Beruflich Dokumente
Kultur Dokumente
September 2005
Troubleshooting
3516B and 3516B High Displacement
Engines for Caterpillar Built Machines
FDB1-Up (Machine)
8WM1-Up (Engine)
7TR1-Up (Engine)
g01206901
Illustration 1
RENR5622 7
Troubleshooting Section
Typical schematic
g01206905
Illustration 2
Typical schematic
8 RENR5622
Troubleshooting Section
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Illustration 3
Typical schematic
RENR5622 9
Troubleshooting Section
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Illustration 4
Front and Left view
(1) Turbocharger compressor outlet (5) Left turbocharger compressor inlet (12) Connector for the remote shutdown
pressure sensor (boost) pressure sensor (13) Low oil level switch
(2) Aftercooler temperature sensor (front) (7) Fuel filter differential pressure switch (14) Unfiltered engine oil pressure sensor
(3) Right turbocharger compressor inlet (8) Filtered engine oil pressure sensor (15) Atmospheric pressure sensor
pressure sensor (9) ECM connector J1/P1 (16) ECM connector J2/P2
(4) Coolant temperature sensor (10) Machine connector (17) Engine speed/timing sensor
(6) Left exhaust temperature sensor (11) Connection for the prelube
10 RENR5622
Troubleshooting Section
g01208648
Illustration 5
Rear and Right view
(18) Aftercooler temperature sensor (rear) (22) Crankcase pressure sensor
(19) Right exhaust temperature sensor (23) Connector for the engine oil renewal
(20) Connector for the wastegate solenoid solenoid
(21) Timing calibration plug (24) Coolant flow switch
RENR5622 11
Troubleshooting Section
Diagnostic Code
Event Code
Diagnostic Code A diagnostic code indicates an
electrical problem such as a short or an open in the
engines wiring or in an electrical component of the
engine.
Active
Logged
Active Codes
An active code indicates that a problem is present.
Service the active code first. For the appropriate
troubleshooting procedure for a particular code, refer
to the following troubleshooting procedure:
Logged Codes
The codes are logged and stored in the ECM
memory. The problem may have been repaired
and/or the problem may no longer exist. If the
system is powered, it is possible to generate an
active diagnostic code whenever a component is
disconnected. If the component is reconnected, the
code is no longer active but the code may become
logged.
12 RENR5622
Troubleshooting Section
i02414932
g01158941
Illustration 6
Connectors for the ECM
RENR5622 13
Troubleshooting Section
Machine Connector
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Illustration 7
40 pin machine connector
g01158896
Illustration 8
14 RENR5622
Troubleshooting Section
Sensor Connectors
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Illustration 9
Typical engine connectors
i02419684
Obtain data.
Diagnose problems.
Read parameters.
Program parameters.
Calibrate sensors.
Two short jumper wires are needed to check the Part Description
continuity of some wiring harness circuits by shorting Number
two adjacent terminals together in a connector. A
N/A Personal Computer (PC)
long extension wire may also be needed to check the
continuity of some wiring harness circuits.
JERD2124 Single user license for Cat ET
Parameters
16 RENR5622
Troubleshooting Section
Connecting Cat ET and the 4. Restore electrical power to the ECM. If Cat ET and
Communication Adapter II the communication adapter do not communicate
with the Electronic Control Module (ECM), refer
to troubleshooting without a diagnostic code
Troubleshooting, Electronic Service Tool Will Not
Communicate with ECM.
i02415084
g01115382
Illustration 10
(1) Personal computer (PC)
(2) 196-0055 Adapter Cable As
(3) 171-4401 Communication Adapter As
(4) 207-6845 Adapter Cable As
Note: Items (2), (3), and (4) are part of the 171-4400
Communication Adapter Gp.
Table 4
Cross-Reference from MID-CID-FMI Code to Functional Test or Procedure
MID-CID-FMI Code Functional Test or Procedure
MID 0036 - CID 0001 - FMI 05 Cylinder #1 Injector open Injector Solenoids
circuit
MID 0036 - CID 0001 - FMI 06 Cylinder #1 Injector short Injector Solenoids
MID 0036 - CID 0002 - FMI 05 Cylinder #2 Injector open Injector Solenoids
circuit
MID 0036 - CID 0002 - FMI 06 Cylinder #2 Injector short Injector Solenoids
MID 0036 - CID 0003 - FMI 05 Cylinder #3 Injector open Injector Solenoids
circuit
MID 0036 - CID 0003 - FMI 06 Cylinder #3 Injector short Injector Solenoids
MID 0036 - CID 0004 - FMI 05 Cylinder #4 Injector open Injector Solenoids
circuit
MID 0036 - CID 0004 - FMI 06 Cylinder #4 Injector short Injector Solenoids
MID 0036 - CID 0005 - FMI 05 Cylinder #5 Injector open Injector Solenoids
circuit
MID 0036 - CID 0005 - FMI 06 Cylinder #5 Injector short Injector Solenoids
MID 0036 - CID 0006 - FMI 05 Cylinder #6 Injector open Injector Solenoids
circuit
MID 0036 - CID 0006 - FMI 06 Cylinder #6 Injector short Injector Solenoids
MID 0036 - CID 0007 - FMI 05 Cylinder #7 Injector open Injector Solenoids
circuit
MID 0036 - CID 0007 - FMI 06 Cylinder #7 Injector short Injector Solenoids
MID 0036 - CID 0008 - FMI 05 Cylinder #8 Injector open Injector Solenoids
circuit
MID 0036 - CID 0008 - FMI 06 Cylinder #8 Injector short Injector Solenoids
MID 0036 - CID 0009 - FMI 05 Cylinder #9 Injector open Injector Solenoids
circuit
MID 0036 - CID 0009 - FMI 06 Cylinder #9 Injector short Injector Solenoids
MID 0036 - CID 0010 - FMI 05 Cylinder #10 Injector open Injector Solenoids
circuit
MID 0036 - CID 0010 - FMI 06 Cylinder #10 Injector short Injector Solenoids
MID 0036 - CID 0011 - FMI 05 Cylinder #11 Injector open Injector Solenoids
circuit
MID 0036 - CID 0011 - FMI 06 Cylinder #11 Injector short Injector Solenoids
MID 0036 - CID 0012 - FMI 05 Cylinder #12 Injector open Injector Solenoids
circuit
MID 0036 - CID 0012 - FMI 06 Cylinder #12 Injector short Injector Solenoids
MID 0036 - CID 0013 - FMI 05 Cylinder #13 Injector open Injector Solenoids
circuit
MID 0036 - CID 0013 - FMI 06 Cylinder #13 Injector short Injector Solenoids
MID 0036 - CID 0014 - FMI 05 Cylinder #14 Injector open Injector Solenoids
circuit
MID 0036 - CID 0014 - FMI 06 Cylinder #14 Injector short Injector Solenoids
MID 0036 - CID 0015 - FMI 05 Cylinder #15 Injector open Injector Solenoids
circuit
(continued)
18 RENR5622
Troubleshooting Section
(Table 4, contd)
Cross-Reference from MID-CID-FMI Code to Functional Test or Procedure
MID-CID-FMI Code Functional Test or Procedure
MID 0036 - CID 0015 - FMI 06 Cylinder #15 Injector short Injector Solenoids
MID 0036 - CID 0016 - FMI 05 Cylinder #16 Injector open Injector Solenoids
circuit
MID 0036 - CID 0016 - FMI 06 Cylinder #16 Injector short Injector Solenoids
MID 0036 - CID 0091 - FMI 08 Throttle Position signal Throttle Position Sensor
abnormal
MID 0036 - CID 0101 - FMI 03 Crankcase Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0101 - FMI 04 Crankcase Pressure short Analog Sensor (Active)
to ground
MID 0036 - CID 0110 - FMI 03 Engine Coolant Temperature Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0110 - FMI 04 Engine Coolant Temperature Analog Sensor (Active)
short to ground
MID 0036 - CID 0168 - FMI 01 System Voltage Low Electrical Power Supply
MID 0036 - CID 0168 - FMI 02 Battery Voltage Electrical Power Supply
intermittent/erratic
MID 0036 - CID 0190 - FMI 08 Engine Speed signal abnormal Engine Speed/Timing Sensor
MID 0036 - CID 0253 - FMI 11 Personality Module mechanical Flash Programming
failure
MID 0036 - CID 0261 - FMI 13 Engine Timing calibration Engine Speed/Timing Sensor - Calibrate
required
MID 0036 - CID 0262 - FMI 03 5 Volt Sensor DC Power Sensor Supply
Supply short to +batt
MID 0036 - CID 0262 - FMI 04 5 Volt Sensor DC Power Sensor Supply
Supply short to ground
MID 0036 - CID 0263 - FMI 03 Digital Sensor Supply short Sensor Supply
to +batt
MID 0036 - CID 0263 - FMI 04 Digital Sensor Supply short Sensor Supply
to ground
MID 0036 - CID 0267 - FMI 02 Incorrect Engine Shutdown Ground Level Shutdown Switch
Switch inputs
MID 0036 - CID 0268 - FMI 02 Check Programmable System Configuration Parameters
Parameters
MID 0036 - CID 0273 - FMI 03 Turbo Outlet Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0273 - FMI 04 Turbo Outlet Pressure short Analog Sensor (Active)
to ground
MID 0036 - CID 0274 - FMI 03 Atmospheric Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0274 - FMI 04 Atmospheric Pressure short Analog Sensor (Active)
to ground
MID 0036 - CID 0275 - FMI 03 Right Turbo Inlet Pressure Analog Sensor (Active)
open/short to +batt
(continued)
RENR5622 19
Troubleshooting Section
(Table 4, contd)
Cross-Reference from MID-CID-FMI Code to Functional Test or Procedure
MID-CID-FMI Code Functional Test or Procedure
MID 0036 - CID 0275 - FMI 04 Right Turbo Inlet Pressure Analog Sensor (Active)
short to ground
MID 0036 - CID 0276 - FMI 03 Left Turbo Inlet Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0276 - FMI 04 Left Turbo Inlet Pressure Analog Sensor (Active)
short to ground
MID 0036 - CID 0279 - FMI 03 Aftercooler Temperature Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0279 - FMI 04 Aftercooler Temperature short Analog Sensor (Active)
to ground
MID 0036 - CID 0296 - FMI 09 Unable to communicate with Cat Data Link
Transmission ECM
MID 0036 - CID 0338 - FMI 05 Pre-lube Relay open circuit Prelubrication System
MID 0036 - CID 0338 - FMI 06 Pre-lube Relay short to ground Prelubrication System
MID 0036 - CID 0526 - FMI 05 Turbo Wastegate Drive Wastegate Solenoid
current low
MID 0036 - CID 0526 - FMI 06 Turbo Wastegate Drive Wastegate Solenoid
current high
MID 0036 - CID 0542 - FMI 03 Unfiltered Engine Oil Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0542 - FMI 04 Unfiltered Engine Oil Pressure Analog Sensor (Active)
short to ground
MID 0036 - CID 0543 - FMI 03 Filtered Engine Oil Pressure Analog Sensor (Active)
open/short to +batt
MID 0036 - CID 0543 - FMI 04 Filtered Engine Oil Pressure Analog Sensor (Active)
short to ground
MID 0036 - CID 0545 - FMI 05 Ether Start Relay open/short Ether Injection System
to +batt
MID 0036 - CID 0545 - FMI 06 Ether Start Relay short to Ether Injection System
ground
MID 0036 - CID 0546 - FMI 05 Ether Hold Relay open/short Ether Injection System
to ground
MID 0036 - CID 0546 - FMI 06 Ether Hold Relay short to +batt Ether Injection System
MID 0036 - CID 0569 - FMI 05 Oil Renewal Solenoid open Engine Oil Renewal Solenoid
circuit
MID 0036 - CID 0569 - FMI 06 Oil Renewal Solenoid short Engine Oil Renewal Solenoid
to ground
MID 0036 - CID 0800 - FMI 09 Unable to communicate with Cat Data Link
VIMS
MID 0036 - CID 0827 - FMI 08 Left Exhaust Temperature Pulse Width Modulated Sensor
signal abnormal
MID 0036 - CID 0828 - FMI 08 Right Exhaust Temperature Pulse Width Modulated Sensor
signal abnormal
MID 0036 - CID 0829 - FMI 03 Rear Aftercool Temperature Analog Sensor (Active)
open/short to +batt
(continued)
20 RENR5622
Troubleshooting Section
(Table 4, contd)
Cross-Reference from MID-CID-FMI Code to Functional Test or Procedure
MID-CID-FMI Code Functional Test or Procedure
MID 0036 - CID 0829 - FMI 04 Rear Aftercool Temperature Analog Sensor (Active)
short to ground
MID 0036 - CID 1495 - FMI 02 Injector Trim Codes Not System Configuration Parameters
Programmed
Table 6
Cross-Reference from Event Code to Troubleshooting Procedure
Event Code Troubleshooting Procedure
E017 High Engine Coolant Temperature Warning Coolant Temperature Is Too High
E021 High Exhaust Temperature Derate Exhaust Temperature Is Too High
E035 Loss of Coolant Flow Warning Coolant Flow Switch
E038 Low Engine Coolant Temperature Warning Coolant Temperature Is Too Low
E072 Oil Level Low Mark Low Engine Oil Pressure
E073 Oil Filter Differential Pressure High Low Engine Oil Pressure
E074 Oil Filter Differential Pressure Very High Low Engine Oil Pressure
E092 Boost Pressure Above Normal Boost Pressure Above Normal
E093 Boost Pressure Below Normal Boost Pressure Below Normal
E095 Fuel Filter Restriction Warning Fuel Filter Differential Pressure Switch
E098 Engine Prelube Override Prelubrication System
E100 Low Engine Oil Pressure Warning Low Engine Oil Pressure
E101 High Crankcase Pressure Warning Crankcase Pressure (High)
E190 Engine Overspeed Warning Engine Overspeed
E265 User Defined Shutdown User Defined Shutdown Input
E272 Inlet Air Restriction Warning Inlet Air Restriction
E279 High Aftercooler Temperature Warning Coolant Temperature Is Too High
g01138880
The number of occurrences of the code
Illustration 12
Example of the typical operating range of a temperature sensor Logged events are listed in chronological order. The
(1) This area represents the normal operating range of the most recent event code is listed first.
parameter. The normal output voltage of the sensor is between
0.2 VDC and 4.2 VDC. This information can be helpful for troubleshooting
(2) In this area, the temperature above 107 C (225 F) is higher intermittent problems. Logged codes can also be
than normal. The output voltage of the sensor will generate an
event code. The sensor does not have an electronic problem.
used to review the performance of the engine.
(3) In these areas, the output voltage of the sensor is too high
or too low. The voltage is outside of the normal range. The
electronic problem will generate a diagnostic code. Refer
Clearing Event Codes
to Troubleshooting, Diagnostic Code List for additional
information on diagnostic codes. A code is cleared from memory when one of the
following conditions occur:
Events are represented in two formats. In the first
format, the E means that the code is an event The code does not recur for 100 hours.
code. The XXX represents a numeric identifier for
the event code. This is followed by a description of A new code is logged and there are already ten
the code. If a warning, a derate, or a shutdown is codes in memory. In this case, the oldest code is
applicable, the numeric identifiers are different. Refer cleared.
to the following example:
The service technician manually clears the code.
E004 Engine Overspeed Shutdown
Always clear logged event codes after investigating
In the second format, the E means that the code is and correcting the problem which generated the
an event code. The XXX-X represents a numeric code.
identifier for the event code. The fourth X identifies
the event as a warning, a derate, or a shutdown. This
is followed by a description of the code. Refer to the
following example:
24 RENR5622
Troubleshooting Section
Fuel supply
Oil level
Oil supply
Wiring
Connectors
Be sure to check the connectors. This is very
important for problems that are intermittent. Refer to
Troubleshooting, Inspecting Electrical Connectors.
Table 7
Trip Points for the Monitoring System
Delay Time in Seconds Trip Point
Condition Action Default
Min Max Default Min Max Default State
E017 High Engine Coolant 102 C
Warning N/A N/A 5 N/A N/A On
Temperatur (216 F)
E021 High Exhaust 500 C 800 C 750 C
Derate(1) 1 60 5 On
Temperature (932 F) (1472 F) (1382 F)
E035 Loss of Coolant
Warning N/A N/A 8 N/A N/A Open On
Flow
E038 Low Engine Coolant
Warning N/A N/A 120 N/A N/A 70 C (158 F) On
Temperature
E072 Oil Level Low Mark Warning N/A N/A 3 N/A N/A Open On
E073 Oil Filter Differential 69 kPa
Warning N/A N/A 240 N/A N/A On
Pressure High (10 psi)
E074 Oil Filter Differential 200 kPa
Warning N/A N/A 240 N/A N/A On
Pressure Very High (29 psi)
The actual
boost
pressure is
E092 Boost Pressure
Derate(2) N/A N/A N/A N/A N/A 20 kPa (3 psi) On
Above Normal
above the
desired boost
pressure.
The actual
boost
pressure is
E093 Boost Pressure
Warning N/A N/A N/A N/A N/A 35 kPa (5 psi) On
Below Normal
below the
desired boost
pressure.
E095 Fuel Filter 138 C
Warning N/A N/A N/A N/A N/A On
Restriction Warning (280 F)
E098 Engine Prelube The engine
Override has started
without
Warning N/A N/A N/A N/A N/A On
completing
the engine
prelubrication.
