resolved. between ground strap (2) and terminal P1-36.
STOP. Expected Result:
Test Step 5. Check for a Short Circuit to The resistance is greater than 20,000 Ohms.
the +Battery Side at Terminal P1-37
Results:
mode and that the 35 amp circuit breaker is OFF. • Yes – The resistance is greater than 20,000 Ohms.
The wiring from terminal P1-36 appears to be OK.
B. Make sure that there is no electrical power to the Do not reconnect any connectors. Proceed to Test
device that provides the 4 to 20 mA signal. Step 7.
C. Remove the two wires (“+” and “-”) for the 4 to • No – The resistance is less than 20,000 Ohms.
20 mA signal from the device that supplies the There is a problem with a connection and/or the
4 to 20 mA signal. Insulate the wire leads with wiring from terminal P1-36.
electrical tape in order to ensure that the leads do
not create a short circuit. Repair: The problem may be between the P1
D. Disconnect the P1 connector from the master problem may be between the P9 connector and
ECM. the device that provides the 4 to 20 mA signal.
E. Use an ohmmeter to measure the resistance Repair the connection and/or the wire, when
between terminals P1-37 and P1-57. possible. Replace parts, if necessary. Verify that
the problem is resolved.
Expected Result:
STOP.
The resistance is greater than 20,000 Ohms.
Test Step 7. Check the Device that
Results: Provides the 4 to 20 mA Signal
• Yes – The resistance is greater than 20,000 Ohms. Measure the 4 to 20 mA signal according to the
The wiring from terminal P1-37 is not shorted to the literature that is provided by the OEM of the device
+Battery side. Do not reconnect any connectors. that provides the 4 to 20 mA signal. Verify that the
Proceed to Test Step 6. correct signal is provided to the master ECM.
• No – The resistance is less than 20,000 Ohms. Verify the correct 4 to 20 mA signal at terminals
There is a problem with a connection and/or the P1-36 and P1-37.
wiring from terminal P1-37.
239
Expected Result: The master Electronic Control Module (ECM) and

the slave ECM supply 8 VDC in order to power the
The correct 4 to 20 mA signal is provided to the sensors. The detonation sensors provide electrical
master ECM. signals to the modules that indicate mechanical
engine vibrations. Each sensor outputs an electrical
Results: signal. The signal is amplified and the signal is
filtered. The frequency of the signal corresponds
• Yes – The correct 4 to 20 mA signal is provided to to the mechanical frequency of the vibrations. The
the master ECM. However, the master ECM is not amplitude of the signal is proportional to the intensity
responding correctly to the signal. There may be of the vibrations.
a problem with the master ECM.
The master ECM monitors the detonation sensors on
Repair: It is unlikely that the master ECM is faulty. the left side of the engine. The slave ECM monitors
Exit this procedure and perform this procedure the detonation sensors on the right side of the engine.
again. If the problem is not resolved, replace Each ECM monitors the signals in order to determine
the master ECM according to Troubleshooting, the presence and the severity of the detonation. The
“Replacing the ECM”. Verify that the problem is master ECM can retard the timing of the cylinders on
resolved. the left side of the engine in order to limit detonation
levels. The slave ECM can retard the timing of the
STOP. cylinders on the right side of the engine in order to
limit detonation levels. The timing may be retarded
• No – The master ECM is not receiving the correct for a single cylinder or for more than one cylinder.
4 to 20 mA signal. There is probably a problem The timing may be retarded for all of the cylinders,
with the device that provides the 4 to 20 mA. if necessary. If retardation of the timing does not
sufficiently limit the detonation, the master ECM will
Repair: Service the device that provides the 4 to shut down the engine.
20 mA according to the literature that is provided
by the OEM of the device. Verify that the problem An ECM can retard timing by as few as three
is resolved. degrees for light detonation levels. The timing can
be retarded up to six degrees for severe detonation.
STOP. For most applications, the minimum allowable actual
timing is ten degrees BTC (five degrees BTC for
propane operation). A proportional strategy is used
i02089065
for advancing the timing after the timing has been
Detonation Sensors retarded. The rate of advance is based upon the level
of detonation. The rate is faster for lighter detonation.
SMCS Code: 1559-038 The fastest rate of proportional timing advance is one
degree per minute.
Each ECM will diagnose the detonation sensors
Detonation sensors are located on the upper cylinder for a signal that is shorted to the −Battery side, to
block between every two cylinders. Each sensor the +Battery side, or for an open circuit. To avoid
monitors two adjacent cylinders. For example, one detecting vibrations that are not related to detonation,
sensor monitors cylinders 1 and 3 and one sensor each ECM only monitors a detonation sensor when
monitors cylinders 2 and 4. 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
Illustration 66
g00951975 master ECM will shut down the engine. Detonation
protection is disabled when the engine speed is less
Arrangement of the detonation sensors
than 250 rpm.
240

to a file.
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.
The troubleshooting procedure may generate

resolved.
241
g01065289
Illustration 67
Schematic for the detonation sensors
242
• Connectors for each of the detonation sensors
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 68
Junction box

position.
Note: For the following steps, refer to

g01065071
Troubleshooting, “Inspecting Electrical Connectors”. Illustration 70
Harness side of the side of the P2 connector
(P2-55) Returnfor the detonation sensors
(P2-56) +8 V supplyfor the detonation sensors
(P2-57) +8 V supplyfor the detonation sensors
g01065290
Illustration 69
Terminal box
(3) J8/P8 connectors for the detonation sensors
243
g01065071
Illustration 72
Harness side of the P4 connector for the slave ECM
g00929380 (P4-54) Return for the detonation sensors
Illustration 71
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 the
(J8-6) 8 V Supply for the detonation sensor for cylinders 1 and 3 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 73
Detonation sensors
(J8-28) Signal from the detonation sensor for cylinders 9 and 11 d. Check the harness and wiring for abrasion and
(J8-29) Signal from the detonation sensor for cylinders 13 and 15 for pinch points from the detonation sensors
(J8-30) Signal from the detonation sensor for cylinders 17 and 19 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.
244
Results: Test Step 3. Check for Active Diagnostic

Codes for the Detonation Sensors
• OK – The components are in good condition with
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 “Active
Test Step 2. Check for Diagnostic Codes Diagnostic” screen of Cat ET and look for the
for the 8 Volt DC Supply diagnostic codes that are listed in Table 18:
A. Connect Cat ET to the service tool connector.

Tools”.

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

Wait at least 30 seconds so that any codes may
become activated. Look for these 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.
245
Table 18 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 in
1501-04 Cylinder #1 Detonation
Sensor short to ground 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 to
2 and 4
1502-04 Cylinder #2 Detonation 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 “short
1509-03 Cylinder #9 Detonation 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 74
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.
246
Results: • No – The voltage is not between 0.4 VDC and 0.6

VDC. If the voltage is less than 0.4 VDC, there
• OK – The voltage is between 7.6 VDC and 8.4 is probably a short to ground or an open circuit
VDC. The correct voltage is available to the sensor. between the connector for the detonation sensor
Do not reconnect the sensor. Proceed to Test Step and the ECM. If the voltage is greater than 4.8
5. VDC, there is probably a short circuit to a +Battery
source between the connector for the detonation
• Not OK – The voltage is not between 7.6 VDC and sensor and the ECM. If you are troubleshooting a
8.4 VDC. The correct voltage is not available to the detonation sensor for the master ECM, proceed to
sensor. There is probably an open circuit in the 8 Test Step 6. If you are troubleshooting a detonation
volt supply or in the return for the sensor. sensor for the slave ECM, proceed to Test Step 7.
Repair: The open circuit may be caused by a poor Test Step 6. Check the Operation of the
electrical connection or a wiring problem between Master ECM
the ECM and the connector for the sensor.
Repair the electrical connection and/or the wiring, Switch the 35 amp circuit breaker OFF.
when possible. Replace the harness, if necessary.
B. Use a 151-6320 Wire Removal Tool to remove
STOP. the signal wire for the suspect sensor from the
P2 connector. This will replace the sensor circuit
Test Step 5. Measure the Voltage of the with an open circuit.
Signal Wire at the Sensor
Note: The run relay and the crank terminate relay

detonation sensor can be generated. Therefore, the
engine must be running. The engine will shut down
soon after the diagnostic code for the detonation
Illustration 75
g00890518 sensor is activated.
Harness connector for the detonation sensors
D. Start the engine. Observe the “Active Diagnostic”
(A) 8 volt supply screen on Cat ET. Allow a minimum of 30 seconds
(B) Return
(C) Signal
for any codes to activate.
A. Measure the voltage between terminals B and C An active “open/short to +batt” diagnostic code is
on the harness connector for the suspect sensor. 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.
247
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.

The master ECM is not operating correctly.

failed. Exit this procedure and perform this

Illustration 76
g01065294 If the problem is resolved with the new ECM,
Master ECM with jumper wire
(1) P2 connector
(2) P1 connector
(3) Jumper wire the original ECM. Refer to Troubleshooting,
“Replacing the ECM”.
F. Fabricate a jumper wire that is long enough to
reach between the P1 connector and the P2 STOP.
connector. Install Deutsch terminals on the ends.
Install one end of jumper wire (3) into the terminal Test Step 7. Check the Operation of the
for the signal wire that was removed from the P2 Slave ECM
connector (1). Install the other end of the jumper
wire into terminal 19 of the P1 connector (2). This A. Set the engine control to the OFF/RESET mode.
will replace the sensor circuit with a short circuit Switch the 35 amp circuit breaker OFF.
to ground.
G. Start the engine. Observe the “Active Diagnostic” the signal wire for the suspect sensor from the
screen on Cat ET. Allow a minimum of 30 seconds P4 connector. This will replace the sensor circuit
for any codes to activate. with an open circuit.
An active “short to ground” diagnostic code is C. Switch the 35 amp circuit breaker ON. Set the
generated for the sensor. engine control to the STOP mode.
Expected Result: Note: The run relay and the crank terminate relay
Active “open/short to +batt” and “short to ground” detonation sensor can be generated. Therefore, the
diagnostic codes are generated according to the engine must be running. The engine will shut down
above steps. soon after the diagnostic code for the detonation
sensor is activated.
Results:
D. Start the engine. Observe the “Active Diagnostic”
• OK – Active “open/short to +batt” and “short to screen on Cat ET. Allow a minimum of 30 seconds
ground” diagnostic codes are generated according for any codes to activate.
to the above steps. The master ECM is operating
correctly. There is probably an open circuit in An active “open/short to +batt” diagnostic code is
a harness between the master ECM and the generated for the sensor.
connector for the sensor.
E. Set the engine control to the OFF/RESET mode.
248
Repair: Remove the jumper wire. Insert the

terminal that was removed from the P4 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.

The slave ECM is not operating correctly.
Repair: It is unlikely that the slave ECM has failed.

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

Illustration 77
g01065295 If the problem is resolved with the new ECM,
Slave ECM with jumper wire
(1) P4 connector
(2) P3 connector
(3) Jumper wire the original ECM. Refer to Troubleshooting,
F. Fabricate a jumper wire that is long enough to
reach between the P4 connector and the P3 STOP.
connector. Install Deutsch terminals on the ends.
Install one end of jumper wire (3) into the terminal i02089084
for the signal wire that was removed from the P4
connector (1). Install the other end of the jumper ECM Output Circuit (Fuel
wire into terminal 19 of the P3 connector (2). This
will replace the sensor circuit with a short circuit Control)
to ground.
SMCS Code: 1901-038
G. Start the engine. Observe the “Active Diagnostic”
screen on Cat ET. Allow a minimum of 30 seconds System Operation Description:
for any codes to activate.
An active “short to ground” diagnostic code is contains the logic and the outputs for starting and
generated for the sensor. stopping the engine. The logic for starting and
stopping is customer programmable. The logic
Expected Result: responds to inputs from the following components:
engine control switch, emergency stop switch, remote
Active “open/short to +batt” and “short to ground” start switch, data link, and other inputs.
diagnostic codes are generated according to the
above steps. The fuel control relay is energize-to-run. To enable
fuel flow to the engine, the relay for the Gas Shutoff
Results: Valve (GSOV) must be energized. The master ECM
provides +Battery voltage to the relay for the GSOV
when the logic determines that fuel is required for
• OK – Active “open/short to +batt” and “short to
ground” diagnostic codes are generated according engine operation. For engine shutdown, the master
to the above steps. The slave ECM is operating ECM removes the voltage from the fuel control relay.
correctly. There is probably an open circuit in the This stops the fuel flow.
harness between the slave ECM and the connector
for the sensor.
249
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 engine to start. The jumper wire must remain
connected in order for the engine to run. Refer to
Illustration 78 for the schematic diagram.

to a file.

poor electrical connection or a problem in a wiring
harness. The next likely cause is a problem with 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.
250
g01065314
Illustration 78
Optional connections for the fuel control relay
251
Test Step 1. Inspect the Electrical C. Thoroughly inspect the following connectors and
Connectors and Wiring the wiring harnesses for the connectors:
• Connectors for the fuel control relay
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 79
Junction box
A. Switch 35 amp circuit breaker (1) to the OFF

position.
g00930126
Illustration 81
(P2-11) Circuit driver for the fuel control relay
(P2-21) Return
g01065317
Illustration 80
Terminal box
(3) J6/P6 connector for the customer
(4) J7/P7 connectors for the harness from the fuel control relay
g00952066
Illustration 82
B. Set the engine control to the OFF/RESET mode. Harness side of the J6 connector
(J6-21) Circuit driver for the fuel control relay
Note: For the following steps, refer to (J6-24) Return
Troubleshooting, “Inspecting Electrical Connectors”. (J6-31) Circuit for the fuel control relay
252
Expected Result:

Results:

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

improper.
Repair: Perform the necessary repairs, when

possible. Replace parts, if necessary.
STOP.

Tools”.

g00929957
Illustration 83
Harness side of the J7 connector C. Wait for 30 seconds and use Cat ET to check for
(J7-50) Circuit driver for the fuel control relay an active “17-05 Fuel Shutoff Valve open circuit”
(J7-64) Return diagnostic code.
c. Perform a 45 N (10 lb) pull test on each of the If there is an active “17-05 Fuel Shutoff Valve
wires that are associated with the fuel control open circuit” diagnostic code, proceed to the
relay. “Results” for this Test Step. Otherwise, continue
this procedure.
Note: The “17-05 Fuel Shutoff Valve open circuit”

diagnostic code cannot be detected when the output
for the fuel control relay is ON. The output is 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
g00869737
Illustration 84 control relay is OFF. The output is OFF when the
Typical fuel control relay engine control is in the STOP mode.
d. Check the harness and wiring for abrasion and E. To prevent the engine from starting, shut the gas
pinch points from the fuel control relay to the supply OFF.
master ECM.
253
Note: To provide the output for the fuel control relay, Test Step 3. Check for a Short Circuit to
the sequence for engine start-up must be initiated. the +Battery Side
Otherwise, a “17-06 Fuel Shutoff Valve short to
ground” or a “17-12 Fuel Shutoff Valve malfunction”
diagnostic code cannot be generated.
F. Set the engine control to the START mode for at Gaseous fuel is present. Personal Injury or Death
least 30 seconds. Then set the engine control to can result from an open flame or spark igniting
the STOP mode. the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres-
G. Use Cat ET to look for a logged “17-06 Fuel ence of gaseous fuel when maintaining and ser-
Shutoff Valve short to ground” or a “17-12 Fuel vicing. Contact you local gas provider immediate-
Shutoff Valve malfunction” diagnostic code again. ly for assistance in the event of a leak.
Expected Result: Note: Open sparks can be generated during this test.
When the engine control was in the STOP mode, A. Make sure that no combustible gas is present in
there was no active “17-05 Fuel Shutoff Valve open the surrounding atmosphere.
circuit” diagnostic code.
B. Verify that the engine control is in the STOP mode.
After the engine was cranked, there was no logged
“17-06 Fuel Shutoff Valve short to ground” or “17-12 C. Disconnect the connector from the fuel control
Fuel Shutoff Valve malfunction” diagnostic code. relay. Then reconnect the connector. Listen for an
audible click from the relay.
Results:
If the ambient noise is too loud, touch the relay
• OK – No diagnostic codes were generated. The when the relay is reconnected in order to feel the
output for the fuel control relay seems to be OK at vibration. The relay will vibrate when the relay is
this time. The initial diagnostic code was probably de-energized and energized.
caused by a poor electrical connection.
Expected Result:
that is causing the codes to be logged, refer There is no audible click and/or vibration when the
to Troubleshooting, “Inspecting Electrical relay is disconnected and reconnected. The relay is
Connectors”. not energized when the engine control is in the STOP
mode.
STOP.
Results:
• Not OK (“17-05 Fuel Shutoff Valve open circuit”
diagnostic code) – A “17-05 Fuel Shutoff Valve • OK – There is no audible click and/or vibration
open circuit” diagnostic code was activated. This when the relay is disconnected and connected.
can be caused by an actual open circuit or by a There is no short circuit to the +Battery side. There
short circuit to the +Battery side. Proceed to Test is an open circuit. Proceed to Test Step 5.
Step 3.
• Not OK – There is an audible click and/or vibration
• Not OK (“17-06 Fuel Shutoff Valve short to ground” when the relay is disconnected and connected.
diagnostic code) – After the engine was cranked, The relay is receiving power when the engine
a “17-06 Fuel Shutoff Valve short to ground” control is in the STOP mode. There is probably a
diagnostic code was generated. Proceed to Test short circuit to the +Battery side in a connector or a
Step 7. wiring harness. Proceed to Test Step 4.
• Not OK (“17-12 Fuel Shutoff Valve malfunction”

diagnostic code) – After the engine was cranked,
a “17-12 Fuel Shutoff Valve malfunction” diagnostic
code was generated. The master ECM disabled
the ignition.
Repair: Set the engine control to the OFF/RESET

mode. Switch the 35 amp circuit breaker OFF.
Replace the fuel control relay.
STOP.
254
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 relay is de-energized and energized.
the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres- If the relay is not energized, there is an
ence of gaseous fuel when maintaining and ser- intermittent problem with a connector and/or the
vicing. Contact you local gas provider immediate- wiring. Refer to Troubleshooting, “Inspecting
ly for assistance in the event of a leak. Electrical Connectors”.
Note: Open sparks can be generated during this test. If the relay is energized, there may be a problem
Switch the 35 amp circuit breaker OFF. It is unlikely that the master ECM has failed.
B. Use a 151-6320 Wire Removal Tool to remove again. If the problem is not resolved, perform
terminals P2-11 and P2-21. the following steps:
C. Switch the 35 amp circuit breaker ON. Set the Temporarily install a new master ECM. Refer to
engine control to the STOP mode. Troubleshooting, “Replacing the ECM”.
D. Disconnect the connector from the fuel control If the problem is resolved with the new ECM,
relay. Then reconnect the connector. Listen for an install the original ECM and verify that the
audible click from the relay. problem returns. If the new ECM operates
correctly and the original ECM does not operate
If the ambient noise is too loud, touch the relay correctly, replace the original ECM. Refer to
when the relay is reconnected in order to feel the Troubleshooting, “Replacing the ECM”.
vibration. The relay will vibrate when the relay is
de-energized and energized. STOP.
Expected Result: • Not OK – There is an audible click and/or vibration

when the relay is disconnected and reconnected.
There is no audible click and/or vibration when the The relay is energized when the wiring is removed
relay is disconnected and reconnected. The relay is from the P2 connector. There is a short circuit to
not energized when the wiring is removed from the the +Battery side in a harness.
P2 connector.
Repair: Repair the wiring and/or the connector,
Results: when possible. Replace parts, if necessary.
• OK – There is no audible click and/or vibration STOP.

when the solenoid is disconnected and
reconnected. The relay is not energized when the Test Step 5. Create a Short Circuit in
wiring is removed from the P2 connector. order to Check for an Open Circuit
Repair: Use the following procedure to determine A. Set the engine control to the OFF/RESET mode.
whether the circuit driver for the relay is faulty: Switch the 35 amp circuit breaker OFF.
1. Set the engine control to the OFF/RESET B. Disconnect the fuel control relay’s connector.
2. Reinstall terminals P2-11 and P2-21. Pull on

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

255
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

g01065318
Illustration 85 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 g01065319
Illustration 86
installed.
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
1. Set the engine control to the OFF/RESET
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 active
4. Make repairs, as needed. “17-05 Fuel Shutoff Valve open circuit” diagnostic
code.
256
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:
B. Disconnect the connector from the fuel control
• OK – When the jumper wire was installed, there relay.
was no active “17-05 Fuel Shutoff Valve open
circuit” diagnostic code. The master ECM detects C. Set the engine control to the STOP mode.
the jumper wire at the P2 connector. However,
the master ECM did not detect the jumper wire D. Use Cat ET to clear the logged “17-06 Fuel Shutoff
at the connector for the fuel control relay. There Valve short to ground” diagnostic code.
is a problem between the P2 connector and the
connector for the fuel control relay. 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. Use a 151-6320 Wire Removal Tool to remove
the jumper wire from the P2 connector. F. Set the engine control to the START mode for at
least 30 seconds. Then set the engine control to
3. Reinstall the terminals into P2-11 and P2-21. the STOP mode.
Pull on the wires in order to verify proper
installation of the terminals. G. Use Cat ET to look for a logged “17-06 Fuel
Shutoff Valve short to ground” diagnostic code
4. Thoroughly inspect the J6/P6 and J7/P7 again.
connectors. Inspect the wiring that is connected
to terminals J6-21 and J6-31. Expected Result:
5. Make repairs, if necessary. A “17-06 Fuel Shutoff Valve short to ground” was not
generated.
STOP.
Results:
• Not OK – When the jumper wire was installed, a
“17-05 Fuel Shutoff Valve open circuit” diagnostic • OK – When the relay was connected, a “short to
code was activated. The master ECM did not ground” diagnostic code was generated. When
detect the jumper wire. There is a problem with the the relay was disconnected, no “short to ground”
master ECM. diagnostic code was generated. There is a problem
with the relay.
mode. Switch the 35 amp circuit breaker OFF. 1. Set the engine control to the OFF/RESET
the jumper wire from the P2 connector. 2. Inspect the relay’s connectors for damage
and/or for corrosion.
3. Reinstall the terminals into P2-11 and P2-21.
Pull on the wires in order to verify proper 3. Make repairs, as needed.
installation of the terminals.
If the problem is not resolved, replace the relay.
4. Replace the master ECM according to
Troubleshooting, “Replacing the ECM”. Verify STOP.
that the problem is resolved.
• Not OK – A “short to ground” diagnostic code
STOP. was generated when the relay was disconnected.
There is a problem with the wiring or with the ECM.
257
Test Step 8. Check the Master ECM • Not OK – A “17-06 Fuel Shutoff Valve short to
ground” diagnostic code was generated when the
A. Set the engine control to the OFF/RESET mode. output to the relay was disconnected from the
Switch the 35 amp circuit breaker OFF. P2 connector. There may be a problem with the
master ECM.
B. Use the 151-6320 Wire Removal Tool to remove
terminal P2-11. Repair: Perform the following procedure:
C. Switch the 35 amp circuit breaker ON. Set the 1. Set the engine control to the OFF/RESET
engine control to the STOP mode. mode. Switch the 35 amp circuit breaker OFF.
D. Use Cat ET to clear the logged “17-06 Fuel Shutoff 2. Reinstall the terminal that was removed from
Valve short to ground” diagnostic code. P2-11. Pull on the wire in order to verify proper
installation of the terminal.
E. To prevent the engine from starting, shut OFF the
main gas supply. 3. It is unlikely that the master ECM has failed.
Note: To provide the output for the fuel control relay, again. If the problem is not resolved, perform
the sequence for engine start-up must be initiated. the following steps:
Otherwise, a “17-06 Fuel Shutoff Valve short to
ground” diagnostic code cannot be generated. Temporarily install a new master ECM. Refer to
F. Set the engine control to the START mode for at
least 30 seconds. Then set the engine control to If the problem is resolved with the new ECM,
the STOP mode. install the original ECM and verify that the
G. Use Cat ET to look for a logged “17-06 Fuel correctly and the original ECM does not operate
Shutoff Valve short to ground” diagnostic code correctly, replace the original ECM. Refer to
again. Troubleshooting, “Replacing the ECM”.
Expected Result: STOP.
The “17-06 Fuel Shutoff Valve short to ground”

i02089116
diagnostic code was not generated.
Results:
ECM Output Circuit (Starting
Motor)
• OK – When the output to the relay was
disconnected from the P2 connector, the “17-06 SMCS Code: 1901-038
Fuel Shutoff Valve short to ground” diagnostic
code was not generated. However, a “short to System Operation Description:
ground” diagnostic code was generated when the
connector was disconnected from the fuel control The master Electronic Control Module (ECM)
relay. There is a problem in the wiring between the contains the logic and the outputs for starting
P2 connector and the connector for the fuel control the engine. The logic for starting is customer
relay. programmable. The logic responds to inputs from
the following components: engine control switch,
Repair: Perform the following procedure: emergency stop switch, remote start switch, data
link, and other inputs.
mode. Switch the 35 amp circuit breaker OFF. Logged diagnostic codes provide a historical record.
2. Reinstall the terminal that was removed from Electronic Technician (ET) to print the logged codes
P2-11. Pull on the wire in order to verify proper to a file.
installation of the terminal.
3. Repair the harness, when possible. Replace poor electrical connection or a problem in a wiring
the harness, if necessary. harness. The next likely cause is a problem with a
magnetic switch or with a relay. The least likely cause
STOP. is a problem with the master ECM.
258

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.
259
g01065332
Illustration 87
Schematic for the electric starting system
g01065333
Illustration 88
Schematic for the air starting system
260
Test Step 1. Inspect the Electrical B. Thoroughly inspect the following connectors and
Connectors and Wiring the wiring harnesses for the connectors:
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 89
Junction box

g01055043
Switch 35 amp circuit breaker (1) to the OFF Illustration 91
position. Harness side of the P2 connector
(P2-10) Start command
Note: For the following steps, refer to (P2-20) Return for the start command
Troubleshooting, “Inspecting Electrical Connectors”.
g01065334
Illustration 90
Terminal box
(3) J7/P7 connectors for the wiring from the starting system
261

Tools”.