Map
E100 Low Engine Oil
Warning 1 15 4 N/A N/A dependent On
Pressure
value (3)
E101 High Crankcase 0.5 kPa 6 kPa
Warning 1 60 3 2 kPa (0.3 psi) On
Pressure (0.07 psi) (0.9 psi)
E190 Engine Overspeed Warning N/A N/A 0 1200 rpm 2400 rpm 2200 rpm On
E265 User Defined
Warning N/A N/A 1 N/A N/A Closed On
Shutdown
3 kPa 7 kPa
E272 Inlet Air Restriction Warning 1 60 5 7 kPa (1 psi) On
(0.4 psi) (1 psi)
E279 High Aftercooler 40 C 102 C 102 C
Warning 1 60 5 On
Temperature (104F) (216 F) (216 F)
(1) The ECM derates the engine in 15 second intervals in 2 percent increments when the exhaust temperature is over the trip point. The
maximum derate is 20 percent.
(2) The fuel is derated by 30 percent. The timing is retarded to four degrees before top dead center. The code is latched until power
is cycled to the ECM.
(3) Refer to Illustration 13.
26 RENR5622
Troubleshooting Section
g01210600
Illustration 13
Low oil pressure map
Table 8
(Table 8, contd)
Default Conditions and System Response
Event Code Conditions which Generate this Code System Response
E072 Oil Level Low Mark The oil level switch opens. The code is active and the code is
logged.
E073 Oil Filter Differential Pressure The oil filter differential pressure is The code is active and the code is
High above the trip point temperature. logged.
The warning for the oil filter differential
E074 Oil Filter Differential Pressure pressure is determined by subtracting
Very High the filtered oil pressure from the
unfiltered oil pressure.
E092 Boost Pressure Above Normal The actual boost pressure is above the The code is active and the code is
desired boost pressure by the trip point logged.
pressure. The fuel is derated by 30 percent. The
Engine speed is between 1275 and timing is retarded to four degrees before
1800 rpm. top dead center. The code is latched
until power is cycled to the ECM.
E093 Boost Pressure Below Normal The actual boost pressure is below the The code is active and the code is
desired boost pressure by the trip point logged.
pressure. The fuel is derated by 30 percent. The
Engine speed is between 1275 and timing is retarded to four degrees before
1800 rpm. top dead center. The code is latched
until power is cycled to the ECM.
E095 Fuel Filter Restriction Warning The restriction across the fuel filter is The code is active and the code is
greater than the trip point pressure. The logged.
fuel filter differential pressure switch
opens.
E098 Engine Prelube Override The engine has started without The code is active and the code is
completing the engine prelubrication. logged.
E100 Low Engine Oil Pressure Warning The engine oil pressure is below a map The code is active and the code is
dependent value. The oil pressure is logged.
below this value for the delay time.
E101 High Crankcase Pressure Engine crankcase pressure is above The code is active and the code is
Warning trip point pressure for the delay time. logged.
E190 Engine Overspeed Warning The engine rpm has exceeded the trip The code is active and the code is
point for engine overspeed for the delay logged.
time.
E265 User Defined Shutdown The ECM detects ground on the input The code is active and the code is
for the user defined shutdown. logged.
E272 Inlet Air Restriction Warning The inlet air restriction is above the trip The code is active and the code is
point pressure for the delay time. logged.
E279 High Aftercooler Temperature The aftercooler temperature is above The code is active and the code is
Warning the trip point temperature for the delay logged.
time.
28 RENR5622
Troubleshooting Section
Programming Parameters Note: The old interlock code and the new interlock
code are required to change the interlock code on a
used Electronic Control Module (ECM).
i01951720
The Cat ET screen for factory passwords will display
Programming Parameters the following parameters:
SMCS Code: 1901-038 Serial number of the ECM
The Caterpillar Electronic Technician (ET) can be Engine serial number
used to view certain parameters that can affect the
operation of the engine. The Cat ET can also be Serial number for Cat ET
used to change certain parameters. Some of the
parameters are protected from unauthorized changes Reason code
by passwords. Parameters that can be changed have
a tattletale number. The tattletale number shows if a Interlock code
parameter has been changed.
Total tattletale
i02385531
Note: Factory passwords are only valid for the current
Factory Passwords Cat ET screen. A different set of factory passwords
will be required if you exit the current Cat ET screen.
SMCS Code: 1901-038 A different set of passwords will be required to
change information on another Cat ET screen.
Passwords
Customer Passwords
Passwords are part of a security system that helps to
prevent unauthorized changing of certain parameters. Customer passwords allow the customer to restrict
Passwords prevent unauthorized erasing of logged access to parameters that can be changed by the
events. Passwords allow the factory to control access customer. The customer passwords cannot be longer
to engine calibration parameters. Passwords allow than eight characters. The customer passwords may
the customer to control access to certain engine consist of alphanumeric characters. The customer
parameters. has the option of entering one or two customer
passwords.
Factory Passwords If customer passwords have been entered, then
the customer passwords are required to change
Factory passwords are required to clear any event any parameter that is customer programmable.
code. Factory passwords are required to change Refer to the diagnostic procedure Troubleshooting,
certain parameters such as Full Load Setting. System Configuration Parameters for more detail
Factory passwords restrict changes to authorized on parameters that are customer programmable.
personnel. When the correct factory passwords have
been entered, the changes can then be made. Note: If the customer passwords are lost, the
parameters that are protected by customer
Note: Factory passwords are calculated on a passwords cannot be changed. You must use factory
computer system that is only available to Caterpillar passwords in order to read the customer passwords.
dealers. You may then use those customer passwords to
change parameters that have been protected by
In order to obtain the proper factory passwords, customer passwords.
certain information must be given to an authorized
Caterpillar dealer. Since the factory passwords
contain alphabetic characters, the Caterpillar i02305288
Electronic Technician (ET) can be used to perform
this function. In order to obtain the factory passwords, Factory Passwords Worksheet
proceed as if you already have the factory passwords.
At some point, if the factory passwords are actually SMCS Code: 1901-038
needed, Cat ET will request the factory passwords
and Cat ET will display the information that is required Factory passwords are required to perform the
to obtain the factory passwords. following functions:
Engine hours
Note: Engine hours do not include service meter
hours.
Table 9
i02414553
Flash Programming
SMCS Code: 1901-038
Table 10
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0253 - FMI 11 The flash file in the engines Electronic The code is active only. The engine will
Personality Module mechanical failure Control Module (ECM) is for a different not run.
application.
Program the correct flash file into the engines ECM. Caterpillar Electronic Technician (ET) is used to flash
program a file into the memory of the engines ECM.
Flash Programming This is a method of
programming or updating the flash file in an engines
ECM.
30 RENR5622
Troubleshooting Section
If you do not have the flash file, use the Flash File i02416716
Search tool on the Service Technician Workbench
(STW) to obtain the flash file for your engine. System Configuration
Alternatively, use the Service Software Files feature Parameters
on SIS Web to obtain the flash file for your engine.
You must have the engine serial number in order to SMCS Code: 1901-038
search for the flash file. After locating the correct
flash file, download the flash file to your PC. Write Use this procedure if any one of the diagnostic codes
down the name of the flash file for future reference. in Table 11 is active.
Table 11
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0268 - FMI 02 Check The engines Electronic Control Module The code is active.
Programmable Parameters (ECM) detects that one or more of the The ECM may use a default torque map
programmable parameters have not or the ECM may limit the engine to low
been programmed. idle.
MID 0036 - CID 1495 - FMI 02 Injector The engines ECM detects that one or
Trim Codes Not Programmed more of the injector trim codes have not
been programmed.
Parameter Table
Table 12
Table 13
Injector Trim Code
Injector Default Range Password
Inj #1 e-trim 0000 4 numeric characters No
Inj #2 e-trim 0000 4 numeric characters No
Inj #3 e-trim 0000 4 numeric characters No
Inj #4 e-trim 0000 4 numeric characters No
Inj #5 e-trim 0000 4 numeric characters No
Inj #6 e-trim 0000 4 numeric characters No
Inj #7 e-trim 0000 4 numeric characters No
Inj #8 e-trim 0000 4 numeric characters No
Inj #9 e-trim 0000 4 numeric characters No
Inj #10 e-trim 0000 4 numeric characters No
Inj #11 e-trim 0000 4 numeric characters No
Inj #12 e-trim 0000 4 numeric characters No
Inj #13 e-trim 0000 4 numeric characters No
Inj #14 e-trim 0000 4 numeric characters No
Inj #15 e-trim 0000 4 numeric characters No
Inj #16 e-trim 0000 4 numeric characters No
i02418875 Table 15
a. Connect Caterpillar Electronic Technician (ET) c. Remove the fuel lines from the ECM (if
to the service tool connector for the engine. equipped).
5. Check the wiring and the connectors for the Check the condition of the alternator drive pulley.
following problems: Look for deep grooves that have been worn into the
pulley by the belt. If there is excessive wear, replace
Damage the pulley. Check that the nut for the pulley has not
become loose. If necessary, tighten the nut.
Abrasion
Alternator Bearings
Corrosion
Check the alternator bearings for signs of wear.
Incorrect attachment Repair the alternator or replace the alternator, as
needed.
6. Check for any logged diagnostic codes.
RENR5622 37
Troubleshooting Section
i02418528
Table 16
Event Code
Description Conditions which Generate this Code System Response
E092 Boost Pressure Above Normal The actual boost pressure is above the The code is logged and the code is
desired boost pressure. active.
Probable Causes
Leaking wastegate diaphragm
Air supply
Wrong Full Load Setting (FLS)
Recommended Actions
Leaking Wastegate Diaphragm
Verify that the exhaust bypass valve for the wastegate
can open. Use Caterpillar Electronic Technician (ET)
to override the wastegate to 100 percent. Perform a
torque converter stall test. After 30 seconds, a low
boost pressure event should result. If a low boost
pressure event occurs, the wastegate is opening
properly.
Air Supply
Verify that the air supply to the wastegate control
valve is at least 345 kPa (50 psi).
Wrong FLS
Check that the FLS is correct.
i02418529
Table 17
Event Code
Description Conditions which Generate this Code System Response
E093 Boost Pressure Below Normal The actual boost pressure is below the The code is logged and the code is
desired boost pressure. active.
Work on the low pressure fuel supply circuit Engine Speed/Timing Signal
Replace the fuel injectors. Check Cat ET for the following logged Diagnostic
Code 190-08. Refer to the diagnostic functional test
b. Purge air from the fuel system with the priming Troubleshooting, Engine Speed/Timing Sensor.
pump and by cranking the engine in 30 second
cycles. After you crank the engine, stop for two
minutes. This will allow the starting motor to
Active Engine Derate
cool. Loosen the vent plug at the fuel return.
Connect Cat ET and check for ACTIVE engine
The plug is located on the rear upper left side
derates. If the active engine derate is due to Axle
of the engine block. Prime the engine again if
Protection, refer to the Service Manual for the
air in fuel continues. A sight glass in the low
transmission or implement control. Perform the
pressure supply line is helpful in diagnosing
air in the fuel. torque converter stall test. Compare the achieved
stall speed to specifications. If the output meets
specifications, continue with diagnostic checks.
RENR5622 39
Troubleshooting Section
Note: If this problem occurs under load, refer to Check fuel lines for the following problems:
the diagnostic procedure Troubleshooting, Low restrictions, collapse, and pinched line. Repair the
Power/Poor Or No Response To Throttle. lines and/or replace the lines.
Leaks in air system 3. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
Valve adjustment to the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the fuel
Injectors pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
Faulty accessory equipment transfer pump, fuel transfer pump coupling, and
fuel pressure regulating valve.
Recommended Actions
Air Inlet Restriction
Derate
Replace plugged air filters and/or clean the filters.
Connect Caterpillar Electronic Technician (ET) and Leaks in the air inlet manifold system can lower Inlet
check for an active derate event. A derate status manifold pressure.
flag will appear on Cat ET if an active engine derate
is occurring. In order to view active events, go to Exhaust Restriction
the Events menu under Diagnostics. Refer to
Troubleshooting, Troubleshooting with an Event Check the exhaust system for restrictions and/or for
Code for the specific events for this application. leaks.
i02423560
i02338332
Recommended Actions
Failure of Oil Cooler Cores
Inspect the oil cooler for leaks. Make repairs, as
needed. Drain the crankcase. Refill the crankcase
with clean lubricant. Change the oil filters.
Table 18
Event Code
Description Conditions which Generate this Code System Response
E038 Low Engine Coolant Temperature The coolant temperature is below the The code is active and the code is
Warning trip point. logged.
Probable Causes
Faulty water temperature regulator
Long idle periods
Very light loads
Recommended Actions
Water Temperature Regulator
A regulator that is stuck open can cause overcooling.
Overcooling also occurs when the water temperature
regulator is stuck between the following positions:
open position and closed position. Coolant leaks
that are around the water temperature regulator can
cause overcooling. An example would be a leak in
the vent line.
i02416900
Table 19
Event Code
Description Conditions which Generate this Code System Response
E017 High Engine Coolant Temperature The engine coolant temperature is The code is active and the code is
Warning above the trip point temperature. logged.
E279 High Aftercooler Temperature The aftercooler temperature is above
Warning the trip point temperature.
Faulty radiator cooling fan (if equipped) Faulty Jacket Water Coolant Pump
Faulty pressure relief valve Inspect the impeller vanes at the jacket water pump
for damage and/or for erosion. Repair impeller vanes
Faulty temperature regulator and/or replace the impeller vanes.
Coolant Leak
Check the cooling system for leaks.
Table 20
Event Code
Description Conditions which Generate this Code System Response
E101 High Crankcase Pressure Engine crankcase pressure is above The code is active and the code is
Warning the trip point for high pressure. logged.
Start the engine. If the engine starts, but the ECM Cat ET and Related Hardware
will not communicate with Cat ET, continue with
this procedure. If the engine will not start, refer to In order to eliminate Cat ET and the related hardware
Troubleshooting, Engine Cranks but Will Not Start. as the problem, connect Cat ET to a different engine.
If the engine will not crank, refer to Troubleshooting, If the same problem occurs on a different engine,
Engine Will Not Crank. check Cat ET and the related hardware in order to
determine the cause of the problem.
Configuration for the Communications
Adapter Electrical Power Supply to the Electronic
Control Module (ECM)
1. Access Preferences under the Utilities menu
on Cat ET. Check power to the ECM. Refer to Troubleshooting,
Electrical Power Supply.
2. Verify that the correct Communications Interface
Device is selected. Note: If the ECM is not receiving battery voltage, the
ECM will not communicate.
3. Verify that the correct port is selected for use by
the communication adapter.
Flash File
Note: The most commonly used port is COM 1.
Ensure that the correct flash file is properly installed
in the ECM.
4. Check for any hardware that is utilizing the
same port as the communications adapter. If any
devices are configured to use the same port, exit
or close the software programs for that device.
RENR5622 45
Troubleshooting Section
Note: The new ECM does not have a flash file. Starting Aids
The engine will not start and the engine will not
communicate with Cat ET until the flash file has 1. If cold ambient conditions exist, check operation
been installed. Refer to Troubleshooting, Flash of starting aids. Verify that the ether system is
Programming. operating correctly. Refer to Troubleshooting,
Ether Injection System.
Cat Data Link
2. Ensure the proper operation of the jacket water
Troubleshoot the Cat Data Link for possible problems. heater. Repair the jacket water heater and/or
Refer to Troubleshooting, Cat Data Link. replace the jacket water heater, if necessary.
Engine Cranks but Will Not Engine Shutdown Switches (If Equipped)
Start The engine shutdown switches should be in the
OFF position. Use Cat ET to verify the status of the
SMCS Code: 1000-038; 1901-038 shutdown switches. When a shutdown occurs, the
keyswitch must be turned to the OFF position for at
Probable Causes least 15 seconds before restarting the engine.
Event codes 1. Crank the engine and observe the engine speed
on the Cat ET status screen. If Cat ET indicates
Electrical power supply to the Electronic Control zero rpm, refer to Troubleshooting, Engine
Module (ECM) Speed/Timing Sensor.
Starting aids (if applicable) Note: Upon initial cranking, the status for engine
speed may indicate that the engine speed signal is
Engine shutdown switches abnormal. This message will be replaced with an
engine speed once the ECM is able to calculate a
Engine speed/timing speed from the signal.
3. Check the fuel tank for foreign objects which may Recommended Actions
block the fuel supply.
Incorrect Engine Oil
NOTICE
Do not crank the engine continuously for more than Use engine oil that is recommended and change the
30 seconds. Allow the starting motor to cool for two engine oil at the interval that is recommended by the
minutes before cranking the engine again. engines Operation and Maintenance Manual.
Engine Has Early Wear An indicator for the engine oil pressure may indicate
sufficient pressure, but a component is worn due to a
SMCS Code: 1000-038; 1901-038 lack of lubrication. In such a case, look at the passage
for the engine oil supply to the component. Refer to
the Systems Operation/Testing and Adjusting manual
Probable Causes for additional information.
SMCS Code: 1000-038; 1901-038 2. Perform the Injector Solenoid Test on Cat ET in
order to determine if all of the injector solenoids
Note: If the symptom is intermittent and the symptom are being energized by the ECM.
cannot be repeated, refer to Troubleshooting,
Intermittent Low Power or Power Cutout. If the 3. Perform the Cylinder Cutout Test on Cat ET in
symptom is consistent and the symptom can be order to identify any misfiring cylinder(s). Refer
repeated, continue with this procedure. to Troubleshooting, Injector Solenoids for more
information.
Probable Causes Fuel Supply
Diagnostic codes 1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
Electrical connectors problems are found with the fuel lines, repair the
lines and/or replace the lines.
Cold mode
2. Check the fuel tank for foreign objects which may
Throttle signal block the fuel supply.
Unit injectors 3. Prime the fuel supply system if any of the following
procedures have been performed:
Fuel supply
Air inlet and exhaust system Replacement of the fuel filters
Service on the low pressure fuel supply circuit
Recommended Actions
Replacement of unit injectors
Note: If the symptom only occurs under certain
operating conditions (high idle, full load, engine Note: A sight glass in the fuel supply line is helpful in
operating temperature, etc), test the engine under diagnosing air in the fuel.
those conditions. Troubleshooting the symptom
under other conditions can give misleading results. 4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Diagnostic Codes Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Check for active diagnostic codes on Caterpillar operation.
Electronic Technician (ET). Troubleshoot any active
codes before continuing with this procedure. 5. Check the fuel pressure during engine cranking.
Check the fuel pressure after the fuel filter. Refer
to the Systems Operation/Testing and Adjusting
Electrical Connectors
manual for the correct pressure values. If the fuel
Check for correct installation of the J1/P1 and J2/P2 pressure is low, replace the fuel filters. If the fuel
pressure is still low, check the following items: fuel
Electronic Control Module (ECM) connectors and the
transfer pump, fuel transfer pump coupling, and
unit injector connectors. Refer to Troubleshooting,
Inspecting Electrical Connectors. fuel pressure regulating valve.
Probable Causes
Engine oil cooler core
Cylinder head gasket
Water pump
Recommended Actions
Engine Oil Cooler Core
1. Inspect the engine oil cooler core for leaks. If a
leak is found, replace the oil cooler core. Refer to
Disassembly and Assembly.
Water Pump
Check the weep hole in the water pump for blockage.
Check the water pump seals.
RENR5622 49
Troubleshooting Section
Table 21
Event Code
Description Conditions which Generate this Code System Response
E190 Engine Overspeed Warning The engine rpm is above the trip point The code is active and the code is
for overspeed. logged.
6. Check the fuel pressure after the fuel filter while Internal engine problem
the engine is being cranked. Refer to the Systems
Operation/Testing and Adjusting manual for the
correct pressure values. If the fuel pressure is low,
Recommended Actions
replace the fuel filters. If the fuel pressure is still
low, check the following items: fuel transfer pump, Batteries and/or Battery Cables
fuel transfer pump coupling, and fuel pressure
regulating valve. 1. Inspect the main power switch, battery posts,
and battery cables for loose connections and
for corrosion. If the battery cables are corroded,
Air Shutoff Valves (if applicable) remove the battery cables and clean the battery
cables. Tighten any loose connections.
1. Verify that the air shutoff valves are open.
2. Inspect the batteries.
2. Check for restrictions in the air inlet system. Refer
to the Systems Operation/Testing and Adjusting
a. Charge the batteries. Refer to Special
manual for information on the air inlet system.
Instruction, SEHS7633, Battery Test
Procedure.
Low Idle
b. Load test the batteries. Refer to Special
Check the low idle setting. Instruction, SEHS9249, Use of 4C-4911
Battery Load Tester for 6, 8 and 12 Volt Lead
Accessory Equipment Acid Batteries.
Check all accessory equipment for problems that Starting Motor Solenoid or Starting
may create excessive load on the engine. Repair
Circuit
any damaged components or replace any damaged
components.
1. Check the operation of the engine start switch.
Monitor the engine start switch on Cat ET.
i02385621
Refer to the appropriate troubleshooting test that
Engine Will Not Crank is applicable to your engine if repairs are required.
SMCS Code: 1000-038; 1901-038 2. Test the operation of the starting motor solenoid.
Hydraulic cylinder lock Ensure that the crank enable switch is not faulty.
RENR5622 51
Troubleshooting Section
Hydraulic pump that is driven from the rear gear Oil Level
group
Inspect the engine oil level. Remove any extra oil
Air compressor from the engine. Recheck all fluid levels.
Bent components
i02304643
Valve adjustment 2. Verify that the crankshaft and the camshaft drive
gears are set with the proper orientation. Refer to
the Disassembly and Assembly manual.
Recommended Actions
Air Shutoff (if applicable) Turbocharger Compressor Outlet
Pressure Sensor, Fuel Position, and/or
Check that both the air shutoffs are open. FRC Fuel Limit
Air Inlet and Exhaust System 1. Monitor the status of Fuel Position and Rated
Fuel Limit while the engine is operating under full
1. Check the air inlet system for restrictions and/or load. If Fuel Position equals Rated Fuel Limit
for leaks. and Fuel Position is less than FRC Fuel Limit,
the electronics are operating correctly. Otherwise,
a. Check for an air filter restriction. proceed to the next Step.
b. Check for derates and for alarms. 2. Verify that there are no active diagnostic codes
for the turbocharger compressor outlet pressure
c. Perform a visual inspection of the system for sensor.
restrictions and/or for leaks.
3. Monitor the status of Turbocharger compressor
2. Check the exhaust system for restrictions. outlet pressure and Atmospheric Pressure for
normal operation on the Caterpillar Electronic
3. Repair any leaks that were found. Remove Technician (ET). When the engine is not running,
any restrictions that were found. Replace any Turbocharger compressor outlet pressure should
damaged components that were found. be 0 kPa (0 psi).
i02421039
Check the water temperature regulators for correct
operation. Verify that the engine reaches full
Excessive White Smoke operating temperature. If the engine does not reach
full operating temperature, a water temperature
SMCS Code: 1000-038; 1901-038 regulator may be stuck open. Remove the water
temperature regulator and inspect the water
Note: Some white smoke may be present during temperature regulator. If necessary, repair the
cold start-up conditions when the engine is operating water temperature regulator and/or replace the
normally. If the white smoke persists, there may be coolant temperature regulator. Refer to the Systems
a problem. Operation/Testing and Adjusting manual for the
proper procedure.
Probable Causes
Engine Speed/Timing
Starting aids (if applicable)
Check the calibration of the engine speed/timing
Coolant temperature sensor sensor. Refer to Troubleshooting, Engine
Speed/Timing Sensor - Calibrate.
Water temperature regulators
Unit Injectors
Engine speed/timing sensor
Perform the Cylinder Cutout Test on Cat ET in order
Unit injectors to try to isolate any injectors that might be misfiring.
Refer to Troubleshooting, Injector Solenoids.
Flash file
Flash File
Fuel supply
Verify that the correct flash file is installed.
Component wear
Fuel Supply
Cooling system
1. Inspect the fuel system components.
Recommended Actions
2. Check the fuel pressure during engine cranking.
Starting Aids (if applicable) Check the filtered fuel pressure. Refer to the
Systems Operation/Testing and Adjusting manual
1. If equipped, check for proper operation of installed for the correct pressure values. If the fuel pressure
starting aids. is low, replace the fuel filters. If the fuel pressure
is still low, check the following items: fuel transfer
a. Ensure that the ether canister is not empty pump, fuel transfer pump coupling, and fuel
and/or low. Replace the ether canister if the pressure regulating valve.
ether canister is empty and/or low.
3. Check the fuel quality. Low cetane fuel can create
b. Actuate the system manually after start-up white smoke. If necessary, replace the fuel with a
and observe results. The ether system will higher cetane fuel.
not operate if the coolant temperature is too
high. Refer to the diagnostic functional test 4. Cold weather adversely affects the characteristics
Troubleshooting, Ether Injection System. of the fuel. Refer to the Operation and
Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Coolant Temperature Sensor
operation.
1. Use the Caterpillar Electronic Technician (ET) to
verify that the engine has exited cold mode.
54 RENR5622
Troubleshooting Section
Component Wear
Check the engine for the following problems:
Excessive valve wear, piston wear, ring wear, liner
wear, and reduced compression pressure.
Cooling System
Check for proper operation of the jacket water heater.
Repair the jacket water heater or replace the jacket
water heater. Check for an internal coolant leak into
the cylinder and/or the exhaust. Refer to the Systems
Operation/Testing and Adjusting manual for more
information.
i02416909
Table 22
Event Code
Description Conditions which Generate this Code System Response
E021 High Exhaust Temperature Derate The exhaust temperature is above the The code is active and the code is
trip point. logged.
i02119587 i01405833
Cracked fuel supply manifold 2. Remove the fuel supply and the fuel return line
from the cylinder head.
Leaking seal on the fuel transfer pump
3. Cap the fuel return connector and apply 700 kPa
(100 psi) maximum air pressure to the fuel supply
Recommended Actions connector. Check for fuel leakage around the unit
injectors. If leakage is present, remove the unit
Leaking Seals on the Case of the Unit injector and install a new O-ring seal.
Injector or on the Barrel of the Unit
Injector i02423656
Look for signs of damage to the seals for the unit Inlet Air Restriction
injectors. Replace any seals that are leaking.
SMCS Code: 1087-038; 1901-038
Leaking Seals on the Fuel Line Adapter
Use this procedure if the following event code is
for the Cylinder Head active.
Look for signs of damage to the seals on the fuel line
adapter for the cylinder head. Repair any leaking fuel
lines or components and/or replace any leaking fuel
lines or components.
Table 23
Event Code
Description Default Conditions which Generate System Response
this Code
E272 Air Filter Restriction Warning The inlet air restriction is above the trip The code is active and the code is
point. logged.
2. Check the fuel tank for foreign objects which may Fuel supply
block the fuel supply.
Probable Causes If any of the above values are changing rapidly for
no apparent reason, there may be an intermittent
Fuel position multiplier (if applicable) problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, Inspecting Electrical
Engine speed/timing sensor(s) Connectors.
Check for an air filter restriction indicator. Replace 5. Check the fuel pressure after the fuel filter
plugged air filters and/or clean filters. Repair any while the engine is being cranked. Refer to
leaks. the Systems Operation/Testing and Adjusting
manual for the correct pressure values. If the
Throttle Signal fuel pressure is low, replace the fuel filters. If
the fuel pressure is still low, check the following
Use Cat ET in order to monitor the status of the items: fuel transfer pump, fuel transfer pump
throttle. Observe the throttle position. Verify that the coupling, and fuel pressure regulating valve. Refer
throttle position is smooth from low idle to high idle. to Systems Operation/Testing and Adjusting for
The throttle position should reach 100 percent at more information.
high idle.
i02417359
ECM Power Supply
Low Engine Oil Pressure
1. Inspect the circuit between the ECM and
the batteries. Refer to the Electrical System SMCS Code: 1300-038; 1901-038
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to NOTICE
Troubleshooting, Electrical Power Supply for Do not operate engine with low oil pressure. Engine
more information. damage will result. If measured engine oil pressure is
low, discontinue engine operation until the problem is
2. Inspect the circuit between the ECM and the corrected.
keyswitch. Refer to the Electrical System
Schematic. Inspect the wires, the connectors,
and the components in the circuit. Refer to Use this procedure in order to troubleshoot low
Troubleshooting, Electrical Power Supply for engine oil pressure or use this procedure if one
more information. of the following event codes is active. Refer to
Troubleshooting, Event Code List for information on
specific trip points for the event codes.
Fuel Supply
1. Check the fuel lines for the following problems:
restrictions, collapsed lines, and pinched lines. If
problems are found with the fuel lines, repair the
lines and/or replace the lines.
Table 24
Event Code
Description Conditions which Generate this Code System Response
E072 Oil Level Low Mark The oil level switch opens. The code is active and the code is
logged.
E073 Oil Filter Differential Pressure The oil filter differential pressure is
High greater than the trip point.
E074 Oil Filter Differential Pressure
Very High
E100 Low Engine Oil Pressure Warning The engine oil pressure is below a map
dependent value.
Crankshaft bearings
i02304726
Cold Mode Operation and Cold Cylinder Operate the engine under full load. Use Cat ET in
order to monitor the following values: turbocharger
Cutout compressor outlet pressure, fuel position, rated fuel
position, and Fuel Ratio Control (FRC). The fuel
Use the Caterpillar Electronic Technician (ET) in position should equal the rated fuel position. The
order to verify that the engine has exited cold mode. FRC fuel position should be greater than the rated
During cold mode, fuel injection timing is modified. fuel position.
When the engine is in cold mode, the cold cylinder
cutout strategy may be active. Cold mode cylinder If any of the above values are changing rapidly for
cutouts may cause variations in vibration and no apparent reason, there may be an intermittent
available power. This is normal operation. problem with the wiring. Refer to the diagnostic
functional test Troubleshooting, Inspecting Electrical
Derate Mode Connectors.
Connect Cat ET and check for logged derate events. Air Inlet Restriction
A derate status flag will appear on Cat ET if an
active engine derate is occurring. The engine speed Check for an air filter restriction indicator. Replace
might be limited due to one of the following possible plugged air filters and/or clean the filters. Repair any
causes: altitude, high exhaust temperatures, air filter leaks.
restriction, high coolant temperature, aftercooler
water temperature, and crankcase pressure. Check the air inlet system for the following problems:
restrictions, collapse, pinched line, and loose fittings.
Fuel Position Multiplier (if applicable) Repair the lines and/or replace the lines.
Engine speed/timing sensor(s) 3. Prime the fuel system if any of the following
procedures have been performed:
Electrical connectors
Replacement of the fuel filters
Injector
Service on the low pressure fuel supply circuit
Fuel supply
Replacement of unit injectors
Air inlet restrictions
Refer to the Operation and Maintenance Manual
Exhaust restrictions for the correct procedure.
Accessory equipment Note: A sight glass in the fuel supply line is helpful in
diagnosing air in the fuel.
Recommended Actions
4. Cold weather adversely affects the characteristics
of the fuel. Refer to the Operation and
Engine Speed/Timing Sensor(s) Maintenance Manual for information on improving
the characteristics of the fuel during cold weather
Check the calibration of the engine speed/timing
operation.
sensor if a CID-FMI 261-13 Engine Timing calibration
required diagnostic code is active. Refer to the
calibration procedure Troubleshooting, Engine
Speed/Timing Sensor - Calibrate.
RENR5622 63
Troubleshooting Section
5. Check the fuel pressure after the fuel filter Recommended Actions
while the engine is being cranked. Refer to
the Systems Operation/Testing and Adjusting Rocker Arm
manual for the correct pressure values. If the
fuel pressure is low, replace the fuel filters. If Check for proper installation of the rocker arm
the fuel pressure is still low, check the following adjustment screw locknut. If the rocker arm
items: fuel transfer pump, fuel transfer pump adjustment screw locknut is loose, adjust the valve
coupling, and fuel pressure regulating valve. Refer lash.
to Systems Operation/Testing and Adjusting for
more information. Check the rocker arms for signs of wear. If there is
too much wear, install new parts or rocker arms.
Air inlet Restrictions Adjust the valve lash.
Inspect the engine air cleaner. Replace plugged air Not Enough Lubrication
filters and/or clean the filters. Check the air inlet
systems for restrictions and for leaks. Check the lubrication in the valve compartment.
Check for sufficient lubrication between the injector
Exhaust Restrictions tappet and the rocker arm buttons.
Check the exhaust systems for restrictions and for Worn Bridges for Valves
leaks.
Check the bridges for signs of wear. Adjust the
Accessory Equipment bridges and/or replace the bridges. If there is too
much wear, install new parts. Adjust the valve lash.
Check attached accessory equipment. Ensure that
the accessory equipment is not lugging down the Worn Pushrods
engine.
Inspect the pushrods for signs of wear. If there is too
i02304819
much wear, install new pushrods. Adjust the valve
lash.
Too Much Valve Lash
Worn Valve Lifters
SMCS Code: 1000-038; 1901-038
Clean the valve train. Install new valve lifters.
Probable Causes
Worn Camshaft
Rocker arm
Check the camshaft for wear.
Not enough lubrication
Worn Valve Stem
Worn rocker arm
Check the valve stem for signs of wear. Check for
Worn bridges for valves free movement of valves. Check for a bent valve
stem. Adjust the valve lash.
Worn pushrods
Loose Retaining Bolt(s) for Rocker Shaft
Worn valve lifters
Repair the retaining bolt for the rocker shaft and/or
Worn camshaft replace the retaining bolt.
Worn valve stem
Worn Valve Springs
Incorrect valve lash
Check the valve springs for damage or for signs of
Loose retaining bolt(s) for rocker shaft wear. If there is too much wear, install new springs.
Adjust the valve lash.
Worn valve springs
Valve seats
64 RENR5622
Troubleshooting Section
Check the valve seats for signs of wear. If there is Valve Rotocoil or Spring Lock
too much wear, install new valve seats. Adjust the Is Free
valve lash.
SMCS Code: 1109-038
i02304874
Probable Causes
Too Much Vibration
SMCS Code: 1000-038; 1901-038
Cracked inlet valve rotocoil
Broken spring locks
Probable Causes
Broken valve spring(s)
Vibration damper
Recommended Actions
Loose engine supports
Fan blade Valve Rotocoil
Determine the cause of the cracked rotocoil. Install
Misfiring cylinder new parts.
Alignment and balance
Spring Locks
Recommended Actions Check the locks. A broken lock can cause the valve
to fall into the cylinder.
Vibration damper
Valve Spring(s)
Check the vibration damper for damage. Tighten
the bolts. Check the vibration damper bolt holes for
Install the new valve spring(s). Replace the valve
damage and/or wear. and/or other damaged parts.
Fan blade
Check the fan blade for damage. Ensure that the fan
blade is balanced.
Misfiring cylinder
Check for a misfiring cylinder. Perform the Cylinder
Cutout Test. Refer to the diagnostic functional test
Troubleshooting, Injector Solenoids.
Diagnostic Functional
Tests
i02408931
Table 25
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0101 - FMI 03 The Electronic Control Module (ECM) The code is logged.
Crankcase Pressure open/short to +batt detects signal voltage that is above The value of the parameter is set to
normal for one second. zero.
The ECM has been powered for at least
three seconds.
MID 0036 - CID 0101 - FMI 04 The ECM detects signal voltage that is
Crankcase Pressure short to ground below normal for one second.
The ECM has been powered for at least
three seconds.
MID 0036 - CID 0110 - FMI 03 Engine The ECM detects signal voltage that is The code is logged.
Coolant Temperature open/short to above normal for one second. The value of the parameter is set to
+batt The ECM has been powered for at least 40 C (40 F).
three seconds.
MID 0036 - CID 0110 - FMI 04 Engine The ECM detects signal voltage that is
Coolant Temperature short to ground below normal for one second.