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

for an active “444-05 Start Relay open circuit”
diagnostic code.
If there is an active “444-05 Start Relay open

circuit” diagnostic code, proceed to the “Results”
for this Test Step. Otherwise, continue this
procedure.
D. Use Cat ET to check the logged diagnostic codes.

If there is a logged “444-06 Start Relay short to
ground” diagnostic code, clear the code.
g00931050
Illustration 92 E. To prevent the engine from starting, shut the gas
Harness side of the J7 connector supply OFF.
(J7-28) Start command
(J7-56) Return for the start command Note: The “444-06 Start Relay short to ground”
c. Perform a 45 N (10 lb) pull test on each of the output for the start command is ON. The output is
wires that are associated with the circuit for the normally ON when the engine control is set from the
starter motor relay. STOP mode to the START mode. The output remains
ON until the crank terminate relay is energized.
for pinch points from the starter motor relay to F. Set the engine control to the START mode for at
the master ECM. least six seconds. Then set the engine control to
the STOP mode.
Expected Result:
G. Use Cat ET to look for a logged “444-06 Start
All connectors, pins, and sockets are connected Relay short to ground” diagnostic code again.
corrosion, abrasion, or pinch points. Expected Result:
Results: When the engine control was in the STOP mode,

there was no active “444-05 Start Relay open circuit”
• OK – The components are in good condition with diagnostic code.
After the engine was cranked, there was no logged
• Not OK – The components are not in good “444-06 Start Relay short to ground” diagnostic code.
improper. Results:
Repair: Perform the necessary repairs, when • OK – No diagnostic codes were activated. The
possible. Replace parts, if necessary. output for the start command seems to be OK at
this time. The initial diagnostic code was probably
STOP. caused by a poor electrical connection.
262
Repair: If there is an intermittent problem Results:

that is causing the codes to be logged, refer
to Troubleshooting, “Inspecting Electrical • OK – There is no audible click and/or vibration
Connectors”. when the air start relay is disconnected and
connected. There is no short circuit to the +Battery
STOP. side. There is an open circuit. Proceed to Test
Step 4.
• Not OK (“444-05 Start Relay open circuit”
diagnostic code) – A “444-05 Start Relay open • Not OK – There is an audible click and/or vibration
circuit” diagnostic code was activated. This can when the air start relay is disconnected and
be caused by an actual open circuit or by a connected. The relay is receiving power when the
short circuit to the +Battery side. If the engine is engine control is in the STOP mode. Proceed to
equipped with an air starting system, proceed Test Step 6.
to Test Step 3. If the engine is equipped with an
electric starting system, proceed to Test Step 9. Test Step 4. Create a Short Circuit in
order to Check for an Open Circuit
• Not OK (“444-06 Start Relay short to ground”
diagnostic code) – After the engine was cranked, A. Set the engine control to the OFF/RESET mode.
a “444-06 Start Relay short to ground” diagnostic Switch the 35 amp circuit breaker OFF.
code was activated. If the engine is equipped with
an air starting system, proceed to Test Step 7. If B. Disconnect the harness connector from the air
the engine is equipped with an electric starting start relay.
system, proceed to Test Step 10.
C. Install a jumper wire into the two terminals of the
Test Step 3. Check for a Short Circuit to harness connector for the air start relay.
the +Battery Side
E. Wait for 30 seconds and use the “Active

Gaseous fuel is present. Personal Injury or Death Diagnostic” screen of Cat ET to look for a “444-05
can result from an open flame or spark igniting Start Relay open circuit” diagnostic code.
the gaseous fuel causing an explosion and/or fire.
Always use a gas detector to determine the pres- Expected Result:
ence of gaseous fuel when maintaining and ser-
vicing. Contact you local gas provider immediate- A “444-05 Start Relay open circuit” diagnostic code
ly for assistance in the event of a leak. was not activated when the jumper wire was installed.
Note: Open sparks can be generated during this test. Results:
A. Make sure that no combustible gas is present in • OK – A “444-05 Start Relay open circuit” diagnostic
the surrounding atmosphere. code was not activated when the jumper wire was
installed. The master ECM detected the short
B. Ensure that the engine control is in the STOP circuit. The harness and the master ECM are OK.
mode. There is a problem with the air start relay.
C. Disconnect the connector from the air start relay. Repair: Perform the following procedure:
Then reconnect the connector. Listen for an
audible click from the relay. 1. Set the engine control to the OFF/RESET
If the ambient noise is too loud, touch the air start
relay when the relay is reconnected in order to 2. Remove the jumper wire from the harness
feel the vibration. The relay will vibrate when the connector.
relay is de-energized and energized.
3. Inspect the relay’s connector and the harness
Expected Result: connector for the relay. Check for damage, for
moisture, and for corrosion.
There is no audible click and/or vibration when the
air start relay is disconnected and reconnected. The 4. Make repairs, as needed.
relay is not energized when the engine control is in
the STOP mode.
263
If the problem is not resolved, replace the air start 4. Repair the harness, when possible. Replace the
relay. harness, if necessary.
STOP. STOP.
• Not OK – A “444-05 Start Relay open circuit” • No – When the jumper wire was installed, a
diagnostic code was activated when the jumper “444-05 Start Relay open circuit” diagnostic code
wire was installed. The master ECM did not detect was activated. The master ECM did not detect the
the short circuit. Proceed to Test Step 5. jumper wire. There is a problem with the master
ECM.
Test Step 5. Check the Master ECM
A. Ensure that the engine control is in the
OFF/RESET mode and that the 35 amp circuit 1. Set the engine control to the OFF/RESET
breaker is OFF. mode. Switch the 35 amp circuit breaker OFF.
B. Use a 151-6320 Wire Removal Tool to remove 2. Use a 151-6320 Wire Removal Tool to remove
terminals P2-10 and P2-20. the jumper wire from the P2 connector.
C. Install a jumper wire into terminals P2-10 and 3. Reinstall terminals P2-10 and P2-20. Pull on
P2-20. Pull on the jumper wire in order to verify the wires in order to verify proper installation
proper installation. of the terminals.
D. Switch the 35 amp circuit breaker ON. Set the It is unlikely that the master ECM has failed. Exit
engine control to the STOP mode. this procedure and perform this procedure again. If
the problem is not resolved, perform the following
E. Wait for 30 seconds and use the “Active steps:
Diagnostic” screen of Cat ET to look for an active
“444-05 Start Relay open circuit” diagnostic code. Temporarily install a new master ECM. Refer to
Expected Result:
There is no active “444-05 Start Relay open circuit” install the original ECM and verify that the problem
diagnostic code. returns. If the new ECM operates correctly and the
Results: the original ECM. Refer to Troubleshooting,
• OK – When the jumper wire was installed,
there was no active “444-05 Start Relay STOP.
open circuit” diagnostic code. The master
ECM detects the jumper wire at the P2 Test Step 6. Create an Open Circuit in
connector. However, the master ECM order to Check for a Short Circuit
did not detect the jumper wire at the relay’s
connector. There is a problem with the wiring. A. Set the engine control to the OFF/RESET mode.
The problem could be between the P2 connector
and the J7 connector. Alternatively, the problem B. Use a 151-6320 Wire Removal Tool to remove
could be in the P7 connector or the wiring that is terminals P2-10 and P2-20.
connected to the P7 connector.
Repair: Perform the following procedure: engine control to the STOP mode.
1. Set the engine control to the OFF/RESET D. To prevent the engine from starting, shut OFF the
mode. Switch the 35 amp circuit breaker OFF. main gas supply.
2. Use a 151-6320 Wire Removal Tool to remove E. Set the engine control to the START mode for at
the jumper wire from the P2 connector. least six seconds. Then set the engine control to
the STOP mode.
3. Reinstall terminals P2-10 and P2-20. Pull on
of the terminals.
264
Expected Result: B. Disconnect the harness connector from the air

start relay.
There is no audible click and/or vibration when the
relay is disconnected and reconnected. The relay is C. Switch the 35 amp circuit breaker ON. Set the
not energized when the engine control is in the STOP engine control to the STOP mode.
mode.
D. To prevent the engine from starting, shut OFF the
Results: main gas supply.
• OK – When the master ECM was connected, the Note: The “444-06 Start Relay short to ground”
relay was receiving power. When the master ECM diagnostic code can only be detected when the
was not connected, the relay was not receiving output for the start command is ON. The output is
power. There may be a problem with the master normally ON when the engine control is set from the
ECM. STOP mode to the START mode. The output remains
ON until the crank terminate relay is energized.
E. Set the engine control to the START mode for at
1. Set the engine control to the OFF/RESET least six seconds. Then set the engine control to
mode. Switch the 35 amp circuit breaker OFF. the STOP mode.
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 again. If A “444-06 Start Relay short to ground” was not
the problem is not resolved, perform the following activated.
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 problem with the air start relay.
original ECM does not operate correctly, replace Repair: Perform the following procedure:
“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. When the master 3. Inspect the connectors for the air start relay.
ECM was not connected, the relay was still Check for damage, for moisture, and for
receiving power. There is a problem with the wiring. corrosion.
The problem could be between the P2 connector 4. Make repairs, as needed.

and the J7 connector. Alternatively, the problem
could be in the P7 connector or the wiring that is If the problem is not resolved, replace the air start
connected to the P7 connector. relay.
Repair: Repair the harness, when possible. STOP.

Replace the harness, if necessary.
• Not OK – A “444-06 Start Relay short to ground”
STOP. diagnostic code was activated when the air start
relay was disconnected. The air start relay is OK.
Test Step 7. Create an Open Circuit at the Proceed to Test Step 8.
Air Start Relay
265
Test Step 8. Check the Master ECM Repair: Perform the following procedure:
A. Set the engine control to the OFF/RESET mode. 1. Set the engine control to the OFF/RESET
Switch the 35 amp circuit breaker OFF. mode. Switch the 35 amp circuit breaker OFF.
B. Use the 151-6320 Wire Removal Tool to remove 2. Reinstall terminals P2-10 and P2-20. Pull on
terminals P2-10 and P2-20. the wires in order to verify proper installation
of the terminals.
engine control to the STOP mode. It is unlikely that the master ECM has failed. Exit
this procedure and perform this procedure again. If
D. To prevent the engine from starting, shut OFF the the problem is not resolved, perform the following
main gas supply. steps:
Note: The “444-06 Start Relay short to ground” Temporarily install a new master ECM. Refer to
diagnostic code can only be detected when the Troubleshooting, “Replacing the ECM”.
output for the start command is ON. The output is
normally ON when the engine control is set from the If the problem is resolved with the new ECM,
STOP mode to the START mode. The output remains install the original ECM and verify that the problem
ON until the crank terminate relay is energized. returns. If the new ECM operates correctly and the
E. Set the engine control to the START mode for at the original ECM. Refer to Troubleshooting,
least six seconds. Then set the engine control to “Replacing the ECM”.
the STOP mode.
STOP.
F. Use Cat ET to look for a logged “444-06 Start
Relay short to ground” diagnostic code again. Test Step 9. Check the “SM” Circuit
Breaker
Expected Result:
The “444-06 Start Relay short to ground” diagnostic

code was not activated.
Results:
• OK – When the wiring was disconnected from

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.

2. Reinstall terminals P2-10 and P2-20. Pull on Illustration 93

g01055051
“SM” circuit breaker (2.5 amp)
of the terminals.
A. Verify that the “SM” circuit breaker is in the ON
3. Repair the harness, when possible. Replace
position.
the harness, if necessary.
Expected Result:
STOP.
The “SM” circuit breaker is in the ON position.
• Not OK – When the wiring was disconnected from
the master ECM, a “444-06 Start Relay short to
ground” diagnostic code was activated. There
seems to be a problem with the master ECM.
266
Results:
• OK – The “SM” circuit breaker is in the ON

position. Proceed to Test Step 10.
• Not OK – The “SM” circuit breaker is not in the

ON position.
Repair: Switch the “SM” circuit breaker to the ON

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.

output for the start command is OFF. The output is
normally OFF when the engine control is in the STOP Illustration 94
g00931289
mode or when the crank terminate relay is energized. Terminals on the junction box
2. Wait for 30 seconds and use Cat ET to check B. Verify that the power is disconnected by checking
for an active “444-05 Start Relay open circuit” for voltage at the “+” and “-” terminals on the
diagnostic code. junction box. The voltage on the terminals should
be zero VDC.
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, proceed to Test Step 10.
Test Step 10. Inspect the Inside of the

Junction Box
A. Disconnect the +24 V power supply from the
engine.
g00931303
Illustration 95
Fasteners for the junction box
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.
267
The inside of the junction box does not have moisture All of the measurements are an open circuit.
or corrosion. All of the electrical connections inside
the junction box are securely connected. Results:
Results: • OK – All of the measurements are an open circuit.

There is not a short circuit to the +Battery. Proceed
• OK – The inside of the junction box does not to Test Step 12.
have moisture or corrosion. All of the electrical
connections inside the junction box are securely • Not OK – At least one measurement is not an
connected. Proceed to Test Step 11. open circuit. There is a short circuit to the +Battery.
• Not OK – The inside of the junction box has Repair: Repair the wiring and/or the connection,
moisture or corrosion and/or there is a loose when possible. Replace parts, if necessary.
electrical connection.
STOP.
Repair: Perform the necessary repairs, when
possible. Replace parts, if necessary. Test Step 12. Check for a Short Circuit
STOP. A. Verify that the “SM” circuit breaker is in the ON
position.
Test Step 11. Check for an Open Circuit
B. Use a multimeter to check for a short circuit
A. Use a 151-6320 Wire Removal Tool to remove between the points that are listed in Table 20:
terminals P2-10 and P2-20.
Note: Refer to Illustration 87, if necessary.
Table 20
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
the “SM” circuit breaker the “SM” circuit breaker
The connection for the The coil terminal of each
“SM” circuit breaker that magnetic switch that
g01055064
Illustration 96 is connected to wire is connected to wire
Section view of the junction box “P6B0B-RD” “C990-RD”
(1) Coil terminals on the magnetic switches The coil terminal of each P2-20
(2) Terminals on the “SM” circuit breaker magnetic switch that
is connected to wire
B. Use a multimeter to check for an open circuit “C991-BK”
between the points that are listed in Table 19:
Table 19
Expected Result:
Points to Check for an Open Circuit All of the measurements are less than two Ohms.
Point Point
Results:
P2-20 “+” terminal on the junction
box • OK – All of the measurements are less than two
P2-10 “+” terminal on the junction Ohms. There is not an open circuit. Proceed to
box Test Step 13.
Each coil terminal (1) on “+” terminal on the junction
each magnetic switch box
• Not OK – At least one measurement is more than
two Ohms. There is a problem with the wiring or
Each terminal (2) on the “+” terminal on the junction with the “SM” circuit breaker.
“SM” circuit breaker box
268
Repair: Repair the wiring and/or the connection, D. Set the engine control to the OFF/RESET mode.
when possible. Replace parts, if necessary. Switch the 35 amp circuit breaker OFF.
STOP. E. Reinstall terminals P2-10 and P2-20. Pull on the

wires in order to verify proper installation of the
Test Step 13. Check the Coils for the terminals.
Magnetic Switches
F. Switch the 35 amp circuit breaker ON.
A. Use a multimeter to measure the resistance of the
coil for each magnetic switch. Note: The “444-06 Start Relay short to ground”
Expected Result: output for the start command is ON. The output is
normally ON when the engine control is set from the
The resistance of each coil is between 16 and 20 STOP mode to the START mode. The output remains
Ohms. ON until the crank terminate relay is energized.
Results: G. Set the engine control to the START mode.

Look for a “444-06 Start Relay short to ground”
• OK – The resistance of each coil is between 16 diagnostic code.
Ohms and 20 Ohms. The coil resistance for each
magnetic switch is correct. A “444-06 Start Relay short to ground” diagnostic
code should not be activated.
Repair:
Expected Result:
1. Install the seven bolts and nuts for the junction
box. No diagnostic codes were activated.
2. Reconnect the +24 V power supply to the Results:

engine.
• OK – No diagnostic codes were activated. The
Proceed to Test Step 14. initial diagnostic code was probably caused by a
poor electrical connection.
• Not OK – The resistance of a coil is not between
16 Ohms and 20 Ohms. The resistance of a coil for Repair: If there is an intermittent problem
a magnetic switch is incorrect. that is causing the codes to be logged, refer
Repair: Replace the magnetic switch. Verify that Connectors”.
the original problem is resolved.
STOP.
STOP.
• Not OK – A diagnostic code was activated. There
Test Step 14. Check the Operation of the may be a problem with the master ECM.
Master ECM
A. Verify that terminals P2-10 and P2-20 are removed failed. Exit this procedure and perform this
from the P2 connector. procedure again. If the problem is not resolved,
B. Verify that the 35 amp circuit breaker is ON. Verify
that the “SM” circuit breaker is ON. Temporarily install a new master ECM. Refer to
diagnostic code can only be detected when the If the problem is resolved with the new ECM,
output for the start command is OFF. The output is install the original ECM and verify that the problem
normally OFF when the engine control is in the STOP returns. If the new ECM operates correctly and the
mode or when the crank terminate relay is energized. original ECM does not operate correctly, replace
C. Set the engine control to the STOP mode. “Replacing the ECM”.
A “444-05 Start Relay open circuit” diagnostic STOP.

code should not be activated.
269
i02089153 “Fault Relay” – This is the shutdown output.

This output indicates that a potentially damaging
ECM Status Indicator Output operating condition was detected by the master
ECM. The master ECM has shut down the engine.
SMCS Code: 7400-038-IND While this output is energized, a short circuit to a
positive voltage source or excessive current through
System Operation Description: the circuit will cause a diagnostic code to become
activated. The master ECM cannot diagnose this
The master Electronic Control Module (ECM) has output while the output is OFF.
four outputs in order to indicate the status of engine
operation: “Run Relay”, “Crank Terminate Relay”, A “323-03 Shutdown Lamp short to +batt” or “324-03
“Engine Control Alarm Status”, and “Fault Relay”. Warning Lamp short to +batt” diagnostic code can
These outputs can be used to energize indicator only be generated if a shutdown condition or an alarm
lamps or the outputs can be used to interface with condition is active. Failure to correct these serious
other controls. conditions can result in engine damage.
The ECM opens an internal circuit in order to set an Use the Caterpillar Electronic Technician (ET)
output to OFF. The ECM closes the circuit in order to to determine the event code or the diagnostic
set the output to ON. When the circuit is closed and code that corresponds to the 323-03 or 324-03
the output is ON, the ECM allows a maximum current diagnostic code. Troubleshoot that event code or
of 0.3 amperes to flow through the circuit to a ground that diagnostic code before you troubleshoot
that is inside the ECM. the 323-03 or 324-03 diagnostic code. Refer to
Troubleshooting, “Troubleshooting with an Event
If excessive current flows through the circuit, a Code” or Troubleshooting, “Troubleshooting with a
diagnostic code is generated. A short circuit to the Diagnostic Code”.
+battery side will also activate a diagnostic code.
The most likely causes of a diagnostic code for a
Note: These circuits do not sink enough current for status indicator is a poor electrical connection or a
illumination of standard incandescent lights. If a lamp problem in a wiring harness. The next likely cause is
is burned out, replace the lamp with the lamp that is a problem with an indicator. The least likely cause is
specified in the engine’s Parts Manual. a problem with the master ECM.
“Run Relay” – This output indicates that the engine Logged diagnostic codes provide a historical record.
is in the “Run” status. The engine will start soon or the Before you begin this procedure, use ET to print the
engine is running. While this output is energized, a logged codes to a file.
short circuit to a positive voltage source or excessive
current through the circuit will cause a diagnostic The troubleshooting procedure may generate
code to become activated. The master ECM cannot additional diagnostic codes. Keep your mind on
diagnose this output while the output is OFF. correcting the cause of the original diagnostic code.
“Crank Terminate Relay” – This output indicates resolved.
that 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
current through the circuit will cause 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
current through the circuit will cause a diagnostic
code to become activated. The master ECM cannot
diagnose this output while the output is OFF.
270
g01065354
Illustration 97
Schematic for the status indicators

g01065355
Illustration 99
Terminal box
g01054206
Illustration 98 (2) J2/P2 connectors for the master ECM
Junction box (3) J6/P6 connectors for the customer

connectors:
position. • J2/P2 connectors
Note: Some indicators may obtain the status of the • J6/P6 connectors
engine via a data link. If all of the status indicators
are not directly controlled by the master ECM, do
not proceed with this test.
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
271
e. Check the harness and wiring for abrasion and

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

Results:

g01055309
Illustration 100
Harness side of the 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 21:
Table 21
Diagnostic Codes and Descriptions with
Corresponding ECM Outputs
Illustration 101
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 the Relay”
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.
272
Results: Exit this procedure. After you have resolved the

condition, return to this procedure in order to
• Yes (Original 443-03 or 445-03 Diagnostic Code) – troubleshoot the 323-03 and/or 324-03 diagnostic
The original diagnostic code was “443-03 Crank code, if necessary.
Terminate Relay short to +batt” or “445-03 Run
Relay short to +batt”. When the engine was started, STOP.
the “Run Relay” indicator and the “Crank Terminate
Relay” indicator (if equipped) illuminated normally. • Not OK (Active 443-03 or 445-03 Diagnostic
The “Engine Control Alarm Status” indicator and Code) – When the engine was started, the “Run
the “Fault Relay” indicator did not illuminate. There Relay” indicator and/or the “Crank Terminate
are no active diagnostic codes. Relay” indicator (if equipped) did not illuminate
normally. The “Engine Control Alarm Status”
Repair: The outputs for the status indicators seem indicator and the “Fault Relay” indicator did not
to be operating correctly at this time. The original illuminate. A 443-03 or 445-03 diagnostic code
diagnostic code was probably caused by a poor was activated. There is a problem with the output
electrical connection. for the “Run Relay” indicator and/or the “Crank
Terminate Relay” indicator (if equipped). Proceed
If there is an intermittent problem that is causing to Test Step 4.
the codes to be logged, refer to Troubleshooting,
“Inspecting Electrical Connectors”. Test Step 3. Check for Proper Operation
of the Status Indicators for the Alarm and
STOP. Shutdown
• Yes (Original 323-03 or 324-03 Diagnostic Note: All active diagnostic codes and active event
Code) – The original diagnostic code was “323-03 codes must be cleared in order for the “Engine
Shutdown Lamp short to +batt” or “324-03 Warning Control Alarm Status” indicator to be OFF.
Lamp short to +batt”. When the engine was started,
the “Run Relay” indicator and the “Crank Terminate Allow the engine operation to continue for this
Relay” indicator (if equipped) illuminated normally. procedure. Operate the engine under low load.
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 condition before a 324-03
diagnostic code can be generated. Both of these
conditions are serious. g01065357
Illustration 102
Repair: Use Cat ET to determine the event code or Right side view
the diagnostic code that corresponds to the 323-03 (1) Unfiltered engine oil pressure sensor
or 324-03 diagnostic code. Troubleshoot that (2) Filtered engine oil pressure sensor
event code or that diagnostic code before you
troubleshoot the 323-03 or 324-03 diagnostic A. During engine operation, disconnect the connector
code. Refer to Troubleshooting, “Troubleshooting for the unfiltered engine oil pressure sensor
with an Event Code” or Troubleshooting, (1). Observe the “Engine Control Alarm Status”
“Troubleshooting with a Diagnostic Code”. indicator on the control panel (if equipped).
273
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 103