The ECM has been powered for three
seconds.
MID 0036 - CID 0273 - FMI 03 Turbo The ECM detects signal voltage that is The code is logged.
Outlet Pressure open/short to +batt above normal for one second. The value of the parameter is set to
The ECM has been powered for at least zero.
three seconds.
MID 0036 - CID 0273 - FMI 04 Turbo The ECM detects signal voltage that is
Outlet Pressure short to ground below normal for one second.
The ECM has been powered for three
seconds.
MID 0036 - CID 0274 - FMI 03 The ECM detects signal voltage that is The code is logged.
Atmospheric Pressure open/short to above normal for one second. The value of the parameter is set to
+batt The ECM has been powered for at least 45 kPa (6.5 psi).
three seconds.
MID 0036 - CID 0274 - FMI 04 The ECM detects signal voltage that is
Atmospheric Pressure short to ground below normal for one second.
The ECM has been powered for three
seconds.
(continued)
66 RENR5622
Troubleshooting Section
g01203777
Illustration 14
Typical schematic
RENR5622 69
Troubleshooting Section
g01208832 g01208831
Illustration 15 Illustration 16
Front and Left view Rear and Right view
(1) Turbocharger compressor outlet pressure sensor (boost) (9) Aftercooler temperature sensor (rear)
(2) Aftercooler temperature sensor (front) (10) Crankcase pressure sensor
(3) Right turbocharger compressor inlet pressure sensor
(4) Coolant temperature sensor
(5) Left turbocharger compressor inlet pressure sensor
(6) Unfiltered engine oil pressure sensor
(7) Filtered engine oil pressure sensor
(8) Atmospheric pressure sensor
70 RENR5622
Troubleshooting Section
g01203763 g01203760
Illustration 17 Illustration 18
P1 ECM connector P2 ECM connector
(P1-1) Aftercooler temperature sensor (front) (P2-36) Turbocharger outlet pressure sensor
(P1-2) 5 V sensor supply (P2-37) Atmospheric sensor
(P1-3) Sensor return (P2-38) Left turbocharger inlet pressure sensor
(P1-6) Aftercooler temperature sensor (rear) (P2-39) Right turbocharger inlet pressure sensor
(P1-7) Coolant temperature sensor (P2-46) Crankcase pressure sensor
(P1-16) Filtered engine oil pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) 5 V sensor supply
(P1-35) Sensor return
g01094844
Illustration 19
Sensor connector
(Pin A) 5 V sensor supply
(Pin B) Sensor return
(Pin C) Signal
C. Monitor the diagnostic codes on Cat ET. Check OK No intermittent problems were found. The
and record any diagnostic codes. harness and connectors appear to be OK. If a
diagnostic code is still active, proceed to Test
Note: Wait at least 30 seconds in order for the Step 1 and continue to troubleshoot the active
diagnostic codes to become active. diagnostic code.
D. Determine if a diagnostic code has occurred Not OK At least one intermittent problem was
several times. indicated.
Note: A diagnostic code that is logged several Repair: Repair the harness or the connector. Refer
times is an indication of an intermittent problem. to the diagnostic functional test Troubleshooting,
Most intermittent problems are the result of a bad Inspecting Electrical Connectors. Verify that the
connection between a socket and a pin in a connector repair eliminates the problem.
or a bad connection between a wire and a terminal.
STOP.
E. Determine if the problem is active and related to
one of the following diagnostic codes: Test Step 3. Check the Supply Voltage at
the Sensor Connector
03
A. Remove electrical power from the ECM.
04
B. Disconnect the suspect sensor(s) at the sensor
Expected Result: connector:
A diagnostic code has occurred several times. C. Restore electrical power to the ECM.
No intermittent problems were detected during the E. Monitor the diagnostic codes on Cat ET. Check
Wiggle Test. for an active 04 diagnostic code for the suspect
sensor.
F. Remove electrical power from the ECM. Repair: Temporarily connect a new sensor to the
harness, but do not install the new sensor in the
Expected Result: engine. Verify that there are no active diagnostic
codes for the sensor. If there are no active
A 04 diagnostic code is now active for the suspect diagnostic codes for the sensor, permanently
sensor(s). install the new sensor. Clear any logged diagnostic
codes.
Results:
STOP.
OK A 03 diagnostic code was active before
creating the short at the sensor connector. A 04 Not OK A 04 diagnostic code is still active for the
diagnostic code became active after creating the suspect sensor. Leave the sensor disconnected.
short at the sensor connector. The harness and The problem may be in the harness or with the
the ECM are OK. There may be a problem with ECM. Proceed to Test Step 6.
the sensor.
Test Step 6. Check the Operation of the
Repair: Temporarily connect a new sensor to the ECM
harness, but do not install the new sensor in the
engine. Verify that there are no active diagnostic A. Remove electrical power from the ECM.
codes for the sensor. If there are no active
diagnostic codes for the sensor, permanently B. Check the operation of the ECM by creating an
install the new sensor. Clear any logged diagnostic open at the ECM.
codes.
a. Remove the signal wire for the suspect sensor
STOP. from the P1 or P2 ECM connector. Refer to
Illustration 14 for terminal locations.
Not OK A 03 diagnostic code is still active for
the suspect sensor(s). The problem may be in the b. Install a jumper wire with Deutsch sockets on
harness or with the ECM. Proceed to Test Step 6. each end into the socket for the signal wire of
the suspect sensor.
Test Step 5. Create an Open at the
Suspect Sensor Connector c. Reconnect the ECM connectors.
A. Remove electrical power from the ECM. d. Restore electrical power to the ECM.
B. Disconnect the sensor connector of the suspect e. Monitor the Active Diagnostic Code screen on
sensor(s) with the active 04 diagnostic code. Cat ET. Wait at least 30 seconds for activation
of the code.
C. Restore electrical power to the ECM.
An open circuit diagnostic code 03 should be
D. Monitor the diagnostic codes on Cat ET. Check active for the suspect sensor.
for an active 03 diagnostic code for the suspect
sensor. C. Check the operation of the ECM by creating a
short at the ECM.
Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. a. Install a wire jumper between the wire jumper
for the signal wire for the suspect sensor and
E. Remove electrical power from the ECM. engine ground.
OK A 04 diagnostic code was active before c. Remove the wire jumper. Reconnect all wires
disconnecting the sensor. A 03 diagnostic code and connectors.
became active after disconnecting the sensor. The
harness and the ECM are OK. There may be a
problem with the sensor.
RENR5622 73
Troubleshooting Section
A 03 diagnostic code is active when the sensor OK The supply voltage is 5.0 0.2 VDC. The
signal wire is removed from the ECM connector. A supply voltage at the ECM is correct. There is a
04 diagnostic code is active when the signal wire is problem in the wiring between the ECM and the
connected to engine ground. sensor connector. Check the supply wires and the
return wire for an open circuit.
Results:
Repair: Repair the connectors or wiring and/or
OK The ECM is operating properly. The problem replace the connectors or wiring.
is in the wiring between the ECM and the connector
for the rail. STOP.
Repair: If the code is active for more than one Not OK The supply voltage is not 5.0 0.2 VDC.
sensor, the problem is most likely in the return wire The voltage at the ECM is not correct.
for the sensor. Repair the return wire for the sensor
or replace the harness. Repair: Replace the ECM. Refer to
Troubleshooting, Replacing the ECM.
If the code is only active for one sensor, the Verify that the problem is resolved.
problem is most likely in the signal wire for the
sensor. Repair the signal wire for the sensor. STOP.
STOP.
i02409119
Expected Result:
Table 26
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0296 - FMI 09 Unable to The engines Electronic Control Module The code is logged.
communicate with Transmission ECM (ECM) detects a failure in the Cat
Data Link. The ECM detects a loss of
communication with the transmission
ECM.
MID 0036 - CID 0800 - FMI 09 Unable The ECM detects a failure in the Cat
to communicate with VIMS Data Link. The VIMS main module has
failed.
g01203833
Illustration 20
Schematic
Expected Result:
Not OK The connectors and/or wiring are not C. Measure the resistance at the connectors of the
OK. other control modules.
Test Step 2. Check for Shorts in the Repair: If the problem is intermittent, perform
Harness the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors.
A. Disconnect ECM connector J1/P1 at the engine
ECM. STOP.
B. Disconnect all control modules from the Cat Data Not OK The resistance measurement does not
Link. indicate a short circuit. There is an open circuit in
the harness or connectors.
C. Disconnect Cat ET from the service tool connector.
Repair: Repair the connectors or wiring and/or
D. Measure the resistance from P1-8 to every replace the connectors or wiring.
terminal on ECM connectors P1 and P2.
STOP.
E. Measure the resistance from P1-8 to the chassis
ground.
i02409173
Results:
STOP.
Table 27
Event Code
Description Default Conditions which Generate System Response
this Code
E035 Loss of Coolant Flow Warning The coolant flow switch opens. The code is active and the code is
logged.
g01208730
Illustration 22
Right side view
(1) Coolant flow switch
g01203867
Illustration 23
Schematic
78 RENR5622
Troubleshooting Section
g01147985 g01147988
Illustration 24 Illustration 25
P1 ECM connector P2 ECM connector
(P1-30) Coolant flow (P2-54) Digital return
Expected Result:
Results:
STOP.
RENR5622 79
Troubleshooting Section
E. Check the harness and wiring for abrasions and Not OK Cat ET does not indicate NO FLOW
for pinch points from the sensors back to the ECM. while the engine is not running. Cat ET does not
indicate FLOW while the engine is running. Cat
Expected Result: ET does not indicate the correct status of the
coolant flow switch. Proceed to Test Step 4.
All connectors, pins, and sockets are completely
inserted and coupled. The harness and wiring are Test Step 4. Create a Short Circuit at the
free of corrosion, of abrasion, and of pinch points. Connector of the Coolant Flow Switch
All connections and grounds are tight and free of
corrosion. A. Disconnect the connector for the coolant flow
switch.
Results:
B. Use a suitable piece of wire to short terminal 1
OK The harness and wiring are OK. Proceed (coolant flow switch) to terminal 2 (engine ground).
to Test Step 3.
C. Turn the keyswitch to the ON position.
Not OK There is a problem in the connectors
and/or wiring. D. Observe the status of Engine Coolant Flow on
Cat ET.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of E. Turn the keyswitch to the OFF position.
the seals are properly in place and ensure that the
connectors are completely coupled. Expected Result:
Verify that the repair eliminates the problem. The status indicates Flow with the jumper wire in
place.
STOP.
Results:
Test Step 3. Check the Status of the
Coolant Flow on Caterpillar Electronic OK The ECM and the wiring are operating
Technician (ET) correctly. Proceed to Test Step 5.
A. Restore electrical power to the engine ECM. Not OK The status indicates NO FLOW.
Proceed to Test Step 6.
B. Connect Cat ET to the service tool connector.
Test Step 5. Check the Coolant Flow C. Reconnect the J1/P1 ECM connector.
Switch
D. Use a suitable piece of wire to short the wire
jumper in P1-30 to engine ground.
Pressurized System: Hot coolant can cause seri- E. Turn the keyswitch to the ON position.
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system F. Observe the status of Engine Coolant Flow on
components are cool. Loosen the cooling system Cat ET.
pressure cap slowly in order to relieve the pres-
sure. G. Turn the keyswitch to the OFF position.
Expected Result:
A. Drain the engine coolant below the coolant flow
switch. The status indicates Flow with the jumper wire in
place.
B. Remove the coolant flow switch from the engine.
Results:
C. Manually close the coolant flow switch. Ensure
that excessive force is not required to close the OK The status indicates Flow with the jumper
switch. wire in place.
D. Measure continuity between termnal 1 and Repair: There is an open in the wire between
terminal 2 with the switch in the closed position. termnal 1 and the ECM and/or there is an open
in the digital return wire between termnal 2 and
Expected Result: P2-54. Repair the wire.
Table 28
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0168 - FMI 01 System The battery supply voltage is less than The code is logged if the engine is
Voltage Low 9 VDC for two seconds. running.
The engines ECM has been powered
for three seconds.
The engine is not being cranked.
MID 0036 - CID 0168 - FMI 02 Battery The engine is running. The battery
Voltage intermittent/erratic voltage falls below 9 VDC for at least
.06 seconds. The voltage returns above
9 VDC.
or
Three voltage readings in the last seven
seconds were below 9 VDC.
g01203933
Illustration 26
Typical schematic
RENR5622 83
Troubleshooting Section
Results:
STOP.
Expected Result:
Results:
g01203934
Illustration 27 OK The voltage is 24 3 VDC. Proceed to Test
P1 ECM connector Step 3.
(P1-52) +Battery
(P1-53) +Battery Not OK The voltage is not 24 3 VDC.
(P1-63) Battery
(P1-65) Battery
(P1-70) Keyswitch
Repair: There is a problem with the batteries
or the charging system. Refer to Systems
Test Step 1. Inspect Electrical Connectors Operation/Testing and Adjusting for information on
the charging system.
and Wiring
A. Remove electrical power from the ECM. STOP.
B. Thoroughly inspect the ECM connectors Test Step 3. Check the Voltage at the
J1/P1. Inspect all of the other connectors. ECM Connector
Refer to Troubleshooting, Inspecting Electrical
Connectors for the proper procedure for A. Disconnect the J1/P1 ECM connector.
inspecting system wiring.
B. Measure the voltage between P1-52 (Unswitched
C. Perform a 45 N (10 lb) pull test on each of the Positive Battery) and P1-63 (Negative Battery).
wires in the ECM connector that are associated
with the circuit. C. Measure the voltage between P1-53 (Unswitched
Positive Battery) and P1-65 (Negative Battery).
D. Check the ECM connector (allen head screw)
for the proper torque. Refer to Troubleshooting, D. Measure the voltage between P1-70 (Keyswitch)
Inspecting Electrical Connectors for details. and P1-63 (Negative Battery).
E. Check the harness and the wiring for abrasion Expected Result:
and for pinch points.
The voltage is 1 VDC from the voltage at the battery
Expected Result: terminals.
Not OK Voltage is not present on terminal B at Repair: If voltage is present at the other two
the keyswitch. test points, check the wire 200-BK for continuity
between engine ground and the main power relay.
Repair: If voltage is not present on terminal B, If wire 200-BK is OK, replace the main power relay.
repair the wire between the +Battery and the
keyswitch. Verify that the breaker for the keyswitch STOP.
is not tripped. Verify that the problem is eliminated.
Not OK The voltage does not measure 24 3
STOP. VDC between wire 109-OR and engine ground.
RENR5622 85
Troubleshooting Section
STOP.
STOP.
i02409475
Event Code
Description Conditions which Generate this Code System Response
E072 Oil Level Low Mark The oil level switch opens. The code is active and the code is
logged.
g01208732
Illustration 28
Left side view
(1) Low oil level switch
g01203953
Illustration 29
Schematic
RENR5622 87
Troubleshooting Section
Expected Result:
Results:
g01203954
Illustration 30
P1 ECM connector OK The harness and wiring are OK. Proceed
(P1-22) Low oil level to Test Step 2.
STOP.
Expected Result:
Results:
A. Connect Cat ET to the service tool connector. Repair: Temporarily replace the switch. Verify
that a new switch solves the problem before you
B. Turn the keyswitch to the ON position. permanently install the new switch.
OK The Engine Oil Level reads OK. Test Step 5. Short the Input Wires of
the Low Oil Level Switch at the ECM
Repair: The switch signal is correct. Connector
STOP. A. Disconnect ECM connector P1.
Not OK The Engine Oil Level does not read B. Remove the wire from P1-22 (low oil level). Install
OK. The switch signal is not correct. Proceed to a wire jumper with a socket on one end into P1-29.
Test Step 4.
C. Remove the wire from P2-66 (digital return). Install
Test Step 4. Short the Wires at the Low a wire jumper with a socket on one end into P2-20.
Oil Level Switch
D. Connect a wire jumper between the wire jumpers
A. Disconnect the connector for the low oil level in P1-22 and P2-66.
switch.
E. Reconnect all connectors.
B. Use a wire to short terminal terminal 1 to terminal
2. Install the wire jumper on the harness side of F. Turn the keyswitch to the ON position.
the connector.
Note: Additional diagnostic codes will be generated
C. Turn the keyswitch to the ON position. because the digital return will no longer be connected
to the other sensors and switches. Ignore the codes
D. Observe the status of the Engine Oil Level on and clear the codes when you complete this test.
Cat ET.
G. Observe the status of the Engine Oil Level on
E. Remove the wire short. Cat ET.
F. Observe the status of the Engine Oil Level on H. Remove the wire short.
Cat ET.
I. Reconnect all connectors.
G. Turn the keyswitch to the OFF position.
J. Observe the status of the Engine Oil Level on
Expected Result: Cat ET.
Cat ET indicates OK when the wire short is K. Turn the keyswitch to the OFF position.
installed. Cat ET indicates LOW when the wire short
is removed. L. Reconnect all connectors.
RENR5622 89
Troubleshooting Section
Expected Result:
Results:
STOP.
STOP.
i02409564
Table 31
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0569 - FMI 05 Oil The engines Electronic Control Module The code is logged.
Renewal Solenoid open circuit (ECM) detects an open circuit or a short
circuit to ground at the output to the oil
renewal solenoid.
The engines ECM has been powered
for two seconds.
MID 0036 - CID 0569 - FMI 06 Oil The engines ECM detects a short
Renewal Solenoid short to ground circuit to the +Battery at the output to
the oil renewal solenoid.
The engines ECM has been powered
for two seconds.
90 RENR5622
Troubleshooting Section
g01152043
Illustration 32
Schematic
P2 ECM connector
RENR5622 91
Troubleshooting Section
Results:
STOP.
All connectors, pins, and sockets are completely D. Select the override for the engine oil renewal
coupled and/or inserted. The harness and wiring are solenoid on Cat ET.
free of corrosion, of abrasion, and of pinch points.