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
caused by a poor electrical connection.
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 P2 connector.
STOP.
C. Connect the positive lead of a voltmeter to the end
• Not OK – The “Engine Control Alarm Status” of the 7X-1710 Multimeter Probe. Connect the
indicator and/or the “Fault Relay” indicator did voltmeter’s negative lead to ground strap (1).
not illuminate normally when the sensors were
disconnected. A “323-03 Shutdown Lamp short to D. Switch the 35 amp circuit breaker ON. Set the
+batt” and/or a “324-03 Warning Lamp short to engine control to the STOP mode.
+batt” diagnostic code was generated. There is a
problem with the output for the status indicators. E. Note the voltage that is displayed on the voltmeter.
The “542-03” and the “100-03” diagnostic codes
were generated. The engine was shut down. F. Set the engine control to the OFF/RESET mode.
Proceed to Test Step 4. Switch the 35 amp circuit breaker OFF.
G. If the customer has equipment for the status

indicators, disconnect one wire from the suspect
indicator. Be sure to disconnect the wire that
comes from the master ECM.
274
H. Insulate the end of the wire with electrical tape C. Use a 151-6320 Wire Removal Tool to remove
in order to ensure that the wire does not create the suspect terminal from the ECM P2 connector.
a short circuit.
D. Insulate the terminal with electrical tape in order
I. Switch the 35 amp circuit breaker ON. Set the to ensure that the terminal does not create a short
engine control to the STOP mode. circuit.
J. Note the voltage that is displayed on the voltmeter. E. Fabricate a jumper wire with Deutsch terminals on
the ends. Insert one end of the jumper wire into
Expected Result: the open terminal of the P2 connector.
Before the suspect indicator was disconnected, F. Connect a voltmeter lead to the end of the jumper
voltage was displayed on the voltmeter. After the wire that is not inserted into the connector.
suspect indicator was disconnected, the voltmeter
displayed approximately zero volts. G. Connect the other lead of the voltmeter to the
ground strap for the master ECM.
Results:
H. Switch the 35 amp circuit breaker ON. Set the
• Yes – Before the suspect indicator was engine control to the STOP mode. Observe the
disconnected, voltage was displayed on voltage reading on the voltmeter.
the voltmeter. After the suspect indicator
was disconnected, the voltmeter displayed Expected Result:
approximately zero volts. There is a problem in the
customer’s equipment. The voltmeter displays approximately zero volts.
Repair: The problem could be caused by a poor Results:

electrical connection, a wire, or a component in the
customer’s equipment. • The voltage is approximately zero – After the
suspect terminal was removed from connector P2,
Set the engine control to the OFF/RESET mode. the reading on the voltmeter was approximately
Switch the 35 amp circuit breaker OFF. zero. There is a problem with a connection and/or
the wiring between the customer’s equipment and
Thoroughly inspect all wiring and all connectors the ECM.
in the customer’s equipment. Refer to
Troubleshooting, “Inspecting Electrical Repair: Perform the following procedure:
Connectors”.
1. Switch the 35 amp circuit breaker OFF. Set the
If you suspect that the indicator has an internal engine control to the OFF/RESET mode.
short circuit, temporarily install a known good
indicator for the suspect indicator. Test the 2. Disconnect the voltmeter leads.
indicator. Verify that the problem is resolved.
Make the necessary repairs, when possible. the jumper wire from the ECM P2 connector.
Replace parts, if necessary.
4. Insert the terminal for the output wire into the P2
STOP. connector. Pull on the wire in order to verify that
the terminal is fully inserted into the connector.
• No – Before the suspect indicator was
disconnected, voltage was displayed on the Repair the connection and/or the wiring, when
voltmeter. After the suspect indicator was possible. Replace parts, if necessary.
disconnected, the voltage was still displayed on
the voltmeter. Proceed to Test Step 5. STOP.
Test Step 5. Check the Master ECM • The voltage remained – After the suspect terminal
was removed from the P2 connector, voltage was
A. Set the engine control to the OFF/RESET mode. still displayed on the voltmeter. There may be a
Switch the 35 amp circuit breaker OFF. problem with the master ECM.
B. Disconnect the voltmeter leads and remove the

7X-1710 Multimeter Probe from the P2 connector.
275
Repair: It is unlikely that the master ECM has For the slave ECM, the input at terminal 70 of the
failed. Exit this procedure and perform this P3 connector (“Switched +Battery”) receives battery
procedure again. If the problem is not resolved, voltage from the engine control when the control is in
perform the following steps: the START mode, in the STOP mode, or in the AUTO
mode. When the slave ECM detects battery voltage
Temporarily install a new master ECM. Refer to at this input, the slave ECM will power up.
The “168-02” diagnostic code indicates that the
If the problem is resolved with the new ECM, voltage of the power supply is intermittent or low
install the original ECM and verify that the problem while the engine is running. If the supply voltage
returns. If the new ECM operates correctly and the drops to zero and stays at zero, neither ECM will log
original ECM does not operate correctly, replace this code. The engine will shut down.
“Replacing the ECM”. The “336-02” diagnostic code indicates that the
master ECM has detected a problem with the circuit
STOP. for the engine control.

i02089172
Electrical Power Supply Electronic Technician (ET) to print the logged codes
to a file.
SMCS Code: 1408-038
This procedure may generate additional diagnostic
System Operation Description: codes. Keep your mind on correcting the cause of the
original diagnostic code. Clear the diagnostic codes
Electrical power is supplied to the following after the problem is resolved.
components:
• Master Electronic Control Module (ECM)

• Slave ECM
• Integrated Temperature Sensing Module (ITSM)
• Fuel metering valve
• 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.
The master ECM input at terminal 70 of the P1

connector (“Switched +Battery”) receives battery
voltage from the engine control when the control is in
the START mode, in the STOP mode, or in the AUTO
mode. When the master ECM detects battery voltage
at this input, the master ECM will power up. When
battery voltage is removed from this input, the master
ECM will power down after the engine has shut down.
276
g01065369
Illustration 104
277
Schematic for the electrical power

g01065370
Illustration 106
Terminal box
g01055400
Illustration 105 (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 • J1/P1 connectors
position.
Troubleshooting, “Inspecting Electrical Connectors”. • J5, J6/P6 and J7/P7 connectors
• Connectors for the 24 VDC power supply
• Connectors for the engine control
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
278
g01055407
Illustration 107
Harness side of connectors P1 and P3
(P1-31) Digital return
(P1-52) Unswitched +Battery
(P1-61) Stop (Master ECM)
(P1-62) Start (Master ECM)
(P1-63) -Battery
(P1-64) Auto (Master ECM)
(P1-65) -Battery
(P1-67) -Battery
(P1-69) -Battery
(P1-70) Switched +Battery
g00931545
Illustration 109
(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.

for pinch points from the power supply to the
master ECM and from the engine control to the
master ECM.
Expected Result:

Illustration 108
g00952120 properly. The connectors and the wiring do not have
(J6-1) +Battery for the customer (10 amperes)
(J6-4) Power for the engine control
Results:
(J6-19) Stop command • OK – The components are in good condition with
(J6-29) Start command proper connections. Proceed to Test Step 2.
(J6-36) Digital return
(J6-39) Auto command
improper.
279
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 VDC. • Not OK – An ECM is not receiving the correct
Troubleshoot the power supply if the voltage is less voltage.
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 be
of the connections. Record the measurement. generated during this step. After you have completed
this step, clear the events from the “Logged Events”
screen of Cat ET.
280
D. Observe the “Active Diagnostic” screen on Cat Note: During these measurements, wiggle the
ET and set the engine control to the STOP mode, harness in order to check for an intermittent problem.
the START mode, and the AUTO mode. Look for Be sure to wiggle the harness near each of the
an active “336-02 Incorrect ECS Switch inputs” connections.
diagnostic code. Repeat this step several times.
E. Set the engine control to the STOP mode and
Expected Result: measure the voltage between terminals P1-31
and P1-61. The correct voltage measurement is
A “336-02 Incorrect ECS Switch inputs” diagnostic less than one volt.
code was not activated when the engine control was
set to the STOP mode, the START mode, and the F. Remove the probe from terminal 61 and insert the
AUTO mode. probe into terminal 62.
Results: G. Set the engine control to the START mode and

measure the voltage between terminals P1-31
• OK – A “336-02 Incorrect ECS Switch inputs” and P1-62. The correct voltage measurement is
diagnostic code was not activated. The inputs from less than one volt.
the engine control are correct. The problem seems
to be resolved. H. Remove the probe from terminal 62 and insert the
probe into terminal 64.
Repair: The problem may be intermittent.
Refer to Troubleshooting, “Inspecting Electrical I. Set the engine control to the AUTO mode and
Connectors”. measure the voltage between terminals P1-31
and P1-64. The correct voltage measurement is
STOP. less than one volt.
• Not OK – A “336-02 Incorrect ECS Switch inputs” J. Remove the probe from terminal 31 and insert the
diagnostic code was activated. The master ECM probe into terminal 69. Remove the probe from
has detected an invalid pattern of inputs from the terminal 64 and insert the probe into terminal 70.
engine control switch. Proceed to Test Step 4.
K. Set the engine control to the STOP mode and
Test Step 4. Check the Circuit of the measure the voltage between terminals P1-69
Engine Control Switch and P1-70 connector. The correct voltage
measurement is at least 20 VDC.
this procedure. For an engine with an electric L. Set the engine control to the START 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. M. Set the engine control to the AUTO mode and
measure the voltage between terminals P1-69
B. Set the engine control to the OFF/RESET mode. and P1-70. The correct voltage measurement is at
Switch the 35 amp circuit breaker OFF. least 20 VDC.
C. Insert two 7X-1710 Multimeter Probes into the Expected Result:

harness side of the P1 connector. Insert the first
probe into terminal 31. Insert the second probe The voltage checks are within the specifications.
into terminal 61. Connect a multimeter to the
probes. Results:
D. Switch the 35 amp circuit breaker ON. • OK – The voltage checks are within the
specifications. Remove the probes from the P1
Note: An “E225 Engine Overcrank” and/or an “E233 connector. Start the engine and run the engine. If
Low Engine Prelube Pressure” event code may be the original problem is not resolved, the master
generated during the test. After you have completed ECM may have a problem.
the test, clear the events from the “Logged Events”
screen of Cat ET. Repair: It is unlikely that the master ECM has
failed. Perform the following procedure:
281


the ECM. Refer to Troubleshooting, “Replacing
the ECM”.
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.
282
i02089204
Engine Speed/Timing Sensor

SMCS Code: 1912-038
g00893441
Illustration 110
Speed/Timing sensor and timing ring
The speed/timing sensor provides information about The number one cylinder is at the top center position
engine speed and the position of the crankshaft to when the rising edge of the third narrow slot passes
the master Electronic Control Module (ECM) and the the center of the sliphead. All 24 teeth pass the
slave ECM. The sensor is powered by the sensor sliphead during one revolution of the camshaft or two
supply (12 VDC) from the master ECM. A magnetic revolutions of the crankshaft.
pickup is located underneath 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 of
The timing ring has a special tooth pattern that the cylinders, the appropriate ECM retards the timing
indicates the position of the camshaft and the of the affected cylinders. Each ECM sends voltage
direction of rotation. The timing ring has 24 slots pulses to the ignition transformers for firing the spark
in the outer diameter. Twenty one of the slots are 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 with
sensor in the following order: the signal from the speed/timing sensor. The ECM
that detected the problem with the signal will activate
• 1 wide slot 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.
283

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

to a file.

resolved.
g01065386
Illustration 111
Schematic for the circuit of the speed/timing sensor
284
Test Step 1. Inspect the Electrical B. Thoroughly inspect the following connections:
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 112
Junction box

g01055533
position. Illustration 114
Harness side of the master ECM P1 connector
Note: For the following steps, refer to (P1-33) Signal
Troubleshooting, “Inspecting Electrical Connectors”. (P1-43) 12 volt supply
(P1-51) Return
g01065390
Illustration 115
Harness side of the slave ECM P3 connector
(P3-33) Signal
g01065389
Illustration 113
Terminal box
(3) J7/P7 connectors for the harness from the speed/timing sensor
285

for pinch points from the speed/timing sensor
to each ECM.
Expected Result:

Results:


improper.

STOP.
Test Step 2. Check the Sensor

g00931722
Illustration 116
Harness side of the P7 connector B. Remove the speed/timing sensor.
(P7-9) Signal
(P7-23) Return
(P7-37) Shield

speed/timing sensor.
g00931748
Illustration 118
Plastic sliphead for the speed/timing sensor
C. Inspect the condition of the plastic sliphead. Look

for signs of wear and for contaminants. Clean any
debris from the plastic sliphead.
D. Check the tension of the plastic sliphead. Gently

extend the plastic sliphead for a minimum of 4 mm
(0.16 inch). Then push back the plastic sliphead.
Expected Result:
The sensor is in good condition. At least 22 N (5 lb)

of force is required to push in the plastic sliphead
from the extended position.
Results:
• OK – The sensor is not damaged. The tension of

g01065391 the plastic sliphead is correct.
Illustration 117
Left side view Repair: Install the sensor.
(5) Speed/timing sensor
286
C. Use the “Active Diagnostic” screen on Cat ET.

NOTICE Look for the following codes:
The plastic sliphead must be fully extended when the
speed/timing sensor is installed so that the sensor • 145-03 12 Volt DC Power Supply short to +batt
maintains the correct clearance with the timing ring.
If the correct clearance is not maintained, the signal • 145-04 12 Volt DC Power Supply short to
from the sensor will not be generated. ground
Do not install the sensor’s plastic sliphead between Expected Result:

the teeth of the timing ring. Damage to the plasic slip-
head will result. Before installing the sensor, ensure None of the above codes are active.
that a tooth of the ring is visible in the mounting hole
for the sensor. Results:
1. Use the following steps to install the

• No active codes – None of the above codes are
active. However, at least one of the codes is
speed/timing sensor: logged.
a. Ensure that a tooth on the timing ring is Repair: Clear the logged codes.
visible in the mounting hole for the sensor.
b. Fully extend the sliphead.
Note: The plastic sliphead is designed to contact

• Active code – One of the above codes is active.
the tooth of the timing ring during installation. As
the timing ring begins to turn, the radial runout of Test Step 4. Use Cat ET to Check the
the timing ring will push the plastic sliphead into Engine RPM
the sensor body slightly. This provides the plastic
sliphead’s air gap with a self-adjusting function. The A. Use the “Status - Group 1” screen in order to
maximum allowable clearance between the sliphead observe “Engine Speed”. Observe the “Engine
and a tooth on the timing ring is 0.5 mm (0.02 inch). Speed” parameter on the screen and set the
engine control to the START mode. Crank the
c. Coat the threads of the sensor with 4C-5597 engine.
Anti-Seize Compound.
B. Continue to observe the screen and allow the
d. Install the sensor. Tighten the sensor to engine rpm to stabilize at the normal cranking
40 ± 5 N·m (30 ± 4 lb ft). speed.
Proceed to Test Step 3. C. Set the engine control to the STOP mode.
• Not OK – The plastic sliphead is damaged and/or Expected Result:
the tension of the sliphead is insufficient.
Before the engine is cranked, the engine speed is
Repair: Install a new sensor. Calibrate the sensor. “0”. The engine speed increases until the speed
Refer to Troubleshooting, “Engine Speed/Timing stabilizes at the normal cranking speed. When the
Sensor - Calibrate”. engine is stopped, the speed decreases back to “0”.
A 320-03 diagnostic code or a 320-08 diagnostic
If the condition is not resolved, proceed to Test code are not activated.
Step 3.
Results:
Test Step 3. Check for Active Diagnostic
Codes for the 12 Volt Sensor Supply • OK – The engine started and the engine
ran properly. A 320-03 diagnostic code or a
A. Connect Cat ET to the service tool connector. 320-08 diagnostic code was not activated. The
Refer to Troubleshooting, “Electronic Service speed/timing sensor is operating properly. STOP.
Tools”.

• Not OK – The engine cranked. However, Cat
ET did not display the correct engine speed or a
engine control to the STOP mode. 320-03 or a 320-08 diagnostic code was activated.
287
• Not OK – The engine cranked but the engine did Expected Result:
not start. Cat ET displayed the correct engine
speed. A 320-03 diagnostic code or a 320-08 When the engine control is in the STOP mode, the
diagnostic code was not activated. Each ECM is voltage is less than 3.0 VDC or the voltage is greater
receiving a valid signal. than 10.0 VDC.
Repair: Refer to Troubleshooting, “Engine Cranks The voltage varied between 2.0 VDC and 4.0 VDC
But Will Not Start”. Make repairs, as needed. during cranking.
STOP. Results:
Test Step 5. Measure the Sensor Supply • OK – The sensor is producing the correct output
Voltage at the Sensor signal.
A. Set the engine control to the OFF mode. Repair: Remove the breakout t from the
connectors for the speed/timing sensor. Reconnect
B. Install a 8T-8726 Adapter Cable As (Three-Pin the connectors for the speed/timing sensor.
Breakout) in series with the connectors for the
speed/timing sensor. If you are troubleshooting the speed/timing
sensor’s signal for the master ECM, proceed
C. Set the engine control to the STOP mode. to Test Step 8. If you are troubleshooting the
Measure the supply voltage between terminals “A” speed/timing sensor’s signal for the slave ECM,
and “B” of the breakout t. proceed to Test Step 9.
Expected Result: • Not OK – The sensor is not producing the correct

output signal.
The voltage is between 11.5 VDC and 13.5 VDC. A
145-03 diagnostic code or a 145-04 diagnostic code Repair: Set the engine control to the OFF/RESET
is not active. mode. Switch the 35 amp circuit breaker OFF.
Results: Remove the breakout t from the connectors for the

speed/timing sensor.
• OK – The sensor is receiving correct supply
voltage. A 145-03 diagnostic code or a 145-04 Install a new speed/timing sensor. Calibrate
diagnostic code is not active. Leave the breakout t the sensor. Refer to Troubleshooting, “Engine
connected. Proceed to Test Step 6. Speed/Timing Sensor - Calibrate”.
• Not OK – The sensor is not receiving correct STOP.

supply voltage or a 145-03 diagnostic code or a
145-04 diagnostic code is active. Remove the Test Step 7. Measure the Sensor Supply
breakout t. Proceed to Test Step 7. Voltage at the Master ECM
Test Step 6. Isolate the Signal Voltage at A. Set the engine control to the OFF/RESET mode.
the Sensor
B. Use two 7X-1710 Multimeter Probes. Insert the
A. Set the engine control to the OFF/RESET mode. probes into terminals P1-33 and P1-51.
B. Ensure that the breakout t is connected in series C. Set the engine control to the STOP mode.
with the connectors for the speed/timing sensor. Measure the supply voltage at the master ECM.
C. Remove the wire from terminal “C” of the breakout Expected Result:
t in order to isolate the sensor signal wire.
The voltage is between 11.5 VDC and 13.5 VDC. A
D. Set the engine control to the STOP mode. 145-03 diagnostic code or a 145-04 diagnostic code
Measure the signal voltage between terminals “B” is not active.
and “C”.
E. Set the engine control to the START mode.

Crank the engine and measure the signal voltage
between terminals “B” and “C”.
288
Results: Expected Result:
• Yes – The sensor supply voltage at the ECM When the engine control is in the STOP mode, the
is between 11.5 VDC and 13.5 VDC. A 145-03 voltage is less than 3.0 VDC or the voltage is greater
diagnostic code or a 145-04 diagnostic code is not than 10.0 VDC.
active. The wiring and/or the connectors between
the sensor and the master ECM has an open circuit The voltage varied between 2.0 VDC and 4.0 VDC
or the circuit has excessive resistance. during cranking.
Repair: Set the engine control to the OFF/RESET Results:

Make the necessary repairs to the harness and/or • OK – Both of the measurements are correct.
connectors. However, the master ECM is not reading the signal.
There may be a problem with the master ECM.
STOP.
• No – The master ECM is not producing the correct failed. Exit this procedure and perform this
sensor supply voltage or a 145-03 or a 145-04 procedure again. If the condition is not resolved,
diagnostic code is active. There may be a problem perform the following steps:
Repair: It is unlikely that the master ECM has Troubleshooting, “Replacing the ECM”.
failed. Exit this procedure and perform this
procedure again. If the condition is not resolved, If the problem is resolved with the new ECM,
perform the following steps: install the original ECM and verify that the problem
Temporarily install a new master ECM. Refer to original ECM does not operate correctly, replace
Troubleshooting, “Replacing the ECM”. the ECM. Refer to Troubleshooting, “Replacing
the ECM”.
install the original ECM and verify that the problem STOP.
original ECM does not operate correctly, replace • Not OK – The signal voltage is not correct. There
the ECM. Refer to Troubleshooting, “Replacing is an intermittent problem in the circuit for the
the ECM”. speed/timing sensor.
STOP. Repair: Refer to Troubleshooting, “Inspecting

Electrical Connectors”. Make repairs, as needed.
Test Step 8. Isolate the Sensor Signal at
the Master ECM and Measure the Sensor STOP.
Signal Voltage at the Master ECM
Test Step 9. Isolate the Sensor Signal at
A. Set the engine control to the OFF/RESET mode. the Slave ECM and Measure the Sensor
Signal Voltage at the Slave ECM
terminals P1-33 and P1-51. A. Set the engine control to the OFF/RESET mode.
C. Connect the leads of a multimeter to the terminals B. Use a 151-6320 Wire Removal Tool to remove
that were removed from the P1 connector. terminal 33 from the P3 connector on the slave
ECM. Remove terminal 51 from the P1 connector
D. Set the engine control to the STOP mode. from the master ECM.
Measure the signal voltage between the terminals.
Record the measurement. C. Connect one lead of a multimeter to the terminal
that was removed from the P3 connector. Connect
E. Set the engine control to the START mode. the other lead of the multimeter to the terminal
Crank the engine and measure the signal that was removed from the P1 connector.
voltage between the terminals again. Record the
measurement. D. Set the engine control to the STOP mode.
Measure the signal voltage between the terminals.
Record the measurement.
289
E. Set the engine control to the START mode. The master ECM sends a command signal for the flow
Crank the engine and measure the signal of fuel and information about the specific gravity of
voltage between the terminals again. Record the the gas to the fuel metering valve. The valve converts
measurement. the command signal and the information into a valve
position that directly corresponds to the desired gas
Expected Result: flow. The position of the valve is compensated by
these additional factors that are internal to the valve:
When the engine control is in the STOP mode, the absolute fuel pressure, differential pressure of the
voltage is less than 3.0 VDC or the voltage is greater valve, and fuel temperature.
than 10.0 VDC.
The following procedure tests whether the command
The voltage varied between 2.0 VDC and 4.0 VDC signal for the flow of fuel and the information about
during cranking. the specific gravity of the gas is properly sent
to the fuel metering valve by the master ECM.
Results: The command signal is a 180 hertz PWM signal.
Information about the specific gravity of the gas is
• OK – Both of the measurements are correct. sent to the fuel metering valve via the CAN Data Link.
However, the slave ECM is not reading the signal.
There may be a problem with the slave ECM. The fuel metering valve sends information to the
master ECM via the CAN Data Link. This procedure
Repair: It is unlikely that the slave ECM has failed. also tests whether the following information is
Exit this procedure and perform this procedure properly sent to the master ECM by the fuel metering
again. If the condition is not resolved, perform the valve: position of the fuel valve, absolute fuel
following steps: pressure, differential pressure of the valve, and fuel
temperature.
Temporarily install a new slave ECM. Refer to
Troubleshooting, “Replacing the ECM”. During normal operation, the valve receives two
command signals from the ECM. One of the signals
If the problem is resolved with the new ECM, is a digital signal that is received via the CAN data
install the original ECM and verify that the problem link. The other signal is a pulse width modulated
returns. If the new ECM operates correctly and the signal (PWM) that is received via a pair of wires. The
original ECM does not operate correctly, replace valve will use the digital signal when both signals are
the ECM. Refer to Troubleshooting, “Replacing available.
the ECM”.
If the PWM signal is not available, the valve
STOP. will continue to use the digital signal. The ECM
will activate a 1446-05 diagnostic code. Engine
• Not OK – The signal voltage is not correct. There performance will be affected.
is an intermittent problem in the circuit for the
speed/timing sensor. If the digital signal is not available, the valve will use
the PWM signal. The ECM will activate a 1446-09
Repair: Refer to Troubleshooting, “Inspecting diagnostic code. Engine performance will be affected.
Electrical Connectors”. Make repairs, as needed.
Status Indicator for the Fuel Metering Valve
STOP.
i02089347
Fuel Metering Valve

SMCS Code: 1741-038
The fuel metering valve is an electronic gas valve

that controls the flow of fuel to the engine. The valve
works with the master Electronic Control Module
(ECM) in order to ensure the correct flow of fuel in all
conditions of engine operation.
290
g00996218
Illustration 119
Status indicator for the fuel metering valve
The fuel metering valve contains a status indicator.