E. Set the override for the engine oil renewal solenoid
to 100 percent.
92 RENR5622
Troubleshooting Section
F. Measure the voltage between terminal 1 and Repair: Replace the ECM. Refer to
terminal 2 at the solenoid connector. Troubleshooting, Replacing the ECM.
Expected Result:
Results:
STOP.
Table 32
Event Code
Description Conditions which Generate this Code System Response
MID 0036 - CID 0190 - FMI 08 Engine The engine speed is greater than zero The engine speed is set to zero rpm.
Speed signal abnormal rpm and the pattern from the timing ring The code is active.
is incorrect for five seconds. The code is logged if the pattern from
the timing ring returns for five seconds.
g01204148
Illustration 35
Schematic
Expected Result:
Results:
g01156100
Not OK There is a problem with the connectors
Illustration 36 and/or wiring.
P1 ECM connector
(P1-5) Digital return Repair: Repair the connectors or wiring and/or
(P1-33) Engine speed/timing signal replace the connectors or wiring. Ensure that all of
(P1-40) Engine timing calibration - the seals are properly in place and ensure that the
(P1-41) Engine timing calibration + connectors are completely coupled.
(P1-43) +12 V supply
Test Step 2. Check for a LOGGED D. Measure the voltage between the sensor signal
Diagnostic Code wire and terminal B of the sensor connector. Crank
the engine and measure the voltage between the
A. Connect Caterpillar Electronic Technician (ET) to sensor signal wire and terminal B.
the service tool connector.
E. Turn the keyswitch to the OFF position.
B. Turn the keyswitch to the ON position.
F. Reconnect the signal wire.
C. Check the diagnostic codes on Cat ET.
Expected Result:
Expected Result:
The voltage measures less than 3 VDC or more than
Cat ET indicates that a 190-08 diagnostic code has 9 VDC when the keyswitch is in the ON position
recently been logged. and the engine is not cranking. While the engine is
cranking, the voltage is between 2.0 VDC and 7.0
Results: VDC.
OK The 190-08 diagnostic code is logged. Note: The voltage output is determined by the
Proceed to Test Step 3. presence or the absence of a tooth on the timing gear.
Repair: The problem is no longer present. If the OK The engine speed/timing sensor is producing
problem is intermittent, refer to Troubleshooting, the correct output signal. Proceed to Test Step 5.
Inspecting Electrical Connectors.
Not OK The engine speed/timing sensor is not
STOP. producing the correct output signal.
Test Step 3. Check the Supply Voltage to Repair: Replace the engine speed/timing sensor.
the Sensor Calibrate the sensor. Perform the calibration
procedure Troubleshooting, Engine Speed/Timing
A. Disconnect the connector for the engine Sensor - Calibrate.
speed/timing sensor.
STOP.
B. Turn the keyswitch to the ON position.
Test Step 5. Check the Signal Voltage at
C. Measure the voltage between terminal A and the ECM
terminal B at the sensor connector.
A. Turn the keyswitch to the OFF position.
Expected Result:
B. Disconnect ECM connector J1/P1.
The supply voltage is 12 1.0 VDC.
C. Remove wire 999-WH from ECM connector P1-33.
Results:
D. Reconnect ECM connector J1/P1.
OK The supply voltage is 12 1.0 VDC. Proceed
to Test Step 4. E. Turn the keyswitch to the ON position.
Not OK The supply voltage is not 12 1.0 VDC. F. Measure the signal voltage between the signal
Proceed to Test Step 6. wire 999-WH and engine ground.
Test Step 4. Check the Signal Voltage at G. Crank the engine and measure the signal voltage
the Sensor between the signal wire 999-WH and engine
ground.
A. Turn the keyswitch to the OFF position.
H. Turn the keyswitch to the OFF position.
B. Remove the wire from terminal C of the sensor
connector. I. Replace all wires. Reconnect ECM connector
J1/P1.
C. Turn the keyswitch to the ON position.
96 RENR5622
Troubleshooting Section
The voltage measures less than 3 VDC or more than OK The supply voltage is 12 1.0 VDC. There is
9 VDC when the keyswitch is in the ON position an open circuit or a short circuit between the ECM
and the engine is not cranking. While the engine is and the connector for the engine speed/timing
cranking, the voltage is between 2.0 VDC and 7.0 sensor.
VDC.
Repair: Repair the connectors and/or wiring or
Note: The voltage signal is generated by the replace the connectors and/or wiring.
presence or the absence of a tooth on the timing
gear. STOP.
STOP.
i02409847
Expected Result:
Table 33
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0545 - FMI 05 Ether The engines Electronic Control Module The code is logged.
Start Relay open/short to +batt (ECM) detects an open circuit and/or a Ether injection is disabled.
short circuit to the +Battery terminal at
the output to the ether start relay.
The ECM has been powered for at least
two seconds.
MID 0036 - CID 0545 - FMI 06 Ether The ECM detects a short circuit to
Start Relay short to ground ground at the output to the ether start
relay.
The ECM has been powered for at least
two seconds.
MID 0036 - CID 0546 - FMI 05 Ether The ECM detects an open circuit and/or The code is logged.
Hold Relay open/short to ground a short circuit to ground at the output to Ether injection is disabled.
the ether hold relay.
The ECM has been powered for at least
two seconds.
MID 0036 - CID 0546 - FMI 06 Ether The ECM detects a short circuit to the
Hold Relay short to +batt +Battery at the output to the ether hold
relay.
The ECM has been powered for at least
two seconds.
When the engine is in AUTO mode the engine The ether start relay initially energizes the ether
uses an ether system to improve starting in cold solenoid for approximately two seconds. After two
temperatures. The duration of the ether cycle is seconds, the ether hold relay energizes and the
based on the engine coolant temperature. The ether start relay de-energizes. The voltage from the
Electronic Control Module (ECM), which controls the ether hold relay to the ether solenoid is less than
ether system uses the engine coolant temperature battery voltage because of the voltage drop over the
sensor to detect the engine temperature. The resistance that is in the resistor and diode assembly.
ECM determines if ether should be injected by The initial higher voltage is needed to actuate the
monitoring the actual engine rpm and the engine ether solenoid. The lower voltage signal is then used
coolant temperature. The ECM will activate the ether to hold the ether solenoid valve open. The solenoid
solenoid if the engine coolant temperature is below will be damaged if full battery voltage is applied
a set temperature and engine rpm is below a certain continuously.
level. The ether will activate for a minimum of 15
seconds at 30 C (86 F) up to a maximum of 130 Two circuits from the ECM are used to control the
seconds at 50 C (58 F). The automatic ether ether cycle. The device drivers in the first circuit
injection system is disabled whenever the engine rpm provide a +Battery voltage to the coil of the ether
exceeds 400 rpm or the engine coolant temperature start relay and a return path to the ECM from the coil
exceeds 30 C (86 F). of the ether start relay. The ECM monitors current
flow at two places in the circuit in order to determine
The ether injection system can also be operated in if there is a problem in the circuit. The ECM monitors
manual mode. The ether system is switched into current flow on the device driver to the coil of the
manual mode whenever the starting aid switch is ether start relay and the ECM monitors current flow
depressed. Manual mode also allows ether to be on the device driver from the coil of the ether start
injected whenever the coolant temperature is less relay. If current is below a threshold on either device
than 30 C (86 F) and the engine rpm is greater driver in the circuit, the ECM will generate a 545-05
than 50 rpm. Ether is injected in manual mode if diagnostic code. If current is above a threshold
the starting aid switch is depressed and the coolant on either device driver in the circuit, the ECM will
temperature is below the maximum limit. generate a 545-06 diagnostic code. If a 545-06
diagnostic code is generated, the ECM will latch both
device drivers open for overcurrent protection.
98 RENR5622
Troubleshooting Section
g01204307
Illustration 37
Typical schematic
RENR5622 99
Troubleshooting Section
g01149844
Illustration 38
Terminal locations for the ether start relay and for the ether hold
relay
g01204311
Illustration 40
P2 ECM connector
(P2-10) Ether hold relay
(P2-20) Ether request
(P2-31) Ether start relay
Illustration 39
g01204310 E. Check the harness and the wiring for abrasion
and for pinch points.
P1 ECM connector
(P1-5) Digital return Expected Result:
OK The harness and wiring are OK. Proceed The parameter for the starting aid switch displays
to Test Step 2. ON while the starting aid switch is toggled. The
parameter for the starting aid switch displays OFF
Not OK There is a problem in the connectors when the starting aid switch is released. An active
and/or wiring. diagnostic code is present or a logged diagnostic
code is present.
Repair: Repair the connectors or wiring and/or
replace the connectors or wiring. Ensure that all of Results:
the seals are properly in place and ensure that the
connectors are completely coupled. OK - Active Code The parameter for the starting
aid switch displays ON while the starting aid
Verify that the repair eliminates the problem. switch is toggled. The parameter for the starting aid
switch displays OFF when the starting aid switch
STOP. is released. Active diagnostics are displayed. Make
a note of the active diagnostic code. Proceed to
Test Step 2. Check the Ether Canisters Test Step 4.
A. Turn the keyswitch to the OFF position. OK - Logged Code The parameter for the starting
aid switch displays ON while the starting aid
B. Remove the ether canister(s) from the ether switch is toggled. The parameter for the starting aid
solenoid(s). Verify that the ether canister is full. switch displays OFF when the starting aid switch
is released. Logged diagnostics are displayed.
Expected Result:
Repair: Check for an intermittent short or for
The ether canister is full. an open in the wiring or in the connectors.
Refer to Troubleshooting, Inspecting Electrical
Results: Connectors. Repair any suspect connectors or
wiring and/or replace the connectors or wiring.
OK The ether canister is full. Proceed to Test Verify that the system is operating correctly.
Step 3. Replace the ether canister on the ether solenoid.
Repair: Replace the empty ether canister with OK - No Codes The parameter for the starting
a full ether canister. Verify that the system is aid switch displays ON while the starting aid
operating correctly. switch is toggled. The parameter for the starting
aid switch displays OFF when the starting aid
STOP. switch is released. No diagnostics are logged or
active. The ether system is not injecting ether.
Test Step 3. Check for Active Diagnostic Proceed to Test Step 8.
Codes
Not OK The parameter for the starting aid switch
Note: Remove the ether canister(s) from the ether does not display ON while the starting aid switch
solenoid(s) before proceeding with the following test is toggled. The parameter for the starting aid
steps. switch does not display OFF when the starting
aid switch is released. The starting aid switch is not
A. Connect Caterpillar Electronic Technician (ET) to functioning correctly. Proceed to Test Step 12.
the cab service tool connector. Start Cat ET.
Test Step 4. Switch the Relays in order to
B. Turn the keyswitch to the ON position. Isolate the Problem
C. Toggle the starting aid switch. Observe the A. Turn the keyswitch to the OFF position.
parameter for the starting aid switch on Cat ET.
B. Remove the ether start relay and the ether hold
D. Determine if CID-FMI 545-05, 545-06, 546-05 or relay. Replace the ether start relay in the base for
546-06 is active or logged. the ether hold relay. Replace the ether hold relay
in the base for the ether start relay.
D. Select the Diagnostic Tests on Cat ET. E. Select the Override Parameters screen on Cat
ET.
NOTICE
Do not allow the ether injection system to be on for F. Activate the ether override.
more than two minutes. Damage to the ether solenoid
may occur. G. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes.
E. Select the Override Parameters screen on Cat Note: Wait at least 30 seconds in order for the
ET. diagnostic codes to become active.
The 05 or 06 diagnostic code is now active for the Repair: The ECM detected the short circuit at
other relay. the relay connector. The problem must be in the
connector for the suspect relay or the problem
Results: must be in the relay assembly.
Test Step 5. Create a Short at the Note: Wait at least 30 seconds in order for the
Connector for the Suspect Relay diagnostic codes to become active.
A. Turn the keyswitch to the OFF position. E. Disable the ether override.
Repair: The ECM detected the open circuit at b. Turn the keyswitch to the ON position.
the relay connector. The problem must be in the
connector for the suspect relay or the problem c. Select the Diagnostic Tests on Cat ET.
must be in the relay assembly.
NOTICE
STOP. Do not allow the ether injection system to be on for
more than two minutes. Damage to the ether solenoid
Not OK The 06 diagnostic code is still active for may occur.
the suspect relay. Proceed to Test Step 7.
Test Step 7. Test the Operation of the d. Select the Override Parameters screen on
ECM Cat ET.
A. Turn the keyswitch to the OFF position. e. Activate the ether override.
B. Fabricate jumper wires that can be used to replace f. Monitor the Active Diagnostic Code screen
the wire(s) in the ECM connector for the suspect on Cat ET.
relay. Crimp a connector socket to one end of the
jumper wires. Check the suspect relay for an active 06
diagnostic code.
C. Disconnect the appropriate ECM connector for
the suspect relay. Note: Wait at least 30 seconds so that any codes
may become active.
D. Remove the wire(s) for the suspect relay from the
ECM connector. g. Disable the ether override.
E. Install the jumper wire(s) into the terminal h. Turn the keyswitch to the OFF position.
location(s) for the suspect relay at the ECM
connector. I. Remove the jumper wire. Return all wiring to the
original configuration.
F. Connect the ECM connectors.
Expected Result:
G. Check the operation of the ECM by creating
an open at the ECM: A 05 diagnostic code is active when the wires or
wire from the suspect relay are open at the ECM
a. Hold the loose end of the jumper wire away connector. A 06 diagnostic code is active if the wires
from any components in order to create an or wire from the suspect relay are shorted at the
open circuit condition. ECM connector.
c. Monitor the Active Diagnostic Code screen OK A 05 diagnostic code is active when the
on Cat ET. wires or wire from the suspect relay are open at
the ECM connector. A 06 diagnostic code is active
Check the suspect relay for an active 05 when the wires or wire from the suspect relay are
diagnostic code. shorted at the ECM connector.
Note: Wait at least 30 seconds so that any codes Repair: The ECM is operating properly.
may become active.
If the suspect relay is the ether start relay, the
d. Turn the keyswitch to the OFF position. problem is in the harness wiring between the ECM
and the connector for the relay. Repair the wires
H. Check the operation of the ECM by creating a or wire.
short circuit at the ECM:
If the suspect relay is the ether hold relay, the
a. If the suspect relay is the ether start relay, short problem is in the harness wiring between the ECM
the jumpers for the return wire and the output and the connector for the relay or in the harness
wire together. wiring between the battery and the ether hold relay.
Repair the wire.
If the suspect relay is the ether hold relay, short
the jumper for the return wire to the +Battery. STOP.
RENR5622 103
Troubleshooting Section
Not OK One of the following conditions exists: Not OK - 24 VDC The voltage did not measure
The 05 diagnostic code is not active when the 24 3 VDC for the first two seconds of injection.
wires or wire from the suspect relay are open at Verify that wire 200-BK has continuity to ground.
the ECM connector. The 06 diagnostic code is not If wire 200-BK has continuity to ground, proceed
active when the wires or wire from the suspect to test step 9.
relay are shorted at the ECM connector.
Not OK - 3 VDC The voltage is approximately
Repair: Replace the ECM. Refer to 24 3 VDC for the first two seconds of injection.
Troubleshooting, Replacing the ECM. The voltage did not decrease to 5 3 VDC for the
Verify that the problem is resolved. remainder of the injection duration. Proceed to test
step 9.
STOP.
Test Step 9. Check the Battery Voltage
Test Step 8. Check the Voltage at the to the Ether Start Relay and to the Ether
Ether Solenoid(s) Hold Relay
A. Turn the keyswitch to the OFF position. A. Disconnect the connector for the ether start relay
and the connector for the ether hold relay.
B. Disconnect the ether solenoid connector at the
solenoid(s). B. Measure the voltage between terminal 1 of the
connector for the ether start relay and ground.
C. Connect a voltmeter to terminal 1 and terminal 2
of the ether solenoid connector(s). C. Measure the voltage between terminal 4 of the
connector for the ether hold relay and ground.
D. Turn the keyswitch to the ON position.
Expected Result:
NOTICE
Do not allow the ether injection system to be on for The voltage measures 24 3 VDC.
more than two minutes. Damage to the ether solenoid
may occur. Results:
Repair: If ether is not being injected, replace OK - Ether hold relay The voltage measures 24
the ether solenoid(s). Verify that the system is 3 VDC at the connector for the ether hold relay.
operating correctly. Reconnect the connector for the ether hold relay.
Proceed to Test Step 10.
STOP.
Not OK The voltage does not measure 24 3
VDC.
104 RENR5622
Troubleshooting Section
Repair: Verify that the breaker for the starting aid C. Connect the positive lead of the multimeter to
is not tripped. Check the wiring between the relay terminal 2 and the negative lead to terminal 1 of
connectors and the battery for an open circuit or the resistor and the diode assembly and observe
for a short circuit. the multimeter.
A. Turn the keyswitch to the OFF position. E. Repeat the measurements for all of the resistor
and the diode assemblies if more than one resistor
B. Disconnect the connector at the resistor and the and diode assembly is present.
diode assembly.
Expected Result:
C. Connect a voltmeter between terminal 1 of the
resistor and the diode assembly and ground. When the positive lead of the multimeter is connected
to terminal 2 and the negative lead to terminal 1, the
D. Turn the keyswitch to the ON position. multimeter displays an overload (OL) condition.
E. Activate the ether override and observe the OK The resistor and the diode assembly is
voltmeter while ether injection is activated. Disable operating correctly.
the ether override.
Repair: There is a problem in the harness between
Expected Result: the resistor and diode assembly and the ether
solenoid(s). Repair the connectors or wiring and/or
The voltage is 24 3 VDC. replace the connectors or wiring. Verify that the
system is operating correctly. Replace the ether
Results: canister on the ether solenoid.