The indicator flashes in order to indicate the status
of the valve. The color of the indicator indicates the
severity of the problem. During operation, the status
indicator will flash one of the following colors:
Green – Normal operation
Orange – The valve has detected a problem and the

valve continues to operate.
Red – The valve has detected a serious problem.

The valve has shut down.
The flash code indicates the particular error that

has been detected by the valve. Before performing
maintenance on the valve, observe the status
indicator. Refer to Installation and Operation Manual,
SEBU7630 for additional information.
291
g01065452
Illustration 120
Schematic for the circuit of the fuel metering valve
292

g01065454
Illustration 122
Terminal box
g01054206
Illustration 121 (2) Ground strap
(1) 35 amp circuit breaker (5) J7/P7 connectors for the harness from the fuel metering valve
(6) J9/P9 connectors for the harness for the CAN data link
A. Set the engine control to the OFF/RESET mode. (7) J10/P10 connectors for the terminating resistor for the CAN
data link
position.
Note: For the following steps, refer to connectors:
• J6/P6, J7/P7, and J9/P9 connectors
• Connectors on the fuel metering valve
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
293
g01012877 g00952267
Harness side of the P1 connector Harness side of the P24 connector for the fuel metering valve
(P1-34) CAN Data Link − (P24-C) CAN Data Link +
(P1-42) CAN shield (P24-D) CAN Data Link + to the throttle actuator
(P1-50) CAN Data Link + (P24-E) CAN Data Link − to the throttle actuator
(P1-58) Signal for the fuel flow (P24-F) CAN Data Link −
(P1-60) Return for the signal for the fuel flow (P24-K) Unswitched +Battery
(P24-L) −Battery
(P24-M) Switched +Battery
(P24-S) Signal for the fuel flow
(P24-T) Return for the signal for the fuel flow

wires that are associated with the fuel metering
valve.
g00931879
Illustration 124
(J7-11) Signal for the fuel flow
(J7-25) Return for the signal for the fuel flow
(J7-39) Shield
294

replace parts, if necessary. Ensure that all of
STOP.

to the service tool connector on the terminal box.

C. Use Cat ET to determine if any of the following

diagnostic codes are active:
• 1446-05 “Fuel Metering Module open circuit”

• 1446-09 “Unable to communicate with Fuel
Metering Module”
• 1446-12 “Fuel Metering Module malfunction”

• 1446-13 “Fuel Metering Module calibration
required”
• 1447-12 “Fuel Metering Sensor Module

malfunction”
Expected Result:
Illustration 126
g01065457 There are no active diagnostic codes.
Top view of the engine. The 60 Hz configuration is shown. The
50 Hz configuration is similar.
Results:
(8) Fuel metering valve
(9) P24/J24 connectors for the fuel metering valve • OK – There are no active diagnostic codes. The
signal and the communication between the master
d. Check the wiring for abrasion and for pinch ECM and the fuel metering valve appear to be OK
points from the fuel metering valve to the at this time. However, diagnostic codes may be
master ECM. logged.
Expected Result: Repair: If you are troubleshooting an intermittent

problem, refer to Troubleshooting, “Inspecting
All of the connectors, pins, and sockets are connected Electrical Connectors”.
corrosion, abrasion, or pinch points. STOP.
Results: • Not OK (Active 1446-05) – The master ECM has

detected an open circuit or a short circuit for the
circuit of the fuel flow signal between the ECM and
• OK – The components are in good condition with the fuel metering valve. Proceed to Test Step 3.
• Not OK – The components are not in good • Not OK (Active 1446-09) – The master ECM has
condition and/or at least one connection is detected an open circuit or a short circuit for the
improper. circuit of the CAN Data Link between the master
ECM and the fuel metering valve. Proceed to Test
Step 4.
295
• Not OK (Active 1446-12) – The fuel metering valve Repair: Replace the fuel metering valve. Verify
has detected an internal malfunction. that the repair has eliminated the original problem.
Repair: Refer to Installation and Operation STOP.

Manual, SEBU7630, “Raptor Gas Regulation and
Metering Valve/Actuator System for Caterpillar”. • Not OK – The voltage, the duty cycle, and/or the
frequency of the signal for the fuel flow is not
STOP. correct at the master ECM P1 connector. Proceed
to Test Step 5.
• Not OK (Active 1446-13) – The fuel metering valve
requires calibration. Test Step 4. Check the Continuity of the
Wiring Harness for the CAN Data Link
Repair: Refer to Installation and Operation
Manual, SEBU7630, “Raptor Gas Regulation and A. Set the engine control to the OFF/RESET mode.
Metering Valve/Actuator System for Caterpillar”. Switch the 35 amp circuit breaker OFF.
STOP. B. Disconnect the master ECM J1/P1 connectors.

Disconnect the harness connector for the fuel
• Not OK (Active 1447-12) – There is a malfunction metering valve.
of the sensor module in the fuel metering valve.
Repair: Refer to Installation and Operation

Manual, SEBU7630, “Raptor Gas Regulation and
Metering Valve/Actuator System for Caterpillar”.
STOP.
Test Step 3. Check the Signal for the Fuel

Flow
B. Insert two 7X-1710 Multimeter Probes into the

g01065458
harness side of the P1 connector. Insert the first Illustration 127
probe into terminal 58. Insert the second probe Connections for the circuit for the fuel metering valve
into terminal 60. Use a multimeter that is capable (P1) Connector for the ECM
of measuring the frequency and the duty cycle. (P24) Connector for the fuel metering valve
Connect the multimeter to the probes. (P1-34) CAN Data Link −
(P1-50) CAN Data Link +
(P24-F) CAN Data Link −
C. Switch the 35 amp circuit breaker ON. Set the (P24-C) CAN Data Link +
C. Use a multimeter to check for continuity between
D. Measure the DC voltage, the duty cycle, and the the points that are listed in Table 22.
frequency of the signal for the fuel flow.
Table 22
Expected Result:
The DC voltage is between 13.7 and 15.7. Connector and Terminal Connector and Terminal
The duty cycle is between 92 and 98 percent. P1-34 P24-F

P1-50 P24-C
The frequency is between 175 and 185 hertz.
P1-34 Ground strap for the ECM
Results: P1-50 Ground strap for the ECM
• OK – The voltage, the duty cycle, and the

frequency of the signal for the fuel flow is correct at Expected Result:
the master ECM P1 connector. There is a problem
with the fuel metering valve. The continuity of the circuits between the terminals
is good.
296
The continuity between the terminals and the ground

strap is open.
Results:
• OK – The continuity of the circuits is good. The

continuity of the circuit between the master ECM
and the ground strap is open.

2. Observe the “Active Diagnostic Codes” screen g01012855

of Cat ET. Illustration 128
Connections for the circuit for the fuel metering valve
If a “1446-09 Unable to communicate with Fuel (P1) Connector for the ECM
Metering Module” diagnostic code is activated, (P24) Connector for the fuel metering valve
troubleshoot the CAN data link. Refer to the (P1-58) Signal for the fuel flow
(P1-60) Return for the signal for the fuel flow
engine’s schematic diagram. (P24-S) Signal for the fuel flow
(P24-T) Return for the signal for the fuel flow
If a 1446-09 diagnostic code is not activated,
proceed to Test Step 6. D. Use a multimeter to check the continuity of the
following circuits:
• Not OK – At least one of the following conditions
is found: There is an open circuit between the • P1-58 and P24-S
plug for the master ECM and the plug for the fuel
metering valve. There is a short circuit between the • P1-58 and the ground strap for the ECM
plug for the master ECM and a component that is
at ground potential. • P1-60 and P24-T
Repair: Perform the necessary repairs to the wiring Expected Result:
and/or connectors. Replace parts, if necessary.
Ensure that all of the seals are properly installed. The continuity of the circuits between the terminals
Ensure that the connectors are properly engaged. is good.
Verify that the repair has eliminated the original
problem. The continuity between the terminal and the ground
strap is open.
STOP.
Results:
Test Step 5. Check the Continuity of the
Circuit for the Fuel Flow • OK – The continuity of the circuit between the
master ECM and the fuel metering valve is good.
A. Set the engine control to the OFF/RESET mode. The continuity of the circuit between the master
Switch the 35 amp circuit breaker OFF. ECM and the ground strap is open. Proceed to
Test Step 6.
B. Disconnect the J1/P1 connector.
• Not OK – One or both of the following conditions is
C. Disconnect the fuel metering valve J24/P24 found: There is an open circuit between the master
connector. ECM and the fuel metering valve. There is a short
circuit between the master ECM and a component
that is at ground potential.
Repair: Repair the wiring and/or connectors.

Replace parts, if necessary. Ensure that all of
STOP.
297
Test Step 6. Check the Resistance of the • The fuel metering valve J24/P24 connectors
Internal Circuit of the Fuel Metering Valve are disconnected.
A. Ensure the following conditions: B. Switch the 35 amp circuit breaker ON. Set the
• The engine control is in the OFF/RESET mode.
Note: The “1446-05 Fuel Metering Module open
• The 35 amp circuit breaker in the terminal box circuit” and “1446-09 Unable to communicate with
is OFF. Fuel Metering Module” diagnostic codes will be
activated.
• The fuel metering valve J24/P24 connectors
are disconnected.
g00952242
Illustration 130
P24 plug on the harness for the fuel metering valve
g00952241
Illustration 129 (P24-K) Unswitched +Battery
J24 connector on the fuel metering valve (P24-L) −Battery
(P24-M) Switched +Battery
(J24-S) Signal for the fuel flow
(J24-T) Return for the signal for the fuel flow
C. Use a multimeter to measure the voltage between
B. Measure the resistance between terminals J24-S the following terminals of the harness connector
and J24-T. for the fuel metering valve:
Expected Result: • P24-M and P24-L

The resistance is between 315,000 Ohms and • P24-K and P24-L
325,000 Ohms.
Expected Result:
Results:
The voltage between terminals P24-M and P24-L is
• OK – The resistance is between 315,000 Ohms between 22.0 VDC and 24.0 VDC.
and 325,000 Ohms. Proceed to Test Step 7.
The voltage between terminals P24-K and P24-L
• Not OK – The resistance is not between 315,000 terminals is 22.0 VDC and 24.0 VDC.
Ohms and 325,000 Ohms.
Results:
Repair: Replace the fuel metering valve. Verify
that the repair has eliminated the original problem. • OK – The voltage is correct at the P24 plug for the
fuel metering valve. However, the fuel metering
STOP. valve is not communicating with the master ECM.
Test Step 7. Check the Supply Voltage to Repair: Replace the fuel metering valve. Verify
the Fuel Metering Valve that the repair has eliminated the original problem.
A. Ensure the following conditions: STOP.
• The engine control is in the OFF/RESET mode. • Not OK – The voltage is not correct at the P24
plug for the fuel metering valve. There is an open
• The 35 amp circuit breaker in the terminal box circuit or a short circuit in the harness to the fuel
is OFF. metering valve.
298
Repair: Perform the necessary repairs for the 1719-04 Diagnostic Code
wiring and/or the connectors. Replace parts, if
necessary. Ensure that all of the seals are properly This code only applies to engines that are equipped
installed. Ensure that the connectors are properly with a power sensor.
engaged. Verify that the repair has eliminated the
original problem. If the engine load is greater than 20 percent and the
voltage on terminal J1-25 is less than 0.2 VDC, the
STOP. master ECM will generate a 1719-04 diagnostic code.
If the engine is running, the engine will shut down.
i02089358
1719-12 Diagnostic Code
Generator Output Power This code only applies to engines that are equipped
Sensor with the EMCP II+.
SMCS Code: 5574-038-PWR The master ECM calculates two values that represent
the engine’s load. One value is calculated by using
System Operation Description: the information on the generator’s load from the
GSC+. The other value is calculated from the
The master ECM monitors the generator’s output following inputs:
power in order to accurately control the air/fuel ratio.
The master ECM uses a load signal from one of the • The value of the “Fuel Quality” parameter
following sources in order to monitor the generator’s
output power: • Inlet air temperature and pressure
• Electronic Modular Control Panel II+ (EMCP II+) • Other factors
• Programmable Logic Controller (PLC) The master ECM compares the two values. If the
value that is calculated by using the information from
• Wattmeter the GSC+ is not within 20 percent of the other value,
the master ECM will generate a 1719-12 diagnostic
The PLC and the wattmeter are also called power code. If the engine is running, the engine will shut
sensors. down.
Only one load signal is connected to the master

ECM. If the generator is equipped with the EMCP II+,
the master ECM receives the load signal from the
Generator Set Control + (GSC+) via the CAT data
link. If the generator is not equipped with the EMCP
II+, the master ECM receives the load signal from
a power sensor via terminal J1-25. The load signal
from the power sensor is an analog voltage. The
load signal increases from 0 VDC to 4.8 VDC as the
generator’s output increases to the maximum output.
1719-03 Diagnostic Code
On powerup, the master ECM will start requesting

information on the generator’s load from the GSC+
via the CAT data link. If two seconds elapse and the
master ECM does not receive a response from the
GSC+, the master ECM will look for a load signal on
terminal J1-25. If there is no load signal on terminal
J1-25, the master ECM will generate a 1719-03
diagnostic code. If the engine is running, the engine
will shut down.
A 1719-03 diagnostic code is also generated if the

voltage on terminal J1-25 ever exceeds 4.8 VDC. If
the engine is running, the engine will shut down.
299
g01065476 g01065477
Schematic of the power sensor’s input with EMCP II+ Schematic of the power sensor’s input with a power sensor
For the actual wiring, refer to the generator’s schematic diagram. For the actual wiring, refer to the generator’s schematic diagram.
The potentiometer is optional. For further information, refer to
Troubleshooting, “Generator Output Power Sensor - Calibrate”.
300
Test Step 1. Inspect the Electrical B. Thoroughly inspect the following components:
• The wiring and the connections between the
master ECM and the GSC+ (if equipped)
• The wiring and the connections between the

master ECM and the power sensor (if equipped)

6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 133
Junction box

position.

g01065479
Illustration 135
(P1-8) Cat data link +
(P1-9) Cat data link −
(P1-19) Load signal +
(P1-25) Load signal −
g01065478
Illustration 134
Terminal box
(2) J1/P1 connectors
(3) J6/P6 connectors for the wiring from the power sensor
301
B. Start the engine and run the engine. Attempt to

apply at least a 30 percent load to the generator.

Allow a minimum of 30 seconds for any codes to
activate. Look for these codes:
• 1719-03
• 1719-04
• 1719-12
D. Stop the engine.
Expected Result:
There are no active codes for the generator output

power sensor.
Results:
g00952302
Illustration 136
Harness side of the J6 connector • No active codes – There are no active codes for
the generator output power sensor. There may be a
(J6-3) Load signal +
(J6-7) Cat data link +
logged code for the generator output power sensor.
(J6-13) Load signal −
(J6-17) Cat data link − Repair: If there is a logged code for the
generator output power sensor, there may be
c. Perform a 45 N (10 lb) pull test on each of the a problem with the wiring and/or a connector.
wires that are associated with the circuit for the Refer to Troubleshooting, “Inspecting Electrical
power sensor. Connectors”.
d. Check the harness and wiring for abrasion and STOP.

for pinch points between the power sensor and
the master ECM. • Active 1719-03 code – There is an active 1719-03
code. If the generator is equipped with EMCP II+,
Expected Result: proceed to Test Step 7. Otherwise, proceed to Test
Step 3.
properly. The connectors and the wiring do not have • Active 1719-04 code – There is an active 1719-04
corrosion, abrasion, or pinch points. code. Proceed to Test Step 5.
Results: • Active 1719-12 code – There is an active 1719-12

code. Proceed to Test Step 7.
proper connections. Proceed to Test Step 2. Test Step 3. Check the “Load Signal”
Wiring for a Short Circuit
condition and/or at least one connection is A. Disconnect the P1 connector from the master
improper. ECM.
Repair: Perform the necessary repairs and/or B. Disconnect the “load signal” wires from the power
replace parts, if necessary. sensor.
STOP. C. Check for continuity between P1-25 and all the

other terminals on the P1 connector.
D. Check for continuity between P1-19 and all the
A. Connect the Cat Electronic Technician (ET) to the other terminals on the P1 connector.
service tool connector. Refer to Troubleshooting,
“Electronic Service Tools”. Expected Result:
Each continuity check indicates an open circuit.

302
Results: Test Step 5. Check the “Load Signal +”

Wire for a Short Circuit
• OK – Each continuity check indicates an open
circuit. The “load signal” wiring does not have a A. Verify that the engine control is in the OFF/RESET
short circuit. mode and that the 35 amp circuit breaker is OFF.
Repair: Reconnect the P1 connector. Reconnect B. Disconnect the P1 connector from the master
the “load signal” wires to the power sensor. Be ECM.
sure to observe the correct polarity.
C. Disconnect the “load signal +” wire from the power
Proceed to Test Step 4. sensor.
• Not OK – At least one continuity check indicates D. Check for continuity between P1-25 and all the
a short circuit. other terminals on the P1 connector.
Repair: The problem may be between the P1 Expected Result:

problem may be between the J6 connector and Each continuity check indicates an open circuit.
the power sensor.
Results:
Repair the harness or the connection, when
possible. Replace parts, if necessary. Verify that • OK – Each continuity check indicates an open
the problem is resolved. circuit. The “load signal +” wire does not have a
short circuit.
STOP.
Repair: Reconnect the P1 connector. Reconnect
Test Step 4. Check the “Load Signal” the “load signal +” wire to the power sensor.
Wiring for Continuity
Note: A potentiometer may be installed in the “load
signal” wiring. A high resistance reading may be • Not OK – At least one continuity check indicates
caused by the potentiometer. a short circuit. There is a short circuit in a harness
or in a connector.
A. Check the continuity of the wiring between P1-25
and the power sensor. Repair: The problem may be between the P1
B. Check the continuity of the wiring between P1-19 problem may be between the J6 connector and the
and the power sensor. generator output power sensor.
Expected Result: Repair the harness or the connection, when

possible. Replace parts, if necessary. Verify that
The “load signal” wiring has continuity. the problem is resolved.
Results: STOP.
• OK – The “load signal” wiring has continuity. Test Step 6. Check the Power Sensor, the
Proceed to Test Step 6. Potential Transformers, and the Current
Transformers
• Not OK – The “load signal” wiring has an open
circuit. The open circuit may be in a wire, in a Verify that the power sensor, the potential
connector, or in the potentiometer. transformers, and the current transformers are
operating correctly. Refer to the appropriate service
Repair: Repair the component, when possible. literature for the components.
Replace parts, if necessary. Verify that the original
problem is resolved. Expected Result:
STOP. The components are operating correctly.

303
Results: 2. Reconnect the P1 connector.
• OK – The components are operating correctly. Proceed to Test Step 8.

• Not OK – At least one check of the resistance for
• Not OK – At least one of the components is not the Cat data link is incorrect. There is a problem
operating correctly. with the wiring for the Cat data link.
Repair: Repair the component, when possible. Repair: Repair the connection and/or the wire,
Replace the component, if necessary. Verify that when possible. Replace parts, if necessary. Verify
the original problem is resolved. that the original problem is resolved.
STOP. STOP.
Test Step 7. Check the Continuity of the Test Step 8. Check the GSC+
Cat Data Link
Verify that the GSC+ is operating correctly. Refer to
A. Set the engine control to the OFF/RESET mode. the appropriate service literature for the EMCP II+.
Expected Result:
B. Disconnect Cat ET from the service tool connector.
The GSC+ is operating correctly.
C. Disconnect the wiring for the Cat data link from
the GSC+. Results:
D. Disconnect the P1 connector from the master • OK – The GSC+ is operating correctly. Proceed to
ECM. Test Step 13.
E. Measure the resistance between the points that • Not OK – The GSC+ is not operating correctly.
are listed in Table 23. During each measurement,
wiggle the wires in the harness in order to check Repair: Repair the GSC+. Refer to the appropriate
for an intermittent problem. Be sure to wiggle the service literature for the EMCP II+. Verify that the
wires near each of the connectors. original problem is resolved.
Table 23 STOP.
Resistance Measurements for the Cat Data Link
Test Step 9. Check the “Fuel Quality”
Connector and Terminal Connector and Terminal parameter
P1-8 Terminal 19 on the GSC+
Verify that the value of the “Fuel Quality” parameter
P1-9 Terminal 20 on the GSC+ is correct. Use the value that is obtained from the
P1-8 Ground strap for the ECM Caterpillar Software, LEKQ6378, “Methane Number
Program”.
P1-9 Ground strap for the ECM
Expected Result:
Expected Result:
The value of the “Fuel Quality” parameter is correct.
Each check of the resistance between the terminals
is less than 5 Ohms. Results:
Each check of the resistance between the terminals • OK – The value of the “Fuel Quality” parameter is
and the ground strap is greater than 20,000 Ohms. correct. Proceed to Test Step 10.
Results: • Not OK – The value of the “Fuel Quality” parameter

is not correct.
• OK – Each check of the resistance for the Cat
data link is within the specification. The wiring for Repair: Enter the correct value for the parameter.
the Cat data link appears to be OK. Verify that the original problem is resolved.
Repair: Perform the following procedure: STOP.
1. Reconnect the wiring to the GSC+. Be sure to

connect each wire to the appropriate terminal.
304
Test Step 10. Check the Sensors for the Test Step 12. Verify that the Output Power
Air Inlet Manifold Reading is Correct
A. If the engine is running, stop the engine. Operate the generator at various loads. Verify that
the value of the “Generator Real kW” parameter in
B. Connect a pressure gauge and a temperature Status Group 1 is within 1 percent of the generator’s
sensor to the air inlet manifold. output power.
C. View the Status Group 1 on Cat ET. Compare Expected Result:

the values on the instruments with the following
parameters: The value of the “Generator Real kW” parameter is
correct.
• “Inlet manifold air pressure (abs)”
Results:
• “Inlet air temperature”
• OK – The value of the “Generator Real kW”
Expected Result: parameter is correct. Proceed to Test Step 13.
The values of the parameters are correct. • Not OK – The value of the “Generator Real kW”
parameter is incorrect.
Results:
Repair: Refer to Troubleshooting, “Generator
• OK – The values of the parameters are correct. Output Power Readings Do Not Match”.
STOP.
• Not OK – One or both of the values of the
parameters are incorrect. Test Step 13. Check the Master ECM
Repair: Replace the appropriate sensor. Verify that It is unlikely that the master ECM has failed. Exit this
the original problem is resolved. procedure and perform this procedure again. If the
problem is not resolved, temporarily install a new
STOP. master ECM. Refer to Troubleshooting, “Replacing
the ECM”.
Test Step 11. Check the GSC+
Expected Result:
Verify that the GSC+ is operating correctly. Refer to
the appropriate service literature for the EMCP II+. The problem is resolved when a new master ECM
is installed.
Expected Result:
Results:
The GSC+ is operating correctly.
• OK – The problem is resolved when a new master
Results: ECM is installed.
• OK – The GSC+ is operating correctly. Proceed to Repair: Install the original ECM and verify that the
Test Step 12. problem returns. If the new ECM operates correctly
and the original ECM does not operate correctly,
• Not OK – The GSC+ is not operating correctly. replace the ECM.
Repair: Repair the GSC+. Refer to the appropriate STOP.

service literature for the EMCP II+. Verify that the
original problem is resolved. • Not OK – The problem is not resolved when a new
ECM is installed.
STOP.
Repair: Reinstall the original ECM. Consult with
Caterpillar customer service for large gas engines.
STOP.
305
i02089430 Table 24
Ignition Transformers Primary Diagnostic Conditions and the Combinations

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

by a condition, refer to Table 24.
306
g01065514
Illustration 137
Schematic for the primary ignition on the left side of the engine
307
g01065515
Illustration 138
Schematic for the primary ignition on the right side of the engine
308

g01065516
Illustration 140
Terminal box
g01054206
Illustration 139 (2) Harness for the primary ignition from the master ECM to the
Junction box left bank
(1) 35 amp circuit breaker (4) J4/P4 connectors for the slave ECM
(5) Harness for the primary ignition from the slave ECM to the
A. Set the engine control to the OFF/RESET mode. right bank
position. B. Thoroughly inspect the following connectors:
Note: For the following steps, refer to • J2/P2 connectors

6 ± 1 N·m (55 ± 9 lb in).
309
g01066020 g01066020
Harness side of the P2 connector Harness side of the P4 connector
(P2-1) Number 2 transformer’s circuit driver (P4-1) Number 1 transformer’s circuit driver
(P2-2) Number 2 transformer’s return (P4-2) Number 1 transformer’s return
b. Perform a 45 N (10 lb) pull test on each of the

wires that are associated with the circuit of the
ignition system.
C. Check the ignition harnesses and wiring for

abrasion and for pinch points from each ignition
transformer to each ECM.
Expected Result:

Results:


improper.