B. Set the multimeter to the Check Diode setting. D. Observe the parameter for the starting aid switch
on Cat ET.
RENR5622 105
Troubleshooting Section
E. Obtain a suitable piece of wire. Short the wires c. Observe the parameter for the starting aid
from the starting aid switch together at the starting switch on Cat ET.
aid switch.
H. Check the operation of the ECM by creating a
F. Observe the parameter for the starting aid switch short circuit at the ECM:
on Cat ET.
a. Short the jumper wires for the starting aid
G. Remove the jumper. Leave the wires disconnected switch together.
from the starting aid switch.
b. Observe the parameter for the starting aid
Expected Result: switch on Cat ET.
The parameter for the starting aid switch displays I. Remove the jumper wires. Return all wiring to the
ON while the wires from the starting aid switch original configuration.
are shorted together. The parameter for the starting
aid switch displays OFF when the wires from the Expected Result:
starting aid switch are not shorted together.
The parameter for the starting aid switch displays
Results: ON while the wires from the starting aid switch
are shorted together. The parameter for the starting
OK The ECM detects the open and the short aid switch displays OFF when the wires from the
from the starting aid switch. starting aid switch are not shorted together.
i02410957
Table 34
Event Code
Description Conditions which Generate this Code System Response
E095 Fuel Filter Restriction Warning The fuel filter differential pressure switch The code is active and the code is
opens. logged.
g01208741
Illustration 41
Left side view
(1) Fuel filter differential pressure switch
RENR5622 107
Troubleshooting Section
g01204990
Illustration 42
Schematic
Results:
A. Replace the fuel filter element. All connectors, pins, and sockets are completely
coupled and/or inserted. The harness and wiring are
Expected Result: free of corrosion, of abrasion, and of pinch points.
Not OK There is a problem in the connectors B. Disconnect the J1/P1 ECM connector.
and/or wiring.
C. Install a jumper wire with Deutsch sockets on each
Repair: Repair the connectors or wiring and/or end into the socket for the signal wire of the fuel
replace the connectors or wiring. Ensure that all of filter differential pressure switch.
the seals are properly in place and ensure that the
connectors are completely coupled. D. Install a wire jumper between the wire jumper
in the socket for the return wire of the fuel filter
Verify that the repair eliminates the problem. differential pressure switch.
STOP. E. Short the jumper wires for the fuel filter differential
pressure switch together.
Test Step 3. Check the Switch Circuit
F. Reconnect the ECM connector.
A. Turn the keyswitch to the OFF position.
G. Start the engine. Increase the engine speed to
B. Disconnect the connector for the fuel filter high idle.
differential pressure switch.
H. Monitor the active diagnostic code screen on Cat
C. Install a wire jumper between the terminals of the ET. Check and record any active diagnostic codes.
connector for the fuel filter differential pressure
switch. Install the wire jumper on the harness side Note: Wait at least 30 seconds in order for the
of the connector. diagnostic codes to become active.
D. Start the engine. Increase the engine speed to I. Remove the short between the jumper wires for
high idle. the fuel filter differential pressure switch.
E. Monitor the active diagnostic code screen on Cat J. Monitor the active diagnostic code screen on Cat
ET. Check and record any active diagnostic codes. ET. Check and record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the Note: Wait at least 30 seconds in order for the
diagnostic codes to become active. diagnostic codes to become active.
F. Check for an event code for the engine fuel filter Expected Result:
restriction.
The event code is not active when the jumper wires
Expected Result: are shorted together. The event code is active when
the jumper wires are not shorted together.
The event code is not active.
Results:
Results:
OK The ECM detects the open and the short.
OK The event code is not active. The wiring
between the connector and the ECM is OK. Repair: There is an open or a short in the wiring
between the connector for the fuel filter differential
Repair: Check for a plugged fuel filter. If the pressure switch and the ECM. Repair the
fuel filter is OK, temporarily replace the fuel filter connectors or wiring and/or replace the connectors
differential pressure switch. Verify that the problem or wiring. Check the harness connector to the
is resolved before permanently replacing the fuel fuel filter differential pressure switch for a good
filter differential pressure switch. connection.
STOP.
i02411006
Table 35
Diagnostic Code
Description Conditions which Generate this Code System Response
MID 0036 - CID 0267 - FMI 02 Incorrect The two inputs from the ground level The code is active and the code is
Engine Shutdown Switch inputs shutdown switch are in the same state. logged.
g01205050
Illustration 44
Schematic
Expected Result:
Results:
Test Step 1. Inspect Electrical Connectors Test Step 2. Check the Status of the
and Wiring Ground Level Shutdown Switch on Cat
ET
A. Turn the keyswitch to the OFF position.
A. Connect Cat ET to the service tool connector.
B. Thoroughly inspect the ECM connector J1/P1. Start Cat ET.
Thoroughly inspect the connectors for the ground
level shutdown switch. Refer to Troubleshooting, B. Turn the keyswitch to the ON position.
Inspecting Electrical Connectors for details.
RENR5622 111
Troubleshooting Section
C. Operate the ground level shutdown switch. I. Observe the status of the ground level shutdown
Observe the status for the ground level shutdown switch on Cat ET.
switch on Cat ET.
J. Turn the keyswitch to the OFF position.
Expected Result:
K. Remove the wire short.
The status of the ground level shutdown switch reads
ON with the ground level shutdown switch in the Expected Result:
SHUTDOWN position. The status of the ground level
shutdown switch reads OFF when the ground level The status of the ground level shutdown switch reads
shutdown switch is in the RUN position. OFF when the wire F716-WH and the wire 998-BR
are shorted together. The ground level shutdown
Results: switch status reads ON when the wire F715-PU and
the wire 998-BR are shorted together.
OK The status of the ground level shutdown
switch reads ON with the ground level shutdown Results:
switch in the SHUTDOWN position. The status
of the ground level shutdown switch reads OFF OK The status of the ground level shutdown
when the ground level shutdown switch is in the switch reads OFF when the wire F716-WH and
RUN position. The ground level shutdown switch is the wire 998-BR are shorted together. The ground
operating normally. level shutdown switch status reads ON when the
wire F715-PU and the wire 998-BR are shorted
Repair: There may be an intermittent problem. If together. The problem is not with the harness or
the problem is intermittent, refer to Troubleshooting, the ECM.
Inspecting Electrical Connectors.
Repair: Temporarily connect a new ground level
STOP. shutdown switch. Verify that the new ground level
shutdown switch solves the problem before you
Not OK The status of the ground level switch permanently install the new ground level shutdown
does not read ON with the ground level shutdown switch.
switch in the SHUTDOWN position. The status of
the ground level shutdown switch does not read STOP.
OFF when the ground level shutdown switch is
in the RUN position. The ground level shutdown Not OK The status of the ground level shutdown
switch is not operating normally. Proceed to Test switch does not read OFF when the wire
Step 3. F716-WH and the wire 998-BR are shorted
together. The ground level shutdown switch status
Test Step 3. Short the Wires together at does not read ON when the wire F715-PU and
the Ground Level Shutdown Switch the wire 998-BR are shorted together. There is a
problem in the harness and/or the ECM. Proceed
A. Turn the keyswitch to the OFF position. to Test Step 4.
B. Record the position of the wiring on the ground Test Step 4. Short the Ground Level
level shutdown switch before removing the wires. Shutdown Switch at the ECM
C. Disconnect the wires from the ground level A. Disconnect the ECM connector J1/P1.
shutdown switch.
B. Remove the wire F715-PU at the ECM connector
D. Create a short circuit at the ground level shutdown P1-23. Remove the wire F716-WH at the ECM
switch between the wire F716-WH and the digital connector P1-28 and the digital return wire
return wire 998-BR. Leave the wire F715-PU open. 998-BR from ECM connector P1-5.
E. Turn the keyswitch to the ON position. C. Insert a wire with socket terminals at each end
into the ECM connector P1-28, P1-23 and P1-5.
F. Observe the status of the ground level shutdown Short the wire jumpers in P1-28 and P1-5.
switch on Cat ET.
D. Reconnect all the connectors.
G. Remove the short between the wire F716-WH and
the wire 998-BR. E. Turn the keyswitch to the ON position.
G. Turn the keyswitch to the OFF position. Use this procedure to troubleshoot the electrical
system if a problem is suspected with the injectors
H. Remove the short between P1-28 and P1-5. or if any one of the diagnostic codes in Table 36 is
active or easily repeated.
I. Short the wire jumpers in P1-23 and P1-5.
Expected Result:
Results:
STOP.
STOP.
RENR5622 113
Troubleshooting Section
Table 36
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0001 - FMI 05 Cylinder The engines Electronic Control Module The code is logged.
#1 Injector open circuit (ECM) detects an open circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0001 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#1 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0002 - FMI 05 Cylinder The engines ECM detects an open The code is logged.
#2 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0002 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#2 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0003 - FMI 05 Cylinder The engines ECM detects an open The code is logged.
#3 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0003 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#3 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0004 - FMI 05 Cylinder The engines ECM detects an open The code is logged.
#4 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0004 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#4 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0005 - FMI 05 Cylinder The engines ECM detects an open The code is logged.
#5 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0005 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#5 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
MID 0036 - CID 0006 - FMI 05 Cylinder The engines ECM detects an open The code is logged.
#6 Injector open circuit circuit. The ECM continues to fire the injector
solenoid.
MID 0036 - CID 0006 - FMI 06 Cylinder The ECM detects a short circuit. The code is logged.
#6 Injector short The ECM will disable the solenoid
circuit. The ECM will periodically try
to fire the injector. If the short circuit
remains, this sequence of events will be
repeated until the problem is corrected.
(continued)
114 RENR5622
Troubleshooting Section
Perform this procedure under conditions that are If an open is detected in the solenoid circuit, a
identical to the conditions that exist when the problem diagnostic code is generated. The ECM continues
occurs. Typically, problems with the injector solenoid to try to fire the injector. If a short is detected in the
occur when the engine is warmed up and/or when solenoid circuit, a diagnostic code is generated. The
the engine is under vibration (heavy loads). ECM will disable the solenoid circuit. The ECM will
periodically try to fire the injector. If the short circuit
These engines have Electronic Unit Injectors (EUI) remains, this sequence of events will be repeated
that are mechanically actuated and electronically until the problem is corrected.
controlled. The ECM sends a 105 volt pulse to each
injector solenoid. The pulse is sent at the proper time
and at the correct duration for a given engine load
and speed. The solenoid is mounted on top of the
fuel injector body.
116 RENR5622
Troubleshooting Section
g01205298
Illustration 46
Typical schematic
118 RENR5622
Troubleshooting Section
Expected Result:
Results:
Test Step 1. Check for Connector Damage OK No 1-05 to 16-05 or 1-06 to 16-06 are
logged. Proceed to Test Step 3.
A. Remove power from the ECM.
RENR5622 119
Troubleshooting Section
Not OK A 1-05 to 16-05 is logged. Proceed to Test Step 4. Check the Harness between
Test Step 4. the ECM and the Injector Connectors for
an Open Circuit
Not OK A 1-06 to 16-06 is logged. Proceed to
Test Step 5.
A. Remove power from the ECM. A. Remove power from the ECM.
B. Verify that the ECM connector J2/P2 and the B. Disconnect the connectors for the suspect
injector connectors are properly connected. injector(s).
C. Restore power to the ECM. C. Fabricate a jumper wire 100 mm (4 inch) long with
Deutsch pins on both ends of the wire.
D. Start the engine.
D. Insert one end of the jumper wire into the socket
E. Apply a load to the engine. for the suspect injectors supply wire. Insert the
other end of the jumper wire into the socket for the
F. Perform the following steps on all suspect suspect injectors return wire. This will replace the
cylinders (solenoids). injector solenoid with a short circuit.
G. Use the diagnostic tests on Cat ET to initiate the E. Restore power to the ECM.
Cylinder Cutout Test.
Note: This test will help the service technician verify
H. Run the Cylinder Cutout Test. Run the Cylinder that the ECM can fire the solenoids. Do not try to
Cutout Test. Disable the suspect cylinder(s) manually crank the engine during this test. The ECM
during the test. will terminate the Injector Solenoid Test.
Expected Result: F. Perform the Injector Solenoid Test at least two
times.
The results indicated that the remaining injectors
used more fuel when the Cylinder Cutout Test G. Repeat this test for each suspect injector. Stop
disabled the suspect injector(s). the Injector Solenoid Test before handling the
jumper wire.
Results:
Expected Result:
OK There was a noticeable change in fuel usage.
Cat ET displays Open for the cylinder with the
Repair: The injectors are firing in all cylinders. jumper wire.
Reset the system and check for diagnostic codes.
Results:
STOP.
OK Cat ET displays Open for the cylinder with
Not OK There was no noticeable change in fuel the jumper wire. There is a problem in the wiring
usage. between the ECM and the injector connector.
Proceed to Test Step 6.
Repair: Verify that the engine valve lash for that
injector is set correctly. Rerun the Cylinder Cutout
Test. If the problem is still present, replace the
Not OK Cat ET displays Short for the cylinder
with the jumper wire. The harness between the
injector. If the new injector has a trim code that is ECM and the injector connector does not have an
different from the old injector, change the trim code open circuit. Proceed to Test Step 7.
in the ECM.
STOP.
120 RENR5622
Troubleshooting Section
Test Step 5. Check the Harness between a. Disconnect the appropriate suspect injector
the ECM and the Connectors for the wire from the P2 ECM connector. Remove the
Injector for a Short Circuit signal wire for the suspect injector(s) from the
ECM connector.
B. Disconnect the connectors for the suspect f. Monitor the Active Diagnostic Code screen on
injector(s). Cat ET. Wait at least 30 seconds for activation
of the code.
C. Restore power to the ECM.
A 05 diagnostic code should be active for the
Note: This test will help the service technician verify suspect injector(s).
that the ECM can fire the solenoids. Do not try to
manually crank the engine during this test. The ECM g. Remove power from the ECM.
will terminate the Injector Solenoid Test.
C. Check the operation of the ECM by creating a
D. Perform the Injector Solenoid Test at least two short at the ECM.
times.
a. Create a short between the wire jumper for the
Expected Result: suspect signal wire and engine ground.
All of the suspect cylinders indicate Open on Cat ET. b. Restore power to the ECM.
Results: Note: This test will help the service technician verify
that the ECM can fire the solenoids. Do not try to
OK All cylinders indicate Open on Cat ET. manually crank the engine during this test. The ECM
The harness between the ECM and the injector will terminate the Injector Solenoid Test.
connector does not have a short circuit. Proceed
to Test Step 7. c. Perform the Injector Solenoid Test.
Not OK One or more cylinders indicate Short d. Monitor the Active Diagnostic Code screen on
on Cat ET. Note the cylinders that indicate Short. Cat ET. Wait at least 30 seconds for activation
Proceed to Test Step 6. of the code.
Test Step 6. Check the ECM for Proper A 04 diagnostic code should be active when
Operation the wire jumper is installed.
A. Remove power from the ECM. A strong electrical e. Remove power from the ECM.
shock hazard is present if power is not removed
from the ECM. f. Remove the wire jumper. Reconnect all wires
and connectors.
B. Check the operation of the ECM by creating an
open at the ECM.
RENR5622 121
Troubleshooting Section
g01131276
Illustration 49
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
g01131211
Illustration 48
Leaky seal at the connector (typical example)
g01131019
Illustration 50
Seal for a three-pin connector (typical example)
RENR5622 123
Troubleshooting Section
Expected Result:
Results:
C. Disconnect the suspect connector and inspect the If moisture was found in the connectors, run the
connector seal. Ensure that the seals are in good engine for several minutes and check again for
condition. If necessary, replace the connector. moisture. If moisture reappears, the moisture is
wicking into the connector. Even if the moisture
D. Thoroughly inspect the connectors for evidence entry path is repaired, it may be necessary to
of moisture entry. replace the wires.
Note: It is normal to see some minor seal abrasion Verify that the repair eliminates the problem.
on connector seals. Minor seal abrasion will not allow
the entry of moisture. STOP.
If moisture or corrosion is evident in the connector, Test Step 2. Check the Wires for Damage
the source of the moisture entry must be found and to the Insulation
the source of the moisture entry must be repaired.
If the source of the moisture entry is not repaired, A. Carefully inspect each wire for signs of abrasion,
the problem will recur. Simply drying the connector of nicks, and of cuts.
will not fix the problem. Check the following items
for the possible moisture entry path: Inspect the wires for the following conditions:
A. Visually inspect each terminal in the connector. Each terminal and each connector easily withstands
Verify that the terminals are not damaged. 45 N (10 lb) of pull and each wire remains in the
Verify that the terminals are properly aligned in connector body.
the connector and verify that the terminals are
properly located in the connector. Results:
Repair: Repair the terminals and/or replace the Test Step 5. Check Individual Pin
terminals, as required. Retention into the Socket
Verify that the repair eliminates the problem.
STOP.
g01131604
Illustration 53
Diagram for testing pin retention (typical example)
Expected Result:
Results:
Expected Result:
Results:
g01132849
OK The connectors are in good repair. Proceed Illustration 55
to Test Step 7. Allen head screw for the 70 pin ECM connector (typical example)
Not OK The connectors locking mechanism is b. Torque the allen head screw for the 70
damaged or missing. pin ECM connector to 6.0 + 1.5 - 0.5 Nm
(55 + 13 - 4 lb in).
Repair: Repair the connector or replace the
connector, as required. Verify that the repair
eliminates the problem.
STOP.
Expected Result:
Results:
STOP.
Table 37
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
E098 Engine Prelube Override The engine has started without The code is logged.
completing the engine prelubrication.
MID 0036 - CID 0338 - FMI 05 Pre-lube The engines Electronic Control Module
Relay open circuit (ECM) detects an open circuit at the
prelube relay.
The ECM detects a short to battery
voltage at the prelube relay.