STOP.
310

for the Primary Circuit
Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
and wiring.
Tools”.
Do not attempt to remove the valve covers when
B. Switch the 35 amp circuit breaker ON.
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
C. Attempt to start the engine. Use Cat ET in order
death may result and the ignition system will be
to determine if the following codes are active or
damaged if the valve covers are removed during
logged:
engine operation. The engine will not operate
without the valve covers.
• 301-05 Ignition Transformer Primary #1 open
circuit through 316-05 Ignition Transformer
Primary #16 open circuit 1. Set the engine control to the OFF/RESET
• 1752-05 Ignition Transformer Primary #17 open
circuit through 1755-05 Ignition Transformer
Primary #20 open circuit
• 301-06 Ignition Transformer Primary #1 short

through 316-06 Ignition Transformer Primary
#16 short
• 1752-06 Ignition Transformer Primary #17 short

through 1755-06 Ignition Transformer Primary
#20 short
Note: If a diagnostic code for the primary circuit is

logged but not currently active, attempt to repeat the
condition that activated the code. Run the engine to
full operating temperature.
Expected Result:
None of the above diagnostic codes are active.
Results: g01057615
Illustration 143
Section view of a cylinder
• Active “open circuit” – There is an open in the
primary circuit. Proceed to Test Step 6. (1) Cover
(2) Transformer
(3) 3-pin connector
• Active “short” – There is a short in the primary
circuit. Proceed to Test Step 3.
2. Remove cover (1) for the suspect cylinder.
Inspect the harness and 3-pin connector (3)
• Logged only – There may be an intermittent of transformer (2). Check for corrosion, for
problem in the ignition harness.
abrasion, and for pinch points.
3. Reconnect the connectors, and reinstall the
cover.
If the problem persists, refer to Troubleshooting,

STOP.
311
Test Step 3. Check the Transformer’s

Primary Circuit and the Secondary Circuit

and wiring.


g01057616
Illustration 145
Schematic for the primary circuit and for the secondary circuit
(4) 3-pin connector for the transformer
(5) Terminal A
(6) Terminal B
(7) Blocking diode
(8) Flyback diode
(9) Primary coil of the transformer
(10) Secondary coil of the transformer
(11) Resistor
(12) Spark plug gap
E. Measure the primary circuit by checking the

voltage of the blocking diode.
g01057615
Illustration 144
(1) Cover
(2) Transformer
(3) 3-pin connector
B. Remove cover (1) for the suspect cylinder.
C. Disconnect 3-pin connector (3). Visually inspect

the 3-pin connectors for corrosion and/or for
damage.
D. Remove transformer (2) from the cylinder head.

312
g00863850
Illustration 147
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 146
g01057618 Measure the resistance between mounting
flange (13) and the extension’s internal terminal
Ignition transformer
(14) for the spark plug.
(A) + Terminal
(B) - Terminal
(13) Mounting flange
Expected Result:
(14) Connector for the spark plug
For the primary circuit, one of the voltage
a. Set the multimeter to the diode scale. Connect measurements is approximately 0.450 VDC. The
the multimeter leads to terminals (A) and (B) of other voltage measurement indicates an open circuit.
the 3-pin connector. The polarity of the leads
is not important. Measure the voltage between For the secondary circuit, the resistance between the
the terminals. Record the measurement. screw for the ground spring and the connector for the
spark plug is within the acceptable tolerance.
b. Reverse the multimeter leads. Measure the
voltage between the terminals again. Record Results:
the measurement.
• OK – All three of the measurements are correct.
F. Measure the resistance of the secondary circuit.
Note: The resistance of the secondary coil will vary
with the temperature. Illustration 147 demonstrates 1. Install the spark plug according to the
the relationship between the secondary coil’s instructions in Operation and Maintenance
resistance and the temperature. A reading that is Manual, “Ignition System Spark Plugs -
within 1000 Ohms is acceptable. For example, if Check/Adjust/Replace”.
the transformer’s temperature is 60 °C (140 °F), the
correct resistance is between 21,000 and 23,000 2. Switch the suspect transformer with a
Ohms. transformer from a different cylinder that is
known to be good. Install the transformers.
Install the valve covers.
3. Reset the control system. Restart the engine.

Clear any logged codes.
4. Operate the engine. Check for a recurrence of

the problem.
313
If the problem stays with the suspect transformer, Repair: Perform the following procedure:
replace the transformer.
1. Connect the ignition harness to the transformer.
If the problem stays with the suspect cylinder,
proceed to Test Step 4. 2. Set the engine control to the START mode and
observe the “Active Diagnostic” screen of Cat
• Not OK – At least one of the three measurements ET while you crank the engine. Look for a “short
is incorrect. circuit” code.
Repair: Replace the ignition transformer. Make Replace the transformer if the original “short
sure that you use the correct transformer for circuit” code is activated.
the G3520C Engine.
If the original “short circuit” code does not
STOP. return, the problem appears to be resolved.
Test Step 4. Check for a Short Circuit
Between the ECM and the Transformer STOP.
Test Step 5. Disconnect the Wiring From

the ECM and Check for a Short Circuit
There is a strong electrical shock hazard when the
crankshaft is rotating.
Do not touch the wires that are associated with There is a strong electrical shock hazard when the
the ignition system when the engine is cranking crankshaft is rotating.
or when the engine is running.
Do not touch the wires that are associated with
the ignition system when the engine is cranking
NOTICE or when the engine is running.
The air inlet, the cylinders, and the exhaust system
can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked. NOTICE
The unburned fuel can ignite unexpectedly and cause The air inlet, the cylinders, and the exhaust system
damage. can be filled with fuel when the gas supply is ON, the
ignition system is disabled, and the engine is cranked.
Turn OFF the gas supply before you perform this step. The unburned fuel can ignite unexpectedly and cause
damage.
A. Shut OFF the fuel supply. Set the engine control Turn OFF the gas supply before you perform this step.
to the OFF mode.
B. Disconnect the 3-pin connector for the suspect A. Set the engine control to the OFF/RESET mode.
transformer. Switch the 35 amp circuit breaker OFF.
C. Set the engine control to the START mode and

observe the “Active Diagnostic” screen of Cat ET
Expected Result:
The “short” code is active when the transformer’s

connector is disconnected.
Results:
• Yes – The “short” code was activated after

the transformer’s connector was disconnected.
g01065517
Illustration 148
• No – The original “short” code was not P2 or P4 connector
activated after the transformer’s connector was
disconnected.
314
B. Use a 151-6320 Wire Removal Tool to remove Repair: Set the engine control to the OFF/RESET
the terminal for the circuit driver of the suspect mode. Switch the 35 amp circuit breaker OFF.
cylinder from the ECM connector. For identification Repair the harness, when possible. Replace the
of the appropriate terminal, refer to Illustration 148 harness, if necessary.
and Table 25.
STOP.
Table 25
Cylinder and Corresponding Terminal of the ECM • No – The ECM continued to activate a “short
Connector for the Ignition Harness circuit” diagnostic code after the wire was
disconnected from the ECM. There is a problem
Cylinder Terminal for the Circuit with the ECM.
Driver
1 P4-1 Repair: Replace the ECM that is appropriate for
the suspect cylinder. Follow the instructions in
2 P2-1
3 P4-14
STOP.
4 P2-14
5 P4-48 Test Step 6. Create a Short Circuit in the
Ignition Harness
6 P2-48
7 P4-24
8 P2-24
9 P4-32
10 P2-32 and wiring.
11 P4-3
12 P2-3 the engine is operating. The transformers are
13 P4-50
14 P2-50 damaged if the valve covers are removed during
15 P4-16
16 P2-16
17 P4-34 NOTICE
18 P2-34 The air inlet, the cylinders, and the exhaust system
19 P4-26 ignition system is disabled, and the engine is cranked.
20 P2-26 The unburned fuel can ignite unexpectedly and cause
damage.
C. Switch the 35 amp circuit breaker ON. Set the Turn OFF the gas supply before you perform this step.
D. Set the engine control to the START mode and A. Shut OFF the fuel supply. Set the engine control
observe the “Active Diagnostic” screen of Cat ET to the OFF/RESET mode.
B. Remove the valve cover for the suspect cylinder.
Expected Result:
C. Disconnect the 3-pin connector for the transformer.
An “open circuit” diagnostic code is activated for the Inspect the connectors. Verify that the connectors
circuit after removal of the wire for the circuit driver. do not have damage or corrosion. Inspect the
harness. Verify that the harness does not have
Results: damage or corrosion.
• Yes – The ECM detected an open circuit after the D. Install a jumper wire into terminals A and B of the
wire was disconnected from the ECM. There is a 3-pin connector on the ignition harness.
short circuit in the wiring.
315
E. Set the engine control to the START mode and 6. Replace the transformer. Make sure that you
observe the “Active Diagnostic” screen of Cat ET use the correct transformer for the G3520C
while you crank the engine. Look for the original Engine.
“open circuit” code.
7. Clear all of the logged diagnostic codes.
Expected Result:
STOP.
The original “open circuit” code is active.
Test Step 7. Check the Engine Harness
Results: for an Open Circuit
• Yes – The original “open circuit” code was
activated after a short circuit was created in the
ignition harness. The ECM did not detect the
jumper wire. Reconnect the ignition harness to the There is a strong electrical shock hazard when the
transformer. Proceed to Test Step 7. crankshaft is rotating.
Do not touch the wires that are associated with

• No – Cat ET displayed an active “short” diagnostic
code after a short circuit was created in the ignition the ignition system when the engine is cranking
harness. The harness and the ECM are OK. or when the engine is running.
Repair: Perform the following steps: NOTICE

There is a strong electrical shock hazard when the The unburned fuel can ignite unexpectedly and cause
crankshaft is rotating. damage.
Do not touch the wires that are associated with Turn OFF the gas supply before you perform this step.
the ignition system when the engine is cranking
or when the engine is running. A. Shut OFF the fuel supply. Set the engine control to
the OFF/RESET mode. Switch the 35 amp circuit
NOTICE breaker to the OFF position.
The unburned fuel can ignite unexpectedly and cause
damage.
Turn OFF the gas supply before you perform this step.

2. Remove the jumper wire from the 3-pin

connector of the ignition harness.
g01013288
3. Reconnect the ignition harness to the Illustration 149
transformer. P2 or P4 connector
4. Set the engine control to the START mode and B. Use a 151-6320 Wire Removal Tool to remove
observe the “Active Diagnostic” screen of Cat two terminals for the circuit driver of the suspect
ET while you crank the engine. Look for the cylinder from the ECM connector. For identification
original “open circuit” code. of the appropriate terminals, refer to Illustration
149 and Table 26.
5. If the original “open circuit” code is activated,
set the engine control to the OFF/RESET mode.
316
Table 26 Results:
Cylinders and Corresponding Terminals of the ECM
Connectors for the Ignition Harnesses • Yes – When the jumper wire was installed into the
connector, a “short circuit” diagnostic code was
Cylinder Terminals for the activated for the suspect cylinder. The original
Cylinder “open circuit” diagnostic code was not active.
1 P4-1 and P4-2 There is an open circuit in the wiring harness for
the suspect cylinder.
2 P2-1 and P2-2
3 P4-14 and P4-15 Repair: Perform the following steps:
4 P2-14 and P2-15 1. Set the engine control to the OFF/RESET
5 P4-48 and P4-49 mode. Switch the 35 amp circuit breaker OFF.
6 P2-48 and P2-49 2. Remove the jumper wire and reinstall the
7 P4-24 and P4-25 terminals that were removed from the connector.
Pull on the wires in order to verify that the
8 P2-24 and P2-25 terminals are fully inserted into the connector.
9 P4-32 and P4-33
3. Repair the harness, when possible. Replace the
10 P2-32 and P2-33 harness, if necessary.
11 P4-3 and P4-4
STOP.
12 P2-3 and P2-4
13 P4-50 and P4-51 • No – When the jumper wire was installed into the
connector, a “Short circuit” diagnostic code was not
14 P2-50 and P2-51 activated. The ECM did not detect the jumper wire.
15 P4-16 and P4-17 There is a problem with the ECM.
16 P2-16 and P2-17 Repair: Replace the ECM that is appropriate for
17 P4-34 and P4-35 the suspect cylinder. Follow the instructions in
18 P2-34 and P2-35
19 P4-26 and P4-27 STOP.
20 P2-26 and P2-27

i02089548
C. Install the ends of a jumper wire into the terminals Ignition Transformers
for the removed wires. This will replace the wiring
with a short circuit. Secondary Circuit and Spark
Plugs
D. Set the engine control to the START mode. Switch
the 35 amp circuit breaker to the ON position. SMCS Code: 1555-038; 1561-038
E. Observe the “Active Diagnostic” screen of Cat System Operation Description:

ET while you crank the engine. Look for a “short
circuit” diagnostic code. The ignition transformers initiate combustion by
providing high voltage to the spark plugs. The positive
Expected Result: output from the secondary circuit of the transformer is
at the connection for the terminal of the transformer
A “short circuit” diagnostic code is activated for the and the terminal of the spark plug. The transformers
suspect cylinder. The original “open circuit” diagnostic are located underneath covers at the top of each
code is not active. cylinder. Each transformer is grounded to the cylinder
head via a mounting flange.
317
Note: Ignition transformers from Electronic Ignition

Systems (EIS) are not interchangeable with the
transformers in this engine.
Caterpillar spark plugs are high voltage devices

with internal resistors. The spark plugs operate at a
voltage that is greater than 5,000 volts.
Most ignition systems are not affected by resistance

in the secondary circuit. If a measurement of the
resistance is desired, a megohmmeter must be
used. A low voltage multimeter will not provide a
reliable reading of the resistance because oxidation
of the spark plug’s internal components will affect the
readings of those meters.
Test Step 1. Check the Status Screen of

Cat ET for the Output of the Secondary
Circuits of the Transformers
g01057652
Illustration 150
Ignition transformer and spark plug
(1) Mounting flange
(2) 3-pin connector
(3) Transformer
(4) Extension
(5) Secondary spark plug terminal Illustration 151
g01054206
(6) O-ring seal
(7) Hole in the spark plug’s precombustion chamber Junction box
The secondary circuit of the transformer provides an
initial 8,000 to 37,000 volts to the spark plug. This A. Set the engine control to the OFF/RESET mode.
voltage ionizes the spark plug gap. This voltage is Switch 35 amp circuit breaker (1) to the OFF
then reduced to about 1000 volts. The total duration position.
of the spark is approximately 400 microseconds.
B. Connect Cat ET to the service tool connector.
Each Electronic Control Module (ECM) can diagnose Refer to Troubleshooting, “Electronic Service
the primary circuit of the ignition transformers for Tools”.
open circuits and/or for short circuits. Secondary
open circuits and short circuits will not directly shut C. Switch the 35 amp circuit breaker ON. Set the
down the engine. However, these conditions may engine control to the STOP mode.
lead to misfire which can cause lugging of the engine.
Lugging of the engine can cause a shutdown. D. Set up two status screens for Cat ET. Use eight
of the following labels for parameters on each
Logged diagnostic codes provide a historical record. status screen:
to a file.
318
Table 27 Repair: Investigate other possible root causes of

Parameters for the Status Screens on Cat ET
the problem. Troubleshoot the symptom. Refer
to Troubleshooting, “Troubleshooting Without A
Screen 1 Screen 2 Diagnostic Code”.
Group 8 Group 9
“Cylinder #1 Transformer “Cylinder #2 Transformer STOP.
Secondary Output Voltage Secondary Output Voltage
Percentage” Percentage” • Not OK – At least one of the outputs displayed a
value of 0 percent or a value that is greater than 90
“Cylinder #3 Transformer “Cylinder #4 Transformer percent. The ignition system components require
Secondary Output Voltage Secondary Output Voltage maintenance. Proceed to Test Step 2.
Percentage” Percentage”
“Cylinder #5 Transformer “Cylinder #6 Transformer Test Step 2. Inspect the Transformer
“Cylinder #7 Transformer “Cylinder #8 Transformer
Secondary Output Voltage Secondary Output Voltage Ignition systems can cause electrical shocks.
“Cylinder #9 Transformer “Cylinder #10 Transformer and wiring.
Percentage” Percentage” Do not attempt to remove the valve covers when
Secondary Output Voltage Secondary Output Voltage grounded to the valve covers. Personal injury or
Percentage” Percentage” death may result and the ignition system will be
“Cylinder #13 Transformer “Cylinder #14 Transformer engine operation. The engine will not operate
Secondary Output Voltage Secondary Output Voltage without the valve covers.
“Cylinder #15 Transformer “Cylinder #16 Transformer A. Set the engine control to the OFF/RESET mode.

E. Start the engine. Apply the normal load at rated

speed. Allow the engine to warm up to normal
operating temperature.
F. Observe the value of the output for the secondary

circuit of each transformer.
Expected Result:
The displayed value of the output for the secondary

circuit of each transformer is between 1 and 90
percent.
g01057615
Results: Illustration 152
• OK – The displayed value of the output for the (1) Cover
secondary circuit of each transformer is between 1 (2) Transformer
and 90 percent. The ignition system components (3) 3-pin connector
are operating properly.
B. Remove cover (1) for the suspect cylinder.
319
NOTICE NOTICE
Pulling on the wiring harness may break the wires. Do The extension can be scratched and damaged with a
not pull on the wiring harness. wire brush. Do not use a wire brush on the extension.
C. Disconnect the ignition harness from 3-pin G. Clean any deposits from the inside of the
connector (3). Remove transformer (2) from the extension. Use a 6V-7093 Brush with isopropyl
engine. 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.
g01057657
Illustration 153
Ignition transformer and spark plug
(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.
E. Inspect internal O-ring seal (7) for damage.
F. The extension has an internal terminal for the

spark plug. Inspect the terminal for looseness,
for corrosion, and/or for damage. Insert a spark
plug into the extension and check the terminal for
spring pressure.
320
Test Step 3. Check the Primary Circuit

and the Secondary Circuit
g01057660
Illustration 155
Ignition transformer
(A) + Terminal
(B) - Terminal
(10) Mounting flange
(11) Connector for the spark plug
a. Set the multimeter to the diode scale. Connect

the multimeter leads to the terminal (A) and
g01057676
Illustration 154 terminal (B) of the 3-pin connector. The polarity
Schematic for the primary circuit and for the secondary circuit of the leads is not important. Measure the
(1) 3-pin connector for the transformer
voltage between the terminals. Record the
(2) Terminal A measurement.
(3) Terminal B
(4) Blocking diode b. Reverse the multimeter leads. Measure the
(5) Flyback diode voltage between the terminals again. Record
(6) Primary coil of the transformer
(7) Secondary coil of the transformer the measurement.
(8) Resistor
(9) Spark plug gap B. Measure the resistance of the secondary circuit.
A. 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 156 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.
321
g01057662
Illustration 157
Spark plug that has a precombustion chamber
B. Perform the following procedures according to

the instructions in the engine’s Operation and
Maintenance Manual.
g00863850
Illustration 156
a. Remove the spark plug from the cylinder head.
Resistance versus temperature
(Y) Resistance in Ohms b. Inspect the spark plug.
(X) Temperature in degrees celsius (degrees fahrenheit)
c. Clean the spark plug.

a. Set the multimeter to the 40,000 Ohm scale.
Measure the resistance between mounting Note: For a spark plug with a precombustion
flange (10) and the extension’s internal terminal chamber, the resistance cannot be measured.
(11) for the spark plug. The minimum service life of a spark plug with a
precombustion chamber is approximately 3000
Expected Result: service hours. The spark plug may be good for a
considerable period beyond 3000 service hours.
For the primary circuit, one of the voltage Experience at the particular site will help to determine
measurements is approximately 0.450 VDC. The the proper interval for replacement of the spark plug.
other voltage measurement indicates an open circuit.
Expected Result:
For the secondary circuit, the resistance between the
mounting flange and the secondary terminal for the The spark plug is in good condition.
spark plug is within the acceptable tolerance.
Results:
Results:
• OK – The spark plug is in good condition. Proceed
• OK – All three of the measurements are correct. to Test Step 5.
• Not OK – The spark plug is not in good condition.
• Not OK – At least one of the measurements is
incorrect. Repair: Discard the spark plug. Install a new spark
plug according to the instructions in the engine’s
Repair: Make sure that the engine control is in Operation and Maintenance Manual.
the OFF/RESET mode and that the 35 amp circuit
breaker is OFF. Replace the ignition transformer. Reset the control system. Restart the engine. Clear
Make sure that you use the correct transformer the logged codes.
for the G3520C Engine.
STOP.
STOP.
Test Step 5. Operate the Engine
Test Step 4. Check the Spark Plug
A. Install the spark plug according to the instructions
A. Switch the 35 amp circuit breaker OFF. in the engine’s Operation and Maintenance
Manual.
B. Install the transformer and the cover.
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.
322
Expected Result: i01811734
A diagnostic code is not generated. Inspecting Electrical