MID 0036 - CID 0338 - FMI 06 Pre-lube The engines ECM detects a short
Relay short to ground circuit at the prelube relay.
Diagnostics
Diagnostic Tests
Override Parameters
128 RENR5622
Troubleshooting Section
g01205415
Illustration 58
Schematic
RENR5622 129
Troubleshooting Section
g01149844
Illustration 61
Terminal locations of the prelube relay
Illustration 59
g01205422 A. Turn the keyswitch to the OFF position.
P1 ECM connector
B. Thoroughly inspect the ECM connectors.
(P1-51) Digital return Inspect all of the other connectors for the circuit.
Refer to Troubleshooting, Inspecting Electrical
Connectors for details.
Expected Result:
Results:
A. Connect Cat ET to the service tool connector. OK A 06 diagnostic code was active before
disconnecting the connector. A 05 diagnostic code
B. Turn the keyswitch to the ON position. became active after disconnecting the connector.
The harness and the ECM are OK. The problem
C. Monitor the active diagnostic code screen on Cat may be in the prelube relay.
ET. Check and record any active diagnostic codes.
Repair: Temporarily connect a new prelube relay
Note: Wait at least 30 seconds in order for the to the harness, but do not install the new prelube
diagnostic codes to become active. relay. Verify that there are no active diagnostic
codes for the prelube relay. If there are no active
Expected Result: diagnostic codes for the prelube relay, permanently
install the new prelube relay. Clear any logged
No diagnostic codes are active. diagnostic codes.
Results: STOP.
OK No diagnostic codes are active, but a Not OK A 06 diagnostic code remains active.
problem is suspected in the prelube system. There is a short between the connector for the
Proceed to Test Step 6. prelube relay and the ECM. Leave the connector
for the prelube relay disconnected. Proceed to Test
Not OK A 06 diagnostic code is active at this Step 5.
time. Proceed to Test Step 3.
Test Step 4. Create a Short at the
Not OK A 05 diagnostic code is active at this Connector for the Prelube Relay
time. Proceed to Test Step 4.
A. Turn the keyswitch to the OFF position.
Test Step 3. Create an Open at the
Connector for the Prelube Relay B. Install a jumper wire between terminal 85 and
terminal 86 of the connector for the prelube relay.
A. Turn the keyswitch to the OFF position.
C. Turn the keyswitch to the ON position.
B. Disconnect the connector for the prelube relay.
Note: Monitor the Active Diagnostic Codes screen
C. Turn the keyswitch to the ON position. on Cat ET after installing the jumper wire.
D. Proceed to the Diagnostic Overrides screen on D. Proceed to the Diagnostic Overrides screen on
Cat ET. Cat ET.
Note: Monitor the Active Diagnostic Codes screen Note: Monitor the Active Diagnostic Codes screen
on Cat ET. on Cat ET.
F. Check for a 05 diagnostic code for the prelube F. Wait at least 30 seconds for activation of the 06
relay. diagnostic code.
Note: Wait at least 30 seconds in order for the G. Turn the keyswitch to the OFF position. Remove
diagnostic codes to become active. the wire jumper.
B. Fabricate jumper wires that can be used to replace I. Turn the keyswitch to the OFF position. Reconnect
the wire(s) in the ECM connector for the prelube all wires to the original configuration.
relay. Crimp a connector socket to one end of the
jumper wires. Expected Result:
C. Disconnect the appropriate ECM connector(s) for A 05 diagnostic code is active when the wires from
the prelube relay. the prelube relay are open at the ECM connector.
A 06 diagnostic code is active if the wires from the
D. Remove the wire(s) for the prelube relay from the prelube relay are shorted at the ECM connector.
ECM connector.
Results:
E. Install the jumper wire(s) into the terminal
location(s) for the prelube relay at the ECM OK The ECM is operating properly. The problem
connector. is in the wiring between the ECM and the connector
for the prelube relay.
F. Connect the ECM connectors.
Repair: Repair the connectors or wiring and/or
G. Check the operation of the ECM by creating replace the connectors or wiring.
an open at the ECM:
STOP.
a. Hold the loose end of the jumper wire away
from any components in order to create an Not OK One of the following conditions exists:
open circuit condition. The 05 diagnostic code is not active when the
wire for the prelube relay is disconnected. The 06
b. Turn the keyswitch to the ON position. diagnostic code is not active when the wire jumper
is installed.
c. Proceed to the Diagnostic Overrides screen
on Cat ET. Repair: Replace the ECM. Refer to
Troubleshooting, Replacing the ECM.
d. Activate the prelube system. Verify that the problem is resolved.
Test Step 6. Check the Voltage to the Coil Test Step 7. Check the Voltage at the
of the Prelube Switch Prelube Motor
A. Disconnect wire 337-WH from the coil of the A. Disconnect the wire to the prelube motor from the
prelube switch. prelube switch at the prelube motor.
B. Connect a voltmeter between wire 337-WH and B. Connect a voltmeter between the wire and engine
engine ground. ground.
C. Turn the keyswitch to the ON position. C. Turn the keyswitch to the ON position.
D. Proceed to the Diagnostic Overrides screen on D. Proceed to the Diagnostic Overrides screen on
Cat ET. Cat ET.
F. Measure the voltage between wire 337-WH and F. Measure the voltage between the wire and engine
engine ground. ground.
G. Turn the keyswitch to the OFF position. G. Turn the keyswitch to the OFF position.
H. Replace all wires to the original configuration. H. Replace all wires to the original configuration.
Results: Results:
OK The voltage is 24 3 VDC. Proceed to Test OK The voltage is 24 3 VDC. Proceed to Test
Step 7. Step 8.
Not OK The voltage is not 24 3 VDC. Not OK The voltage is not 24 3 VDC.
Repair: Perform the following steps. Repair: Perform the following steps.
1. Remove wire 337-WH from terminal 85 on the 1. Remove the wire to the prelube motor from the
prelube relay. Activate the prelube override and prelube switch at the prelube switch. Activate
measure the voltage between terminal 85 on the prelube override and measure the voltage
the prelube relay and engine ground. If voltage between the terminal on the prelube switch
is present on terminal 85 on the prelube relay, and engine ground. If voltage is present on the
repair the wire 337-WH. terminal, repair the wire to the prelube motor.
If 24 3 VDC is not present on terminal 85 2. If voltage is not present on the terminal, verify
on the prelube relay, measure the voltage to that the wire 200-BK has continuity to engine
terminal 30 on the prelube relay. If 24 3 VDC ground. If wire 200-BK has continuity to engine
is not present on terminal 30 of the prelube ground, measure the voltage to the other side of
relay, verify that the 20A start aid breaker is the contacts of the prelube switch. If 24 3 VDC
not tripped. Verify that the wiring between the is present on the contacts of the prelube switch
battery and the prelube relay is OK. and the wire 200-BK is not open, replace the
prelube switch and retest the prelube system.
2. If 24 3 VDC is present on terminal 30 on the
prelube relay, replace the prelube relay and 3. If 24 3 VDC is not present on the other side
retest the prelube system. of the contacts of the prelube switch, repair
the wiring between the battery and the prelube
STOP. switch.
STOP.
RENR5622 133
Troubleshooting Section
Expected Result:
Results:
STOP.
STOP.
i02412085
Table 38
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0827 - FMI 08 Left The engines Electronic Control Module The code is logged.
Exhaust Temperature signal abnormal (ECM) detects a sensor frequency that The value of the parameter is set to
is greater than 1000 Hz or less than zero.
MID 0036 - CID 0828 - FMI 08 Right 150 Hz.
Exhaust Temperature signal abnormal The engines ECM detects a duty cycle
that is greater than 90 percent or a duty
cycle that is less than 10 percent.
System Operation
Terminal A 8 V supply
Terminal B sensor return
Terminal C sensor signal
The ECM performs an automatic calibration of these
sensors whenever the ECM is powered and the
engine has been off for at least five seconds.
g01208743
Illustration 62
Sensor locations
(1) Left exhaust temperature sensor (2) Right exhaust temperature sensor
g01205563
Illustration 63
Typical schematic
136 RENR5622
Troubleshooting Section
g01205567 g01205569
Illustration 64 Illustration 65
P1 ECM connector P2 ECM connector
(P1-4) 8 V supply (P2-55) Digital return
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
(P1-60) Digital return
g01094844
Illustration 66
Sensor connector
(Pin A) Sensor supply
(Pin B) Sensor return
(Pin C) Signal
Note: Wait at least 30 seconds in order for the Not OK At least one intermittent problem was
diagnostic codes to become active. indicated.
C. Determine if a diagnostic code has occurred Repair: Repair the harness or the connector. Refer
several times. to the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors. Verify that the
Note: A diagnostic code that is logged several repair eliminates the problem.
times is an indication of an intermittent problem.
Most intermittent problems are the result of a bad STOP.
connection between a socket and a pin in a connector
or a bad connection between a wire and a terminal. Test Step 3. Check the Digital Supply
Voltage at the Sensor Connector
D. Determine if a 08 diagnostic code is active or if a
08 diagnostic code has been logged. A. Disconnect the suspect sensor(s) at the sensor
connector:
Expected Result:
B. Measure the voltage on the ECM side of the
No diagnostic code is active for the exhaust sensor connector between pin A and pin B for the
temperature sensors. suspect sensor(s).
OK No diagnostic codes are active. The supply voltage is 8.0 0.4 VDC.
Repair: Repair the connectors or wiring and/or B. Remove the suspect signal wire for the sensor
replace the connectors or wiring. from ECM connector P1. Refer to Illustration 63
for the terminal locations for the ECM connector.
STOP.
C. Restore power to the ECM.
Not OK The supply voltage is not 8.0 0.4 VDC.
The voltage at the ECM is not correct. D. Measure the duty cycle between the sensors
signal wire and the sensors return wire.
Repair: Replace the ECM. Refer to
Troubleshooting, Replacing the ECM. Note: Set the multimeter to VDC. Press the Hz
Verify that the problem is resolved. button twice so that the % symbol is displayed.
A. Remove power from the ECM. The duty cycle is between 10 to 90 percent.
Results:
Sensor Supply
SMCS Code: 5574-038
OK The duty cycle is correct. Proceed to Test
Step 6. System Operation Description:
Not OK The duty cycle is incorrect. Use this procedure to troubleshoot the electrical
system if a problem is suspected with a sensor
Repair: Replace the sensor. Verify that no supply or if any one of the diagnostic codes in Table
diagnostic codes are active for the suspect sensor 39 is active or easily repeated.
before permanently installing the sensor.
STOP.
Table 39
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0262 - FMI 03 5 Volt The analog sensor supply voltage is The code is logged.
Sensor DC Power Supply short to +batt above normal for two seconds. All sensors are set to default values.
MID 0036 - CID 0262 - FMI 04 5 Volt The analog sensor supply voltage is
Sensor DC Power Supply short to below normal for two seconds.
ground
MID 0036 - CID 0263 - FMI 03 Digital The digital sensor supply voltage is
Sensor Supply short to +batt above normal for two seconds.
MID 0036 - CID 0263 - FMI 04 Digital The digital sensor supply voltage is
Sensor Supply short to ground below normal for two seconds.
g01203777
Illustration 67
Typical 5 V supply
RENR5622 141
Troubleshooting Section
g01205563
Illustration 68
Typical 8 V supply
g01206359 g01206347
Illustration 69 Illustration 70
P1 ECM connector P2 ECM connector
(P1-1) Aftercooler temperature sensor (front) (P2-36) Turbocharger outlet pressure sensor
(P1-2) 5 V sensor supply (P2-37) Atmospheric sensor
(P1-3) Sensor return (P2-38) Left turbocharger inlet pressure sensor
(P1-4) 8 V supply (P2-39) Right turbocharger inlet pressure sensor
(P1-6) Aftercooler temperature sensor (rear) (P2-46) Crankcase pressure sensor
(P1-7) Coolant temperature sensor (P2-55) Digital return
(P1-11) Left exhaust temperature
(P1-12) Right exhaust temperature
(P1-16) Filtered engine oil pressure sensor
(P1-17) Unfiltered engine oil pressure sensor
(P1-18) 5 V sensor supply
(P1-35) Sensor return
(P1-60) Digital return
142 RENR5622
Troubleshooting Section
STOP.
Note: Wait at least 30 seconds in order for the D. Remove the wires from terminal locations P2-18
diagnostic codes to become active. (5 V sensor supply) and P2-35 (sensor return).
Install a jumper wire into each of these terminal
a. Disconnect the following sensors one at a time: locations.
Aftercooler temperature sensor (front) F. Restore electrical power to the engine ECM.
Atmospheric pressure sensor G. Measure the voltage between the jumper wire in
P1-2 (5 V sensor supply) and the jumper wire in
Coolant temperature sensor P1-3 (sensor return).
Crankcase pressure sensor H. Measure the voltage between the jumper wire in
P2-18 (5 V sensor supply) and the jumper wire in
Filtered engine oil pressure sensor P2-35 (sensor return).
Turbocharger outlet pressure sensor I. Remove electrical power from the ECM.
Right turbocharger inlet pressure sensor Each voltage measurement is 5.0 0.2 VDC.
B. Remove electrical power from the ECM. OK The voltage measurement is 5.0 0.2 VDC.
The ECM is operating correctly.
Expected Result:
Repair: One of the supply wires is shorted to
The diagnostic code deactivates when a particular another wire in the harness or one of the supply
sensor is disconnected. wires is shorted to engine ground. To isolate
the problem to a specific harness, perform the
Results: following test steps:
OK The 262-03 or 262-04 diagnostic 1. One at a time, reinstall the wiring for each 5 V
code deactivates when a particular sensor is supply while you check Cat ET for an active
disconnected. 262-03 or 262-04 diagnostic code.
Repair: Connect the suspect sensor. If the code a. Disconnect the ECM connector.
returns, replace the sensor. Connect all of the
connectors. Verify that the problem is resolved. b. Install the wires that were removed for the
5 V supply at the ECM connector. Refer to
STOP. Illustration 67 for wiring information.
B. Fabricate four jumper wires that are long enough f. If a diagnostic code becomes active for
to be used to measure the supply voltage at the this 5 V supply, there is a problem in this
ECM connectors. Crimp connector sockets to one harness between the ECM and the sensor
end of each jumper wire. connector.
2. Repair the wiring and/or the connector. Replace B. Fabricate two jumper wires that are long enough
parts, if necessary. Verify that the problem is to be used to measure the supply voltage at the
resolved. ECM connectors. Crimp connector sockets to one
end of each jumper wire.
STOP.
C. Remove the wires from terminal locations P1-4 (8
Not OK The voltage measurement is not 5.0 V sensor supply) and P1-60 (sensor return). Install
0.2 VDC. a jumper wire into each of these terminal locations.
Repair: Replace the ECM. Refer to D. Connect the J1/P1 ECM connector.
Troubleshooting, Replacing the ECM.
E. Restore electrical power to the engine ECM.
STOP.
F. Measure the voltage between the jumper wire
Test Step 5. Disconnect the 8 Volt in P1-4 (8 V sensor supply) and P1-60 (sensor
Sensors while you Monitor the Active return).
Diagnostic Codes
G. Remove electrical power from the ECM.
A. Monitor the active diagnostic code screen on Cat
ET while you disconnect each 8 Volt sensor at Expected Result:
the sensor connector. Check for an active 263-03
code or an active 263-04 code. The voltage measurement is 8.0 0.4 VDC.
Exhaust temperature sensor (LH) Repair: One of the supply wires is shorted to
another wire in the harness or one of the supply
Exhaust temperature sensor (RH) wires is shorted to engine ground. To isolate
the problem to a specific harness, perform the
B. Remove electrical power from the ECM. following test steps:
Expected Result: 1. Reinstall the wiring for the 8 V supply while you
check Cat ET for an active 263-03 or 263-04
The diagnostic code deactivates when a particular diagnostic code.
sensor is disconnected.
a. Disconnect the ECM connector.
Results:
b. Install the wires that were removed for the
OK The 263-03 or 263-04 diagnostic 8 V supply at the ECM connector. Refer to
code deactivates when a particular sensor is Illustration 67 for wiring information.
disconnected.
c. Connect the ECM connector.
Repair: Connect the suspect sensor. If the code
returns, replace the sensor. Connect all of the d. Restore electrical power to the engine ECM.
connectors. Verify that the problem is resolved.
e. Monitor the active diagnostic code screen on
STOP. Cat ET. Check for an active 263-03 code or
an active 263-04 code.
Not OK The 263-03 or 263-04 diagnostic code
remains active after the sensors are disconnected. Note: Wait at least 30 seconds in order for the
Leave the sensors disconnected. The sensors are diagnostic codes to become active.
not the cause of the diagnostic code. Proceed to
Test Step 6. f. If a diagnostic code becomes active for
this 8 V supply, there is a problem in this
Test Step 6. Check the 8 Volt Supply harness between the ECM and the sensor
Voltage at the ECM connector.
STOP.
STOP.
i02413879
Table 40
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0091 - FMI 08 Throttle The Engines Electronic Control Module The code will be active.
Position signal abnormal (ECM) detects a sensor frequency The throttle signal defaults to a zero
that is less than 150 Hz or a sensor percent duty cycle.
frequency that is greater than 1000 Hz
for two seconds.
or
The engines ECM detects a duty cycle
that is less than 5 percent or a duty
cycle that is greater than 95 percent for
one second.
g01206563
Illustration 72
Typical schematic
g01151263 g01206568
Illustration 73 Illustration 74
P1 ECM connector Machine connector
(P1-4) +8 V digital supply (Terminal 8) +8 V digital supply
(P1-5) Digital return (Terminal 9) Digital return
(P1-10) Throttle signal (Terminal 10) Throttle signal
Test Step 2. Check the Throttle Position The voltage is 8.0 0.4 VDC.
with Caterpillar Electronic Technician
(ET) Results:
A. Connect Cat ET to the service tool connector. OK The voltage is 8.0 0.4 VDC. The supply
Start Cat ET. voltage is reaching the sensor. Proceed to Test
Step 4.