Connectors
Results:
SMCS Code: 7553-040-WW
• OK – A diagnostic code is not generated. Proceed
with normal operation. STOP. System Operation Description:
• Not OK – A diagnostic code is generated. Proceed Many of the troubleshooting procedures direct you
to Test Step 6. to a specific electrical connector. Use the following
test steps to help determine whether the connector
Test Step 6. Isolate the Spark Plug and is the cause of the problem. If a problem is found in
the Transformer a connector, repair the connector and verify that the
problem is corrected.
A. Switch the suspect transformer with a transformer
from a different cylinder that is known to be good. Intermittent electrical problems are often caused
Install the transformers. Install the covers. by poor connections. Always check for an active
diagnostic code before you open any connection.
B. Reset the control system. Clear any logged Immediately after you reconnect the connector, check
diagnostic codes. for codes again. Sometimes, simply disconnecting
a connector and then reconnecting the connector
C. Start the engine and operate the engine in order can solve a problem. If this occurs, the following
to generate the diagnostic code again. conditions are likely causes:
Expected Result: • Loose terminals
The diagnostic code is generated for the suspect • Bent terminals
transformer.
• Improperly crimped terminals
Results:
• Improperly mated connectors
• Yes – The diagnostic code is generated for the
suspect transformer. • Moisture
Repair: Make sure that the engine control is in • Corrosion
the OFF/RESET mode and that the 35 amp circuit
breaker is OFF. Replace the faulty transformer.
Make sure that you use the correct transformer
for the G3520C Engine. Reset the control system.
Clear any logged diagnostic codes.
STOP.
• No – The diagnostic code is generated for the

original cylinder.
Repair: Make sure that the engine control is

in the OFF/RESET mode and that the 35 amp
circuit breaker is OFF. Install a new spark plug
according to the instructions in Operation and
g00700045
Maintenance Manual, “Ignition System Spark Illustration 158
Plugs - Check/Adjust/Replace”. Reset the control
system. Clear any logged diagnostic codes. The MS connectors have a metal housing. The pins
and the sockets are soldered to the electrical wires.
STOP. The solder connections are usually protected by a
chemical potting which prevents access to the solder
point.
323
g00700064
Illustration 159
Deutsch connectors have a plastic housing. The pins

and the sockets are crimped onto the electrical wires.
The connector has a locking mechanism in order to
hold the pins and the sockets. These connectors are
repairable without cutting the wires.
g00928006
Illustration 160
Use the following test steps in order to thoroughly B. For the MS connectors, make sure that the
inspect the connectors and determine if the receptacle is turned fully in the clockwise direction.
connectors are the cause of the problem. Check that the threading is properly aligned and
securely mated.
Test Step 1. Check the Connectors.
A. Always set the engine control to the OFF/RESET
mode before you inspect electrical conductors.
324
C. For the Deutsch HD connectors, make sure that Verify that the repair eliminates the problem.
the plug and the receptacle are aligned properly
with the index markings. Make sure that the STOP.
receptacle is turned fully in the clockwise direction.
Verify that the receptacle is clicked into the locked Test Step 3. Perform a Pull Test on Each
position. Make sure that the two halves cannot Wire Connection.
be pulled apart.
A. Each terminal and each connector should easily
D. For the Deutsch DT style, make sure that the withstand 45 N (10 lb) of pull and each wire should
orange wedge is used in order to lock the pins. remain in the connector body. This test checks
Check that the receptacle has clicked into the whether the wire was properly crimped in the
locked position. Make sure that the two halves terminal and whether the terminal was properly
cannot be pulled apart. inserted into the connector.
Expected Result: B. The DT connectors use an orange wedge to lock

the terminals in place. Ensure that the orange
All connectors are properly mated and free of wedge is not missing and that the orange wedge
damage. is installed properly on the DT connectors.
Results: Note: Terminals should ALWAYS be crimped onto

the wires with a crimp tool. Do not solder terminals.
• OK – Proceed to Test Step 2. Use the 1U-5804 Crimp Tool.
• Not OK Expected Result:
Repair: Repair the connectors and/or replace the Each terminal and each connector easily withstands
connectors. Reconnect all of the connectors. 45 N (10 lb) of pull and each wire remains in the
connector body.
STOP.
Results:
Test Step 2. Check the Allen Head Screw
on the Rectangular Connectors • OK – Proceed to Test Step 4.
A. Ensure that each allen head screw is properly • Not OK
tightened. Be careful not to overtighten the screw
and break the screw. Repair: Repair the circuit.
B. When you connect a 70-pin connector to an Verify that the repair eliminates the problem.
Electronic Control Module (ECM), do not exceed
6 ± 1 N·m (55 ± 9 lb in) of torque on the screw. STOP.
C. When you connect a rectangular connector to Test Step 4. Monitor the Electronic
the terminal box, do not exceed 2.25 ± 0.25 N·m Service Tool While the Wiring and the
(20 ± 2 lb in) of torque on the screw. Connectors Are Being Pulled.
Expected Result:
Each rectangular connector is secure and the allen

head screw is properly torqued. There is a strong electrical shock hazard when
the crankshaft is rotating. Do not touch wires that
Results: are associated with the ignition transformer cir-
cuit when the engine is cranking or running.
• OK – Proceed to Test Step 3.
A. If there is an active diagnostic code that pertains
• Not OK to the circuit, perform the following steps:
Repair: Repair the connector or replace the a. Set the engine control to the OFF/RESET
connector, as required. mode. Switch the 35 amp circuit breaker OFF.
325
b. Connect the Caterpillar Electronic Technician Verify that the repair eliminates the problem.
(ET) to the service tool connector on the
terminal box. STOP.
c. Switch the 35 amp circuit breaker ON. Set Test Step 5. Check Wires for Nicks or
the engine control to the STOP mode. Then Abrasion in the Insulation.
start the engine. Run the engine under normal
operating conditions. A. Set the engine control to the STOP mode. Allow
the engine to coast to a stop.
d. Monitor the “Active Diagnostic Code” screen
on Cat ET while you pull on all harnesses and B. Set the engine control to the OFF/RESET mode.
connectors for the circuit with the active code. Switch the 35 amp circuit breaker OFF.
If the harness is being pulled and the active C. Carefully inspect each wire for signs of abrasion,
diagnostic code disappears, there is a problem of nicks, or of cuts.
in the wiring or the connector.
The following areas are likely locations:
B. If there are no active diagnostic codes that pertain
to the circuit, perform the following test: • Places with exposed insulation
a. Run the engine under normal operating • Points with wiring that rubs against the engine
conditions.
• Places with wiring that rubs against a sharp
b. Monitor the “Display Status” screen on Cat ET point
while you pull on all harnesses and connectors
for the circuit. D. Check all of the hold down clamps for the harness
in order to verify that the harness is properly
If the harness is being pulled and the reading clamped. Also, check all of the hold down
changes erratically, there is a problem in the clamps in order to verify that the harness is not
wiring or the connector. compressed by the clamps. Pull back the harness
sleeves in order to check for flattening of the wires
C. If there are no active diagnostic codes and there by the clamps.
are complaints about intermittent changes in
speed or power cutouts, perform the following test: Expected Result:
a. Run the engine under normal operating The wires do not have abrasion, nicks, or cuts and
conditions. the harness is properly clamped.
b. Listen for speed burps or power cutouts while Results:

the wiring and/or the connectors are pulled.
If the harness is being pulled and the engine
has a speed burp or a power cutout, there could • Not OK
be a problem in the wiring or the connector.
Repair: Repair the wires or replace the wires, as
Expected Result: required.
The problem appears to be external to the harnesses Verify that the repair eliminates the problem.
and connectors. Pulling on the harness and on the
connectors does not affect the active diagnostic STOP.
code, component status, or engine performance.
Results:

• Not OK
Repair: Set the engine control to the OFF/RESET
Repair the circuit.
326
Test Step 6. Check the Connectors for Note: It is normal to see some minor seal abrasion
Moisture or Corrosion. on the ECM connector seals. Minor seal abrasion will
not allow the entry of moisture.
If moisture or corrosion is evident in the connector,

the source of the moisture entry must be found and
the source of the moisture entry must be repaired. If
the repair is not made, the problem will recur. Simply
drying the connector will not fix the problem. The
following list includes likely paths for the entrance
of moisture:
• Missing seals or plugs

• Improperly installed seals or plugs
• Nicks in exposed insulation
• Improperly mated connectors
Moisture can also wick from one connector through
the inside of a wire to an ECM connector. If moisture
is found in an ECM connector, thoroughly check all
Illustration 161
g00690571 connectors and wires on the harness that connects to
the ECM. The ECM is not the source of the moisture.
A. Ensure that the connector seals and the white Do not replace an ECM if moisture is found in either
sealing plugs are in place. If any of the seals ECM connector.
or plugs are missing, replace the seal or plug. If
necessary, replace the connector. 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
connectors are completely coupled.
g00690568
Illustration 162
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.
327
Verify that the repair eliminates the problem by Note: This is especially important for intermittent
running the engine for several minutes and by problems.
checking again for moisture. If moisture reappears,
the moisture is wicking into the connector. Even A. One at a time, insert a new pin into each socket.
if the moisture entry path is repaired, it may Make sure that the pin is properly gripped by the
be necessary to replace the wires that have socket.
moisture. These wires may have moisture that is
trapped inside the insulation. Verify that the repair B. One at a time, insert a new socket onto each pin.
eliminates the problem. Make sure that the pin is properly gripped by the
socket. Verify that the socket holds the pin when
STOP. the connector hangs freely.
Test Step 7. Inspect the Connector Expected Result:

Terminals.
Each socket firmly grips each pin.
Verify that the terminals are not damaged. Verify that
the terminals are properly aligned in the connector Results:
and verify that the terminals are properly located in
the connector. • OK – The pins and sockets mate properly. STOP.
Expected Result: • Not OK – The pins and sockets do not mate
properly.
The terminals are properly aligned and the terminals
appear undamaged. Repair: Repair any bad pins and sockets. Replace
the connectors, if necessary. Replace the wiring, if
Results: necessary.
• OK – Proceed to Test Step 7. Verify that the repair eliminates the problem.
• Not OK STOP.
Repair: Repair the terminals and/or replace the

i02089552
terminals, as required.
Verify that the repair eliminates the problem.

Integrated Temperature
Sensing Module (ITSM)
STOP.
SMCS Code: 1901-038
Test Step 8. Check the Individual
Retention of the Pins and Sockets. System Operation Description:

monitors type K 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
Illustration 163
g00690572 • High inlet temperature to the turbocharger turbine
328
• 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.

Before you begin this procedure, use Cat ET to print
the logged codes to a file.

resolved.
329
g01065625
Illustration 164
Schematic for the circuit of the ITSM for 1500 RPM engines
330
g01065626
Illustration 165
331
Schematic for the circuit of the ITSM for 1800 RPM engines
• Master ECM J1/P1 connectors

• J3/P3 connectors for the slave ECM
• J7/P7 and J9/P9 connectors on the terminal box
6 ± 1 N·m (53 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01054206
Illustration 166
Junction box

position.
g01065145
Illustration 168
Note: For the following steps, refer to Harness side of the P1 connector
Troubleshooting, “Inspecting Electrical Connectors”. (P1-8) CAT data link +
(P1-9) CAT data link −

wires that are associated with the circuit for
the ITSM.
g01065628
Illustration 167
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
332
g01065630
Illustration 169
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.
333
Test Step 2. Verify the Active Diagnostic

Codes
A. Access the “Active Diagnostic” screen for the
ITSM on Cat ET. Determine if any of the following
diagnostic codes for the thermocouples are active:
• 1489-03 through 1492-03 (“short to +batt”)

• 1489-04 through 1492-04 (“short to ground”)
• 1489-05 through 1492-05 (“open circuit”)
• 1531-03 through 1550-03 (“short to +batt”)
• 1531-04 through 1550-04 (“short to ground”)
• 1531-05 through 1550-05 (“open circuit”)
Expected Result:
Illustration 170
g01065631 None of the above diagnostic codes for the
ITSM
thermocouples are active.
(10) 54-pin connectors for the harness to the thermocouples
(11) ITSM
Results:
(12) 14-pin connectors for the harness to the terminal box for the
master ECM • No Active Codes – None of the above diagnostic
codes for the thermocouples are active.
e. Thoroughly inspect 54-pin connectors (10) and
14-pin connectors (12) for ITSM (11). Check Repair: If any of the codes are logged, there may
the harnesses and wiring for abrasion and for be an intermittent condition that is causing the
pinch points from the ITSM to the master ECM. codes to be generated. If the engine is not running
properly, refer to Troubleshooting, “Troubleshooting
Expected Result: Without a Diagnostic Code”.
All of the connectors, pins, and sockets are connected STOP.

corrosion, abrasion, or pinch points. • Active “short to ground” or “short to +batt” – At
least one “short to ground” or “short to +batt”
Results: diagnostic code is active. Proceed to Test Step 3.
• OK – The components are in good condition with • Active “open circuit” – At least one “open circuit”
proper connections. Proceed to Test Step 2. diagnostic code is active. Proceed to Test Step 4.
• Not OK – The components are not in good Test Step 3. Create an Open Circuit
improper. A. Set the engine control to the OFF/RESET mode.
replace parts, if necessary. If the wiring harness B. Disconnect the connector for the thermocouple
from the thermocouples to the ITSM requires with the short circuit diagnostic code.
repair, replace the harness in order to ensure
reliable operation. C. Switch the 35 amp circuit breaker ON. Set the
All of the wiring from the thermocouples to the
ITSM must be type K. The polarity of the wires D. Access the “Active Diagnostic” screen for the
from each thermocouple to the ITSM must be ITSM on Cat ET. Allow a minimum of 30 seconds
maintained in order for the ITSM to read the correct for any diagnostic codes to be generated.
temperatures.
Expected Result:
STOP.
There is an active “open circuit” diagnostic code for
the disconnected thermocouple.
334
Results: F. Remove the jumper wire and observe the “Active

Diagnostic” screen. Allow a minimum of 30
• Yes – There is an active “open circuit” diagnostic seconds for any diagnostic codes to be generated.
code for the disconnected thermocouple. The
ITSM and the harness are OK. Expected Result:
Repair: Perform the following procedure: When the jumper wire was installed, a “short circuit”
diagnostic code was generated. When the jumper
1. Thoroughly inspect the thermocouple’s wire was removed, the “open circuit” diagnostic code
connectors. Ensure that the connectors and the recurred.
seals are in good condition.
Results:
2. Reconnect the thermocouple’s connectors and
check for an active short circuit diagnostic code. • Yes – When the jumper wire was installed, a
“short circuit” diagnostic code was generated.
If the short circuit diagnostic code becomes When the jumper wire was removed, the “open
active again, there is a problem with the circuit” diagnostic code recurred. The ITSM and
thermocouple. the harness are OK.
3. Disconnect the suspect thermocouple and Repair: Perform the following procedure:
connect a thermocouple that is known to be
good. Do not install the thermocouple into the 1. Thoroughly inspect the thermocouple’s
engine yet. connectors. Ensure that the connectors and the
seals are in good condition.
4. Check for an active short circuit diagnostic code.
2. Reconnect the thermocouple’s connectors and
If the diagnostic code is not generated with check for an active open circuit diagnostic code.
the good thermocouple, remove the suspect
thermocouple from the engine. Install the good If the open circuit diagnostic code becomes
thermocouple. active again, there is a problem with the
thermocouple.
5. Clear the logged diagnostic codes.
3. Disconnect the suspect thermocouple and
STOP. connect a thermocouple that is known to be
good. Do not install the good thermocouple into
• No – There is not an active “open circuit” diagnostic the engine yet.
code for the disconnected thermocouple. There
is a short circuit between the harness for the 4. Check for an active open circuit diagnostic code.
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. Observe Test Step 5. Check the ITSM
the “Active Diagnostic” screen.
335
B. Disconnect the 54-pin connector from the ITSM. • No – Either of the following results or both of the
Thoroughly inspect the 54-pin connectors. Ensure results occurred: When the 54-pin connectors were
that the connectors are in good condition. disconnected, an “open circuit” diagnostic code
was not generated for the suspect sensor. When
C. Switch the 35 amp circuit breaker ON. Set the the jumper wire was installed, a “short circuit”
engine control to the STOP mode. diagnostic code was not generated. There may be
a problem with the ITSM.
Note: When the 54-pin connectors are disconnected,
an active “open circuit” diagnostic code will be Repair: It is unlikely that the ITSM has failed. Exit
generated for all of the thermocouples. This is this procedure and perform this procedure again. If
normal. Only pay attention to the diagnostic codes for the problem is not resolved, perform the following
the suspect thermocouple. steps:
D. Access the “Active Diagnostic” screen for the 1. Set the engine control to the OFF/RESET
ITSM on Cat ET. Allow a minimum of 30 seconds mode. Switch the 35 amp circuit breaker OFF.
for any diagnostic codes to be generated. Observe
the “Active Diagnostic” screen. 2. Remove the jumper wire from the connector on
the ITSM.
E. Set the engine control to the OFF/RESET mode.
Switch the 35 amp circuit breaker OFF. 3. Temporarily install a new ITSM. Refer to
Troubleshooting, “Replacing the ITSM”.
F. Install a jumper wire into the terminals for the
suspect sensor on the 54-pin connector on the 4. If the problem is resolved with the new ITSM,
ITSM. For identification of the terminals, refer to install the original ITSM and verify that the
Illustration 164 or 165. problem returns. If the new ITSM operates
correctly and the original ITSM does not operate
G. Switch the 35 amp circuit breaker ON. Set the correctly, replace the original ITSM. Refer to
engine control to the STOP mode. Observe the Troubleshooting, “Replacing the ITSM”.
“Active Diagnostic” screen. Allow a minimum of 30
seconds for any diagnostic codes to be generated. STOP.
Expected Result:
i02089570
When the 54-pin connectors were disconnected, an

“open circuit” diagnostic code was generated for the
PWM Sensor
suspect sensor. When the jumper wire was installed, SMCS Code: 5574-038
a “short circuit” diagnostic code was generated.
Results:
The engine contains the following Pulse Width
• Yes – When the 54-pin connectors were Modulated sensors (PWM):
disconnected, an “open circuit” diagnostic code
was generated for the suspect sensor. When
the jumper wire was installed, a “short circuit”
• Engine coolant pressure (outlet)
diagnostic code was generated. The ITSM is
OK. There is a problem in the harness between
• Inlet manifold air pressure
the ITSM and the connector for the suspect A PWM sensor produces a digital signal. In a digital
thermocouple. signal, the duty cycle varies as the input condition
changes. The frequency remains constant. Refer to
Repair: Remove the jumper wire. Replace the Illustration 171.
harness in order to ensure reliable operation. Clear
the logged diagnostic codes and verify that the
problem is resolved.
All of the wiring from the thermocouples to the

ITSM must be K type. The polarity of the wires
from each thermocouple to the ITSM must be
maintained in order for the ITSM to read the correct
temperatures.
STOP.
336

resolved.
g01065665
Illustration 171
Duty cycles that are low, medium, and high

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.

Before you begin this procedure, print the logged
codes to a file.
337
g01065666
Illustration 172
Schematic for the PWM sensors

g01065667
Illustration 174
Terminal box
g01054206
Illustration 173 (2) J2/P2 connectors for the master ECM
(4) J7/P7 connectors for the PWM sensors
B. Thoroughly inspect the following connectors:
position.
Troubleshooting, “Inspecting Electrical Connectors”. • J7/P7 connectors
• The connectors for each PWM sensor
338

6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
g01057769
Illustration 175
(P1-5) Return
(P1-10) Signal for inlet manifold air pressure
g00933045
Illustration 177
(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)

PWM sensors.
g01057771
Illustration 176
(P2-68) Signal for engine coolant pressure (outlet)
339
g01065668
Illustration 178
Top view
(5) Sensor for engine coolant pressure (6) Sensor for inlet manifold air pressure
(outlet)
d. Check the harness and wiring for abrasion and C. Observe the “Active Diagnostic” screen on Cat ET.
for pinch points from each of the PWM sensors Allow a minimum of thirty seconds for any codes
to the master ECM. 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 not
replace parts, if necessary. 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:
• 106-03 Air Inlet Pressure Sensor open/short to

+batt
340
• 106-08 Air Inlet Pressure Sensor noisy signal Results:
• 109-03 Engine Coolant Outlet Pressure • OK – The voltage is within the specification. The
open/short to +batt correct voltage is present at the sensor connector.
• 109-08 Engine Coolant Outlet Pressure noisy
signal • Not OK – The voltage is not within the specification.
The correct voltage is not present at the sensor
Expected Result: connector. The correct voltage must be present
at the sensor connector in order to continue this
One of the above codes is active. procedure.
Results: Repair: Verify that the wiring and/or connectors

are OK. Repair any faulty wiring and/or connectors,
• Yes – At least one of the above diagnostic codes when possible. Replace any faulty wiring and/or
is active. Proceed to Test Step 4. connectors, if necessary. Refer to Troubleshooting,
• No – None of the above codes are active.
STOP.
Repair: If any of the above codes are logged
and the engine is not running properly, refer to Test Step 5. Verify that +Battery Voltage
Troubleshooting, “Troubleshooting Without a is Not Present in the Signal Wire
Diagnostic Code”.
If the engine is running properly at this time,

there may be an intermittent problem in the
harness that is causing the codes to be logged.
Refer to Troubleshooting, “Inspecting Electrical
Connectors”.
STOP. Illustration 180

g00896299
Harness connector for the PWM sensors

Test Step 4. Verify the Supply Voltage to
the Sensor (B) Return
(C) Signal

A. At the harness connector for the suspect sensor,
B. Disconnect the suspect sensor. measure the voltage between terminal (B) and
terminal (C).
C. Set the engine control to the STOP mode.
Expected Result:
Results:
• OK – The voltage is between 7.0 VDC and 8.0

VDC. The battery voltage is not present in the
g00896288
signal wire. Proceed to Test Step 6.
Illustration 179
Harness connector for the PWM sensors • Not OK – The voltage is approximately equal to
(A) 8 volt supply the battery voltage. The signal wire is probably
(B) Return shorted to the battery between the sensor and the
master ECM.
D. At the harness connector for the suspect sensor,
measure the voltage between terminals (A) and Repair: Set the engine control to the OFF/RESET
(B). mode. Switch the 35 amp circuit breaker OFF.
Repair the harness, when possible. Replace the
Expected Result: harness, if necessary.
The voltage is between 7.6 VDC and 8.4 VDC. STOP.

341
• Not OK – The voltage is approximately 0 volts. 4. Disconnect the sensor. Connect a sensor that is
The signal wire is probably shorted to ground known to be good. Do not install the new sensor
between the sensor and the master ECM. into the engine yet.
Repair: Set the engine control to the OFF/RESET 5. Set the engine control to the STOP mode. Allow
mode. Switch the 35 amp circuit breaker OFF. a minimum of 30 seconds for any codes to
Repair the harness, when possible. Replace the activate.
harness, if necessary.
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 the terminals that are appropriate for the suspect
breakout t. sensor.
D. Set the engine control to the STOP mode. The terminals for the connection of the probes are
identified in Table 28.
E. Measure the duty cycle and the frequency of the
suspect sensor. Table 28
Terminals for the Connection of the Probes

Expected Result:
Suspect Sensor Connector and Terminals
The duty cycle is between 5 percent and 95 percent. Engine coolant pressure J2-68 and J1-5
(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
• OK – The duty cycle is between 5 percent and both the duty cycle and the frequency. Connect
95 percent. The frequency is between 400 and the multimeter to the probes.
600 Hz. A valid signal is produced by the sensor.
Proceed to Test Step 7. D. Switch the 35 amp circuit breaker ON. Set the
• Not OK – The duty cycle or the frequency is
incorrect. The sensor is receiving the correct E. Measure the duty cycle and the frequency of the
supply voltage but the sensor is not producing a suspect sensor.
valid signal.
Expected Result:
The duty cycle is between 5 percent and 95 percent.
1. Thoroughly inspect the connector for the sensor
according to Troubleshooting, “Inspecting The frequency is between 400 and 600 Hz.
Results:
2. Check the duty cycle and the frequency of the
sensor signal again. • OK – The duty cycle is between 5 percent and 95
percent. The frequency is between 400 and 600
3. If the duty cycle and the frequency of the sensor Hz. The ECM is receiving a valid signal from the
signal are incorrect, set the engine control to sensor.
the OFF/RESET mode.
342
1. Set the engine control to the OFF/RESET The master ECM and the throttle actuator
mode. Switch the 35 amp circuit breaker OFF. communicate via the CAN data link. The master
ECM sends a command signal to the actuator. The
2. Switch the 35 amp circuit breaker ON. Set the actuator sends the following information to the master
engine control to the STOP mode. ECM: actuator position, CCM heartbeat, software
version, and internal fault diagnosis.
3. Check “Status Screen Group 2” on Cat ET. Look
for a valid signal. If the master ECM cannot communicate with the
throttle actuator, the master ECM activates a 1440-09
It is possible that the actual air inlet pressure is diagnostic code and the engine is shut down. A
less than the pressure that can be measured by 1440-09 diagnostic code is probably caused by a
the sensor during low idle operation (26.7 kPa problem with an electrical connector or a harness.
(3.87 psi)). This causes the master ECM to set The next likely cause is a problem with the actuator.
the 106-03 diagnostic code although there is no The least likely cause is a problem with the master
short circuit to the +Battery side. In this case, ECM.
adjust the derivative gain and the fuel quality in
order to make the engine more stable at low idle. Terminating resistors must be connected to each
Refer to Troubleshooting, “System Configuration end of the CAN data link. The terminating resistors
Parameters”. improve the communication between the devices. If
there is an intermittent diagnostic code for any of the
Otherwise, verify that the master ECM is receiving devices that are connected to the CAN data link, be
the correct voltage. Refer to Troubleshooting, sure to check the terminating resistor that is inside
“Electrical Power Supply”. the terminal box. Also check the jumper wire that is
connected between terminals J and K on the actuator
If the condition is not resolved, temporarily install for the bypass valve. Make repairs, when possible.
a new master ECM. Refer to Troubleshooting, Replace parts, if necessary.
If the problem is resolved with the new ECM, Before you begin this procedure, use the Caterpillar
install the original ECM and verify that the problem Electronic Technician (ET) to print the logged codes
returns. If the new ECM operates correctly and the to a file.
the original ECM. Refer to Troubleshooting, This troubleshooting procedure may generate
“Replacing the ECM”. additional diagnostic codes. Keep your mind on
STOP. Clear the diagnostic codes after the problem is
resolved.
• Not OK – The duty cycle or the frequency is
incorrect. The sensor is producing a valid signal
but the signal does not reach the master ECM.
There is a problem in the harness between the
sensor and the master ECM.
Repair: Repair the harness, when possible.

Replace the harness, if necessary.
STOP.
i02089593
Throttle Actuator
SMCS Code: 1716-038
The throttle actuator is an electronic actuator that

works with the master Electronic Control Module
(ECM) in order to ensure the correct throttle position
in all conditions of engine operation.
343
g01065716
Illustration 181
Schematic for the circuit of the throttle actuator
344

g01065717
Illustration 183
Terminal box
g01054206
Illustration 182 (2) Ground strap
(4) J9/P9 connectors for the CAN data link
(1) 35 amp circuit breaker (5) J10/P10 connectors for the terminating resistor for the CAN
data link
A. Set the engine control to the OFF/RESET position.
Switch 35 amp circuit breaker (1) to the OFF B. Thoroughly inspect each of the following
position. connectors:
Note: For the following steps, refer to • J1/P1 connectors

• Connectors on the throttle actuator
6 ± 1 N·m (55 ± 9 lb in).

torque is 2.25 ± 0.25 N·m (20 ± 2 lb in).
345
g01054209
Illustration 184
(P1-34) CAN data link −
(P1-42) CAN shield
(P1-50) CAN data link +
g01065718
Illustration 186
Right side view with the throttle actuator
d. Check the wiring for abrasion and for pinch

points from the throttle actuator to the master
ECM.
Expected Result:
All of the connectors, pins, and sockets are connected

Results:


g00934039
Illustration 185 improper.
(J9-6) CAN data link + Repair: Perform the necessary repairs and/or
(J9-12) CAN data link − replace parts, if necessary. Ensure that all of
(J9-18) CAN shield the seals are properly installed. Ensure that the
c. Perform a 45 N (10 lb) pull test on each of repair has eliminated the original problem.
the wires that are associated with the throttle
actuator. STOP.

to the service tool connector on the terminal box.

C. Use Cat ET in order to determine if a 1440-09

diagnostic code is active.
346
The 1440-09 code is not active. The continuity of the circuits between the terminals
is good.
Results:
Results:
• OK – The 1440-09 code is not active. The
communication between the master ECM and the • OK – The continuity of the circuits between the
throttle actuator appears to be OK at this time. terminals is good. Proceed to Test Step 4.
However, diagnostic codes may be logged.
• Not OK – At least one of the continuity checks
Repair: If you are troubleshooting an intermittent indicates an open circuit. There is an open circuit
problem, refer to Troubleshooting, “Inspecting for the CAN data link between the throttle actuator
Electrical Connectors”. and the master ECM.
Terminating resistors must be connected to each Repair: The open circuit could be caused by a poor
end of the CAN data link. The terminating resistors electrical connection in a connector. Alternatively,
improve the communication between the devices. the open circuit could be caused by one of the
If there is an intermittent diagnostic code for any of following components:
the devices that are connected to the CAN data
link, be sure to check the terminating resistor that • The harness inside the terminal box
is inside the terminal box. Also check the jumper
wire that is connected between terminals J and K • The harness between the terminal box and the
on the actuator for the bypass valve. Make repairs, fuel metering valve
• The harness between the fuel metering valve
STOP. and the throttle actuator
• Not OK (Active 1440-09) – The master ECM • The fuel metering valve
has detected a problem with the communication
between the master ECM and the throttle actuator. Make repairs, when possible. Replace parts, if
Proceed to Test Step 3. necessary.
Test Step 3. Check the CAN Data Link for STOP.

Continuity Between the Throttle Actuator
and the Master ECM Test Step 4. Check the CAN Data Link for
a Short Circuit
Switch the 35 amp circuit breaker OFF. A. Verify that the engine control is in the OFF/RESET
mode and that the 35 amp circuit breaker is OFF.
B. Disconnect the P1 connector. Disconnect the
connector for the throttle actuator. B. Use a multimeter to check for continuity between
the points that are listed in Table 30. During each
C. Use a multimeter to check for continuity between measurement, wiggle the harnesses in order to
the points that are listed in Table 29. During each check for an intermittent problem with the harness.
measurement, wiggle the harnesses in order to Be sure to wiggle the harness near each of the
check for an intermittent problem with the harness. connectors. Be sure to wiggle the harness near
Be sure to wiggle the harness near each of the the fuel metering valve.
connectors. Be sure to wiggle the harness near
the fuel metering valve.
Table 29
Connector and Harness Connector for the
Terminal Throttle Actuator
P1-34 Terminal B (CAN data link −)
P1-50 Terminal A (CAN data link +)
P1-42 Terminal M (CAN shield)
347
Table 30 Expected Result:

The 1440-09 code is not active.
P1-34 (CAN Data Link −) P1-50 (CAN Data Link +)
Results:
P1-42 (CAN Shield)
P1-52 (+ Battery) • OK – The 1440-09 code is not active. The problem
Ground strap for the ECM seems to be resolved. The initial diagnostic
P1-50 (CAN Data Link +) P1-42 (CAN Shield) connection.
P1-52 (+ Battery)
Ground strap for the ECM
P1-42 (CAN Shield) P1-52 (+ Battery) that is causing the code to be logged, refer
Ground strap for the ECM to Troubleshooting, “Inspecting Electrical
Connectors”.
Expected Result:
STOP.
All of the measurements indicate an open circuit.
• Not OK – The 1440-09 code is active.
Results:
Repair: The active 1440-09 code could be caused
by one of the following components:
• OK – All of the measurements indicate an open
circuit. The CAN data link does not have a short
circuit. • The master ECM
Repair: Reconnect the P1 connector. Reconnect • The throttle actuator

the connector for the throttle actuator.
• The actuator for the bypass valve
• The fuel metering valve
• Not OK – At least one of the measurements It is unlikely that any of the components that are
indicate a short circuit.
listed above have failed. Exit this procedure and
Repair: The short circuit could be caused by a poor perform this procedure again. If the 1440-09 code
electrical connection in a connector. Alternatively, remains active, perform the following procedure:
the short circuit could be caused by one of the
following components: 1. Temporarily install a new master ECM. Refer
to Troubleshooting, “Replacing the ECM”. If
the problem is resolved with the new ECM,
• The harness inside the terminal box install the original ECM and verify that the
• The harness between the terminal box and the correctly and the original ECM does not operate
fuel metering valve
correctly, replace the original ECM. Refer to
Troubleshooting, “Replacing the ECM”. If the
• The harness between the fuel metering valve problem is not resolved with a new ECM, install
and the throttle actuator
the original ECM. Continue with this procedure.
• The fuel metering valve 2. Temporarily install a new throttle actuator. If
Make repairs, when possible. Replace parts, if the new throttle actuator operates correctly,
necessary. the problem is resolved. If the new throttle
actuator does not operate correctly, install the
STOP. original throttle actuator and continue with this
procedure.
3. Temporarily install a new actuator for the bypass
A. Switch the 35 amp circuit breaker ON. Set the valve. If the new actuator for the bypass valve
engine control to the STOP mode. operates correctly, the problem is resolved. If
the new actuator for the bypass valve does not
B. Use Cat ET in order to determine if a 1440-09 operate correctly, install the original actuator
diagnostic code is active. for the bypass valve and continue with this
procedure.
348
4. Temporarily install a new fuel metering valve.

If the new fuel metering valve operates
correctly, the problem is resolved. If the new
fuel metering valve does not operate correctly,
install the original fuel metering valve. Refer
Connectors”.
STOP.
349
Calibration Procedures
i02089646
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 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).
350
Test Step 1. Install the Transducer
g01065745
Illustration 187
Right side view
(1) 6V-3093 Transducer Adapter (3) Connector for the 7X-1695 cable
(2) 6V-2197 Magnetic Transducer (4) 7X-1695 Cable
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 the on the terminal box. For instructions, refer to
left side or the right side of the flywheel housing. Troubleshooting, “Electronic Service Tools”. Start
Install 6V-3093 Transducer Adapter (1) into the Cat ET.
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 (2). 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 the C. Use either of the following methods in order to
adapter in order to secure the transducer in place. initiate the calculation of the new timing reference:
C. Connect the one end of 7X-1695 Cable (4) to the • Press the space bar on the keyboard of the PC.
transducer. Connect the other end of the cable to
connector (3) on the side of the engine. • Click the left mouse button on the “Continue”
button in the lower left corner of the Cat ET
D. Set the engine control to the STOP mode. screen.
351
Cat ET will indicate “Please wait...Calculating the i02089716

new Timing Reference”. After a few moments,
Cat ET will display “The ECM has calculated the Generator Output Power
Timing Reference” and “Choose the Continue Sensor - Calibrate
button to program the Timing Reference”.
D. Use either of the following methods in order to
program the new timing reference: System Operation Description:
• Press the space bar on the keyboard of the PC. The master Electronic Control Module (ECM) must
receive an accurate signal that indicates the power
• Click the left mouse button on the “Continue” output of the generator. When the generator is
button in the lower left corner of the Cat ET stopped, the signal must be less than 0.01 VDC. The
screen. offset voltage is the voltage level of the signal when
the generator is stopped.
Expected Result:
An offset voltage above 0.01 VDC can be reduced by
After a few moments, Cat ET will display adding resistance to the circuit.
“CALIBRATION SUCCESSFUL”.
The following steps describe the procedure for adding
Results: the correct amount of resistance to the circuit in order
to reduce the offset voltage to an acceptable level.
• OK – The timing calibration was successful.
Disconnect the transducer and the cable. Remove Test Step 1. Identify the Configuration of
the adapter and reinstall the timing calibration plug. the Wiring
Replace the protective cover on the transducer.
STOP. A. Remove the electrical power from the engine.
• 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.
Repair: Replace the master ECM according to

the instructions in Troubleshooting, “Replacing the
ECM”.
STOP.
352
g01065858
Illustration 188
Schematic for the wiring between the generator output power sensor and the ECM
B. Carefully inspect the wiring between the generator B. Connect an ohmmeter to the end terminals of the
output power sensor and the ECM. Refer to potentiometer. Measure the resistance between
Illustration 188. Determine if a potentiometer has the end terminals.
been connected to the wiring.
C. Adjust the potentiometer in order to create the
Expected Result: minimum resistance across the terminals.
A potentiometer is connected to the wiring. D. Refer to Illustration 188. Connect the

potentiometer to the wiring. Use 16 gauge wire in
Results: order to make the connections. You may connect
the potentiometer to the positive terminal or to the
• Yes – A potentiometer is connected to the wiring. negative terminal of the generator output power
Proceed to Test Step 3. sensor.
• No – A potentiometer is not connected to the Expected Result:

wiring. Proceed to Test Step 2.
The potentiometer is connected correctly.
Test Step 2. Install a Potentiometer
Results:
The potentiometer must have the following
characteristics: • OK – The potentiometer is connected properly.
• 5000 Ohms
• Not OK – The potentiometer is not connected
• Linear taper properly.
• 10 turns Repair: Make repairs to the installation, as needed.
The wattage rating of the potentiometer is not STOP.

important. 122-9457 Potentiometer meets these
specifications. Test Step 3. Adjust the Potentiometer to
the Minimum Value
A. Connect the terminal for the wiper to an end
terminal. Use a piece of 16 gauge wire in order A. Disconnect one of the wires that is used to
to make the connection. connect the potentiometer to the circuit.
353
B. Connect an ohmmeter to the end terminals of the

potentiometer.
C. Adjust the potentiometer in order to create the

minimum resistance across the terminals.
D. Reconnect the wire to the circuit.
Expected Result:
The potentiometer is set to the minimum value.
Results:
• OK – The potentiometer is set to the minimum

value. Proceed to Test Step 4.
• Not OK – The potentiometer is not set to the

minimum value.
Repair: The potentiometer must be set to the

minimum value before you continue with this
procedure. Perform this Test Step again. When
the potentiometer is set to the minimum value,
continue with this procedure.
STOP.
Test Step 4. Adjust the Potentiometer

Note: The multimeter must be connected to the P1
connector.
g01066039
Illustration 189
Terminal box
(P1-19) Return for the input from the generator output power
sensor
(P1-25) Input from the generator output power sensor
A. Insert 7X-1710 Multimeter Probes into terminals

P1-19 and P1-25. Connect a digital voltmeter to
the probes. The polarity of the connections is not
important.
B. Restore the electrical power to the engine. Set the

engine control to the STOP position.
C. Verify that the probes are making good contact

with the terminals inside the connector. Measure
the DC voltage at the terminals.
D. While you are measuring the voltage at the

terminals of the master ECM, slowly adjust the
potentiometer. The voltage reading will decrease
as you increase the resistance. The adjustment
is correct when the voltage reading is between
±0.00 VDC and ±0.01 VDC. A reading of zero
VDC is ideal.
354
Expected Result:
The voltage decreases as the potentiometer is

adjusted. The final voltage is between ±0.0 VDC and
±0.01 VDC.
Results:
• OK – The voltage is between ±0.0 VDC and

±0.01 VDC. The calibration procedure has been
completed successfully.
Repair: Adjust the “Power Monitoring” parameters.

“Electronic Control System Parameters”.
STOP.
• Not OK – The potentiometer cannot be adjusted

in order to attain a DC voltage between ±0.0 VDC
and ±0.01 VDC.
Repair: Replace the potentiometer and perform

this entire procedure again.
STOP.
355
Index Section
Index
Numerics E129 Engine Oil Filter Diff Pressure High
Warning ............................................................. 157
+5V Sensor Voltage Supply................................. 199 E130 Engine Oil Filter Diff Pressure High
+8V Sensor Voltage Supply................................. 206 Shutdown........................................................... 157
E135 Low Jacket Water Pressure Shutdown ...... 157
E223 High Gas Temperature ............................... 158
A E224 High Jacket Water Inlet Pressure............... 158
E225 Engine Overcrank ...................................... 158
Analog Sensor Signal .......................................... 214 E226 Driven Equipment Not Ready..................... 158
E229 Fuel Energy Content Setting Low .............. 159
E230 Fuel Energy Content Setting High.............. 159
C E231 Fuel Quality Out of Range.......................... 159
E243 High Left Turbo Turbine Outlet
Calibration Procedures ........................................ 349 Temperature....................................................... 159
CAT Data Link ..................................................... 223 E244 High Right Turbo Turbine Outlet
Compressor Bypass ............................................ 229 Temperature....................................................... 160
Customer Passwords ............................................ 27 E245 High Right Turbo Turbine Inlet
Temperature....................................................... 160
E246 High Left Turbo Turbine Inlet Temperature.. 161
D E264 Emergency Stop Activated......................... 161
E268 Unexpected Engine Shutdown................... 161
Desired Speed Input (4 - 20 mA)......................... 235 E269 Customer Shutdown Requested ................ 161
Detonation ............................................................. 36 E270 Driven Equipment Shutdown Requested ... 162
Probable Causes ............................................... 36 E337 High Engine Oil to Engine Coolant Diff
Recommended Repairs ..................................... 37 Temp .................................................................. 162
Detonation Sensors ............................................. 239 E401 Cylinder #1 Detonation............................... 163
Diagnostic Codes .................................................. 65 E402 Cylinder #2 Detonation............................... 163
Active Diagnostic Codes .................................... 66 E403 Cylinder #3 Detonation............................... 163
Logged Diagnostic Codes.................................. 66 E404 Cylinder #4 Detonation............................... 163
Diagnostic Functional Tests................................. 199 E405 Cylinder #5 Detonation............................... 164
Driven Equipment .................................................. 38 E406 Cylinder #6 Detonation............................... 164
Probable Causes ............................................... 38 E407 Cylinder #7 Detonation............................... 164
Recommended Repairs ..................................... 38 E408 Cylinder #8 Detonation............................... 164
E409 Cylinder #9 Detonation............................... 165
E410 Cylinder #10 Detonation............................. 165
E E411 Cylinder #11 Detonation ............................. 165
E412 Cylinder #12 Detonation............................. 165
E004 Engine Overspeed Shutdown .................... 152 E413 Cylinder #13 Detonation............................. 166
E016 High Engine Coolant Temperature E414 Cylinder #14 Detonation............................. 166
Shutdown........................................................... 152 E415 Cylinder #15 Detonation............................. 166
E017 High Engine Coolant Temperature E416 Cylinder #16 Detonation............................. 166
Warning ............................................................. 153 E417 Cylinder #17 Detonation............................. 167
E019 High Engine Oil Temperature Shutdown .... 153 E418 Cylinder #18 Detonation............................. 167
E020 High Engine Oil Temperature Warning....... 153 E419 Cylinder #19 Detonation............................. 167
E026 High Inlet Air Temperature Shutdown ........ 153 E420 Cylinder #20 Detonation............................. 167
E027 High Inlet Air Temperature Warning ........... 154 E421 Cylinder #1 Detonation Shutdown.............. 168
E038 Low Engine Coolant Temperature E422 Cylinder #2 Detonation Shutdown.............. 168
Warning ............................................................. 154 E423 Cylinder #3 Detonation Shutdown.............. 168
E040 Low Engine Oil Pressure Shutdown........... 154 E424 Cylinder #4 Detonation Shutdown.............. 168
E042 Low System Voltage Shutdown.................. 155 E425 Cylinder #5 Detonation Shutdown.............. 169
E043 Low System Voltage Warning .................... 155 E426 Cylinder #6 Detonation Shutdown.............. 169
E050 High System Voltage Warning ................... 155 E427 Cylinder #7 Detonation Shutdown.............. 169
E053 Low Fuel Pressure Warning....................... 155 E428 Cylinder #8 Detonation Shutdown.............. 169
E096 High Fuel Pressure .................................... 156 E429 Cylinder #9 Detonation Shutdown.............. 170
E100 Low Engine Oil Pressure Warning ............. 156 E430 Cylinder #10 Detonation Shutdown............ 170
E127 Engine Oil Filter Diff Pressure Low E431 Cylinder #11 Detonation Shutdown............ 170
Warning ............................................................. 156 E432 Cylinder #12 Detonation Shutdown............ 171
E128 Engine Oil Filter Diff Pressure Low E433 Cylinder #13 Detonation Shutdown............ 171
Shutdown........................................................... 156 E434 Cylinder #14 Detonation Shutdown............ 171
E435 Cylinder #15 Detonation Shutdown............ 171
356
Index Section
E436 Cylinder #16 Detonation Shutdown............ 172 E846 Cyl #6 Exhaust Port Temp Deviating Low .. 191
E440 Cylinder #20 Detonation Shutdown............ 173 E850 Cyl #10 Exhaust Port Temp Deviating
E801 Cylinder #1 High Exhaust Port Temp ......... 173 Low .................................................................... 193
E802 Cylinder #2 High Exhaust Port Temp ......... 173 E851 Cyl #11 Exhaust Port Temp Deviating Low.. 193
E803 Cylinder #3 High Exhaust Port Temp ......... 174 E852 Cyl #12 Exhaust Port Temp Deviating
E810 Cylinder #10 High Exhaust Port Temp ....... 177 Low .................................................................... 195
E811 Cylinder #11 High Exhaust Port Temp........ 177 E856 Cyl #16 Exhaust Port Temp Deviating
E813 Cylinder #13 High Exhaust Port Temp ....... 178 E857 Cyl #17 Exhaust Port Temp Deviating
E821 Cyl #1 Exhaust Port Temp Deviating High.. 181 E864 Low Gas Fuel Differential Pressure ........... 197
E822 Cyl #2 Exhaust Port Temp Deviating High.. 181 E865 High Gas Fuel Differential Pressure........... 197
E823 Cyl #3 Exhaust Port Temp Deviating High.. 182 E866 Low Gas Fuel Flow Rate............................ 197
E824 Cyl #4 Exhaust Port Temp Deviating High.. 182 E867 Improper Gas Flow Control Valve
E825 Cyl #5 Exhaust Port Temp Deviating High.. 183 Response........................................................... 198
E826 Cyl #6 Exhaust Port Temp Deviating High.. 183 E868 Gas Flow Control Valve Malfunction .......... 198
E827 Cyl #7 Exhaust Port Temp Deviating High.. 183 ECM Output Circuit (Fuel Control)....................... 248
E828 Cyl #8 Exhaust Port Temp Deviating High.. 184 ECM Output Circuit (Starting Motor).................... 257
E829 Cyl #9 Exhaust Port Temp Deviating High.. 184 ECM Status Indicator Output............................... 269
E830 Cyl #10 Exhaust Port Temp Deviating ECM Will Not Accept Factory Passwords.............. 38
High ................................................................... 185 Probable Causes ............................................... 38
E831 Cyl #11 Exhaust Port Temp Deviating Recommended Repairs ..................................... 38
High ................................................................... 185 Electrical Connectors and Functions ..................... 16
E832 Cyl #12 Exhaust Port Temp Deviating Harness Wire Identification ................................ 16
High ................................................................... 185 Junction Box ...................................................... 18
E833 Cyl #13 Exhaust Port Temp Deviating Terminal Box ...................................................... 16
High ................................................................... 186 Electrical Power Supply....................................... 275
E834 Cyl #14 Exhaust Port Temp Deviating Electronic Service Tool Will Not Communicate with
High ................................................................... 186 ECM (The Caterpillar Electronic Technician (ET)
E835 Cyl #15 Exhaust Port Temp Deviating Will Not Communicate With an Electronic Control
High ................................................................... 187 Module (ECM) and/or the Integrated Temperature
E836 Cyl #16 Exhaust Port Temp Deviating Sensing Module (ITSM))...................................... 38
High ................................................................... 187 Electronic Service Tools ........................................ 18
E838 Cyl #18 Exhaust Port Temp Deviating Caterpillar Electronic Technician (ET)................ 19
High ................................................................... 188 Electronic Troubleshooting .................................... 10
E839 Cyl #19 Exhaust Port Temp Deviating Engine Coolant Temperature (High) ...................... 39
High ................................................................... 189 Engine Coolant Temperature (Low)....................... 41
E841 Cyl #1 Exhaust Port Temp Deviating Low .. 189 Probable Causes ............................................... 41
E842 Cyl #2 Exhaust Port Temp Deviating Low .. 189 Recommended Repairs ..................................... 41
E843 Cyl #3 Exhaust Port Temp Deviating Low .. 190 Engine Cranks but Will Not Start ........................... 41
E844 Cyl #4 Exhaust Port Temp Deviating Low .. 190 Probable Causes ............................................... 41
E845 Cyl #5 Exhaust Port Temp Deviating Low .. 191 Recommended Repairs ..................................... 41
357
Index Section
Engine Misfires, Runs Rough or Is Unstable......... 42 F