B. Turn the keyswitch to the ON position.
Not OK The voltage is not 8.0 0.4 VDC. The
C. Observe the throttle position reading on Cat ET. supply voltage is not reaching the sensor. Proceed
to Test Step 7.
D. Depress the throttle and release the throttle.
Test Step 4. Check the Duty Cycle at the
Expected Result: Throttle Position Sensor Connector
The throttle position reads 0 percent when the throttle A. Turn the keyswitch to the OFF position.
pedal is released. The throttle position increases
to 100 percent when the throttle pedal is fully B. Remove wire F702-GN from Terminal C at the
depressed. sensor connector.
OK The throttle position reads 0 percent when D. Measure the duty cycle between wire F702-GN
the throttle pedal is released. The throttle position and Terminal B at the sensor connector.
increases to 100 percent when the throttle pedal is
fully depressed. The throttle position sensor is OK. Note: Set the multimeter to VDC. Press the Hz
button twice so that the % symbol is displayed.
Repair: There may be an intermittent problem. If
the problem is intermittent, perform the diagnostic E. Depress the throttle and release the throttle.
functional test Troubleshooting, Inspecting
Electrical Connectors. F. Turn the keyswitch to the OFF position.
Expected Result:
OK A valid duty cycle is present at the sensor D. Turn the keyswitch to the OFF position.
connector. Proceed to Test Step 5.
Expected Result:
Not OK A valid duty cycle is not present at the
sensor connector. The throttle position reads 0 percent when the throttle
pedal is released. The throttle position increases
Repair: Replace the throttle position sensor. Verify to 100 percent when the throttle pedal is fully
that the new sensor is operating correctly. depressed.
A. Remove wire F702-GN from P1-10 at the ECM OK The throttle position reads 0 percent when
connector P1. the throttle pedal is released. The throttle position
increases to 100 percent when the throttle pedal
B. Turn the keyswitch to the ON position. is fully depressed. The throttle position sensor is
OK. There is an intermittent problem in the wiring
C. Measure the duty cycle between wire F702-GN and/or connectors between the ECM and the
and P1-5 of ECM connector J1/P1. throttle position sensor.
Note: Set the multimeter to VDC. Press the Hz Repair: If the problem is intermittent, perform
button twice so that the % symbol is displayed. the diagnostic functional test Troubleshooting,
Inspecting Electrical Connectors.
D. Depress the throttle and release the throttle.
STOP.
E. Turn the keyswitch to the OFF position.
Not OK The throttle position does not read 0
F. Reconnect all connectors and wires. percent when the throttle pedal is released. The
throttle position does not increase to 100 percent
Expected Result: when the throttle pedal is fully depressed.
The duty cycle is between 6 and 10 percent when the Repair: The ECM is not reading the throttle
throttle is released. The duty cycle is between 85 and position sensor signal correctly. Replace the ECM.
94 percent when the throttle is fully depressed. Refer to the diagnostic procedure Troubleshooting,
Replacing the ECM..
Results:
STOP.
OK A valid duty cycle is present at the ECM
connector. Proceed to Test Step 6. Test Step 7. Check the 8 Volt Supply
Voltage at the ECM
Not OK A valid duty cycle is not present at the
ECM connector. A. Disconnect the J1/P1 ECM connector.
Repair: There is a problem in the wiring and/or B. Fabricate two jumper wires that are long enough
connectors between the ECM and the throttle to be used to measure the supply voltage at the
position sensor. Repair the connectors or wiring ECM connectors. Crimp connector sockets to one
and/or replace the connectors or wiring. end of each jumper wire.
Expected Result:
Results:
STOP.
STOP.
i02414014
Table 41
g01206647
Illustration 75
Typical schematic
g01206650 g01206655
Illustration 76 Illustration 77
P1 ECM Connector Machine Connector
(P1-21) User defined shutdown (Terminal 13) User defined shutdown
C. Perform a 45 N (10 lb) pull test on each of the Test Step 3. Create a Short at the
wires in the ECM connector that are associated Connector for the User Defined
with the circuit. Shutdown
D. Check the allen head screw on each ECM A. Use a jumper wire with a socket terminal at one
connector for the proper torque. Refer end to short wire F721-GY to the chassis ground.
to Troubleshooting, Inspecting Electrical Create the short at the connector for the user
Connectors for the correct torque values. defined shutdown.
E. Check the harness and the wiring for abrasion Expected Result:
and for pinch points.
Cat ET indicates User Shutdown ON when the wire
Expected Result: F721-GY is shorted to chassis ground.
D. Turn the keyswitch to the ON position. D. Measure the resistance at the ECM connector
between P1-21 and the engine ground.
E. Observe the status for the user defined shutdown
on Cat ET. Expected Result:
A. Measure the resistance at the ECM connector Repair: Repair the connectors and/or wiring or
between P1-21 and engine ground. replace the connectors or wiring. There may be an
intermittent problem. If the problem is intermittent,
B. Remove the wire short. refer to Troubleshooting, Inspecting Electrical
Connectors.
Expected Result:
STOP.
The resistance measurement indicates a short circuit.
Not OK Cat ET does not indicate User
Results: Shutdown ON with the wire short in place. Cat ET
does not indicate User Shutdown OFF when the
OK The resistance measurement indicates a wire short is removed. Cat ET does not indicate
short circuit. The resistance is within acceptable the correct status.
limits. Proceed to Test Step 6.
Repair: Replace the ECM. Refer to
Not OK The resistance measurement does not Troubleshooting, Replacing the ECM.
indicate a short circuit. There is an open circuit or
excessive resistance in the harness. STOP.
STOP.
Wastegate Solenoid
SMCS Code: 1057-038
Test Step 6. Short the Wire at the ECM
System Operation Description:
A. Remove the wire from the ECM connector at
P1-21. Use this procedure to troubleshoot any suspect
problems with the wastegate solenoid.
B. Insert a wire with a socket terminal at one end into
the ECM connector at P1-21. Use this procedure if a problem is suspected with the
wastegate solenoid or if any one of the diagnostic
C. Reconnect ECM connector J1/P1. codes in Table 42 is active or easily repeated.
D. Turn the keyswitch to the ON position.
Expected Result:
Table 42
Diagnostic Codes Table
Description Conditions which Generate this Code System Response
MID 0036 - CID 0526 - FMI 05 Turbo The engines Electronic Control Module The code is logged.
Wastegate Drive current low (ECM) detects an open circuit and/or a
short circuit to the +Battery terminal at
the output to the wastegate solenoid.
MID 0036 - CID 0526 - FMI 06 Turbo The ECM detects a short circuit to
Wastegate Drive current high ground at the output to the wastegate
solenoid.
g01206721
Illustration 78
Typical schematic
154 RENR5622
Troubleshooting Section
Results:
STOP.
All connectors, pins, and sockets are completely Not OK A 05 diagnostic code is active at this
coupled and/or inserted. The harness and wiring are time. Proceed to Test Step 4.
free of corrosion, of abrasion, and of pinch points.
RENR5622 155
Troubleshooting Section
Test Step 3. Create an Open at the B. Install a jumper wire between terminal 1 and
Connector for the Wastegate Solenoid terminal 2 of the connector for the wastegate
solenoid.
A. Turn the keyswitch to the OFF position.
C. Turn the keyswitch to the ON position.
B. Disconnect the connector for the wastegate
solenoid. D. Proceed to the Diagnostic Overrides screen on
Cat ET.
C. Turn the keyswitch to the ON position.
E. Select the override for the wastegate on Cat ET.
D. Proceed to the Diagnostic Overrides screen on
Cat ET. F. Set the override for the wastegate to 100 percent.
E. Select the override for the wastegate solenoid on G. Wait at least 30 seconds for activation of the 06
Cat ET. diagnostic code.
F. Set the override for the wastegate solenoid to 100 H. Turn the keyswitch to the OFF position. Remove
percent. the wire jumper.
E. Install the jumper wire(s) into the terminal I. Turn the keyswitch to the OFF position. Reconnect
location(s) for the wastegate solenoid at the ECM all wires to the original configuration.
connector.
Expected Result:
F. Connect the ECM connectors.
A 05 diagnostic code is active when the wires
G. Check the operation of the ECM by creating from the wastegate solenoid are open at the ECM
an open at the ECM: connector. A 06 diagnostic code is active if the wires
from the wastegate solenoid are shorted at the ECM
a. Hold the loose end of the jumper wires away connector.
from any components in order to create an
open circuit condition. Results:
b. Turn the keyswitch to the ON position. OK The ECM is operating properly. The problem
is in the wiring between the ECM and the connector
c. Proceed to the Diagnostic Overrides screen for the wastegate solenoid.
on Cat ET.
Repair: Repair the connectors or wiring and/or
d. Select the override for the wastegate solenoid replace the connectors or wiring.
on Cat ET.
STOP.
e. Set the override for the wastegate to 100
percent. Not OK One of the following conditions exists:
The 05 diagnostic code is not active when the wire
f. Monitor the Active Diagnostic Code screen for the wastegate solenoid is disconnected. The 06
on Cat ET. diagnostic code is not active when the wire jumper
is installed.
Check the wastegate solenoid for an active 05
diagnostic code. Repair: Replace the ECM. Refer to
Troubleshooting, Replacing the ECM.
Note: Wait at least 30 seconds so that any codes Verify that the problem is resolved.
may become active.
STOP.
g. Turn the keyswitch to the OFF position.
Calibration Procedures
i02415146
Table 43
The engine speed/timing sensor is calibrated B. Connect Caterpillar Electronic Technician (ET) to
through a two-step process. A new timing reference the service tool connector.
is calculated first. The reference is based on
the signals from the transducer and the engine C. Remove the timing calibration plug from the
speed/timing sensor. Next, the new timing reference flywheel housing.
is programmed into the permanent memory of the
engines Electronic Control Module (ECM). D. Examine the flywheel through the timing
calibration hole. Ensure that the probe is not
The engine speed/timing sensor provides engine inserted into the timing pin hole. If necessary,
information to the ECM. The ECM powers the engine rotate the engine.
speed/timing sensor with 12.5 1.0 VDC. The sensor
senses the tooth pattern on the timing reference gear E. Install the 6V-3093 Transducer Adapter into the
that is attached to the left camshaft. As the timing hole for the timing calibration at the flywheel.
gear rotates past the engine speed/timing sensor, a
signal is generated in the sensor. This signal is sent F. Insert the 6V-2197 Transducer through the
to the ECM. The ECM uses this signal in order to 6V-3093 Transducer Adapter. Insert the
calculate the engine position and the engine speed. transducer until contact is made with the surface
of the flywheel. Move the transducer 0.9 mm
A loss of the engine speed/timing signal causes the (0.04 inch) away from the flywheel.
ECM to stop sending power to the fuel injectors.
NOTICE
Calibration of the timing is required only after the Do not install the timing calibration probe over the tim-
following circumstances: ing pin hole in the flywheel or damage will result.
The ECM has been replaced.
G. Tighten the nut on the 6V-3093 Transducer
The speed/timing sensor has been replaced. Adapter.
The timing gear and/or the rear gear train have H. Connect the 7X-1695 Cable As between the
been adjusted. transducer and the timing calibration connector
P26.
The timing gear and/or the rear gear train have
been replaced. I. Turn the keyswitch to the START position.
Test Step 1. Check for an ACTIVE J. Start the engine. Allow the engine to exit cold
Diagnostic Code. mode operation.
A. Turn the keyswitch to the OFF position. K. Monitor the diagnostic codes on Cat ET. Check
and record any diagnostic codes.
158 RENR5622
Troubleshooting Section
Note: Wait at least 15 seconds in order for the Repair: Disconnect the timing calibration probe
diagnostic codes to become active. before you exit the Timing Calibration screen
on Cat ET. Reset the system and check for any
Expected Result: diagnostic codes.
STOP.
Expected Result:
Results:
Index
A Electrical Connectors and Functions ..................... 12
Engine Electronic Control Module (ECM) .......... 12
Alternator (Noisy Operation).................................. 36 Machine Connector............................................ 13
Probable Causes ............................................... 36 Sensor Connectors ............................................ 14
Recommended Actions...................................... 36 Service Tool Connector for Cat ET .................... 13
Analog Sensor (Active).......................................... 65 Electrical Power Supply......................................... 80
Electronic Service Tool Will Not Communicate with
ECM..................................................................... 44
B Probable Causes ............................................... 44
Recommended Actions...................................... 44
Boost Pressure Above Normal .............................. 37 Electronic Service Tools ........................................ 14
Probable Causes ............................................... 37 Caterpillar Electronic Technician (ET)................ 15
Recommended Actions...................................... 37 Optional Service Tools ....................................... 15
Boost Pressure Below Normal............................... 37 Required Service Tools ...................................... 14
Probable Causes ............................................... 38 Electronic Troubleshooting ...................................... 4
Engine Cranks but Will Not Start ........................... 45
Probable Causes ............................................... 45
C Recommended Actions...................................... 45
Engine Has Early Wear ......................................... 46
Calibration Procedures ........................................ 157 Probable Causes ............................................... 46
Can Not Reach Top Engine RPM .......................... 39 Recommended Actions...................................... 46
Probable Causes ............................................... 39 Engine Misfires, Runs Rough or Is Unstable......... 47
Recommended Actions...................................... 39 Probable Causes ............................................... 47
Cat Data Link......................................................... 73 Recommended Actions...................................... 47
Coolant Flow Switch .............................................. 76 Engine Oil in Cooling System ................................ 48
Coolant in Engine Oil............................................. 40 Probable Causes ............................................... 48
Probable Causes ............................................... 40 Recommended Actions...................................... 48
Recommended Actions...................................... 40 Engine Oil Level Switch......................................... 85
Coolant Temperature Is Too High .......................... 41 Engine Oil Renewal Solenoid ................................ 89
Probable Causes ............................................... 41 Engine Overspeed................................................. 48
Recommended Actions...................................... 42 Probable Causes ............................................... 49
Coolant Temperature Is Too Low........................... 40 Recommended Actions...................................... 49
Probable Causes ............................................... 41 Engine Speed/Timing Sensor ................................ 92
Recommended Actions...................................... 41 Engine Speed/Timing Sensor - Calibrate ............ 157
Crankcase Pressure (High) ................................... 42 Engine Stalls at Low RPM ..................................... 49
Probable Causes ............................................... 43 Probable Causes ............................................... 49
Recommended Actions...................................... 43 Recommended Actions...................................... 49
Customer Parameters Worksheet ......................... 33 Engine Will Not Crank ........................................... 50
Probable Causes ............................................... 50
Recommended Actions...................................... 50
D Ether Injection System........................................... 96
Event Code List ..................................................... 21
Diagnostic Code List.............................................. 16 Active Event Codes............................................ 22
Active Diagnostic Codes .................................... 21 Clearing Event Codes ........................................ 23
Cross-Reference Information for Diagnostic Cross-Reference Information for Event Codes .. 21
Codes............................................................... 16 Default Conditions for the Monitoring System.... 26
Diagnostic Codes............................................... 20 Logged Event Codes ......................................... 23
Logged Diagnostic Codes.................................. 21 Trip Points for the Monitoring System................ 24
Diagnostic Functional Tests................................... 65 Troubleshooting ................................................. 24
Excessive Black Smoke ........................................ 51
Probable Causes ............................................... 51
E Recommended Actions...................................... 52
Excessive Engine Oil Consumption....................... 51
ECM Will Not Accept Factory Passwords.............. 43 Probable Causes ............................................... 51
Probable Causes ............................................... 43 Recommended Actions...................................... 51
Recommended Actions...................................... 43 Excessive White Smoke ........................................ 53
ECM Will Not Communicate with Other Systems or Probable Causes ............................................... 53
Display Modules .................................................. 43 Recommended Actions...................................... 53
160 RENR5622
Index Section
S
G
Self-Diagnostics...................................................... 11
Ground Level Shutdown Switch .......................... 109 Diagnostic Codes................................................ 11
Sensor Supply ..................................................... 138
Symptoms.............................................................. 36
I System Configuration Parameters......................... 30
Injector Trim Code ............................................. 32
Important Safety Information ................................... 2 Parameter Table................................................. 32
Injector Solenoids ................................................. 112 System Overview..................................................... 4
Inlet Air Restriction ................................................ 55 Electronic Controls............................................... 4
Probable Causes ............................................... 56
Recommended Actions...................................... 56
Inspecting Electrical Connectors ......................... 121 T
Intermittent Engine Shutdown ............................... 56
Probable Causes ............................................... 56 Table of Contents..................................................... 3
Recommended Actions...................................... 56 Throttle Position Sensor ...................................... 145
Intermittent Low Power or Power Cutout............... 57 Too Much Valve Lash ............................................ 63
Probable Causes ............................................... 57 Probable Causes ............................................... 63
Recommended Actions...................................... 57 Recommended Actions...................................... 63
Too Much Vibration................................................ 64
Probable Causes ............................................... 64
L Recommended Actions...................................... 64
Troubleshooting Section.......................................... 4
Low Engine Oil Pressure ....................................... 58 Troubleshooting without a Diagnostic Code .......... 36
Probable Causes ............................................... 59
Recommended Actions...................................... 59
Low Power/Poor or No Response to Throttle ........ 59 U
Probable Causes ............................................... 59
Recommended Actions...................................... 60 User Defined Shutdown Input.............................. 149
M V
Mechanical Noise (Knock) in Engine..................... 61 Valve Rotocoil or Spring Lock Is Free ................... 64
Probable Causes ............................................... 61 Probable Causes ............................................... 64
Recommended Actions...................................... 61 Recommended Actions...................................... 64
RENR5622 161
Index Section