Probable Causes ............................................... 42
Recommended Repairs ..................................... 42 Factory Passwords ................................................ 27
Engine Monitoring System..................................... 20 Factory Passwords Worksheet.............................. 28
Changing the Settings of the Monitoring Flash Programming ............................................... 29
System ............................................................. 21 Flash Programming............................................ 29
Default Settings of the Monitoring System......... 22 Fuel Energy Content.............................................. 55
Monitoring Parameters....................................... 21 Probable Causes ............................................... 55
Programmable Parameters of the Integrated Recommended Repairs ..................................... 55
Temperature Sensing Module .......................... 25 Fuel Metering Valve....................................... 55, 289
Engine Oil Filter Differential Pressure ................... 44 Probable Causes ............................................... 55
Probable Causes ............................................... 44 Recommended Repairs ..................................... 55
Recommended Repairs ..................................... 44 Fuel Pressure ........................................................ 55
Engine Oil Pressure (Low)..................................... 44 Probable Causes ............................................... 55
Recommended Repairs ..................................... 44
Engine Oil Temperature (High) .............................. 45
Probable Causes ............................................... 45 G
Engine Overcrank.................................................. 46 Gas Fuel Differential Pressure (High).................... 55
Probable Causes ............................................... 46 Probable Causes ............................................... 55
Recommended Repairs ..................................... 46 Recommended Repairs ..................................... 56
Engine Overload.................................................... 47 Gas Fuel Differential Pressure (Low) .................... 56
Recommended Repairs ..................................... 47 Recommended repairs....................................... 56
Engine Overspeed................................................. 47 Gas Fuel Flow Rate (Low)..................................... 56
Engine Shutdown .................................................. 48 Gas Temperature (High) ........................................ 57
Engine Shutdown (Unexpected)............................ 48 Generator Output Power Readings Do Not
Probable Causes ............................................... 48 Match ................................................................... 58
Recommended Repair ....................................... 48 Probable Causes ............................................... 58
Engine Shutdown without a Diagnostic Code........ 50 Recommended Repairs ..................................... 58
Probable Causes ............................................... 50 Generator Output Power Sensor ......................... 298
Recommended Repairs ..................................... 50 Generator Output Power Sensor - Calibrate ....... 351
Engine Speed/Timing Sensor .............................. 282
Engine Speed/Timing Sensor - Calibrate ............ 349
Engine Starts but Stalls Immediately..................... 51 I
Probable Causes ............................................... 51
Recommended Repairs ..................................... 51 Ignition Transformers Primary Circuit .................. 305
Engine Timing Does Not Match Programmed Ignition Transformers Secondary Circuit and Spark
Timing .................................................................. 51 Plugs.................................................................. 316
Probable Causes ............................................... 51 Important Safety Information ................................... 2
Recommended Repairs ..................................... 51 Inlet Air Temperature (High) .................................. 59
Engine Will Not Crank ........................................... 52 Probable Causes ............................................... 59
Recommended Repairs ..................................... 52 Inspecting Electrical Connectors ......................... 322
Event Codes ........................................................ 150 Integrated Temperature Sensing Module
Active Event Codes.......................................... 151 (ITSM)................................................................ 327
Diagnostic Codes and Event Codes ................ 151 Intermittent Engine Shutdown ............................... 60
Logged Event Codes ....................................... 152 Probable Causes ............................................... 60
Operator Information........................................ 151 Recommended Repairs ..................................... 60
Other Symptoms .............................................. 151
Troubleshooting ............................................... 151
Exhaust Port Temperature (High) .......................... 53 J
Probable Causes ............................................... 53
Recommended Repairs ..................................... 53 Jacket Water Inlet Pressure (High)........................ 60
Exhaust Port Temperature (Low)........................... 54 Probable Causes ............................................... 60
358
Index Section
Jacket Water Pressure (Low) ................................ 61 MID 033 - CID 0320 - FMI 08 Engine Speed/Timing
Probable Causes ............................................... 61 signal abnormal ................................................... 74
Recommended Repairs ..................................... 61 MID 033 - CID 0401 - FMI 05 Ignition Transformer
Jacket Water to Engine Oil Differential Temperature Secondary #1 open circuit ................................... 74
(Low).................................................................... 61 MID 033 - CID 0401 - FMI 06 Ignition Transformer
Probable Causes ............................................... 61 Secondary #1 short to ground ............................. 74
Recommended Repairs ..................................... 62 MID 033 - CID 0403 - FMI 05 Ignition Transformer
Secondary #3 open circuit ................................... 75
L Secondary #3 short to ground ............................. 75
Location of Components........................................ 12 Secondary #5 open circuit ................................... 75
Actuators............................................................ 12 MID 033 - CID 0405 - FMI 06 Ignition Transformer
Fuel Metering Valve ........................................... 12 Secondary #5 short to ground ............................. 76
Integrated Temperature Sensing Module........... 15 MID 033 - CID 0407 - FMI 05 Ignition Transformer
Sensors.............................................................. 12 Secondary #7 open circuit ................................... 76
Thermocouples .................................................. 14 MID 033 - CID 0407 - FMI 06 Ignition Transformer
M Secondary #9 open circuit ................................... 77
MID 033 - CID 0041 - FMI 03 8 Volt DC Supply short Secondary #9 short to ground ............................. 77
to +batt................................................................. 66 MID 033 - CID 0411 - FMI 05 Ignition Transformer
MID 033 - CID 0041 - FMI 04 8 Volt DC Supply short Secondary #11 open circuit ................................. 78
to ground.............................................................. 67 MID 033 - CID 0411 - FMI 06 Ignition Transformer
MID 033 - CID 0168 - FMI 02 System Voltage Secondary #11 short to ground............................ 78
intermittent/erratic ................................................ 67 MID 033 - CID 0413 - FMI 05 Ignition Transformer
MID 033 - CID 0301 - FMI 05 Ignition Transformer Secondary #13 open circuit ................................. 79
Primary #1 open circuit ........................................ 67 MID 033 - CID 0413 - FMI 06 Ignition Transformer
MID 033 - CID 0301 - FMI 06 Ignition Transformer Secondary #13 short to ground ........................... 79
Primary #1 short .................................................. 68 MID 033 - CID 0415 - FMI 05 Ignition Transformer
Primary #3 open circuit ........................................ 68 MID 033 - CID 0415 - FMI 06 Ignition Transformer
MID 033 - CID 0303 - FMI 06 Ignition Transformer Secondary #15 short to ground ........................... 80
Primary #3 short .................................................. 68 MID 033 - CID 0590 - FMI 09 Unable to communicate
MID 033 - CID 0305 - FMI 05 Ignition Transformer with Engine ECM ................................................. 80
Primary #5 open circuit ........................................ 69 MID 033 - CID 1501 - FMI 03 Cylinder #1 Detonation
MID 033 - CID 0305 - FMI 06 Ignition Transformer Sensor open/short to +batt .................................. 81
Primary #5 short .................................................. 69 MID 033 - CID 1501 - FMI 04 Cylinder #1 Detonation
MID 033 - CID 0307 - FMI 05 Ignition Transformer Sensor short to ground ........................................ 81
Primary #11 open circuit ...................................... 71 MID 033 - CID 1513 - FMI 03 Cylinder #13 Detonation
Primary #11 short................................................. 71 MID 033 - CID 1513 - FMI 04 Cylinder #13 Detonation
Primary #13 open circuit ...................................... 72 MID 033 - CID 1517 - FMI 03 Cylinder #17 Detonation
Primary #13 short ................................................ 72 MID 033 - CID 1517 - FMI 04 Cylinder #17 Detonation
Primary #15 open circuit ...................................... 72 MID 033 - CID 1748 - FMI 05 Ignition Transformer
Primary #15 short ................................................ 73 MID 033 - CID 1748 - FMI 06 Ignition Transformer
MID 033 - CID 0320 - FMI 03 Speed/Timing Sensor Secondary #17 short to ground ........................... 84
short to +batt........................................................ 73
359
Index Section
Secondary #19 open circuit ................................. 85 Primary #4 open circuit ........................................ 96
Secondary #19 short to ground ........................... 85 Primary #4 short .................................................. 97
Primary #17 open circuit ...................................... 85 Primary #6 open circuit ........................................ 97
Primary #17 short to ground ................................ 86 Primary #6 short .................................................. 97
Primary #19 open circuit ...................................... 86 Primary #8 open circuit ........................................ 98
Primary #19 short to ground ................................ 87 Primary #8 short .................................................. 98
MID 036 - CID 0017 - FMI 05 Fuel Shutoff Valve open MID 036 - CID 0310 - FMI 05 Ignition Transformer
circuit ................................................................... 87 Primary #10 open circuit ...................................... 98
MID 036 - CID 0017 - FMI 06 Fuel Shutoff Valve short MID 036 - CID 0310 - FMI 06 Ignition Transformer
to ground.............................................................. 87 Primary #10 short ................................................ 99
MID 036 - CID 0017 - FMI 12 Fuel Shutoff Valve MID 036 - CID 0312 - FMI 05 Ignition Transformer
malfunction .......................................................... 88 Primary #12 open circuit ...................................... 99
MID 036 - CID 0041 - FMI 03 8 Volt DC Supply short MID 036 - CID 0312 - FMI 06 Ignition Transformer
to +batt................................................................. 88 Primary #12 short .............................................. 100
MID 036 - CID 0041 - FMI 04 8 Volt DC Supply short MID 036 - CID 0314 - FMI 05 Ignition Transformer
to ground.............................................................. 88 Primary #14 open circuit .................................... 100
MID 036 - CID 0100 - FMI 03 Engine Oil Pressure MID 036 - CID 0314 - FMI 06 Ignition Transformer
open/short to +batt............................................... 89 Primary #14 short .............................................. 100
MID 036 - CID 0100 - FMI 04 Engine Oil Pressure MID 036 - CID 0316 - FMI 05 Ignition Transformer
short to ground..................................................... 89 Primary #16 open circuit .................................... 101
MID 036 - CID 0106 - FMI 03 Air Inlet Pressure MID 036 - CID 0316 - FMI 06 Ignition Transformer
Sensor short to +batt ........................................... 90 Primary #16 short .............................................. 101
MID 036 - CID 0106 - FMI 08 Air Inlet Pressure MID 036 - CID 0320 - FMI 03 Speed/Timing Sensor
Sensor noisy signal.............................................. 90 short to +batt...................................................... 101
MID 036 - CID 0109 - FMI 03 Coolant Outlet Pressure MID 036 - CID 0320 - FMI 08 Engine Speed/Timing
open/short to +batt............................................... 90 signal abnormal ................................................. 102
MID 036 - CID 0109 - FMI 08 Engine Coolant Outlet MID 036 - CID 0323 - FMI 03 Shutdown Lamp short
Pressure Sensor noisy signal .............................. 91 to +batt............................................................... 102
MID 036 - CID 0110 - FMI 03 Engine Coolant MID 036 - CID 0324 - FMI 03 Warning Lamp short to
Temperature open/short to +batt ......................... 91 +batt................................................................... 102
MID 036 - CID 0110 - FMI 04 Engine Coolant MID 036 - CID 0336 - FMI 02 Incorrect ECS Switch
Temperature short to ground ............................... 91 inputs ................................................................. 103
MID 036 - CID 0145 - FMI 03 12 Volt DC Power MID 036 - CID 0402 - FMI 05 Ignition Transformer
Supply short to +batt............................................ 92 Secondary #2 open circuit ................................. 103
MID 036 - CID 0145 - FMI 04 12 Volt DC Power MID 036 - CID 0402 - FMI 06 Ignition Transformer
Supply short to ground......................................... 92 Secondary #2 short to ground ........................... 103
MID 036 - CID 0168 - FMI 02 System Voltage MID 036 - CID 0404 - FMI 05 Ignition Transformer
intermittent/erratic ................................................ 92 Secondary #4 open circuit ................................. 104
MID 036 - CID 0172 - FMI 03 Intake Manifold Air MID 036 - CID 0404 - FMI 06 Ignition Transformer
Temp open/short to +batt..................................... 93 Secondary #4 short to ground ........................... 104
MID 036 - CID 0172 - FMI 04 Intake Manifold Air MID 036 - CID 0406 - FMI 05 Ignition Transformer
Temp short to ground........................................... 93 Secondary #6 open circuit ................................. 105
MID 036 - CID 0175 - FMI 03 Engine Oil Temperature MID 036 - CID 0406 - FMI 06 Ignition Transformer
open/short to +batt............................................... 93 Secondary #6 short to ground ........................... 105
MID 036 - CID 0175 - FMI 04 Engine Oil Temperature MID 036 - CID 0408 - FMI 05 Ignition Transformer
short to ground..................................................... 94 Secondary #8 open circuit ................................. 105
MID 036 - CID 0261 - FMI 13 Engine Timing MID 036 - CID 0408 - FMI 06 Ignition Transformer
calibration required .............................................. 94 Secondary #8 short to ground ........................... 106
MID 036 - CID 0262 - FMI 03 5 Volt Sensor DC MID 036 - CID 0410 - FMI 05 Ignition Transformer
Power Supply short to +batt ................................ 95 Secondary #10 open circuit ............................... 106
MID 036 - CID 0262 - FMI 04 5 Volt Sensor DC MID 036 - CID 0410 - FMI 06 Ignition Transformer
Power Supply short to ground ............................. 95 Secondary #10 short to ground ......................... 107
Primary #2 open circuit ........................................ 96 Secondary #12 open circuit ............................... 107
Primary #2 short .................................................. 96 Secondary #12 short to ground ......................... 107
360
Index Section
Secondary #14 open circuit ............................... 108 Power Sensor open/short to +batt ...................... 118
Secondary #14 short to ground ......................... 108 Power Sensor short to ground ............................ 118
Secondary #16 open circuit ............................... 108 Power Sensor malfunction.................................. 119
MID 036 - CID 0416 - FMI 06 Ignition Transformer MID 036 - CID 1720 - FMI 09 Turbocharger
Secondary #16 short to ground ......................... 109 Compressor Bypass Valve Actuator not
MID 036 - CID 0443 - FMI 03 Crank Terminate Relay communicating on link ........................................ 119
short to +batt...................................................... 109 MID 036 - CID 1749 - FMI 05 Ignition Transformer
MID 036 - CID 0444 - FMI 05 Start Relay open Secondary #18 open circuit ................................ 119
circuit .................................................................. 110 MID 036 - CID 1749 - FMI 06 Ignition Transformer
MID 036 - CID 0444 - FMI 06 Start Relay short to Secondary #18 short to ground ......................... 120
ground................................................................. 110 MID 036 - CID 1751 - FMI 05 Ignition Transformer
MID 036 - CID 0445 - FMI 03 Run Relay short to Secondary #20 open circuit ............................... 120
+batt.................................................................... 110 MID 036 - CID 1751 - FMI 06 Ignition Transformer
MID 036 - CID 0524 - FMI 03 Desired Engine Speed Secondary #20 short to ground ......................... 120
Sensor short to +batt .......................................... 111 MID 036 - CID 1753 - FMI 05 Ignition Transformer
MID 036 - CID 0524 - FMI 04 Desired Engine Speed Primary #18 open circuit .................................... 121
Sensor short to ground ....................................... 111 MID 036 - CID 1753 - FMI 06 Ignition Transformer
MID 036 - CID 0542 - FMI 03 Unfiltered Engine Oil Primary #18 short to ground .............................. 121
Pressure open/short to +batt .............................. 111 MID 036 - CID 1755 - FMI 05 Ignition Transformer
MID 036 - CID 0542 - FMI 04 Unfiltered Engine Oil Primary #20 open circuit .................................... 121
Pressure short to ground .................................... 112 MID 036 - CID 1755 - FMI 06 Ignition Transformer
MID 036 - CID 1042 - FMI 09 Unable to communicate Primary #20 short to ground .............................. 122
with ITSM............................................................ 112 MID 111 - CID 0591 - FMI 12 EEPROM checksum
MID 036 - CID 1440 - FMI 09 Unable to communicate fault or ECM not programmed ........................... 122
with Throttle Actuator Drv ................................... 113 MID 111 - CID 1489 - FMI 03 Left Turbo Turbine Out
MID 036 - CID 1446 - FMI 05 Fuel Metering Module Temp Sens short to +batt................................... 122
open circuit ......................................................... 113 MID 111 - CID 1489 - FMI 04 Left Turbo Turbine Out
MID 036 - CID 1446 - FMI 09 Unable to communicate Temp Sens short to ground................................ 123
with Fuel Metering Module.................................. 113 MID 111 - CID 1489 - FMI 05 Left Turbo Turbine Out
MID 036 - CID 1446 - FMI 12 Fuel Metering Module Temp Sens open circuit ..................................... 123
malfunction ......................................................... 114 MID 111 - CID 1490 - FMI 03 Rt Turbo Turbine Out
MID 036 - CID 1446 - FMI 13 Fuel Metering Module Temp Sens short to +batt................................... 123
calibration required ............................................. 114 MID 111 - CID 1490 - FMI 04 Rt Turbo Turbine Out
MID 036 - CID 1447 - FMI 12 Fuel Metering Sensor Temp Sens short to ground................................ 124
Module malfunction............................................. 114 MID 111 - CID 1490 - FMI 05 Rt Turbo Turbine Out
MID 036 - CID 1502 - FMI 03 Cylinder #2 Detonation Temp Sens open circuit ..................................... 124
Sensor open/short to +batt ................................. 114 MID 111 - CID 1491 - FMI 03 Rt Turbo Turbine In
MID 036 - CID 1502 - FMI 04 Cylinder #2 Detonation Temp Sens short to +batt................................... 124
Sensor short to ground ....................................... 115 MID 111 - CID 1491 - FMI 04 Rt Turbo Turbine In
MID 036 - CID 1506 - FMI 03 Cylinder #6 Detonation Temp Sens short to ground................................ 125
Sensor open/short to +batt ................................. 115 MID 111 - CID 1491 - FMI 05 Rt Turbo Turbine In
Sensor short to ground ....................................... 115 MID 111 - CID 1492 - FMI 03 Left Turbo Turbine In
MID 036 - CID 1510 - FMI 03 Cylinder #10 Detonation Temp Sens short to +batt................................... 125
Sensor open/short to +batt ................................. 116 MID 111 - CID 1492 - FMI 04 Left Turbo Turbine In
MID 036 - CID 1510 - FMI 04 Cylinder #10 Detonation Temp Sens short to ground................................ 126
Sensor short to ground ....................................... 116 MID 111 - CID 1492 - FMI 05 Left Turbo Turbine In
Sensor open/short to +batt ................................. 116 MID 111 - CID 1531 - FMI 03 Cyl #1 Exhaust Port
MID 036 - CID 1514 - FMI 04 Cylinder #14 Detonation Temp Sensor short to +batt ............................... 126
Sensor short to ground ....................................... 117 MID 111 - CID 1531 - FMI 04 Cyl #1 Exhaust Port
MID 036 - CID 1518 - FMI 03 Cylinder #18 Detonation Temp Sensor short to ground ............................ 127
Sensor open/short to +batt ................................. 117 MID 111 - CID 1531 - FMI 05 Cyl #1 Exhaust Port
MID 036 - CID 1518 - FMI 04 Cylinder #18 Detonation Temp Sensor open circuit .................................. 127
Sensor short to ground ....................................... 117 MID 111 - CID 1532 - FMI 03 Cyl #2 Exhaust Port
MID 036 - CID 1636 - FMI 09 Loss of Communication Temp Sensor short to +batt ............................... 127
with Engine #2 (Slave)........................................ 118 MID 111 - CID 1532 - FMI 04 Cyl #2 Exhaust Port
Temp Sensor short to ground ............................ 128
361
Index Section
Temp Sensor open circuit .................................. 128 Temp Sensor short to +batt ............................... 140
Temp Sensor short to +batt ............................... 129 Temp Sensor short to ground ............................ 140
Temp Sensor short to ground ............................ 129 Temp Sensor open circuit .................................. 141
MID 111 - CID 1540 - FMI 05 Cyl #10 Exhaust Port
Temp Sensor open circuit .................................. 137
MID 111 - CID 1541 - FMI 03 Cyl #11 Exhaust Port P
Temp Sensor short to +batt ............................... 138
MID 111 - CID 1541 - FMI 04 Cyl #11 Exhaust Port Programming Parameters ..................................... 27
Temp Sensor short to ground ............................ 138 PWM Sensor ....................................................... 335
MID 111 - CID 1542 - FMI 03 Cyl #12 Exhaust Port R
Temp Sensor short to +batt ............................... 139
MID 111 - CID 1542 - FMI 04 Cyl #12 Exhaust Port Replacing the ECM................................................ 30
Temp Sensor short to ground ............................ 139 Replacing the ITSM ............................................... 32
362
Index Section
Self-Diagnostics...................................................... 11
Symptoms.............................................................. 36
Diagnostic Codes and Event Codes .................. 36
Operator Information.......................................... 36
Other Symptoms ................................................ 36
System Configuration Parameters......................... 29
System Overview................................................... 10
Air/Fuel Ratio Control......................................... 10
Engine Monitoring and Protection....................... 11
Engine Speed Governing................................... 10
Ignition Control.................................................... 11
Introduction ........................................................ 10
Start/Stop Sequencing ....................................... 10
System Voltage...................................................... 62
Probable Causes ............................................... 62
Table of Contents..................................................... 3
Throttle Actuator .................................................. 342
Troubleshooting Data Sheet.................................. 34
Report the Service Information .......................... 35
Troubleshooting Section........................................ 10
Troubleshooting with a Diagnostic Code ............... 65
Troubleshooting with an Event Code................... 150
Troubleshooting without a Diagnostic Code .......... 36
Turbocharger Turbine Temperature (High) ............ 62
Probable Causes ............................................... 62
Turbocharger Turbine Temperature (Low)............. 63
Probable Causes ............................................... 63
363
Index Section
©2004 Caterpillar
All Rights Reserved Printed in U.S.A.

G3520C Trouble Shooting

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RENR5979-03

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 Inlet Air Temperature (High) .................................. 59

Troubleshooting Section Desired engine speed is determined by the status

Ignition Control • Logged

A code is cleared from memory when one of the

• The service technician manually clears the code. Actuators

Event Code – An event code is generated when

Fuel Metering Valve

Throttle actuator (1) and the actuator for the

The sensors also enable the activation of alarms

The fuel metering valve is electrically controlled

Illustration 6 shows the locations of the

Integrated Temperature Sensing

Illustration 7 shows the location of the ITSM. Refer to

i02088018 Terminal Box

Harness Wire Identification

RD Red Rear view

WH White (1) Terminal box

For example, a code of J011-RD on the schematic

The schematic also identifies the size of the wire.

Electronic Service Tools

Caterpillar Electronic Service Tools are designed to

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 slave

Check the continuity between terminals J3-29

Engine Monitoring System

Changing the Settings of the “Engine Overspeed”

“Low System Voltage” “Low Oil Filter Differential Pressure”

“Low System E043 (1) Warning 20 volts 20

“High Engine Oil E020 (1) Warning 102 °C Customer 85 to 102 °C

Separate timers are used in the master ECM for each

For example, the warning for “High Engine Coolant

Conditions for Parameters

The conditions are designed to eliminate false events

If the trip point for a shutdown is programmed to

Programmable Parameters of the

If a temperature exceeds an acceptable range, the

• Select the available responses.

The default settings for the parameters are

Table 5 lists default examples of the values for the

If the trip point for a shutdown is programmed to

Separate timers are used in the ITSM for each

For example, the warning for the “High Exhaust

Programming Parameters After the customer passwords are entered, the

NOTICE The passwords are now programmed into the

SMCS Code: 0785

Factory passwords are required to program the i02089534

• Serial number of the engine Customer’s Name

i01866010 A list of flash files will appear.

“WinFlash” will try to detect an ECM. Allow a few i01945454

moments for “WinFlash” to detect the electronic

Refer to Systems Operation/Testing and Adjusting, (Table 8, contd)

Perform the following procedure to replace the ECM.

1. Use the “Service/Copy Configuration/ECM

Save the file. You can select “Load from ECM”.

Note: Before you replace an ECM, record all of the

a. Connect the Cat ET with the communications